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Bryant 581A Installation And Service Instructions Manual

Single package rooftop electric cooling/gas heating units
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See also: User's Information Manual , User Manual
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
I. Step 1 - Provide Unit Support . . . . . . . . . . . . . . 1
II. Step 2 - Rig and Place Unit . . . . . . . . . . . . . . . . 3
Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VI. Step 6 - Trap Condensate Drain . . . . . . . . . . . . 8
VII. Step 7 - Install Gas Piping . . . . . . . . . . . . . . . . . 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
XI. Step 11 - Install All Accessories . . . . . . . . . . . 13
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-34
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 35-37
START-UP CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters.
All other operations should be performed by trained service
personnel. When working on air-conditioning equipment,
observe precautions in the literature, tags and labels
attached to the unit, and other safety precautions that may
apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguishers available for all brazing operations.
WARNING: Before performing service or mainte-
nance operations on unit, turn off mail power switch to
unit. electrical shock could cause personal injury.
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
ELECTRIC COOLING/GAS HEATING UNITS
Cancels: II 581A-155-2
Page
WARNING:
1. Improper installation, adjustment, alteration,
service, or maintenance can cause property
damage, personal injury, or loss of life. Refer to
the User's Information Manual provided with
this unit for more details.
2. Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
4. If you cannot reach your gas supplier, call the
fire department.
WARNING: Disconnect gas piping from unit when
pressure testing at pressure greater than 0.5 psig.
Pressures greater than 0.5 psig will cause gas valve
damage resulting in hazardous condition. If gas valve
is subjected to pressure greater than 0.5 psig, it must
be replaced before use. When pressure testing field-
supplied gas piping at pressures of 0.5 psig or less, a
unit connected to such piping must be isolated by clos-
ing the manual gas valve(s).
IMPORTANT: Units have high ambient operating limits. If
limits are exceeded, the units will automatically lock the
compressor out of operation. Manual reset will be required to
restart the compressor.
I. STEP 1 - PROVIDE UNIT SUPPORT
A. Roof Curb
Assemble or install accessory roof curb or horizontal supply
roof curb in accordance with instructions shipped with this
accessory. See Fig. 1 and 2. Install insulation, cant strips,
roofing, and counter flashing as shown. Ductwork can be
installed to roof curb or horizontal supply roof curb before
unit is set in place.
581A
Sizes 155-240
II 581A-155-3
6/15/99
INSTALLATION
(Instructions continued on page 3.)

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  • Page 1: Table Of Contents

    installation, start-up and 581A service instructions Sizes 155-240 SINGLE PACKAGE ROOFTOP ELECTRIC COOLING/GAS HEATING UNITS Cancels: II 581A-155-2 II 581A-155-3 6/15/99 CONTENTS Page WARNING: SAFETY CONSIDERATIONS ..... . 1 1.

  • Page 2: Installation

    NOTES: CURB 1. Roof curb accessory is shipped disassembled. PKG. NO. REF. HEIGHT DESCRIPTION 2. Insulated panels: 1 in. thick neoprene coated 1 lb density. ft-in. (mm) 3. Dimensions in ( ) are in millimeters. Standard Curb CRRFCURB010A00 (305) 14” High Direction of airflow.

  • Page 3: Step 2 - Rig And Place Unit

    B. Alternate Unit Support When a curb or adapter cannot be used, install unit on a noncombustible surface. Support unit with sleepers, using unit curb support area. If sleepers cannot be used, support long sides of unit with a minimum of 3 equally spaced 4-in. x 4-in.
  • Page 4 ECONO- STD UNIT CORNER CORNER CORNER CORNER MIZER DIM A DIM B DIM C UNIT WEIGHT WEIGHT 581A ft-in. ft-in. ft-in. 1725 1051 1-10 1800 1070 1-10 NOTES: 1. Refer to print for roof curb accessory dimensions. 2. Dimensions in ( ) are in millimeters. Center of Gravity.
  • Page 5 ECONOMIZER UNIT STD. UNIT WEIGHT WEIGHT 581A240 1900 lbs (862 kg) 110 lbs (50 kg) NOTES: 1. Refer to print for roof curb accessory dimensions. 2. Dimensions in ( ) are in millimeters. Center of Gravity. Direction of airflow. 5. Ductwork to be attached to accessory roof curb only. 6.
  • Page 6 Table 1 — Physical Data UNIT 581A NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Al/Al* 1725 1800 1900 Al/Cu* 1875 1950 2050 Cu/Cu* 2005 2080 2180 Economizer Roof Curb† COMPRESSOR Quantity Number of Refrigerant Circuits Crankcase Heater Watts Oil (oz) (Ckt 1, Ckt 2) 60,66 85,60 110,110...

  • Page 7: Step 3 - Field Fabricate Ductwork

    III. STEP 3 — FIELD FABRICATE DUCTWORK ductwork may be connected as shown in Fig. 7 and 8. Attach all ductwork to roof curb and roof curb basepans. Refer to On vertical units, secure all ducts to roof curb and building installation instructions shipped with accessory roof curb for structure.

  • Page 8: Step 6 - Trap Condensate Drain

    All field wiring must comply with NEC and local require- INDUCED DRAFT ments. Insulate low-voltage wires for highest voltage con- MOTOR tained within conduit when low-voltage control wires are run in the same conduit as high-voltage wires. INDOOR MOTOR ACCESS COMBUSTION MAIN BURNER HEAT EXCHANGER...

  • Page 9: Step 9 - Make Outdoor-Air Inlet Adjustments

    An incorrect phasing will cause the compressor to rotate in the Install a Bryant approved accessory thermostat assembly wrong direction. This may lead to premature compres- according to the installation instructions included with the sor failure.
  • Page 10 Table 2 — Electrical Data NOMINAL COMPRESSOR VOLTAGE POWER COMBUSTION POWER UNIT VOLTAGE RANGE EXHAUST FAN MOTOR SUPPLY No. 1 No. 2 581A (3 Ph, 60 FLA (ea) MOCP* 8.8/ — — 0.57 59/59 70/70 208/230 20.7 19.3 18.8 0.57 64/63 80/80 (Standard...

  • Page 11: Step 10 - Install Outdoor-Air Hood

    Fig. 16 — 25% Outdoor-Air Section Details Fig. 19 — Economizer Motor Control Module Location Damper Vent Position Setting 1. Set fan switch at ON position (continuous fan opera- tion) and close night switch if used. 2. Set system selector switch at OFF position. 3.
  • Page 12 3. Secure lower filter retainer and long section of filter 8. Insert outdoor-air inlet screens and spacer in channel support bracket to unit. See Fig. 22. Leave screws created by lower filter retainer and filter support loose on 180 and 240 units. bracket.

  • Page 13: Step 11 - Install All Accessories

    11. Reinstall economizer hood if removed. CONTROL CONTROL POINT IMPORTANT: Be sure all seal strips and RTV sealant are CURVE (Approx Deg) intact. A watertight seal to inside of unit must be AT 50% RH maintained. XI. STEP 11 — INSTALL ALL ACCESSORIES After all the factory-installed options have been adjusted, install all field-installed accessories.

  • Page 14: Start-Up

    Sensor Assembly — Install the sensor assembly in the loca- Replace Outdoor Motor tion shown in Fig. 26. Replace outdoor-fan motor no. 1 with motor included in Motor Mount — To ensure proper fan height, replace the accessory kit. Existing motor is not Motormaster III existing motor mount with the new motor mount provided compatible.
  • Page 15 2700. Do not adjust motor rpm such that 6. Use of a field-supplied motor may affect wiring size. Contact your motor maximum bhp and/or watts is exceeded at the maximum Bryant representative for details. operating cfm. —15—...
  • Page 16 3775. Do not adjust motor rpm such that will not be affected. motor maximum bhp and/or watts is exceeded at the maximum 6. Use of a field-supplied motor may affect wiring size. Contact your operating cfm. Bryant representative for details. —16—...
  • Page 17 5180. Do not adjust motor rpm such that will not be affected. motor maximum bhp and/or watts is exceeded at the maximum 6. Use of a field-supplied motor may affect wiring size. Contact your operating cfm. Bryant representative for details. —17—...
  • Page 18 7915 (for 208-v units) and 8640 (for 230 and 460-v units). 6. Use of a field-supplied motor may affect wiring size. Contact your Do not adjust motor rpm such that motor maximum bhp and/or watts Bryant representative for details. is exceeded at the maximum operating cfm. —18—...
  • Page 19 2700. Do not adjust motor rpm such that will not be affected. motor maximum bhp and/or watts is exceeded at the maximum 6. Use of a field-supplied motor may affect wiring size. Contact your operating cfm. Bryant representative for details. —19—...
  • Page 20 3775. Do not adjust motor rpm such that will not be affected. motor maximum bhp and/or watts is exceeded at the maximum 6. Use of a field-supplied motor may affect wiring size. Contact your operating cfm. Bryant representative for details. —20—...
  • Page 21 5180. Do not adjust motor rpm such that will not be affected. motor maximum bhp and/or watts is exceeded at the maximum 6. Use of a field-supplied motor may affect wiring size. Contact your operating cfm. Bryant representative for details. —21—...
  • Page 22 7915 (for 208 and 575-v units) and 8640 (for 230 and 460-v 6. Use of a field-supplied motor may affect wiring size. Contact your units). Do not adjust motor rpm such that motor maximum bhp and/ Bryant representative for details. or watts is exceeded at the maximum operating cfm. —22—...
  • Page 23 Table 11 — Air Quantity Limits UNIT MINIMUM MAXIMUM 581A 3600 6,000 4500 7,500 6000 10,000 Table 12 — Evaporator Fan Motor Specifications UNIT NOMINAL VOLTAGE EFF. 581A WATTS AMPS 2700 85.8% 3.13 2.34 9.46 (Standard 2700 85.8% 3.13 2.34 2700 85.8% 3.13...
  • Page 24 When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches, the hall effect sensor, as well as the flame sensor. If the unit is controlled through a room thermostat set for fan auto.,45 seconds after ignition occurs, the indoor-fan motor will be energized (and the outdoor-air dampers will open to their minimum posi- tion).

  • Page 25: Service

    Upon a second-stage call for cooling, compressor no. 1 is Use caution with ceramic heat exchanger baffles. When energized and mechanical cooling is integrated with econo- installing retaining clip, be sure the center leg of the clip extends inward toward baffle. See Fig. 29. mizer cooling.
  • Page 26 II. LUBRICATION 2. Slide fan pulley along fan shaft. 3. Make angular alignment by loosening motor from A. Compressors mounting plate. Each compressor is charged with the correct amount of oil at the factory. Conventional white oil (Sontex 200LT) is used. IV.
  • Page 27 10. Disconnect wiring connections and remove the 4 mounting bolts. 11. Remove the motor. 12. To install the new motor, reverse Steps 1-11. V. BELT TENSION ADJUSTMENT To adjust belt tension: 1. Loosen fan motor bolts. 2. Size 155 Units: Move motor mounting plate up or down for proper belt tension ( in.
  • Page 28 4. Tighten setscrews and replace rubber hubcap to pre- 5. Set the outdoor-air thermostat (OAT), located in the vent hub from rusting to motor shaft. economizer section of the unit (see Fig. 17) to 75 F. 5. Fill hub recess with permagum if rubber hubcap is 6.
  • Page 29 9. Remove 2 screws that hold the burner support plate BOTH CIRCUITS ALL OUTDOOR FANS MUST BE OPERATING flange to the vestibule plate. 10. Lift burner assembly out of unit. B. Cleaning and Adjustment 1. Remove burner rack from unit as described in Main ADD CHARGE IF ABOVE CURVE Burner Removal section above.
  • Page 30 C. Condenser-Fan Motor Protection XIV. RELIEF DEVICES Each condenser-fan motor is internally protected against All units have relief devices to protect against damage from overtemperature. excessive pressures (i.e., fire). These devices protect the high and low side. D. High- and Low-Pressure Switches XV.
  • Page 31 DETAIL "C" 581A155225 DETAIL "C" 581A180270, 581A240270, AND 581A155300 DETAIL "C" 581A180360 AND 581A240360 Fig. 37 — Spark Gap Adjustment —31—...
  • Page 32 LEGEND Fig. 38 — Typical Wiring Schematic and Fig. 39 — Typical Component Arrangement — Adjustable Heat Anticipator — Indoor (Evaporator) Fan Contactor Terminal (Marked) BKR W/AT — Breaks with Amp Turns Indoor (Evaporator) Fan Circuit IFCB — Burner Relay —...
  • Page 33 Fig. 38 — Typical Wiring Schematic (581A180, 208/230 V Unit Shown) (cont) —33—...
  • Page 34 ECONOMIZER OPTION/ACCESSORY Fig. 39 — Typical Component Arrangement (581A180 Shown) —34—...

  • Page 35: Troubleshooting

    TROUBLESHOOTING Refer to Tables 18 and 19 for troubleshooting details. Table 18 — Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and condenser fan will Power failure. Call power company. not start. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, Replace component.
  • Page 36 Table 19 — Heating Service Analysis PROBLEM CAUSE REMEDY Burners will not ignite. Misaligned spark electrodes. Check flame ignition and sensor electrode positioning. Adjust as needed. No gas at main burners. Check gas line for air; purge as necessary. After purging gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.

  • Page 37: Troubleshooting

    Refer to Fig. 40 for IGC troubleshooting information. LEGEND IDM — Induced-Draft Motor Integrated Gas Unit Controller IGC — NOTE: Thermostat Fan Switch in the “AUTO” position. Fig. 40 — IGC Control (Heating and Cooling) —37—...
  • Page 38 Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1-800-962-9212 ] Packaged Service Training ] Classroom Service Training Copyright 1999 Bryant Heating & Cooling Systems CATALOG NO. 5358-101...

  • Page 40: Start-Up Checklist

    REFRIGERANT DISCHARGE CIRCUIT NO. 1 PSIG CIRCUIT NO. 2 PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 29. GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS CL-1 Copyright 1999 Bryant Heating & Cooling Systems CATALOG NO. 5358-101...

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