Bryant DURAPAC PLUS 581B Installation & Service Instructions Manual
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Bryant DURAPAC PLUS 581B Installation & Service Instructions Manual

Bryant DURAPAC PLUS 581B Installation & Service Instructions Manual

Single package rooftop gas heating/electric cooling units
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
I. Step 1 - Provide Unit Support. . . . . . . . . . . . . . . . . 1
II. Step 2 - Field Fabricate Ductwork . . . . . . . . . . . . . 2
and External Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IV. Step 4 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . 4
V. Step 5 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . 4
VI. Step 6 - Install Gas Piping . . . . . . . . . . . . . . . . . . . 4
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-37
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-44
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .45-49
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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 basic maintenance func-
tions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. 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.
CAUTION: Ensure voltage listed on unit data plate
agrees with electrical supply provided for the unit.
WARNING: Disconnect gas piping from unit when
leak testing at pressure greater than
greater than
1
/
psig will cause gas valve damage result-
2
ing in hazardous condition. If gas valve is subjected to
pressure greater than
1
/
use. When pressure testing field-supplied gas piping at
1
pressures of
/
psig or less, a unit connected to such
2
piping must be isolated by manually closing the gas
valve(s).
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
1
/
psig. Pressures
2
psig, it must be replaced before
2
Dura Pac Plus Series
Cancels: II 581B-36-6
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch to
unit. Electrical shock could cause personal injury.
Page
Unit is shipped in the vertical configuration. To convert to
horizontal application, remove side duct opening covers.
Using the same screws, install covers on vertical duct open-
ings with the insulation-side down. Seals around duct open-
ings must be tight. See Fig. 1.
I. STEP 1 - PROVIDE UNIT SUPPORT
A. 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. Duct-
work must be attached to curb. If gas is to be routed through
the curb, attach the accessory thru-the-curb service connec-
tion plate to the roof curb in accordance with the accessory
installation instructions. Connection plate must be installed
before unit is set in roof curb.
IMPORTANT: The gasketing of the unit to the roof curb is crit-
ical for a watertight seal. Install gasket supplied with the roof
curb as shown in Fig. 2. Improperly applied gasket can also
result in air or water leaks and poor unit performance.
Curb should be level. This is necessary for unit drain to func-
tion properly. Unit leveling tolerances are shown in Fig. 3.
Refer to Accessory Roof Curb Installation Instructions for
additional information as required.
B. Slab Mount (Horizontal Units Only)
Provide a level concrete slab that extends a minimum of 6 in.
beyond unit cabinet. Install a gravel apron in front of con-
denser coil air inlet to prevent grass and foliage from
obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if
required.
C. Alternate Unit Support
A non-combustible sleeper rail can be used in the unit curb
support area. If sleeper rails cannot be used, support the long
sides of the unit with a minimum of 3 equally spaced 4-in. x
4-in. pads on each side.
581B
Sizes 036-072
3 to 6 Tons
II 581B-36-7

INSTALLATION

10/1/05

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  • Page 1: Table Of Contents

    installation, start-up and service instructions SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNITS CONTENTS SAFETY CONSIDERATIONS ......1 INSTALLATION .

  • Page 2: Step 2 - Field Fabricate Ductwork

    II. STEP 2 — FIELD FABRICATE DUCTWORK On vertical units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. For horizontal applications, field-supplied flanges should be attached to horizontal discharge openings and all ductwork secured to the flanges.
  • Page 3 D ALT CONNECTOR DRAIN PKG. ACCY. HOLE CRBTMPWR001A01 CRBTMPWR002A01 ″ ″ 1′-9 1′-4″ CRBTMPWR003A01 [551] [406] [44.5] CRBTMPWR004A01 ACCESSORY POWER CONTROL ″ [19] NPT ″ ″ ″ [31.7] [19] NPT [12.7] ″ ″ ″ [19] NPT [12.7] ″ [12.7] NPT ″...

  • Page 4: Step 4 - Rig And Place Unit

    MAXIMUM ALLOWABLE DIFFERENCE (in.) Fig. 3 — Unit Leveling Tolerances HORIZONTAL DRAIN PLUG DRAIN PLUG NOTE: Drain plug is shown in factory-installed position. Fig. 4 — Condensate Drain Pan NOTE: Trap should be deep enough to offset maximum unit static dif- ference.
  • 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 grav- ity.
  • Page 6 UNIT SIZE 581B NOMINAL CAPACITY OPERATING WEIGHT (lb) Unit EconoMi$er IV Perfect Humidity™ Dehumidification System Roof Curb COMPRESSOR Quantity Oil (oz) REFRIGERANT TYPE Operating Charge (lb-oz) Standard Unit Unit With Perfect Humidity Dehumidification System CONDENSER FAN Quantity...Diameter (in.) Nominal Cfm Motor Hp...Rpm Watts Input (Total) CONDENSER COIL...
  • Page 7 UNIT SIZE 581B FURNACE SECTION Rollout Switch Cutout Temp (F)† Burner Orifice Diameter (in..drill size)** Natural Gas — Std Liquid 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 8 — —...

  • Page 9: Step 7 - Make Electrical Connections

    X DIMENSION tom connection kit is required. This is available (ft) through the local Bryant distributor. This kit is required to ensure a reliable water-tight connection. 2. If unit is mounted on roof curb and accessory thru- the-bottom connections are used, route wire through connection plate.
  • Page 10 BRYANT ELECTRONIC THERMOSTAT 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 IPD/X OUTDOOR AIR SENSOR THERMOSTAT DIPSWITCH SETTINGS LEGEND Field Wiring NOTE: Underlined letter indicates active thermostat output when con- figured for A/C operation.
  • Page 11 Table 2A — Electrical Data — Standard Motor Units Without Electrical Convenience Outlet VOLTAGE UNIT NOMINAL VOLTAGE RANGE 581B (V-Ph-Hz) 208/230-1-60 208/230-3-60 (3 Tons) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 (4 Tons) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 (5 Tons) 460-3-60 575-3-60 208/230-3-60 460-3-60 (6 Tons) 575-3-60 Table 2B —...
  • Page 12 Table 2C — Electrical Data — High-Static Motor Units Without Electrical Convenience Outlet VOLTAGE NOMINAL UNIT RANGE VOLTAGE 581B (V-Ph-Hz) 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 Table 2D — Electrical Data — High-Static Motor Units With Electrical Convenience Outlet VOLTAGE NOMINAL UNIT...

  • Page 13: Step 8 - Adjust Factory-Installed Options

    B. Perfect Humidity™ Dehumidification System Perfect Humidity system operation can be controlled by field installation of a Bryant-approved humidistat device (Fig. 13), or light commercial Thermidistat™ device (Fig. 14). To install the humidistat device: 1.
  • Page 14 DEHUM T STAT WIRES LEGEND — Circuit Breaker — Light Commercial Thermidistat™ Device LLSV — Liquid Line Solenoid Valve LTLO — Low Temperature Lockout Fig. 16 — Typical Rooftop Unit with Perfect Humidity™ Dehumidification System with Thermidistat Device C. Convenience Outlet An optional convenience outlet provides power for rooftop use.
  • Page 15 Fig. 19 — Optional Manual Outdoor-Air Damper with Hood Attached Fig. 20 — Outdoor-Air Damper Position Setting E. Optional EconoMi$er IV See Fig. 21 for EconoMi$er IV component locations. NOTE: These instructions are for installing the optional EconoMi$er IV only. Refer to the accessory EconoMi$er IV installation instructions when field installing an EconoMi$er IV accessory.
  • Page 16 IMPORTANT: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly. 3. The indoor coil access panel will be used as the top of the hood.
  • Page 17 LEGEND Potentiometer Defaults Settings: Power Exhaust DCV— Demand Controlled Ventilation Minimum Pos. IAQ — Indoor Air Quality DCV Max. LA — Low Ambient Lockout Device DCV Set OAT — Outdoor-Air Temperature Enthalpy POT — Potentiometer RAT — Return-Air Temperature 2500 2000 1500 1000...
  • Page 18 Table 3 — Supply Air Sensor Temperature/Resistance Values TEMPERATURE (F) RESISTANCE (ohms) –58 –40 –22 –4 G. EconoMi$er IV Control Modes Determine the EconoMi$er IV control mode before set up of the control. Some modes of operation may require different sensors. Refer to Table 4.
  • Page 19 ECONOMI$ER IV Fig. 34 — Return Air Temperature or Enthalpy Sensor Mounting Location Outdoor Enthalpy Changeover For enthalpy control, accessory enthalpy sensor (part num- ber HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location.
  • Page 20 CONTROL CONTROL POINT CURVE APPROX. °F (°C) AT 50% RH 73 (23) 70 (21) 67 (19) 63 (17) (10) (10) APPROXIMATE DRY BULB TEMPERATURE— °F (°C) Fig. 35 — Enthalpy Changeover Set Points 24 Vac Open Free Cool Fig. 36 — EconoMi$er IV Control (29) (32) (35)
  • Page 21 See Table 5. Use setting 1 or 2 for Bryant equipment. See Table 5. 1. Press Clear and Mode buttons. Hold at least 5 sec- onds until the sensor enters the Edit mode.

  • Page 22: Step 9 - Adjust Evaporator-Fan Speed

    SETTING EQUIPMENT OUTPUT Proportional Interface w/Standard Proportional Building Control System Exponential Proportional Proportional Economizer Exponential Exponential Health & Safety Proportional Parking/Air Intakes/ Proportional Loading Docks LEGEND ppm — Parts Per Million IX. STEP 9 — ADJUST EVAPORATOR-FAN SPEED Adjust evaporator-fan speed to meet jobsite conditions. Tables 6A and 6B show fan rpm at motor pulley settings for standard and alternate motors.
  • Page 23 0.35 0.25 0.15 0.05 1000 Fig. 38 — Humidi-MiZer™ Adaptive Dehumidification System Static Pressure Drop (in. wg) MOTOR MOUNTING PLATE NUTS Fig. 39 — Belt-Drive Motor Mounting Table 7 — Evaporator-Fan Motor Data — Standard Motor UNIT UNIT MAXIMUM 581B PHASE CONTINUOUS BHP* Single...
  • Page 24 Table 8 — Evaporator-Fan Motor Data — High-Static Motors UNIT UNIT MAXIMUM 581B PHASE CONTINUOUS BHP* Three 2.40 Three 2.40 Three 2.90 Three 2.90 LEGEND Bhp — Brake Horsepower Table 9 — Accessory/FIOP EconoMi$er IV Static Pressure* (in. wg) COMPONENT Vertical EconoMi$er IV Horizontal EconoMi$er IV LEGEND...
  • Page 25 Table 12 — Fan Performance 581B036 — Vertical Discharge Units; High-Static Motor (Belt Drive)* AIRFLOW Watts 0.15 1000 0.18 1100 0.22 1200 0.26 1300 0.31 1400 0.36 1500 0.42 AIRFLOW Watts 1016 0.51 1080 1000 1041 0.59 1104 1100 1066 0.68 1129 1200...
  • Page 26 Table 14 — Fan Performance 581B048 — Vertical Discharge Units; High-Static Motor (Belt Drive)* 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 Watts 1200 1093 0.77 1155 1300...
  • Page 27 Table 16 — Fan Performance 581B060, Three-Phase — Vertical Discharge Units; 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 1173 1.23...
  • Page 28 Table 18 — Fan Performance 581B072 — Vertical Discharge Units; Standard Motor (Belt Drive)* 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 29 Table 20 — Fan Performance 581B036 — Horizontal Discharge Units; Standard Motor (Belt Drive)* AIRFLOW Watts 0.14 1000 0.16 1100 0.20 1200 0.23 1300 0.28 1400 0.33 1500 0.38 AIRFLOW Watts 1019 0.64 1084 1000 1042 0.70 1107 1100 1065 0.77 1130 1200...
  • Page 30 Table 22 — Fan Performance 581B048 — Horizontal Discharge Units; Standard Motor (Belt Drive)* 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 Watts 1200 1089 0.84 1153 1300 1113...
  • Page 31 Table 24 — Fan Performance 581B060, Single-Phase — Horizontal Discharge Units; 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 2400 —...
  • Page 32 Table 26 — Fan Performance 581B060 — Horizontal Discharge Units; High-Static Motor (Belt Drive)* 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...
  • Page 33 Unit warranty will not be affected. See Tables 7 and 8 for additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Bryant repre- sentative to verify.

  • Page 34: Pre-Start-Up

    PRE-START-UP WARNING: Failure to observe the following warn- ings could result in serious personal injury. 1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system. 2. Do not operate compressor or provide any elec- tric power to unit unless compressor terminal cover is in place and secured.
  • Page 35 *As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. †Orifice available through your local Bryant distributor. Table 29B — Altitude Compensation* — ELEVATION...
  • Page 36 A. To Shut Off Unit Set system selector switch at off position. Resetting heating selector lever below room temperature will temporarily shut unit off until space temperature falls below thermostat setting. XIII. SAFETY RELIEF A soft-solder joint at the suction service Schrader port provides pressure relief under abnormal temperature and pressure conditions.
  • Page 37 Hot Gas Reheat Mode When the humidity levels in the space require humidity con- trol, a hot gas solenoid valve (specific to hot gas reheat mode only) will open to bypass a portion of hot gas refrigerant around the condenser coil (see Fig. 43). This hot gas will mix with liquid refrigerant leaving the con- denser coil and flow to the subcooling/reheat dehumidification coil.

  • Page 38: Service

    SERVICE CAUTION: When servicing unit, shut off all elec- trical power to unit and install lockout tag to avoid shock hazard or injury from rotating parts. I. CLEANING Inspect unit interior at the beginning of heating and cooling season and as operating conditions require. A.
  • Page 39 Fig. 44 — Cleaning Condenser Coil Fig. 45 — Propping Up Top Panel Fig. 46 — Separating Coil Sections UNIT 581B FAN HEIGHT — “A” (in.) 036-060 and 072 (208/230 V) 072 (460 and 575 V) Fig. 47 — Condenser-Fan Adjustment A.
  • Page 40 Fig. 50 — Cooling Charging Chart, Standard 581B060 Fig. 48 — Cooling Charging Chart, Standard 581B036 Fig. 49 — Cooling Charging Chart, Standard 581B048 Fig. 51 — Cooling Charging Chart, Standard 581B072 — —...
  • Page 41 CONDENSER FAN MUST BE OPERATING NOTE: When using the charging charts, it is important that only the subcooling/reheat dehu- midification coil liquid line solenoid valve be energized. The subcooling/reheat dehumidifica- tion coil liquid line solenoid valve MUST be energized to use the charging charts and the outdoor motor speed controller jumpered to run the fan at full speed.
  • Page 42 5. Reinstall burners on rack. 6. Reinstall burner rack as described above. XV. REPLACEMENT PARTS A complete list of replacement parts may be obtained from your Bryant distributor upon request. Refer to Fig. 59 for a typical unit wiring schematic. — —...
  • Page 43 INDUCED- DRAFT MOTOR MOUNTING PLATE BURNER SECTION INDUCED- DRAFT MOTOR MANIFOLD PRESSURE Fig. 56 — Burner Section Details ROLLOUT SWITCH FLUE EXHAUST VESTIBULE PLATE Fig. 57 — Burner Tray Details BLOWER HOUSING VALVE Fig. 58 — Spark Gap Adjustment — —...
  • Page 44 — 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 45: Troubleshooting

    TROUBLESHOOTING I. UNIT TROUBLESHOOTING Refer to Tables 32-36. SYMPTOM Hardware Failure Loss of power to control module (IGC). (LED OFF) Fan ON/OFF Delay Modified High limit switch opens during heat (LED/FLASH) exchanger warm-up period before fan-on delay expires. Limit switch opens within three minutes after blower-off delay timing in Heating mode.
  • Page 46 PROBLEM Burners Will Not Misaligned spark electrodes. Ignite No gas at main burners. Water in gas line. No power to unit. No 24 v power supply to control circuit. Miswired or loose connections. Burned-out heat anticipator in thermostat. Broken thermostat wires. Inadequate Heating Dirty air filter.

  • Page 47: Cooling

    PROBLEM Compressor and Condenser Fan Will Not Start Compressor Will Not Start But Condenser Fan Runs Compressor Cycles (Other Than Normally Satisfying Thermostat) Compressor Operates Continuously Excessive Head Pressure Head Pressure Too Low Excessive Suction Pressure Suction Pressure Too Low Evaporator Fan Will Not Shut Off Table 36 —...
  • Page 48 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 avail- able from Bryant to help with EconoMi$er IV training and troubleshooting. A. EconoMi$er IV Preparation This procedure is used to prepare the EconoMi$er IV for troubleshooting.

  • Page 49: Troubleshooting

    G. EconoMi$er IV Troubleshooting Completion This procedure is used to return the EconoMi$er IV to opera- tion. 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 50: Index

    Gas connection Gas input Gas piping 4, 9, 34 Gas pressure 1, 7 Heat anticipator settings 7, 9 Copyright 2005 Bryant Heating & Cooling Systems INDEX Heat exchanger High flow valves High pressure switch Horizontal units 1, 2 Humidistat Indoor air quality sensor...

  • Page 52: Start-Up Checklist

    GAS MANIFOLD PRESSURE REFRIGERANT SUCTION REFRIGERANT DISCHARGE VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR ROTATING IN CORRECT DIRECTION Copyright 2005 Bryant Heating & Cooling Systems START-UP CHECKLIST (Remove and Store in Job File) SERIAL NO.:________________________________________ TECHNICIAN: ______________________________________...

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