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Installation

Instructions

479

Sizes

180

&

Series

D

ALL

WEATHER

HEATING

and

COOLING

UNIT

bryant

Cancels:

39479D6

I

39479D8

|

9/20/71

A70680

Model

479.

■

it

■

j

.

c—

L

PjMpjMffi

__gn

MB

■

■

Important

-

Read

before

Installing

1.

Check

all

local

or

other

applicable

codes

for

infor¬

mation

concerning

proximity

to

property

lines,

height

above

roof,

obstructions,

etc.

2.

Be

sure

the

power

supply

available

(voltage,

frequency

and

phase)

corresponds

to

that

specified

on

the

unit.

3.

Check

the

electrical

service

provided

by

the

utility

for

the

building

to

be

sure

that

the

service

capacity

is

sufficient

to

handle

the

load

imposed

by

this

unit.

4.

Refer

to

the

regulations

of

the

serving

gas

supplier

and

the

local

building,

heating,

plumbing

or

other

codes

in

effect

in

the

area

in

which

installation

is

to

be

made.

5.

Refer

to

the

dimensional

drawing

on

page

2

for

electrical,

gas,

duct

and

drain

connections

prior

to

set¬

ting

the

unit

in

place.

GENERAL

The

Bryant

Model

479

is

an

all

weather

heating

and

cooling

unit

designed

for

outdoor

installation

only.

It

can

be

installed

at

ground

level

or

on

a

rooftop.

The

479

is

factory

assembled,

pre-wired

and

charged

with

the

primary

refrigerant.

Installation

consists

of

the

following:

I.

Locating

the

Unit

II.

I

nstalling

Vent

Caps

III.

Duct

Connections

IV.

Gas

Connections

V.

E

l

ectrical

Connections

VI.

C

hilled

Water

System

VII.

S

tart-Up

and

Adjustments

VIII.

F

urnace

Operation

IX,

Cooling

Operation

X.

Maintenance

Read

the

entire

Installation

Instructions

before

star¬

ting

installation

.

I.

LOCATE

AND

MOUNT

THE

UNIT

The

condenser

air

discharges

upward;

therefore,

avoid

locations

where

obstructions

will

deflect

the

hot

condenser

discharge

air

back

into

the

condenser

inlet

air

supply.

In

all

cases,

the

condenser

should

be

at

least

2

feet

from

any

wall

or

obstruction

and

outside

of

the

plumb

line

from

any

overhang.

Use

caution

to

prevent

damage

when

moving

the

unit.

Use

an

adequate

rope

or

cable

sling

and

keep

the

unit

in

an

upright

position

at

all

times

during

rigging

and

moving

operations.

CAUTION:

Protect

the

top

and

sides

so

that

the

rigging

sling

will

not

damage

the

unit.

240

4-L-

12

i

'

^8

66

,W

1%

-687

(THERMOMETER

WELL

(4)

15

2

ERT.

DRAIN

^CONNECTION

<L=J<

H

op

—

J

“32

fi

3

_

6

16

1M.RT

GAS

CONNECTION

28,4

7

5

JT

*

Q

_

76t

18

t

t

L

ERT.

DRAIN

CONNECTION

-B-

I

i

SIZE

A

B

C

D

180

175

68

39-1/8

16-15/16

240

195

88

39413/16

21-1/32

l*

3

84—

16

4

1

3

2

Approximate

Shipping

Weights

180-479._

.

..

.

_

.

.

.

4900

]bs.

240-479_.....'._5700

lbs.

,59

'S4~jf

|

33

TTiii

FUSE

a

SWITCH

BOX

T—C

~TT

]

AIR

OUT

*194

—

;w

jL±

9

t

5

“16

%

ERT.

GAS

CONNECTIONS

Figure

2—Dimensional

Drawing

A70224

TABLE

I

HEATING

RATINGS

and

CAPACITIES

180/240-479

Input

1st

Stage

Btuh

225,000

Output

1st

Stage

Btuh

168,000

Input

1st

and

2nd

Stage

Btuh

450,000

Output

1st

and

2nd

Stage

Btuh

337,000

Approved

Temp

Rise

Model

180-479

°F

45

-

75

Model

240-479

°F

20

-

50

TABLE

II

COOLING

RATINGS

and

CAPACITIES

MODEL

180-479

240-479

Capacity

(Total

Cooling)

Btuh

180,000

240,000

Air

Flow

CFM

6,000

8,000

External

Static

Pressure

In.

wg.

0.3

0.4

Entering

Air

Temperature

°F

80/67

80/67

Entering

Water

Temperature

°F

45

45

Gas

Input

(Total)

Btuh

450,000

600,000

Electrical

Input

(Total)

KW

5.0

6.0

Refrigerant

Type

R717

R717

Amount

per

Chiller

Lbs.

18

26

Total

Solution

per

Chiller

Lbs.

55

79

-

2

-

Mounting

Bases

The

mounting

base

should

comply

with

local

codes

and

be

made

of

noncombustible

material.

The

recom¬

mended

types

of

mounting

bases

for

all

installations

are:

a.

Precase

concrete

lintels.

Use

three

lintels

run

the

depth

of

the

unit;

one

under

the

right

end,

one

under

the

left

end,

and

one

at

the

center

of

the

unit.

b.

Steel

beams.

Use

three

I-beams

run

the

depth

of

the

unit;

one

under

each

end

and

one

at

the

center.

c.

Concrete

Slab.

A

minimum

thickness

of

four

inches

is

required.

Rooftop

Installation

When

installing

the

479

on

a

roof

or

other

com¬

bustible

material,

use

noncombustible

supports

and

allow

a

6

inch

clearance

beneath

the

unit's

subbase

for

proper

air

circulation.

Be

sure

the

roof

construc¬

tion

will

support

the

weight

of

the

equipment.

Locate

the

unit

above

a

load-bearing

wall

whenever

possible.

Condensate

Drain

The

479

is

furnished

with

a

3/4

inch

FPT

drain

con¬

nection.

If

the

installation

requires

draining

the

con¬

densate

away

from

the

roof

of

the

building,

connect

tubing,

pipe,

hose

or

trough

and

pitch

downward

one

inch

for

every

ten

feet

of

horizontal

run.

Ground

Level

Installation

The

479

should

be

placed

on

a

concrete

slab

at

least

4

inches

thick.

Level

the

unit

on

the

slab

and

be

sure

there

is

adequate

drainage

away

from

its

base.

Clearances

The

minimum

clearances

are

6

inches

from

the

duct

side

and

24

inches

from

all

other

sides.

II.

I

N

S

TALLING

VENT

CAPS

The

vent

cap

assemblies

are

packaged

and

shipped

in

the

heating

section

coil

compartment.

Install

the

vent

cap

assemblies

as

follows.

See

Figure

3.

1.

Remove

the

cover

on

each

of

the

vents

on

the

roof

of

the

unit.

2.

Use

the

FAJ5606B

screws

supplied

with

the

assem¬

blies

to

fasten

the

base

section

of

the

vent

cap

assem¬

bly.

3.

Remove

the

three

self-tapping

screws

in

the

top

cover,

located

approximately

7

inches

behind

each

vent

cap.

Attach

one

of

the

air

deflectors

in

this

location

for

each

vent

cap,

using

the

screws

removed.

III.

D

U

C

T

CONNECTIONS

Before

attaching

the

ducting

to

the

unit,

remove

the

sheet

metal

panel

that

is

used

to

protect

the

outlet

and

return

openings.

The

ductwork

may

be

screwed

or

bolted

to

the

unit

flange

with

suitable

gaskets

to

in¬

sure

a

weathertight

seal.

Be

sure

the

sheet

metal

overlaps

the

flange

on

the

unit.

CAUTION:

Take

care

not

to

puncture

the

evaporator

coil

when

drilling

the

duct

flange.

All

duct

work

external

of

the

structure

must

be

properly

insulated

and

water-proofed.

All

openings

in

the

structure

must

be

properly

flashed

and

vibration

isolated

in

accordance

with

local

codes

and

good

building

practices.

Supply

and

return

duct

work

should

be

provided

with

an

approved

vibration

eliminator.

The

vibration

eliminator

must

be

located

within

the

structure.

IV.

G

A

S

CONNECTIONS

The

gas

supply

pipe

for

the

Model

479

should

be

a

direct

line

from

the

gas

meter

or

propane

supply

tank.

The

gas

supply

pipe

should

terminate

at

the

unit

with

a

tee.

The

size

of

the

gas

pipe

used

depends

upon

the

length

of

run

and

allowable

pressure

loss

established

by

the

utility.

Never

use

pipe

smaller

than

the

gas

connection

to

the

unit

manifold.

The

following

are

pertinent

recommendations:

1.

Avoid

low

spots

in

long

runs

of

pipe.

It

is

best

to

grade

all

pipe

1/4

inch

in

every

15

feet

to

prevent

traps.

All

horizontal

runs

should

grade

up

to

risers.

2.

A

drip

leg

must

be

provided

at

any

point

in

the

line

of

pipe

where

condensate

may

collect.

Such

drip

leg

or

drip

legs

shall

be

installed

in

locations

readily

ac¬

cessible

to

permit

cleaning

or

emptying.

The

drip

legs

should

not

be

located

where

they

are

subject

to

freezing.

See

Figure

4.

Check

local

codes

for

size

and

capacity

of

drip

legs.

3.

Three

manual

shutoff

valves

should

be

installed;

one

valve

between

the

gas

supply

pipe

and

heating

section,

and

one

between

each

chiller

and

the

gas

sup¬

ply

pipe.

4.

A

ground

joint

union

should

be

installed

between

the

individual

gas

controls

manifold

and

each

manual

shutoff

valve.

-

3

-

DRIP

LEG

WITHIN

STRUCTURE

A70676

Figure

4—Drip

Leg

Location

5.

The

joint

compound

(pipe

dope)

used

must

be

resistant

to

the

action

of

propane

gas.

6.

Support

all

piping

with

appropriate

hangers.

Use

a

minimum

of

one

hanger

every

ten

feet.

7.

After

all

gas

connections

are

made,

check

for

leakage

using

soap

and

water

solution,

or

leak-check

unit

in

accordance

with

local

utility

regulations.

WARNING:

NEVER

USE

A

MATCH

OR

OPEN

FLAME

FOR

LEAK

TESTING.

Purging

Gas

Lines

After

making

all

gas

connections

and

checking

for

leaks,

it

is

now

necessary

to

purge

the

supply

lines

to

eliminate

trapped

air.

WARNING:

NEVER

PURGE

GAS

LINES

INTO

THE

COMBUSTION

CHAMBERS

OF

THE

FUR¬

NACE

OR

CHILLERS.

1.

With

the

furnace

manual

gas

valve

and

pilot

shutoff

valve

closed,

disconnect

the

pilot

supply

tube

at

the

pilot

shutoff

valve

on

the

furnace.

2.

Open

the

manual

shutoff

valve;

then

open

the

pilot

shutoff

valve

and

allow

the

supply

line

to

purge

until

the

odor

of

gas

is

detected.

Immediately

upon

detec¬

ting

a

gas

odor,

turn

off

the

gas

and

reconnect

the

pilot

supply

tube.

Allow

at

least

five

minutes

to

elapse

before

lighting

pilot.

3.

Purge

the

gas

line

to

each

chiller

in

the

same

man¬

ner

as

described

for

the

furnace.

V.

ELECTRICAL

CONNECTIONS

The

Model

479

requires

a

3

wire,

230

volt,

60

cycle,

3

phase

power

supply.

Check

the

unit

rating

plate

to

make

sure

the

power

supply

meets

all

the

electrical

specifications.

Electrical

connections

must

be

made

in

accordance

with

the

National

Electrical

Code

and

the

electrical

code

of

the

local

area.

The

field

high

voltage

connections

are

made

to

the

disconnect

box

located

between

the

two

chillers

at

the

right

end

of

the

unit.

The

field

low

voltage

wiring

consists

of

running

seven

wires

from

the

thermostat

subbase

to

the

low

voltage

terminal

block

in

the

furnace.

See

Figure

5

for

low

voltage

field

wiring.

Thermostat

P/N

34427D55

and

Subbase

P/N

34427D59

4

-

VI.

CHILLED

WATER

SYSTEM

The

cooling

section

of

Model

180-479

is

comprised

of

two

90,000

BTUH

chillers

and

a

180,000

BTUH

cooling

coil

which

is

divided

into

two

separate

90,000

BTUH

sections

(top

and

bottom).

The

bottom

section

of

the

chilled

water

coil

is

supplied

chilled

water

by

one

chiller

(1st

stage

cooling)

while

the

top

section

of

the

chilled

water

coil

is

supplied

chilled

water

by

the

other

chiller

(2nd

stage

cooling).

The

chilled

water

circuit

of

each

chiller

is

independent

of

the

other;

therefore,

each

chiller

must

be

charged

with

water

before

the

cooling

section

can

be

operated.

The

design

of

Model

240-479

is

basically

the

same

as

that

of

Model

180-479

except

the

240-479

utilizes

two

120,000

BTUH

chillers

and

a

240,000

BTUH

cooling

coil

which

is

divided

into

two

separate

120,000

BTUH

sections.

Each

chiller

of

the

Model

240-479

must

also

be

charged

with

water

since

the

chilled

water

circuit

of

each

chiller

is

independent

of

the

other.

CAUTION:

The

water

seals

will

be

damaged

if

the

pumps

are

operated

without

water

in

the

system.

Freezing

conditions

will

not

damage

the

pumps;

however,

do

not

operate

the

pumps

when

the

chillers

or

chilled

water

lines

are

frozen.

Charging

the

System

with

Water

Charge

the

chilled

water

system

with

water

as

follows:

1.

Turn

off

manual

gas

valves

to

both

chillers

and

turn

off

electrical

power

at

disconnect

switch.

2.

Remove

access

panel

from

both

of

the

chillers

at

the

chiller

tank

end.

Remove

chilled

water

tank

lids.

3.

Fill

both

chiller

tanks

with

water

having

less

than

100

ppm

chlorides

until

distributor

pans

are

covered,

or

add

12.2

gallons

to

each

chiller

of

Model

180-479

or

13.6

gallons

to

each

chiller

of

Model

240-479.

NOTE:

If

the

local

tap

water

has

more

than

100

ppm

chlorides,

charge

the

chilled

water

system

with

distilled

or

deionized

water.

Check

the

local

water

company

and/or

county

agricultural

agent

for

analysis

of

tap

water

being

used

in

your

area.

CAUTION:

Never

use

home

soft

water,

water

sof¬

tening

additives,

water

cleaning

compounds,

coloring

additives,

acidizing

materials,

stop

leak

additives,

or

other

commercial

water

additives

in

the

chilled

water

system.

WARNING:

To

prevent

personal

injury,

disconnect

condenser

fan

motor

lead

in

the

control

box

of

each

chiller

at

this

time.

4.

Replace

both

chiller

tank

lids,

then

start

water

pumps.

If

water

of

either

chiller

does

not

circulate

when

the

pumps

are

started,

air

may

be

trapped

in

the

system.

Most

chillers

are

equipped

with

a

Gorman-Rupp

water

pump

(plastic).

On

these

chillers,

it

is

necessary

to

disconnect

the

chilled

water

line

at

the

chiller

tank

to

bleed

the

air.

Operate

water

pumps

until

water

ap¬

pears

at

the

disconnected

water

line,

then

reconnect

water

line

to

chiller

tank.

If

the

chiller

with

the

trapped

air

is

equipped

with

a

Wayne

water

pump

(metal),

it

is

not

necessary

to

disconnect

the

water

line

to

bleed

the

trapped

air.

Bleed

the

air

from

the

pump

through

the

1/4-inch

slot¬

ted

head

valve

located

on

top

of

the

pump

discharge.

See

Figure

6.

Open

valve

with

a

screwdriver.

Close

valve

when

a

steady

stream

of

water

appears.

5.

Leak

test

the

chilled

water

system.

6.

Remove

operating

level

drain

plug

(located

on

side

of

tank)

from

both

chilled

water

tanks

and

continue

to

operate

pumps

until

water

stops

flowing

from

drain

openings.

NOTE:

With

the

pumps

running,

the

water

level

is

correct

for

each

chiller

when

water

stops

flowing

from

its

drain

opening.

7.

Replace

operating

level

drain

plugs,

then

turn

off

pumps.

8.

Refer

to

“Freezing

Weather

Protection”

on

page

6.

If

freeze

protection

is

required,

decide

on

which

type

of

antifreeze

to

use.

The

procedure

for

adding

Ucar-17

is

given

in

Step

9.

The

procedure

for

adding

methanol

antifreeze

is

given

in

Step

10.

If

antifreeze

is

not

required,

disregard

Steps

9

and

10.

9.

Adding

Ucar-17

Antifreeze

-

Refer

to

Table

III.

Drain

out

amount

of

water

from

each

chiller

tank,

equal

to

amount

of

antifreeze

to

be

added.

Add

required

amount

of

Ucar-17

to

each

chiller

tank.

Recheck

operating

water

level

and

correct.

Do

not

use

any

chilled

water

additive

when

using

Ucar-17

in

the

recommended

concentration.

Omit

Steps

10

and

11.

10.

Adding

Methanol

Antifreeze

-

Refer

to

Table

III.

Drain

out

amount

of

water

from

each

chiller,

equal

to

amount

of

antifreeze

to

be

added.

Add

required

amount

of

methanol

antifreeze.

Add

the

contents

of

the

chilled

water

additive

package

as

described

in

Step

11.

11.

Remove

chiller

tank

lids,

and

add

contents

of

chilled

water

package

(one

package

to

each

chilled

water

tank

is

sufficient).

12.

Replace

both

chiller

tank

lids

and

reconnect

con¬

denser

fan

motor

leads

in

the

chiller

control

boxes.

13.

Turn

on

water

pumps.

Pumps

should

operate

a

minimum

of

10

minutes

to

dissolve

all

chilled

water

additive

when

chilled

water

additive

is

used.

14.

Replace

access

panels

and

turn

on

manual

gas

valves

to

both

chillers.

Cooling

section

is

now

ready

to

operate.

Corrosion

Protection

The

metallic

components

of

the

chilled

water

system

must

be

protected

from

corrosion

by

the

addition

of

an

inhibitor

to

the

chilled

water

circuit

of

each

chiller.

Two

packages

of

chilled

water

additive

are

furnished

with

the

unit.

The

contents

of

one

package

of

Chilled

Water

Additive

P/N

62875D1

must

be

added

to

the

chilled

water

circuit

of

each

chiller

when

water

only

or

when

water

and

methanol

antifreeze

are

used

in

the

chilled

water

system.

Do

not

add

any

chilled

water

additive

to

the

system

when

Ucar-17

is

used

for

freeze

protection.

Ucar-17

contains

sufficient

inhibitor

when

used

in

the

recom¬

mended

concentrations

as

shown

in

Table

III.

Freezing

Weather

Protection

Freeze

protection

is

only

required

when

the

chilled

water

coil

is

subjected

to

freezing

temperatures

or

when

the

unit

is

to

operate

under

freezing

conditions.

The

cooling

section

is

equipped

with

galvanized

chillers.

Ucar-17

is

the

only

permanent

(glycol-base)

antifreeze

approved

for

use

in

the

chilled

water

system.

When

Ucar-17

is

used

for

freeze

protection,

the

minimum

concentration

must

be

33%

by

volume.

Table

III

gives

the

types

of

antifreeze,

percent

of

an¬

tifreeze

concentration,

and

amount

of

antifreeze

to

use

in

each

chiller

of

the

180

and

240-479

at

various

outdoor

temperatures.

VII.

START-UP

AND

ADJUSTMENTS

Important:

Before

starting

the

heating

or

cooling

sec¬

tion,

make

certain

all

electrical

connections

have

been

made

and

the

gas

piping

has

been

connected,

purged

and

leak

tested.

CAUTION:

Recheck

all

factory

and

field

connections,

making

sure

they

are

tight.

Pilot

Adjustment

Remove

necessary

access

panels

from

furnace

and

chillers.

Light

pilots

according

to

instructions

on

furnace

and

chillers.

For

Natural

Gas.

Flame

should

be

of

sufficient

length

to

provide

good

impingement

on

the

monometal

of

the

Bryant

pilot.

The

flame

should

extend

upward

bet¬

ween

the

carryover

ports

of

the

two

adjacent

burners.

For

Propane

Gas.

Flame

should

surround

tip

of

the

thermocouple

element

of

the

pilot

and

extend

down¬

ward

to

include

3/8”

to

1/2”

of

the

thermocouple.

The

flame

must

not

come

in

contact

with

any

other

part

of

the

thermocuple

or

its

lead

wire.

The

flame

lies

under

the

carryover

ports

of

the

burners

and

merges

with

the

carryover

flames.

The

pilot

flame

can

be

adjusted

if

it

does

not

have

the

appearance

described

above.

The

pilot

adjusting

screw

for

natural

and

propane

units

(chillers

and

fur¬

nace)

is

located

under

a

screw

cap

in

the

handle

of

the

manual

pilot

shut

off

valve.

Adjust

as

follows:

1.

Remove

the

screw

cap

to

expose

the

adjusting

screw,

then

turn

pilot

flame

to

full

on

position.

2.

Turn

the

adjusting

screw

until

the

flame

has

the

desired

appearance.

TABLE

III

APPROVED

ANTIFREEZE

TYPES

Amount

Required

(Gallons)

Lowest

Outdoor

Percent

of

Concentration

180-479

(Each

Chiller)

240-479

(Each

Chiller)

Temperature

(°F)

*Methanol

**Ucar-17

Methanol

Ucar-17

Methanol

Ucar-17

20

20

33

2-1/2

4-1/4

2-3/4

4-1/2

15

20

33

2-1/2

4-1/4

2-3/4

4-1/2

10

22

33

2-3/4

4-1/4

3-1/4

4-1/2

5

26

33

3-1/4

4-1/4

3-3/4

4-1/2

0

29

33

3-3/4

4-1/4

4

4-1/2

-5

32

36

4

4-1/2

4-1/2

5

’10

34

39

4-1/4

4-3/4

4-3/4

5-1/4

-15

36

42

4-1/2

5-1/4

5

5-3/4

-20

38

45

4-3/4

5-1/2

5-1/4

6-1/4

-25

43

47

5-1/4

5-3/4

6

6-1/2

-30

44

49

5-1/2

6

6

6-3/4

*Chilled

water

Additive

(Borax

and

Chromate)

P/N

62875D1

must

also

be

used.

Refer

to

“Corrosion

Protection”

on

page

6.

**No

chilled

water

additive

required.

Refer

to

“Corrosion

Protection”

on

page

6.

-

6

-

Adjusting

Gas

Input

Gas

input

of

the

furnace

and

each

chiller

must

be

checked

and

adjusted

if

necessary

to

agree

with

that

shown

on

the

rating

plates.

The

burners

are

equipped

with

fixed

orifices.

CAUTION:

The

chillers

may

be

run

for

short

periods

with

the

panels

removed.

Prolonged

operation

with

panels

removed

should

be

avoided.

Natural

gas

units

are

equipped

with

adjustable

gas

pressure

regulators.

Propane

gas

units

are

not

equip¬

ped

with

a

pressure

regulator.

One

of

the

following

two

methods

may

be

used

to

check

natural

gas

input

on

both

the

furnace

and

chillers.

A.

Measuring

Gas

Flow

at

Meter

All

gas

appliances

must

be

turned

off

except

the

bur¬

ners

on

the

manifold

being

checked

when

measuring

the

gas

flow

at

the

meter

to

adjust

the

gas

input.

Proceed

as

follows:

1.

Determine

the

number

of

seconds

required

for

the

gas

meter

test

dial

to

complete

one

revolution.

2.

Divide

3600

by

the

number

of

seconds

in

Step

1.

3.

Multiply

the

result

in

Step

2

by

the

number

of

cubic

feet

of

gas

flow

per

hour.

4.

Multiply

the

result

of

Step

3

by

the

Btu

heating

value

of

the

gas

(consult

local

utility

for

value).

This

is

the

total

measured

Btu/hr

input.

Compare

this

value

with

the

one

shown

on

the

rating

plate.

Example:

Suppose

the

size

of

the

test

dial

is

5

cu.

ft.;

it

takes

40

seconds

for

the

dial

to

complete

one

revolution;

heating

value

of

the

gas

is

1050

Btu/cu.

ft.

Proceed

as

follows:

40

seconds

to

complete

one

revolution

3600

divided

40

equals

90

90

x

5

-

450

cu.

ft.

per

hour

of

gas

flow

450

x

1050

-

472,5000

Btuh

input

Only

minor

changes

should

have

to

be

made

at

the

pressure

regulator

to

bring

it

within

the

rated

input

of

the

unit.

If

the

manifold

pressure

must

be

changed

more

than

0.3”

w.c.

to

obtain

the

rated

input,

the

orifices

should

be

changed

accordingly.

B.

Using

Water

Manometer

Proceed

as

follows

when

using

a

water

manometer

to

measure

the

manifold

pressure

when

adjusting

the

gas

input:

1.

Connect

a

water

manometer

to

the

1/8”

pressure

tap

on

the

manifold

or

gas

valve.

2.

With

the

burners

fired,

set

the

correct

manifold

pressure

as

shown

in

Table

IV.

Check

with

the

gas

utility

for

the

Btu

valve

and

specific

gravity

of

gas

in

the

area.

TABLE

IV—MANIFOLD

PRESSURE

(Inches

w.c.)

Specific

Gravity

0.59

0.61

0.63

0.65

0.67

900

3.9”

4.0”

4.1”

4.2”

4.3”

950

3.5”

3.6”

3.7”

3.8”

3.9”

1000

3.1”

3.2”

3.3”

3.4”

3.5”

1025

3.0”

3.1”

3.2”

3.3”

3.4”

1050

2.8”

2.9”

3.0”

3.1”

3.2”

1100

2.6”

2.7”

2.8”

2.9”

3.0”

Adjusting

Pressure

Regulator

If

the

measured

and

rated

input

are

not

ap¬

proximately

the

same,

the

gas

pressure

regulator

may

be

adjusted

as

follows:.

To

increase

input.

Remove

regulator

sealing

cap

and

turn

gas

pressure

regulator

adjusting

screw

clockwise.

To

decrease

input.

Remove

regulator

sealing

cap

and

turn

gas

pressure

adjusting

screw

counterclockwise.

Checking

Propane

Gas

Input

The

burner

orifices

are

sized

for

rated

input

with

a

manifold

pressure

of

11.0”

w.c.

for

propane

gas.

Con¬

nect

a

manometer

of

the

1/8”

pressure

tap

on

the

chiller

manifold

gas

valve.

With

the

burners

fired,

ad¬

just

regulator

at

the

supply

tank

to

provide

a

pressure

of

11.0”

w.c.

Check

manifold

pressure

of

each

chiller.

Check

the

furnace

manifold

pressure

to

see

that

it

is

also

11.0

inches

w.c.

Burner

Adjustment

To

adjust

the

primary

air

to

each

burner,

partially

close

the

air

shutter

until

there

is

a

slight

yellow

tip

at

the

top

of

each

flame,

then

open

the

air

shutter

until

the

yellow

tip

just

disappears.

This

should

be

done

af¬

ter

the

burners

have

been

operating

at

full

input

for

5

minutes.

VIII.

FURNACE

OPERATION

In

order

to

check

the

furnace

for

proper

performance,

the

following

sequence

of

control

operation

is

given.

CAUTION:

The

pilot

valve

and

main

burner

manual

valve

must

be

closed

for

at

least

five

minutes

before

starting

the

furnace.

1.

Set

the

thermostat

system

switch

to

“heat”,

set

the

fan

switch

to

“auto”

and

set

the

thermostat

below

room

temperature.

2.

Turn

on

electrical

power

to

the

unit.

3.

Open

pilot

gas

valve.

Gas

will

flow

to

the

pressure

switch

and

to

the

pilot.

The

electrical

contacts

in

the

pressure

switch

close,

energizing

the

reignition

coil

which

ignites

the

pilot

gas.

(Natural

gas

only;

pilots

on

propane

unit

must

be

lighted

manually

per

instruc¬

tion

on

rating

plate.)

The

pilot

flame

causes

the

monometal

contacts

in

the

Bryant

733

pilot

to

“Break”

the

re-ignition

coil

circuit

-

7

-

and

“make”

the

circuit

to,

but

not

through,

the

first

stage

gas

valve.

On

propane

units,

with

themocouple

energized,

the

pilot

relay

switch

action

makes

the

cir¬

cuit

to

gas

valve.

4.

Set

the

thermostat

above

room

temperature.

This

completes

the

circuit

and

energizes

the

gas

valve.

5.

Gas

flows

through

the

gas

valve

to

the

burners

via

bypass

where

it

ignites.

If

the

conditioned

space

tem¬

perature

continues

to

drop,

the

second

stage

of

the

thermostat

closes

and

opens

the

second

gas

valve

bringing

the

unit

to

full

input.

With

the

furnace

operating,

make

the

following

checks:

The

automatic

pilot

should

turn

the

main

gas

off

if

the

pilot

flame

goes

out.

Check

this

while

the

furnace

is

operating

by

shutting

off

the

pilot

gas.

The

main

burners

should

shutdown.

Allow

the

furnace

to

cool

and

the

blowers

to

stop,

then

check

the

upper

limit

switch.

Limit

Control

The

furnace

is

equipped

with

a

lower

and

upper

limit

control.

When

the

lower

limit

opens,

the

first

stage

gas

valve

is

de-energized,

shutting

off

the

gas.

The

upper

limit

control

has

a

dual

function;

its

primary

action

is

to

shut

off

the

first

stage

gas

valve

if

the

unit

overheats;

as

the

gas

valve

is

shut

off,

the

fan

delay

relay

is

energized,

starting

the

blower.

The

upper

limit

is

a

single

pole

double

throw

switch.

The

recommended

method

for

checking

the

limit

con¬

trols

is

to

gradually

block

off

the

return

air

after

the

furnace

has

been

operating

for

a

period

of

at

least

five

minutes.

As

soon

as

the

limit

has

proven

safe,

the

return

air

openings

should

be

unblocked

to

allow

nor¬

mal

air

circulation

through

the

unit.

Whether

or

not

the

limit

is

functioning

properly,

and

will

“fail-safe”

in

case

of

motor

failure

or

overheating

of

the

unit

can

be

determined

using

this

method.

Fan

Relay

The

unit

is

equipped

with

a

fan

delay

relay

switch

located

in

the

control

box.

When

the

observer

faces

the

control,

the

adjustment

lever

is

moved

upward

to

lengthen

the

off

cycle.

When

the

off

cycle

is

lengthened,

the

on

cycle

is

shortened

automatically.

Reverse

the

process

to

shorten

the

off

cycle.

Airflow

and

Temperature

Rise

The

temperature

rise

is

the

difference

between

the

temperature

of

the

air

in

the

return

duct

and

that

in

the

discharge

duct

near

the

furnace.

This

temperature

rise,

measured

after

equilibrium

has

been

attained

(approximately

five

minutes),

should

be

within

the

range

of

45°F

to

75°F

for

Model

180-479

and

20°F

to

50°F

for

Model

240-479.

An

adjustable

sheave

on

the

blower

motor

pulley

is

used

to

adjust

the

blower

speed

as

follows:

CAUTION:

Turn

off

electric

power

to

unit

before

removing

or

replacing

blower

belt.

Proceed

as

follows.

r

1.

Loosen

the

motor

from

the

base

and

slide

the

motor

toward

the

blower

housing.

Remove

the

belt

from

the

blower.

2.

Loosen

the

set

screw

in

the

movable

flange

of

the

sheave.

Screw

the

movable

flange

toward

the

fixed

flange

to

increase

the

blower

speed,

away

from

the

fixed

flange

to

reduce

the

blower

speed.

Tighten

the

set

screw

on

one

of

the

two

flat

surfaces

on

the

pulley

hub.

Important:

Increasing

the

blower

speed

will

impose

a

greater

load

on

the

blower

motor.

Do

not

exceed

the

rated

current

draw

of

the

motor.

3.

Replace

the

belt

and

adjust

for

proper

tension.

The

belt

should

have

approximately

1”

sag

under

normal

finger

pressure.

4.

Check

motor

pulley

and

blower

pulley

for

proper

alignment.

IX.

COOLING

OPERATION

Perform

the

following

steps

to

check

the

cooling

sec¬

tion

for

proper

operation.

WARNING:

The

main

manual

gas

valve

for

both

chillers

must

be

closed

for

at

least

5

minutes

before

operating

the

cooling

sections.

1.

Be

sure

the

manual

gas

valves

for

both

chillers

are

in

the

OFF

position.

Light

pilots

as

described

on

In¬

struction

Plate.

2.

With

the

thermostat

subbase

switch

levers

on

COOL

and

AUTO,

turn

on

both

manual

gas

valves.

Set

thermostat

at

its

lowest

setting.

Make

certain

both

chillers

are

operating.

To

check

for

correct

operation

of

the

electrical

circuit;

observe

operation

of

gas

valve

and

solution

pump

of

each

chiller,

all

condenser

fan

motors

and

the

blower.

Increase

the

setting

of

the

thermostat

gradually

until

one

chiller

shuts

off.

Set

thermostat

above

room

temperature

and

observe

that

the

other

chiller

shuts

off.

3.

Set

thermostat

subbase

fan

switch

to

ON

and

check

blower

operation.

The

blower

should

run

continually

with

the

thermostat

set

above

or

below

room

tem¬

perature.

4.

To

place

the

system

in

operation,

replace

all

panels

and

set

thermostat

at

the

desired

temperature.

SEQUENCE

OF

OPERATION

(Cooling

Section)

Both

the

180-479

and

240-479

are

equipped

with

two

stage

cooling.

Chiller

No.

1

operates

on

the

initial

call

for

cooling

(single

stage

cooling).

When

additional

cooling

is

required,

Chiller

No.

2

is

also

activated

(two-stage

cooling).

Refer

in

Figures

7

and

8.

When

the

thermostat

system

switch

is

in

the

COOL

position

and

the

fan

switch

is

in

the

AUTO

position,

the

first

stage

cooling

bulb

in

the

thermostat

will

close

the

circuit

between

terminals

Yl

and

R,

and

between

terminals

Yl

and

G

when

the

thermostat

calls

for

cooling.

Closing

the

circuit

between

terminals

Yl

and

G

energizes

the

blower

relay

(2A1)

and

closes

its

nor-

-

8

-

mally

open

contacts.

This

causes

current

to

flow

through

the

contactor

(2M)

winding

and

energizes

the

contactor.

The

energized

contactor

starts

the

blower

motor

(3E).

Closing

the

circuit

between

terminals

Yl

and

R

com¬

pletes

the

control

circuit

for

Chiller

No.

1

and

turns

this

chiller

on

for

single

stage

cooling.

Chiller

No.

2

is

inactive

and

will

not

operate

until

the

temperature

in

the

conditioned

space

rises

and

calls

for

additional

cooling.

If

the

cooling

load

of

the

conditioned

space

is

too

large

for

Chiller

No.

1

to

provide

sufficient

cooling,

the

thermostat’s

second

stage

cooling

bulb

will

close

the

circuit

between

Y2

and

R.

Closing

the

circuit

between

Y2

and

R,

places

the

con¬

trol

relay

(2A2)

across

the

secondary

of

Chiller

No.

1

transformer

(1A1).

The

energized

control

relay

(2A2)

completes

the

control

circuit

of

Chiller

No.

2

and

turns

this

chiller

on

(two

stage

operation).

When

the

thermostat

is

satisfied,

the

thermostat’s

second

bulb

will

break

the

circuit

between

terminals

R

and

Y2.

This

action

de-energizes

the

control

relay

(2A2)

which

opens

the

control

circuit

of

Chiller

No.

2

and

turns

off

Chiller

No.

2.

Chiller

No.

2

will

remain

idle

until

additional

cooling

is

required.

HIGH

TEMPERATURE

CUTOFF

(Model

180-479)

Refer

to

Figure

7.

Each

chiller

of

Model

180-479

is

equipped

with

a

high

temperature

limit

switch

(7H1

on

Chiller

No.

1

and

7H3

on

Chiller

No.

2)

located

on

the

front

of

the

generator,

plus

a

circuit

breaker

(2J1

on

Chiller

No.

1

and

2J2

on

Chiller

No.

2).

The

circuit

breaker

for

each

chiller

is

located

in

the

chiller

con¬

trol

box.

If

the

generator

of

either

chiller

becomes

overheated,

its

associated

limit

switch

(7H1

or

7H3)

will

open,

providing

a

current

path

through

heater

element

of

the

circuit

breaker

(2J1

or

2J2)

of

the

respective

chiller.

The

current

flow

through

the

heater

element

of

the

circuit

breaker

will

cause

its

normally

closed

contacts

to

open

and

break

the

24-volt

circuit

to

the

magnetic

gas

valve

(5B1

or

5B2).

The

de-energized

gas

valve

will

turn

off

the

gas

supply

to

the

burners

of

the

overheated

generator.

The

remaining

normally

operating

chiller

will

continue

to

operate.

The

circuit

breaker

must

be

reset

manually

by

pushing

the

red

reset

button

that

protrudes

through

the

rear

of

the

chiller

control

box.

A

secondary

high

temperature

limit

switch

(7H2

on

Chiller

No.

1

and

7H4

on

Chiller

No.

2)

is

connected

in

series

with

the

gas

valve

(5B1

on

Chiller

No.

1

and

5B2

on

Chiller

No.

2)

to

insure

closing

of

the

gas

valve

in

the

event

of

a

high

temperature

failure

and

the

limit

switch

(7H1

on

Chiller

No.

1

and

7H3

on

Chiller

No.

2)

does

not

open.

The

secondary

limit

switch

is

located

on

the

generator

header

and

must

be

reset

manually.

HIGH

TEMPERATURE

CUTOFF

(Model

240-479)

Refer

to

Figure

8.

Each

chiller

of

the

240-479

is

equipped

with

two

high

temperature

limit

switches

(7H1

&

7H2

on

Chiller

No.

1,

and

7H5

&

7H6

on

Chiller

No.

2).

A

high

temperature

limit

switch

is

located

on

the

front

of

each

generator

of

each

chiller.

If

either

generator

of

Chiller

No.

1

becomes

overheated,

the

associated

high

temperature

limit

switch

(7H1

or

7H2)

will

open,

causing

the

circuit

breaker

(2J1)

to

go

into

lockout

position.

The

open

contacts

of

the

circuit

breaker

de-energizes

the

gas

valve

and

shuts

off

the

gas

supply

to

the

burners

of

both

Chiller

No.

1

generators.

The

circuit

breaker

(2Jl).for

Chiller

No.

1

is

located

in

the

Chiller

No.

1

control

box

and

must

be

reset

manually.

Two

secondary

high

temperature

limit

switches

(7H3

and

7H4-one

on

each

generator

header

of

Chiller

No.

1)

are

connected

in

series

with

the

Chiller

No.

1

gas

valve

(5B1).

If

a

generator

overheats

and

its

associated

high

temperature

limit

switch

(7Hl

or

7H2)

does

not

open,

the

secondary

high

temperature

limit

switch

(7H3

or

7H4)

on

the

header

of

this

generator

will

open

and

break

the

circuit

to

the

gas

valve,

de-energizing

the

gas

valve

and

shutting

off

the

gas

supply

to

the

burners

of

both

Chiller

No.

1

generators.

The

high

temperature

cutoff

circuit

of

Chiller

No.

2

functions

the

same

as

the

high

temperature

cutoff

cir¬

cuit

of

Chiller

No.

1.

The

high

temperature

cutoff

cir¬

cuit

of

Chiller

No.

2

is

comprised

of

high

temperature

limit

switches

7H5

and

7H6,

circuit

breaker

2J2,

secondary

high

temperature

limit

switches

7H7

and

7H8.

If

a

high

temperature

failure

should

occur

and

disable

Chiller

No.

1,

Chiller

No.

2

will

continue

to

operate

and

provide

single

stage

cooling;

likewise,

Chiller

No.

1

will

provide

single

stage

cooling

if

a

high

tem¬

perature

failure

should

disable

Chiller

No.

2.

AMBISTAT

PART

LOAD

CONTROL

(Models

180-479

and

240-479)

Refer

to

Figures

7

and

8.

Each

chiller

is

equipped

with

an

ambistat

part

load

control

(7L1

on

Chiller

No.

1

and

7L2

on

Chiller

No.

2).

The

circuit

consists

of

a

temperature

sensitive

switch

(located

in

the

chiller

control

box)

and

a

capillary

tube.

One

end

of

the

capillary

tube

is

connected

to

the

switch

and

the

other

end

is

inserted

in

the

chilled

water

supply

line.

The

switch

contacts

open

when

the

chilled

water

tem¬

perature

drops

below

40°F.

and

breaks

the

circuit

to

the

gas

valve,

shutting

off

the

gas

supply

to

the

burners.

The

chiller

power

relay

remains

energized

and

the

condenser

fan

motors,

solution

pump

and

water

pump

will

continue

to

run.

-

9

-

The

ambistat

switch

contacts

will

close

again

when

the

chilled

water

supply

temperature

rises

to

42°F.

The

energized

gas

valve

turns

the

gas

on

again.

X.

MAINTENANCE

Cleaning

the'Heating

Unit.

1.

Be

sure

that

the

main

line

disconnect

switch

is

in

the

OFF

position.

TAG

SWITCH

WITH

A

SUITABLE

WARNING

LABEL.

2.

Remove

the

front

access

panel.

3.

Turn

off

the

manual

gas

valve

and

the

pilot

valve.

4.

Disconnect

the

pilot

and

escapement

tubing.

5.

Remove

the

burners.

6.

Remove

the

flue

baffle

retainer

and

the

flue

baf¬

fles.

7.

Clean

the

flue

passages

with

a

suitable

brush.

8.

Reassemble

the

furnace

by

reversing

the

above

procedure,

making

sure

all

seals

are

reinstalled

properly.

9.

Check

belt

conditions

and

proper

tension

of

belt

(approximately

1/2

inch

deflection).

10.

Filters

in

the

180-479

are

of

the

disposable

type

and

should

be

inspected

periodically

and

replaced

when

dirty

with

filters

of

the

same

type

and

size.

Filters

in

the

240-479

are

permanent

type

filters

and

should

be

cleaned

periodically.

Make

sure

the

arrows

on

the

edge

of

the

filter

point

in

the

direction

of

the

airflow.

Lubrication

Some

blower

motors

are

equipped

with

permanent

lubricated

bearings

and

require

no

further

lubrication.

Blower

motors

that

require

lubrication

are

equipped

with

oil

cups.

Oil

motor

bearings

with

SAE

10-20

non¬

detergent

oil

each

heating

and

cooling

season.

NOTE:

BLOWER

BEARINGS

ARE

OF

THE

PER¬

MANENT

LUBRICATED

TYPE

AND

DO

NOT

REQUIRE

ANY

FURTHER

OILING.

Cleaning

the

Condenser

Coil

The

condenser

coil

fin

surfaces

should

be

inspected

from

time

to

time

and

cleaned

as

necessary.

Cleaning

may

be

accomplished

by

washing

the

fins

with

low

pressure

water

from

a

garden

hose.

Detergent

may

be

used,

prior

to

rinsing,

when

oil

or

grease

has

coated

the

fin

surfaces.

Care

must

be

taken

to

be

sure

that

the

soft

aluminum

fins

are

not

bent.

WARNING:

Disconnect

the

electric

power

before

cleaning

the

cooling

coil.

Summer

Chiller

Operation

It

may

be

necessary

to

drain,

flush

and

refill

the

chilled

water

system

of

each

chiller

with

tap

water

if

antifreeze

was

used

for

winter

protection.

A

high

an¬

tifreeze

concentration

will

result

in

a

reduction

of

the

cooling

capacity

of

the

unit.

Be

sure

to

add

one

package

of

Chilled

Water

Additive

P/N

62875D1

to

the

chiller

tank

of

each

chiller

of

Model

180-479

or

the

Model

240-479

when

water

only

is

used

in

the

chilled

water

system

for

summer

operation.

10

-