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I

Installation Instructions

IMPORTANT: 

Effective January 1, 2015, all split system and packaged

air  conditioners  must  be  installed  pursuant  to  applicable  regional

efficiency standards issued by the Department of Energy.

NOTE: 

  Read  the  entire  instruction  manual  before  starting  the

installation.

NOTE: 

  Installer:  Make  sure  the  Owner’s  Manual  and  Service

Instructions are left with the unit after installation.

Table of Contents

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Receiving and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Pre-Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

A170030

Fig. 1 – Unit 577C

(Low NOx Model Available)

Safety Considerations

Improper installation, adjustment, alteration, service maintenance, or use

can  cause  explosion,  fire,  electrical  shock,  or  other  conditions  which

may  cause  death,  personal  injury,  or  property  damage.  Consult  a

qualified  installer,  service  agency,  or  your  distributor  or  branch  for

information  or  assistance.  The  qualified  installer  or  agency  must  use

factory-authorized  kits  or  accessories  when  modifying  this  product.

Refer to the individual instructions packaged with the kits or accessories

when installing.
Follow  all  safety  codes. Wear  safety  glasses,  protective  clothing,  and

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

thoroughly and follow all warnings or cautions included in literature and

attached to the unit. consult local building codes, the current editions of

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

National Electrical Code (NEC) NFPA 70.
In  Canada  refer  to  the  current  editions  of  the  National  Standards  of

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

codes, and Canadian Electrical Code CSA C22.1

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

you see this symbol on the unit and in instructions or manuals, be alert to 

the potential for personal injury. Understand these signal words: DAN

-

GER, WARNING, and CAUTION. These words are used with the safe

-

ty-alert symbol. DANGER identifies the most serious hazards which will 

result in severe personal injury or death. WARNING signifies hazards 

which could result in personal injury or death. CAUTION is used to iden

-

tify unsafe practices which may result in minor personal injury or product 

and property damage. NOTE is used to highlight suggestions which will 

result in enhanced installation, reliability, or operation.

Introduction

This unit (see 

Fig. 1

) is a fully self-contained, combination Category I

gas heating/electric cooling unit designed for outdoor installation (See

Fig. 3

  and 

Fig. 4

  for  unit  dimensions). All  unit  sizes  have  return  and

discharge  openings  for  both  horizontal  and  downflow  configurations,

and are factory shipped with all downflow duct openings covered. Units

may be installed either on a rooftop or on a cement slab. (See 

Fig. 5

 for

roof curb dimensions).
In  gas  heating  mode, this unit is  designed  for  a  minimum continuous

return-air  temperature  of  55°F  (13°C)  db  and  a  maximum  continuous

return-air  temperature  of  80°F  (27°C)  db.  Failure  to  follow  these

return-air temperature  limits may affect reliability of heat exchangers,

motors, and other components.

577C--C, 577C--E, 577C--F

Legacy™14 SEER Single-Packaged Air

Conditioner and Gas Furnace System with Puron®

(R-410A) Refrigerant

Single Phase 2-5 Nominal Tons (Sizes 24-60)

Three Phase 3-5 Nominal Tons (Sizes 36-60)

WARNING

!

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing  or servicing  system, always turn off main  power to

system and install lockout tag. There may be more than one disconnect

switch. Turn off accessory heater power switch if applicable.

WARNING

!

FIRE, EXPLOSION, ELECTRICAL SHOCK AND 

CARBON MONOXIDE POISONING HAZARD

Failure to  follow this  warning could  result  in personal  injury  or unit

damage.

A qualified installer or agency must use only factory-authorized kits or

accessories when modifying this product.

Summary of Contents for LEGACY 577C-C

Page 1: ...ential for personal injury Understand these signal words DAN GER WARNING and CAUTION These words are used with the safe ty alert symbol DANGER identifies the most serious hazards which will result in...

Page 2: ...s to the curb are required when using this kit 2 An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKIT001A00...

Page 3: ...on Prior to initial use and at monthly intervals all rigging shackles clevis pins and straps should be visually inspected for any damage evidence of wear structural deformation or cracks Particular at...

Page 4: ...7C C 577C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 4 A200008 Fig 3 577C 24 36 Dimensio...

Page 5: ...7C C 577C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 5 A190120 Fig 4 577C 42 60 Dimensio...

Page 6: ...ss 1 lb density Fig 5 Roof Curb Dimensions UNIT SIZE CATALOG NUMBER A IN mm B small common base IN mm B large base IN mm Part Number CPRCURB011B00 can be used on both small and large basepan units The...

Page 7: ...61 164 390 177 Rigging Weight 455 206 480 218 497 225 ACCESS PANELS MUST BE IN PLACE WHEN RIGGING PANNEAUX D ACCES DOIT TRE EN PLACE POUR MANIPULATION 50CY502286 2 0 CAUTION NOTICE TO RIGGERS PRUDENCE...

Page 8: ...17 4 7 3 17 4 7 INDOOR BLOWER Nominal Cooling Airflow CFM Size in Size mm Motor HP RPM 800 10x10 254x254 1 2 1050 800 10x10 254x254 1 2 1050 1000 10x10 254x254 1 2 1050 1000 10x10 254x254 1 2 1050 115...

Page 9: ...installations Table 1 Physical Data Continued UNIT SIZE 48090 48115 48130 60090 60115 60130 NOMINAL CAPACITY ton 4 4 4 5 5 5 SHIPPING WEIGHT lb SHIPPING WEIGHT kg 480 218 480 218 480 218 497 225 497 2...

Page 10: ...ll pipe 1 4 in 6 35 mm for every 15 ft 4 6 m of length to prevent traps Grade all horizontal runs downward to risers Use risers to connect to heating section and to meter 2 Protect all segments of pip...

Page 11: ...lation by removing duct covers 2 Select and size ductwork supply air registers and return air grilles according to American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE recom...

Page 12: ...ion Control Voltage Connections Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the...

Page 13: ...or shipping and handling damage such as broken lines loose parts disconnected wires etc b Inspect all field and factory wiring connections Be sure that connections are completed and tight c Ensure wir...

Page 14: ...inside of the control access panel to start the heating section NOTE Make sure that gas supply has been purged and that all gas piping has been checked for leaks A07679 Fig 11 Burner Assembly C99021...

Page 15: ...meter test dial to make one revolution 4 Divide number of seconds in Step 3 into 3600 number of seconds in one hr 5 Multiply result of Step 4 by the number of cubic feet cu ft shown for one revolutio...

Page 16: ...Installations from 2000 to 4500 ft 610 1372 m use U S A column 2001 to 3000 ft 611 to 914 m 0 to 2000 ft 0 610 m 2001 to 3000 ft 611 to 914 m 3001 to 4000 ft 915 to 1219 m 4001 to 5000 ft 1220 to 1524...

Page 17: ...F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 17 A150502 Fig 14 208 230 1 60 24 36 60 Size Connect...

Page 18: ...C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 18 A150510 Fig 15 208 230 1 60 24 36 60 Size Ladde...

Page 19: ...7C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 19 A200011 Fig 16 208 230 1 60 30 Size Connection...

Page 20: ...577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 20 A200012 Fig 17 208 230 1 60 30 Size Ladder W...

Page 21: ...E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 21 A150508 Fig 18 208 230 3 60 Connection Wir...

Page 22: ...C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 22 A150511 Fig 19 208 230 3 60 Ladder Wirin...

Page 23: ...C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 23 A150509 Fig 20 460 3 60 Connection Wirin...

Page 24: ...77C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 24 A150512 Fig 21 460 3 60 Ladder Wiring...

Page 25: ...rners The blower motor continues to run until LS resets When the air temperature at the limit switch drops to the low temperature setting of the limit switch the switch closes and completes the contro...

Page 26: ...rom obstructions and adjusted properly This unit has independent fan speeds for gas heating and cooling modes Single phase models also have a dedicated continuous fan speed All models 1 phase and 3 ph...

Page 27: ...use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection In either case the dehumidification control must open the control circuit on humidity ri...

Page 28: ...lower motor stops The unit is in a standby condition waiting for the next call for cooling from the room thermostat A14399 Fig 22 Single Phase IGC Board A09058 Fig 23 Interface Fan Board IFB DH DH DH...

Page 29: ...d 80 F 27 C dry bulb 67 F 19 C wet bulb indoor condition Where a dash appears do not attempt to check charge or charge unit under these conditions using the superheat method Weigh in method should be...

Page 30: ...Alternate Heating CFM 840 759 677 600 505 411 293 x x x BHP 0 14 0 15 0 16 0 16 0 17 0 17 0 18 x x x Gas Heat Rise F 53 NA NA NA NA NA NA NA NA NA Gas Heat Rise C 30 NA NA NA NA NA NA NA NA NA Medium...

Page 31: ...M 1223 1186 1151 1115 1075 1039 1001 957 914 870 BHP 0 34 0 34 0 35 0 36 0 37 0 37 0 38 0 39 0 40 0 41 Gas Heat Rise F 37 38 39 40 42 43 45 47 49 52 Gas Heat Rise o C 20 21 22 22 23 24 25 26 27 29 Med...

Page 32: ...d Cooling Alternate Heating CFM 1403 1358 1316 1265 1217 1167 1116 1067 1012 956 BHP 0 29 0 30 0 31 0 33 0 34 0 35 0 36 0 37 0 38 0 39 Gas Heat Rise F 48 50 51 53 56 58 61 63 NA NA Gas Heat Rise C 27...

Page 33: ...Cooling Alternate Heating CFM 1658 1622 1585 1549 1512 1476 1442 1402 1360 1322 BHP 0 39 0 40 0 41 0 42 0 44 0 45 0 46 0 47 0 48 0 49 Gas Heat Rise F 58 59 61 62 63 65 NA NA NA NA Gas Heat Rise C 32 3...

Page 34: ...A NA NA NA NA NA NA NA NA Med Low Pink CFM 1403 1361 1320 1276 1236 1192 1145 1099 1054 1012 BHP 0 28 0 29 0 30 0 31 0 31 0 33 0 34 0 35 0 36 0 37 Rise F NA NA NA NA NA NA NA NA NA NA Rise C NA NA NA...

Page 35: ...e oF NA NA NA NA NA NA NA NA NA Heating Rise oC NA NA NA NA NA NA NA NA NA Med Low Pink CFM 1136 1080 1015 957 912 861 808 723 633 Heating Rise oF 58 61 65 NA NA NA NA NA NA Heating Rise oC 32 34 36 N...

Page 36: ...34 Medium Red CFM 1736 1695 1642 1601 1553 1512 1465 1427 1381 Heating Rise o F 39 39 41 42 43 44 46 47 48 Heating Rise o C 21 22 23 23 24 25 25 26 27 Med High Orange CFM 2149 2111 2062 2026 1980 194...

Page 37: ...25 25 26 26 28 Medium Red CFM 1962 1915 1880 1843 1794 1753 1711 1675 1628 Heating Rise o F NA 35 36 36 37 38 39 40 41 Heating Rise o C NA 19 20 20 21 21 22 22 23 Med High Orange CFM 2131 2088 2065 2...

Page 38: ...1888 1860 1785 Heating Rise oF 45 46 46 47 48 49 50 51 53 Heating Rise oC 25 25 26 26 27 27 28 28 30 High Black CFM 2461 2409 2339 2286 2192 2140 2062 1968 1874 Heating Rise o F 39 40 41 42 43 44 46...

Page 39: ...16 17 18 19 20 20 22 23 25 27 High Black CFM 1560 1491 1416 1337 1255 1233 1160 1082 998 911 WATTS 708 699 683 674 660 634 624 606 581 566 BHP 0 76 0 75 0 73 0 72 0 71 0 68 0 67 0 65 0 62 0 61 Heatin...

Page 40: ...o F 29 31 33 35 34 36 38 40 42 45 Heating Rise o C 16 17 18 19 19 20 21 22 24 25 42090 35 65oF 19 36oC Low Blue CFM 952 882 806 746 671 605 530 551 486 435 WATTS 124 134 140 150 156 166 171 182 188 1...

Page 41: ...o F NA NA NA NA NA NA NA NA NA NA Heating Rise o C NA NA NA NA NA NA NA NA NA NA 48115 30 60oF 17 33oC Low Blue CFM 1503 1457 1423 1374 1330 1287 1241 1199 1153 1111 WATTS 225 233 246 254 269 282 292...

Page 42: ...o F 38 38 39 40 41 42 44 45 47 49 Heating Rise o C 21 21 22 22 23 23 24 25 26 27 60090 35 65oF 19 36oC Low Blue CFM 1479 1436 1387 1346 1298 1253 1206 1160 1114 1061 WATTS 224 239 247 262 270 284 300...

Page 43: ...BHP 0 24 0 26 0 26 0 28 0 29 0 30 0 32 0 33 0 34 0 35 Heating Rise oF 64 NA NA NA NA NA NA NA NA NA Heating Rise o C 36 NA NA NA NA NA NA NA NA NA Med Low Pink CFM 1841 1796 1761 1724 1690 1651 1616...

Page 44: ...SCFM 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 600 1400 CFM 12x20x1 12x20x1 305x508x25 305x508x25 2 0 2 5 3 0 0 09 0 14 0 16 0 18 0 25 0 28 0 30 1200 1800 CFM 1...

Page 45: ...ower wheel and motor in relation to blower housing before disassembly e Loosen setscrew s that secures wheel to motor shaft remove screws that secure motor mount brackets to housing and slide motor an...

Page 46: ...acket forward bottom first to remove See Fig 24 6 Remove wires connected to gas valve Mark each wire 7 Remove the mounting screw that attaches the burner rack to the unit base See Fig 24 8 Partially s...

Page 47: ...o the unit Remove access panels see Fig 25 to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connecti...

Page 48: ...f charge low airflow across indoor coil dirty filters etc It opens at 50 psig If system pressure is above this switch should be closed To check switch 1 Turn off all power to unit 2 Disconnect leads o...

Page 49: ...sure switch metering device coil accumulator or reversing valve Synthetic Roof Precautionary Procedure 1 Cover extended roof working area with an impermeable polyethylene plastic drip cloth or tarp Co...

Page 50: ...harge or undercharge Recover refrigerant evacuate system and recharge to capacities shown on rating plate Defective compressor Replace and determine cause Insufficient line voltage Determine cause and...

Page 51: ...r air Purge as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate before attempting to light unit 2 Check gas valve Inadequate heating Dirty air filter Clean...

Page 52: ...ame sense fault LED 3 flashes The IGC sensed flame that should not be present Reset unit If problem persists replace control board 4 consecutive limit switch faults LED 4 flashes Inadequate airflow to...

Page 53: ...Y THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS III START UP ELECTRICAL SUPPLY VOLTAGE_______________________________________ COM...

Page 54: ...eet Indianapolis IN 46231 Catalog No II577C 17 Edition Date 01 20 Replaces II577C 16 577C C 577C E 577C F Installation Instructions Manufacturer reserves the right to change at any time specifications...

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