Bryant 581B036--072 Installation Instructions Manual
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Bryant 581B036--072 Installation Instructions Manual

Bryant 581B036--072 Installation Instructions Manual

Single-package rooftop heating/cooling standard and low nox units
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581B036- -072
581C024- -060
SINGLE- - PACKAGE ROOFTOP HEATING/COOLING
STANDARD AND LOW NOx UNITS

TABLE OF CONTENTS

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SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install, repair,
or service air-conditioning equipment.
Untrained personnel can perform 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
Installation Instructions
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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
1
quenching cloth for unbrazing operations. Have fire extinguishers
1
available for all brazing operations.
2
Recognize safety information. This is the safety- -alert symbol
2
. When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
2
Understand the signal words DANGER, WARNING, and
2
CAUTION. These words are used with the safety- -alert symbol.
2
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
2
which could result in personal injury or death. CAUTION is used
2
to identify unsafe practices which may result in minor personal
2
injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
4
reliability, or operation.
4
!
8
8
ELECTRICAL SHOCK HAZARD
8
Failure to follow this warning could cause personal
8
injury or death.
16
Before performing service or maintenance operations
on unit, turn off main power switch to unit and install
16
lockout tag. Ensure electrical service to rooftop unit
agrees with voltage and amperage listed on the unit
16
rating plate.
16
18
!
19
20
FIRE, EXPLOSION HAZARD
25
Failure to follow this warning could cause death and/or
property damage.
41
Disconnect gas piping from unit when leak testing at
41
pressure greater than
45
psig will cause gas valve damage resulting in hazardous
condition. If gas valve is subjected to pressure greater
55
1
than
/
psig, it must be replaced before use. When
2
60
pressure testing field-supplied gas piping at pressures of
1
/
psig or less, a unit connected to such piping must be
2
isolated by manually closing the gas valve(s).
Unit is shipped in the vertical discharge configuration. To convert
to horizontal discharge application, remove duct opening covers.
Using the same screws, install covers on duct openings in
basepan of unit with insulation-side down. Seals around
openings must be tight. (See Fig. 1.)
1
WARNING
WARNING
1
/
psig. Pressures greater than
2

INSTALLATION

1
/
2

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  • Page 1: Table Of Contents

    581B036- -072 581C024- -060 SINGLE- - PACKAGE ROOFTOP HEATING/COOLING STANDARD AND LOW NOx UNITS Installation Instructions TABLE OF CONTENTS SAFETY CONSIDERATIONS ......INSTALLATION .

  • Page 2: Step 1 -Provide Unit Support

    Fig. 1 --- Horizontal Conversion Panels Step 1 —Provide Unit Support Roof Curb Assemble and install accessory roof curb in accordance with instructions shipped with curb. (See Fig. 2.) Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb, not to the unit.
  • Page 3 D ALT CONNECTOR DRAIN PKG. ACCY. HOLE CRBTMPWR001A01 CRBTMPWR002A01 1 -9 1 -4 CRBTMPWR003A01 [551] [406] [44.5] CRBTMPWR004A01 ACCESSORY POWER CONTROL POWER [19] NPT [19] NPT [31.7] [19] NPT [12.7] [12.7] [12.7] NPT [31.7] [19] NPT Fig. 2 --- Roof Curb Details ROOF CURB UNIT ACCESSORY...

  • Page 4: Step 5 -Install Flue Hood

    MAXIMUM ALLOWABLE DIFFERENCE (in.) Fig. 3 --- Unit Leveling Tolerances Be sure that unit is installed such that snow will not block the combustion intake or flue outlet. Unit may be installed directly on wood flooring or on Class A, B, or C roof-covering material when roof curb is used.
  • Page 5 NOTES: 1. Place unit on curb as close as possible to the duct end. 2. Dimension in ( ) is in millimeters. 3. Hook rigging shackles through holes in base rail as shown in detail “A.” Holes in base rails are centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging straps from damaging unit.

  • Page 8: Step 7 -Make Electrical Connections

    (See Fig. 2.) Field Control Wiring Install a Bryant-approved accessory thermostat assembly according to installation instructions included with the accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance with thermostat installation instructions.
  • Page 9 BASE UNIT 581B NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Perfect Humidity™ Adaptive Dehumidification System EconoMi$er IV Roof Curb COMPRESSOR Quantity Oil (oz) REFRIGERANT TYPE Expansion Device Operating Charge (lb-oz) Standard Unit Unit With Perfect Humidity Adaptive Dehumidification System CONDENSER FAN Quantity...Diameter (in.) Nominal Cfm Motor Hp...Rpm...
  • Page 10 UNIT SIZE 581B FURNACE SECTION Rollout Switch Cutout Temp (F)† Burner Orifice Diameter (in..drill size)** Natural Gas —Std Propane —Alt†† Thermostat Heat Anticipator Setting (amps) 208/230/460 v First Stage Second Stage Gas Input (Btuh) First Stage/Second Stage (3 ---phase units) Efficiency (Steady State) (%) Temperature Rise Range Manifold Pressure (in.
  • Page 11 BASE UNIT 581C NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Perfect Humidity™ Adaptive Dehumidification System EconoMi$er IV Roof Curb COMPRESSOR Quantity Oil (oz) REFRIGERANT TYPE Expansion Device Operating Charge (lb-oz) Standard Unit Unit With Perfect Humidity Adaptive Dehumidification System CONDENSER FAN Quantity...Diameter (in.) Nominal Cfm Motor Hp...Rpm...
  • Page 12 UNIT SIZE 581C FURNACE SECTION Rollout Switch Cutout Temp (F)† Burner Orifice Diameter (in..drill size)** Natural Gas —Std Propane —Alt†† Thermostat Heat Anticipator Setting (amps) 208/230/460 v First Stage Second Stage Gas Input (Btuh) First Stage/Second Stage (3 ---phase units) Efficiency (Steady State) (%) Temperature Rise Range Manifold Pressure (in.
  • Page 13 EQUIP FIELD POWER SUPPLY DISCONNECT 208/230-1-60 PER NEC (SIZES 581B036-060, 581C024-060) TO COMP FIELD POWER SUPPLY 208/230-3-60 460-3-60 DISCONNECT (SIZES 581B060, 072, PER NEC 581C0060) COOL STAGE 1 Y1/W2 HEAT STAGE 1 W/W1 COOL STAGE 2 Y/Y2 HEAT STAGE 2 O/W2 24 VAC HOT 24 VAC COM...

  • Page 16: Step 8 - Adjust Factory-Installed Options

    Perfect Humidity™ Adaptive Dehumidification System Perfect Humidity system operation can be controlled by field installation of a Bryant- -approved humidistat. (See Fig. 15.) NOTE: A light commercial Thermidistat™ device (Fig. 16) can be used instead of the humidistat if desired. The Thermidistat device includes a thermostat and a humidistat.
  • Page 17 LEGEND — Circuit Breaker — Cooling Relay — Dehumidify Relay — Discharge Solenoid Valve — Heater Relay — Low Pressure Switch — Liquid Solenoid Valve LTLO — Low Temperature Lockout Field Splice Fig. 17 --- Typical Perfect Humidityt Adaptive Dehumidification System DEHUM TS TAT WIRES LEGEND...

  • Page 18: Optional Economi$Er

    Fig. 21 --- Outdoor- -Air Damper With Hood Attached Fig. 22 --- Outdoor- -Air Damper Position Setting ECONOMI$ER IV CONTROLLER OUTSIDE AIR WIRING TEMPERATURE SENSOR HARNESS LOW AMBIENT SENSOR ACTUATOR Fig. 23 --- EconoMi$er IV Component Locations Optional Economi$er IV See Fig.

  • Page 19: Economi$Er Iv Standard Sensors

    Fig. 25 --- Hood Box Removal CAULK HERE INDOOR COIL ACCESS PANEL Fig. 26 --- Indoor Coil Access Panel Relocation LEFT HOOD SCREW SIDE 19 1/16” HOOD DIVIDER Fig. 27 --- Outdoor- -Air Hood Construction Economi$er IV Standard Sensors Outdoor Air Temperature (OAT) Sensor The outdoor air temperature sensor (HH57AC074) is a 10 to 20 mA device used to measure the outdoor-air temperature.

  • Page 20: Economi$Er Iv Control Modes

    Economi$er IV Control Modes Determine the EconoMi$er IV control mode before set up of the control. Some modes of operation may require different sensors. (See Table 6.) The EconoMi$er IV is supplied from the factory with a supply- -air temperature sensor and an outdoor- - air temperature sensor.
  • Page 21 Potentiometer Defaults Settings: LEGEND Power Exhaust DCV— Demand Controlled Ventilation Minimum Pos. IAQ — Indoor Air Quality DCV Max. LA — Low Ambient Lockout Device DCV Set OAT — Outdoor-Air Temperature Enthalpy POT — Potentiometer RAT — Return-Air Temperature 2500 2000 1500 1000...
  • Page 22 SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION SUPPLY AIR TEMPERATURE SENSOR Fig. 34 --- Supply Air Sensor Location Fig. 35 --- EconoMi$er IV Controller Potentiometer and LED Locations Indoor Air Quality (IAQ) Sensor Input The IAQ input can be used for demand control ventilation control based on the level of CO measured in the space or return air duct.
  • Page 23 To control the minimum damper position remotely, remove the factory-installed jumper on the P and P1 terminals on the EconoMi$er IV controller. Wire the field-supplied potentiometer to the P and P1 terminals on the EconoMi$er IV controller. (See Fig. 39.) Damper Movement Damper movement from full open to full closed (or vice versa) takes 2...
  • Page 24 CONTROL CONTROL POINT CURVE APPROX. deg. F (deg. C) AT 50% RH 73 (23) 70 (21) 67 (19) 63 (17) APPROXIMATE DRY BULB TEMPERATURE--degrees F (degrees C) 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).

  • Page 25: Step 9 - Adjust Evaporator-Fan Speed

    (See Table 7.) Use setting 1 or 2 for Bryant equipment. (See Table 7.) 1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.
  • Page 26 SETTING EQUIPMENT OUTPUT Proportional Interface w/Standard Proportional Building Control System Building Control System Exponential Proportional Proportional Economizer Economizer Exponential Exponential Health & Safety Proportional Parking/Air Intakes/ Proportional Loading Docks LEGEND ppm — Parts Per Million 0.35 0.25 0.15 0.05 1000 Fig.
  • Page 27 Table 8—581B and 581C Fan Rpm at Motor Pulley Setting With Standard Motor* UNIT UNIT 1044 1008 1185 1144 1102 1460 1425 1389 1585 1538 1492 *Approximate fan rpm shown (standard motor/drive). Table 9—581B Fan Rpm at Motor Pulley Setting With High-Static Motor* UNIT UNIT 1455...
  • Page 28 Unit warranty will not be affected. See Tables 8 and 9 for additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Bryant representative to verify. 4. Interpolation is permissible. Do not extrapolate.
  • Page 29 Table 16—Fan Performance 581B 036, 581C 036 — Vertical Discharge Units; Standard Motor AIRFLOW AIRFLOW Watts 0.15 1000 0.18 1100 0.22 1200 0.26 1300 0.31 1400 0.36 1500 0.42 AIRFLOW AIRFLOW Watts 1016 0.51 1080 1000 1041 0.59 1104 1100 1066 0.68 1129...
  • Page 30 Table 18—Fan Performance 581B 048, 581C 048 — Vertical Discharge Units; Standard Motor AIRFLOW AIRFLOW Watts 1200 0.26 1300 0.31 1400 0.36 1500 0.42 1600 0.49 1700 0.57 1800 0.66 1900 0.75 1014 2000 0.85 1049 AIRFLOW AIRFLOW Watts 1200 1093 0.77 1155...
  • Page 31 Table 19—Fan Performance 581B 048, 581C 048 — Vertical Discharge Units; High-Static Motor (Belt Drive)* AIRFLOW AIRFLOW Watts 1200 0.26 1300 0.31 1400 0.36 1500 0.42 1600 0.49 1700 0.57 1800 0.66 1900 0.75 1014 2000 0.85 1049 AIRFLOW AIRFLOW Watts 1200 1093...
  • Page 32 Table 21—Fan Performance 581B 060, 581C 060 Three-Phase — Vertical Discharge Units; AIRFLOW AIRFLOW Watts 1500 0.42 1600 0.49 1004 1700 0.57 1040 1800 0.65 1077 1900 1007 0.75 1115 2000 1048 0.85 1153 2100 1090 0.97 1191 2200 1131 1.09 1230 2300...
  • Page 33 Table 23—Fan Performance 581C 072 — Vertical Discharge Units; Standard Motor (Belt Drive)* AIRFLOW AIRFLOW Watts 1800 0.63 1075 1900 1008 0.72 1112 2000 1049 0.82 1151 2100 1091 0.93 1189 2200 1133 1.05 1229 2300 1176 1.18 1047 1268 2400 1218 1.32...
  • Page 34 Table 24—Fan Performance 581C 072 — Vertical Discharge Units; High-Static Motor (Belt Drive)* AIRFLOW AIRFLOW Watts 1800 0.63 1075 1900 1008 0.72 1112 2000 1049 0.82 1151 2100 1091 0.93 1189 2200 1133 1.05 1229 2300 1176 1.18 1047 1268 2400 1218 1.32...
  • Page 35 Table 26—Fan Performance 581B 036, 581C 036 — Horizontal Discharge Units; Standard Motor AIRFLOW AIRFLOW Watts 0.14 1000 0.16 1100 0.20 1200 0.23 1300 0.28 1400 0.33 1500 0.38 AIRFLOW AIRFLOW Watts 1019 0.64 1084 1000 1042 0.70 1107 1100 1065 0.77 1130...
  • Page 36 Table 28—Fan Performance 581B 048, 581C 048 — Horizontal Discharge Units; Standard Motor AIRFLOW AIRFLOW Watts 1200 0.23 1300 0.28 1400 0.33 1500 0.38 1600 0.45 1700 0.52 1800 0.59 1900 0.68 2000 0.77 1006 AIRFLOW AIRFLOW Watts 1200 1089 0.84 1153 1300...
  • Page 37 Table 30—Fan Performance 581B 060, 581C 060 Single-Phase — Horizontal Discharge Units; AIRFLOW AIRFLOW Watts 1500 0.39 1600 0.46 1700 0.54 1800 0.63 1010 1900 0.73 1047 2000 1001 0.84 1085 2100 1043 0.96 1123 2200 1085 1.09 1162 2300 1127 1.23 1092...
  • Page 38 Table 31—Fan Performance 581B 060, 581C 060 Three-Phase — Horizontal Discharge Units; AIRFLOW AIRFLOW Watts 1500 0.39 1600 0.46 1700 0.54 1800 0.63 1010 1900 0.73 1047 2000 1001 0.84 1085 2100 1043 0.96 1123 2200 1085 1.09 1162 2300 1127 1.23 1092...
  • Page 39 Table 33—Fan Performance 581B 072 — Horizontal Discharge Units; Standard Motor (Belt Drive)* AIRFLOW AIRFLOW Watts 1800 0.64 1010 1900 0.73 1046 2000 0.84 1083 2100 1032 0.95 1120 2200 1073 1.07 1158 2300 1114 1.21 1074 1196 2400 1155 1.36 1204 1234...
  • Page 40 Table 34—Fan Performance 581B 072 — Horizontal Discharge Units; High-Static Motor (Belt Drive)* AIRFLOW AIRFLOW Watts 1800 0.64 1010 1900 0.73 1046 2000 0.84 1083 2100 1032 0.95 1120 2200 1073 1.07 1158 2300 1114 1.21 1074 1196 2400 1155 1.36 1204 1234...

  • Page 41: Pre-Start-Up

    PRE-START-UP WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death and/or property damage: 1. Follow recognized safety practices and wear protective goggles when checking or servicing a refrigerant system. Do not operate the compressor or provide any electric power to the unit unless the compressor terminal cover is in place and secured.

  • Page 42: Main Burners

    *As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, the input rate should be reduced at higher alti- tudes. †Orifices are available through your local Bryant distributor. 150,000 BTUH 150,000 BTUH NOMINAL INPUT...
  • Page 43 Heating 1. Purge gas supply line of air by opening union ahead of the gas valve. If gas odor is detected, tighten union and wait 5 minutes before proceeding. 2. Turn on electrical supply and manual gas valve. 3. Set system switch selector at HEAT position and fan switch at AUTO or ON position.
  • Page 44 Heating - - Units With Economi$er IV When the room temperature calls for heat, the heating controls are energized as described in the Heating, Units Without Economizer section. During the occupied mode, whenever the indoor fan contactor is energized, the economizer damper moves to the minimum position.

  • Page 45: Service

    Table 37—Perfect Humidity Adaptive Dehumidification System Sequence of Operation and System Response — Single Compressor Unit (581C 024- -060, 581B 036- -072) THERMOSTAT INPUT ECONOMIZER FUNCTION OAT. < Economizer Set Point — — NOTE: On a thermostat call for W1, all cooling and dehumidification will be off. LEGEND OAT --- Outdoor Air Temperature The net effect of the rooftop when in hot gas reheat mode is to...
  • Page 46 Fig. 49 --- Separating Coil Sections 4. Remove screws securing coil to compressor plate and compressor access panel. 5. Remove fastener holding coil sections together at return end of condenser coil. Carefully separate the outer coil section 3 to 4 in. from the inner coil section. (See Fig. 49.) 6.
  • Page 47 Low Charge Cooling Using Cooling Charging Charts, Fig. 51- -54 and 59- -62, vary refrigerant until the conditions of the charts are met. Note the charging charts are different from type normally used. Charts are based on charging the units to the correct superheat for the various operating conditions.
  • Page 48 Fig. 54 --- Cooling Charging Chart, Standard 581B 072 Fig. 55 --- Cooling Charging Chart, 581B 036 with Optional Perfect Humidity Adaptive Dehumidification System C06142 Fig. 56 --- Cooling Charging Chart, 581B 048 with Optional Perfect Humidity Adaptive Dehumidification NOTE: When using the charging charts, it is important that only the subcooling/reheat dehumidification coil liquid line solenoid valve be energized.
  • Page 49 Fig. 57 --- Cooling Charging Chart, 581B 048 with Optional Perfect Humidity Adaptive Dehumidification System Fig. 58 --- Cooling Charging Chart, 581B 072 with Optional Perfect Humidity Adaptive Dehumidification System To Use Cooling Charging Chart, Standard Unit Take the outdoor ambient temperature and read the suction pressure gauge.
  • Page 50 581C - 2 TON CHARGING CHART Suction Line Temperature (deg C) 10.5 15.5 105.0 100.0 95.0 90.0 85.0 80.0 75.0 70.0 65.0 Suction Line Temp (deg F) Fig. 59 --- Cooling Charging Chart, Standard 581C 024 581C - - 3 TON CHARGING CHART Suction Line Temperature (deg C) 11.1 16.1...
  • Page 51 581C - - 4 TON CHARGING CHART Suction Line Temperature (deg C) 10.6 15.6 97.0 87.0 77.0 67.0 Suction Line Temp (deg F) Fig. 61 --- Cooling Charging Chart, Standard 581C 048 581C - - 5 TON CHARGING CHART Suction Line Temperature (deg C) 10.0 15.0 115.0...
  • Page 52 Step 11 —Combustion- -Air Blower Clean periodically to ensure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency. To inspect blower wheel, remove draft hood and screen. Shine a flashlight into opening to inspect wheel.
  • Page 53 Fig. 65 --- Spark Gap Adjustment 5. Reinstall burner rack as described above. Step 15 —Replacement Parts A complete list of replacement parts may be obtained from any Bryant distributor upon request. Refer to Fig. 66 for a typical unit wiring schematic. C06154...
  • Page 54 — Contactor, Compressor — Capacitor — Compressor Lockout COMP — Compressor Motor EQUIP — Equipment — Freeze Up Protection Thermostat — Fuse — Ground — High-Pressure Switch — Hall-Effect Sensor — Ignitor — Induced-Draft Motor — Indoor Fan Contactor — Indoor Fan Motor —...

  • Page 55: Troubleshooting

    A functional view of the EconoMi$er IV is shown in Fig. 60. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$er IV simulator program is available from your Bryant distributor to help with EconoMi$er IV training and troubleshooting. Economi$er IV Preparation This procedure is used to prepare the EconoMi$er IV for troubleshooting.
  • Page 56 Economi$er IV Troubleshooting Completion This procedure is used to return the EconoMi$er IV to operation. No troubleshooting or testing is done by performing the following procedure. 1. Disconnect power at TR and TR1. 2. Set enthalpy potentiometer to previous setting. 3.
  • Page 57 PROBLEM CAUSE Burners Will Not Burners Will Not Misaligned spark electrodes. Ignite. No gas at main burners. No gas at main burners. Water in gas line. No power to furnace. No 24 v power supply to control circuit. Miswired or loose connections. Burned-out heat anticipator in thermostat.
  • Page 58 PROBLEM Compressor and Condenser Fan Compressor and Condenser Fan Will N Will Not Start. Compressor Will Not Start But Condenser Fan Runs. But Condenser Fan Runs. Compressor Cycles (Other Than Normally Satisfying Thermostat). Normally Satisfying Thermostat). Compressor Operates Continuously. Compressor Operates Continuously. Excessive Head Pressure.
  • Page 59 INPUTS Enthalpy* Demand Control Demand Control Outdoor Outdoor Ventilation (DCV) til ti (DCV) Below set Below set High High (DCV LED Off) (DCV LED Off) (Free Cooling LED Off) LED Off) (Free Cooling LED On) LED O ) Above set Above set High High...

  • Page 60: Start- -Up Checklist

    VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS E2007 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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581c024-060

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