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Bryant 580G Installation, Start-Up And Service Instructions Manual

Sizes 240-360 single package rooftop electric cooling/gas heating units
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
I. Provide Unit Support . . . . . . . . . . . . . . . . . . . . . .
II. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . .
III. Field Fabricate Ductwork . . . . . . . . . . . . . . . . . . .
IV. Unit Duct Connections . . . . . . . . . . . . . . . . . . . . .
V. Flue Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VI. Trap Condensate Drain . . . . . . . . . . . . . . . . . . . . .
VII. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VIII. Electrical Connections . . . . . . . . . . . . . . . . . . . . .
IX. Outdoor-Air Inlet Assembly . . . . . . . . . . . . . . . .
Damper Hood . . . . . . . . . . . . . . . . . . . . . . . . . . .
XI. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,21
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-28
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
III. Field Test Operation . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V. Gas Valve Adjustment . . . . . . . . . . . . . . . . . . . .
VI. Main Burners . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII. Power Exhaust Operation . . . . . . . . . . . . . . . . . . 28
VIII. Head Pressure Control . . . . . . . . . . . . . . . . . . .
IX. Low Ambient Kit . . . . . . . . . . . . . . . . . . . . . . . . .
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-32
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V. Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . .
VI. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . .
VII. Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IX. Protective Devices . . . . . . . . . . . . . . . . . . . . . . .
X. Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . .
XI. Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . .
XII. Compressor Lockout Logic . . . . . . . . . . . . . . .
XIII. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-41
I. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . .
II. Error Code Summary . . . . . . . . . . . . . . . . . . . . .
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . CL-1, CL-2
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
ELECTRIC COOLING/GAS HEATING UNITS
Page
Cancels: II 580G,H-240-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
1
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
2
Untrained personnel can perform basic maintenance func-
2
tions of cleaning coils and filters and replacing filters. All other
7
operations should be performed by trained service personnel.
7
When working on air-conditioning equipment, observe pre-
8
cautions in the literature, tags and labels attached to the unit,
8
and other safety precautions that may apply.
8
9
Follow all safety codes. Wear safety glasses and work gloves.
14
Use quenching cloth for unbrazing operations. Have fire
extinguishers available for all brazing operations.
18
19
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch
to unit. Electrical shock could cause personal injury.
21
WARNING:
1. Improper installation, adjustment, alteration, serv-
22
ice, or maintenance can cause property damage, per-
24
sonal injury, or loss of life. Refer to the User's
Information Manual provided with this unit for more
24
details.
25
2. Do not store or use gasoline or other flammable
28
vapors and liquids in the vicinity of this or any other
appliance.
28
28
What to do if you smell gas:
28
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any phone in
29
your building.
29
3. IMMEDIATELY call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
31
4. If you cannot reach your gas supplier, call the fire
31
department.
31
31
32
WARNING: Disconnect gas piping from unit when
32
pressure testing at pressure greater than 0.5 psig. Pres-
32
sures greater than 0.5 psig will cause gas valve dam-
32
age resulting in hazardous condition. If gas valve is
32
subjected to pressure greater than 0.5 psig, it must be
32
replaced before use. When pressure testing field-
32
supplied gas piping at pressures of 0.5 psig or less, a
unit connected to such piping must be isolated by clos-
33
ing the manual gas valve(s).
34
34
580G,H
Sizes 240-360
II 580G,H-240-2
11/1/97

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Summary of Contents for Bryant 580G

  • Page 1: Table Of Contents

    installation, start-up and 580G,H service instructions Sizes 240-360 SINGLE PACKAGE ROOFTOP ELECTRIC COOLING/GAS HEATING UNITS Cancels: II 580G,H-240-1 II 580G,H-240-2 11/1/97 CONTENTS SAFETY CONSIDERATIONS Page Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical compo- SAFETY CONSIDERATIONS .

  • Page 2: Installation

    NOTE: On retrofit jobs, ductwork may be attached to old unit INSTALLATION instead of roof curb. Be careful not to damage ductwork when I. PROVIDE UNIT SUPPORT removing old unit. CAUTION: All panels must be in place when rig- B. Alternate Unit Support ging.
  • Page 3 NOTES: 1. Weights include economizer (STD). Center of gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min. clearances to be: Adjacent Units: 15 -0 Top of Units: No Overhang Condenser Coil: 4 -0 Economizer Side: 6 -0 Heat Side: 4 -0 Filter Access Side: 10 -0 (For Removal of Evapo- rator Coil)
  • Page 4 NOTES: 1. Weights include economizer (STD). Center of gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min. clearances to be: Adjacent Units: 15 -0 Top of Units: No Overhang Condenser Coil: 4 -0 Economizer Side: 6 -0 Heat Side: 4 -0 Filter Access Side: 10 -0 (For Removal of Evapora- tor Coil)
  • Page 5 CAUTION: NOTICE TO RIGGERS: ALL PANELS MUST BE IN PLACE WHEN RIGGING. NOTE: Rig with four cables and spread with two 92 in. (2337 mm) spreader bars. Maintain a distance of 74 in. (1880 mm) from top of unit to eyehook. NOTE: Add 32 lb (14.5 kg) for domestic crating.
  • Page 6 Table 1 — Specifications UNIT 580G,H NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Al/Al* (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu* (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in. curb) COMPRESSOR Type Ckt 1 06D328 06D328 06D537 06D537 Ckt 2 06D818...

  • Page 7: Field Fabricate Ductwork

    Table 2 — Evaporator Fan Motor Data MOTOR MOTOR BELT UNIT SHEAVE BUSHING SHEAVE BUSHING OUTSIDE MOTOR SHAFT SHAFT MOTOR BELT TENSION SIZE PITCH DIAMETER PITCH DIAMETER BELT DIA. SPEED SHEAVE SHEAVE (QUANTITY) (lb at 580G,H DIAMETER (in.) DIAMETER (in.) LENGTH (in.) (rpm)

  • Page 8: Flue Hood

    V. FLUE HOOD Flue hood is shipped inside gas section of unit. To install, se- cure flue hood to access panel. See Fig. 7. NOTE: When properly installed, flue hood will line up with combustion fan housing. See Fig. 8. Fig.

  • Page 9: Electrical Connections

    VIII. ELECTRICAL CONNECTIONS local codes requirements, of adequate size (Table 3). When- ever external electrical sources are used, unit must be elec- A. Controls Options trically grounded in accordance with local codes, or in absence The standard constant volume (CV) units, as shipped, are of local codes, with NEC, ANSI C1-latest year.
  • Page 10 LEGEND COM — Common — Relay — Diode SIO — Serial Input/Output — Light-Emitting Diode SW — Switch N.C. — Normally Closed — Terminal N.O. — Normally Open *Where X is the unit control software version number (1 or 2). Fig.
  • Page 11 3. Cap orange wire. JUMPER CONNECTION 4. Splice red wire and black unit power wire. Cap wires. FOR VOLTAGE OUTPUT IMPORTANT: Be certain unused wires are capped. Failure to do so may damage the transformers. D. Field Control Wiring Install an approved accessory thermostat. Control box dia- gram is shown in Fig.
  • Page 12 Table 3— Electrical Data — 580G,H240-360 COMPRESSOR VOLTAGE POWER COMBUSTION POWER SUPPLY UNIT NOMINAL RANGE EXHAUST FAN MOTOR No. 1 No. 2 SIZE VOLTAGE Qty Hp FLA 580G,H (3 Ph 60 Hz) Min Max RLA LRA RLA LRA (ea) Hp FLA FLA LRA MOCP* 5 16.7/...
  • Page 13 Table 3— Electrical Data — 580G,H240-360 (cont) COMPRESSOR VOLTAGE POWER COMBUSTION POWER SUPPLY UNIT NOMINAL RANGE EXHAUST FAN MOTOR No. 1 No. 2 SIZE VOLTAGE Min Max RLA LRA RLA LRA Qty Hp FLA 580G,H (3 Ph 60 Hz) (ea) Hp FLA FLA LRA MOCP* 10 30.8/ —...

  • Page 14: Outdoor-Air Inlet Assembly

    FLANGE BLACK HOOD SIDE SEAL STRIP Fig. 16 — Adding Seal Strip to Top of Hood Sides Fig. 15 — Field Control Thermostat Wiring IX. OUTDOOR-AIR INLET ASSEMBLY A. Economizer NOTE: If accessory power exhaust or barometric relief pack- ages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods.
  • Page 15 HOOD SIDE (SLOTTED) MOUNTING HOOD FLANGE HOOD SIDE Fig. 21 — Adding Foam Strip to Hood Side Fig. 18 — Adding Seal Strip to Mounting Flange of Hood Sides HOOD TOP HOOD SIDE BLOCKOFF BAFFLE GRAY FOAM STRIP Fig. 19 — Add Seal Strip to Hood Top Mounting Flange GRAY FOAM STRIP Fig.
  • Page 16 4. Remove screws along bottom of damper assembly. Lo- MOUNTING ANGLE cate and mount blockoff baffle using these screws. (WITHOUT TABS) 5. Assemble 2 filter tracks side-by-side with the as- sembled ends together. FILTER TRACK 6. a. Attach mounting angle (without tabs) to the as- ASSEMBLY sembled end of the filter track.
  • Page 17 HH57AC077 ENTHALPY CONTROL NOTE: Switches shown in high enthalpy state. Termi- nals 2 and 3 close on enthalpy decrease. Fig. 27 — Wire Connections for Solid-State Enthalpy Control (HH57AC077) HH57AC078 C 7 4 0 0 A 1 0 0 4 CONTROL POINT ENTHALPY SENSOR (USED WITH CONTROL...

  • Page 18: Power Exhaust/Barometric Relief Damper Hood

    8. Use field-supplied wire ties to attach the violet wire to X. POWER EXHAUST/BAROMETRIC RELIEF DAMPER HOOD the + terminal and the blue wire to the SR terminal. All electrical connections have been made and adjusted at the 9. Replace economizer filters. factory.

  • Page 19: Accessories

    NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. Fig. 30 — Barometric Relief Damper and Power Exhaust Mounting Details XI. ACCESSORIES BOTH SIDES After all the factory-installed options have been adjusted, in- stall all field-installed accessories.

  • Page 20: Pre-Start-Up

    3. Make the following inspections: a. Inspect for shipping and handling damages such as broken lines, loose parts, disconnected wires, etc. b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, halide torch, or liquid-soap solution.

  • Page 21: Pre-Start-Up

    Table 4 — DIP Switch Configuration SETTING Time Guard Override ON Expansion Field Modulated Heat Pump IN CONJUNCTION OPEN — — Board Test Power Gas Heat Operation WITH FIELD TEST — Operation Exhaust Set Minimum Damper Position Field Thermostat Base Control Time Guard Air Conditioner CLOSED...

  • Page 22: Heating Section Start-Up And Adjustments

    compressor 2 will turn on. If Y2 is deenergized at any time, 4. The evaporator fan and heaters will cycle off with no only the last stage of compression that was energized will be delay after thermostat temperature is satisfied. turned off.
  • Page 23 controls up to 2 stages of power exhaust to maintain building Once installed, the sensor must be enabled. The sensor is con- pressure. The power exhaust package can be configured to figured with default values which may be changed through deliver positive or negative building pressure.

  • Page 24: Field Test Operation

    It is specifically designed for use on Tables 8 and 9 for Fan Performance data. See Table 10 for Bryant equipment and controls the condenser-fan motor speed Motor Limitation data. See Table 11 for air quantity limits.

  • Page 25: Gas Valve Adjustment

    To adjust regulator: 1. Set thermostat at setting for no call for heat. 2. Turn field-supplied main gas valve to OFF position. 3. Remove ⁄ -in. pipe plug from manifold. Install a water manometer pressure-measuring device. 4. Set main gas valve to ON position. 5.
  • Page 26 Table 8 — Fan Performance, 580G240-360 — Vertical Discharge Units For 580H units, reduce net available external static pressure by 0.3 in. wg. AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) AIRFLOW (Cfm) 4,000 0.83 1.17 1.52 1.90 2.29 2.69 3.11 3.53 5,000 1.25 1.61...
  • Page 27 Table 9 — Fan Performance — Power Exhaust 580G,H240-360 Low Speed Medium Speed High Speed Airflow 208 v 230, 460, 575 v 208 v 230, 460, 575 v 208 v 230, 460, 575 v (Cfm) Watts Watts Watts Watts Watts Watts 6,500 0.32...

  • Page 28: Main Burners

    VI. MAIN BURNERS IX. LOW AMBIENT KIT For all applications, main burners are factory set and should Low Ambient Kit is a fan speed control device actuated by require no adjustment. a temperature sensor. The field-installed accessory is specifi- cally designed for use on this equipment and controls the A.

  • Page 29: Service

    SERVICE NOTE: The unit requires industrial grade throwaway filters capable of withstanding face velocities up to 625 fpm. WARNING: Before beginning any maintenance, be To replace filters, open filter access door (marked with label). sure to turn off power at the main disconnect switch. Remove inner access panel.
  • Page 30 Fig. 40 — Spark Gap Adjustment NOTES: 1. Torque setscrews on blower wheel to 70 in. lbs ± 2 in. lbs. 2. Torque setscrew on propeller fan to 15 in. lbs ± 2 in. lbs. 3. Dimensions are in inches. Fig.

  • Page 31: Evaporator Fan Service And Replacement

    B. Fan Shaft Bearings Unit panels must be in place when unit is operating during charging procedure. Lubricate the bearings at least twice annually with suitable bearing grease. Do not over grease. Typical lubricants are shown A. No Charge below: Use standard evacuating techniques.

  • Page 32: Filter Drier

    VII. FILTER DRIER D. High- and Low-Pressure Switches Replace whenever refrigerant system is exposed to If either switch trips, or if the compressor overtemperature atmosphere. switch activates, that refrigerant circuit will be automa- tically locked out. To reset, manually move the thermostat VIII.

  • Page 33: Troubleshooting

    TROUBLESHOOTING Typical refrigerant circuiting diagram is shown in Fig. 44. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 44 — Typical Refrigerant Circuiting I. DIAGNOSTIC LEDs (Light-Emitting Diodes) operation. A series of quick blinks indicates an alarm. Refer to Table 12 for a description of alarms.

  • Page 34: Error Code Summary

    Table 12 — Control Board LED Alarms ERROR TROUBLESHOOTING DESCRIPTION BLINKS CODE COMMENTS Normal Operation The control board flashes the red LED in one-second intervals when the board is operating properly. Make sure DIP switch 3 is closed. HF-13 Compressor 1 Safety The high or low pressure safety switch for compressor no.
  • Page 35 Table 14 — I/O Channel Designations Base Module TERMINAL ASSIGNMENT T1-2 — T3-4 — T5-6 OAT — 5K Thermistor T7-8 SAT — 5K Thermistor T9-10 — T11-12 — T13-14 — T15-16 — T17-25 Y1 — DI (24 vac) T18-25 Y2 — DI (24 vac) T19-25 W1 —...
  • Page 36 LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Controller NOTE: Thermostat Fan Switch in the ‘‘AUTO’’ position. Fig. 45 — IGC Control (Heating and Cooling) —36—...
  • Page 37 LEGEND FOR FIG. 46-50 — Adjustable Heat Anticipator — Ignitor — Rollout Switch — Building Pressure — Induced-Draft Motor — Supply-Air Thermistor — Burner Relay — Indoor Fan Contactor — Switch — Contactor, Compressor IFCB — Indoor Fan Circuit Breaker —...
  • Page 38 NOTES: TABLE A 1. Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v. If The Following Compressors Have Two 208/230 v units are run with a 208 v power supply connect to H2. Parallel Wires Run From TB1 to the 2.
  • Page 39 NOTES: 1. Connect TRAN1 to H4 for 575V units. 2. Connect TRAN2 to black lead for 575V units. 3. Circuit breaker must trip amps are equal to or less than 156% FLA for CB1 and CB2. All others are 140%. 4.
  • Page 40 NOTE: Red wire and violet wire are spliced together at the factory. The brown wire has a wire nut added at the factory. Fig. 49 — 24 V Control Schematic; 580G,H240-360...
  • Page 41 Fig. 50 — Component Arrangement; 580G,H240-360 —41—...
  • Page 42 PACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover: • Maintenance • Unit Familiarization • Operating Sequence • Installation Overview A large selection of product, theory, and skills programs is available. All programs include a video cassette and/or slides and a companion booklet.

  • Page 43: Start-Up Checklist

    START-UP CHECKLIST SERIAL NO.: MODEL NO.: SOFTWARE VERSION (SEE FIG. 11) TECHNICIAN: DATE: PRE-START-UP: VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS...
  • Page 44 GENERAL SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS ENSURE DRIVES OPERATE WITHIN LIMITS OF FAN PERFORMANCE TABLES. HIGH-PRESSURE SWITCH SETTING PSIG LOW-PRESSURE SWITCH SETTING PSIG MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE FILTER QUANTITY FILTER SIZES ADDITIONAL NOTES: Copyright 1997 Carrier Corporation...

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