Bryant DURAPAC 580F Installation, Start-Up And Service Instructions Manual
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Bryant DURAPAC 580F Installation, Start-Up And Service Instructions Manual

Bryant DURAPAC 580F Installation, Start-Up And Service Instructions Manual

Durapac series single package rooftop gas heating/electric cooling units 15 to 25 tons
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See also: User Manual , Installation, Start-up and Service Instructions Manual
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
I. Step 1 - Provide Unit Support. . . . . . . . . . . . . . . . . 1
II. Step 2 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . 4
III. Step 3 - Field Fabricate Ductwork . . . . . . . . . . . . 11
VI. Step 6 - Trap Condensate Drain . . . . . . . . . . . . . . 11
VII. Step 7 - Orifice Change. . . . . . . . . . . . . . . . . . . . . 12
VIII. Step 8 - Install Gas Piping . . . . . . . . . . . . . . . . . . 13
XI. Step 11 - Install Outdoor-Air Hood. . . . . . . . . . . . 15
XII. Step 12 - Install All Accessories . . . . . . . . . . . . . 16
XIV. Step 14 - Install Control Accessory for Optional
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-34
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-42
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .43-47
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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 extin-
guishers available for all brazing operations.
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch to
unit and install lockout tag to disconnect switch. Elec-
trical shock could cause personal injury.
installation, start-up and

service instructions

SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
Cancels: II 580F-180-2
WARNING:
1. Improper installation, adjustment, alteration, ser-
vice, or maintenance can cause property damage,
personal injury, or loss of life. Refer to the User's
Information Manual provided with this unit for
Page
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. Pres-
sures 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 pip-
ing at pressures of 0.5 psig or less, a unit connected to
such piping must be isolated by closing the manual gas
valve(s).
IMPORTANT: Units have high ambient operating limits. If
limits are exceeded, the units will automatically lock the com-
pressor 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 adapter
roof curb in accordance with instructions shipped with this
accessory. See Fig. 1A, 1B, and 2. Install insulation, cant
strips, roofing, and counter flashing as shown. Ductwork can
be installed to roof curb or horizontal adapter roof curb before
unit is set in place. Curb or adapter roof curb should be level.
This is necessary to permit unit drain to function properly.
Unit leveling tolerance is ±
tion. Refer to Accessory Roof Curb or Horizontal Adapter Roof
Curb Installation Instructions for additional information as
required. When accessory roof curb or horizontal adapter roof
curb is used, unit may be installed on class A, B, or C roof cov-
ering material.
580F
Dura Pac Series
Sizes 180-300
15 to 25 Tons
II 580F-180-3

INSTALLATION

1
/
in. per linear ft in any direc-
16
Instructions continued on page 4.
3/15/06

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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 — —...
  • Page 3 — —...

  • Page 4: Step 2 - Rig And Place Unit

    NOTE: CRRFCURB013A00 is a fully factory preassembled horizontal adapter and includes an insulated transition duct. The pressure drop through the adapter curb is negligible. For horizontal return applications: The power exhaust and barometric relief dampers must be installed in the return air duct. Fig.
  • Page 5 NOTES: 1. Dimensions in ( ) are in millimeters. 2. Refer to Fig. 4-6 for unit operating weights. 3. Remove boards at ends of unit and runners prior to rigging. 4. Rig by inserting hooks into unit base rails as shown. Use corner 5.
  • Page 6 — —...
  • Page 7 — —...
  • Page 8 — —...
  • Page 9 UNIT 580F NOMINAL CAPACITY (tons) OPERATING WEIGHT EconoMi$erIV Perfect Humidity™ Dehumidification Package COMPRESSOR/MANUFACTURER Quantity...Model (Ckt 1, Ckt 2) Capacity Stages (%) Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Expansion Device Operating Charge (lb-oz) Circuit 1† Circuit 2 CONDENSER COIL Rows...Fins/in.
  • Page 10 UNIT 580F FURNACE SECTION Rollout Switch Cutout Temp (F)*** Burner Orifice Diameter (in..drill size) Natural Gas Thermostat Heat Anticipator Setting (amps) 208/230 v Stage 1 Stage 2 460 v Stage 1 Stage 2 Gas Input Stage 1 Stage 2 Efficiency (Steady-State) (%) Temperature Rise Range Manifold Pressure (in.

  • Page 11: Iii. Step 3 — Field Fabricate Ductwork

    III. STEP 3 — FIELD FABRICATE DUCTWORK Secure all ducts to building structure. Use flexible duct con- nectors between unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applica- ble codes.

  • Page 12: Vii. Step 7 — Orifice Change

    Table 2 to identify the correct orifice size for the elevation. See Table 3 for the number of orifices required for each unit size. Purchase these orifices from your local Bryant dealer. Follow instructions in accessory Installation Instruc- tions to install the correct orifices.

  • Page 13: Ix. Step 9 — Make Electrical Connections

    B. Field Control Wiring Install a Bryant-approved accessory thermostat assembly (or light commercial Thermidistat™ device for units equipped with Perfect Humidity™ option) according to the installation instructions included with accessory. Locate thermostat assembly on a solid interior wall in the conditioned space to sense average temperature.
  • Page 14 LEGEND EQUIP — Equipment — Ground — National Electrical Code — Terminal Board NOTE: The maximum wire size for TB1 is 2/0. Fig. 15 — Field Power Wiring Connections 4. Tighten the Allen bolt to lock the shaft into position. 5.

  • Page 15: Step 10 - Make Outdoor-Air Inlet Adjustments

    VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 580F (3 Ph, 60 Hz) 208/230 32.1 16.4 208/230 30.1 15.5 208/230 19.2 208/230 187.2 253 20.7 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor —...

  • Page 16: Xii. Step 12 — Install All Accessories

    IMPORTANT: If the unit is equipped with the optional EconoMi$erIV component, move the outdoor-air tempera- ture sensor prior to installing the outdoor-air hood. See the Optional EconoMi$erIV section for more information. NOTE: The hood top panel, upper and lower filter retainers, hood drain pan, baffle (size 300), and filter support bracket are secured opposite the condenser end of the unit.
  • Page 17 Motor Mount — To ensure proper fan height, replace the existing motor mount with the new motor mount provided with accessory. Transformer (460-v Units Only) — On 460-v units, a trans- former is required. The transformer is provided with the accessory and must be field-installed.

  • Page 18: Step 13 - Adjust Factory-Installed Options

    FROM FUSE BLOCK 12 13A 2 5 6 TO PRESSURE TRANSDUCER Fig. 24 — Motormaster® V Control XIII. STEP 13 — ADJUST FACTORY-INSTALLED OPTIONS A. Optional EconoMi$erIV See Fig. 25 and 26 for EconoMi$erIV component locations. NOTE: These instructions are for installing the optional EconoMi$erIV only.
  • Page 19 LEGEND Potentiometer Default Settings: Power Exhaust DCV — Demand Controlled Ventilation Minimum Pos. IAQ — Indoor Air Quality DCV Max. LALS — Low Temperature Compressor DCV Set Lockout Switch Enthalpy OAT — Outdoor-Air Temperature POT — Potentiometer Table 10 — Supply Air Sensor Temperature/ Resistance Values TEMPERATURE (F) RESISTANCE (ohms)
  • Page 20 APPLICATION Outdoor Air Dry Bulb None. The outdoor air dry bulb sensor is factory installed. Differential Dry Bulb Single Enthalpy Differential Enthalpy for DCV Control using a Wall-Mounted CO Sensor for DCV Control using a Duct-Mounted CO Sensor *CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may contain parts that will not be needed for installation.
  • Page 21 for cooling. For example, when the outdoor air has a lower enthalpy than the return air and is below the set point, the EconoMi$erIV opens to bring in outdoor air for free cooling. Replace the standard outside air dry bulb temperature sen- sor with the accessory enthalpy sensor in the same mounting location.
  • Page 22 Open Free Cool Fig. 32 — EconoMi$erIV Controller CO SENSOR MAX RANGE SETTING 6000 5000 4000 3000 2000 1000 DAMPER VOLTAGE FOR MAX VENTILATION RATE Fig. 33 — CO Sensor Maximum Range Setting To determine the minimum position setting, perform the following procedure: 1.
  • Page 23 Loading Docks LEGEND ppm — Parts Per Million Use setting 1 or 2 for Bryant equipment. See Table 12. 1. Press Clear and Mode buttons. Hold at least 5 sec- onds until the sensor enters the Edit mode. 2. Press Mode twice. The STDSET Menu will appear.

  • Page 24: Install Humidistat For Optional Perfect Humidity™ Dehumidification Package

    XIV. STEP 14 — INSTALL HUMIDISTAT FOR OPTIONAL PERFECT HUMIDITY™ DEHUMIDIFICATION PACKAGE Perfect Humidity dehumidification package operation can be controlled by field installation of a Bryant-approved humidistat. To install the humidistat perform the following procedure: 1. Locate humidistat on a solid interior wall in the conditioned space.
  • Page 25 Fig. 36 — Perfect Humidity™ Dehumidification Package Operation Diagram (Single Circuit Shown) — —...

  • Page 26: Start-Up

    START-UP Use the following information and Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up. I. UNIT PREPARATION Check that unit has been installed in accordance with these installation instructions and all applicable codes. II. COMPRESSOR MOUNTING Compressors are internally spring mounted.
  • Page 27 Table 13 — Fan Performance — 580F180275 (Low Heat Units)* AIRFLOW (Cfm) Watts 4500 1307 1.53 4800 1384 1.62 5100 1465 1.72 5700 1911 2.24 6000 2164 2.54 6300 2439 2.86 6600 2737 3.21 6900 3057 3.59 1013 7200 3401 3.99 1047 7500...
  • Page 28 Table 14 — Fan Performance — 580F180360 (High Heat Units)* AIRFLOW (Cfm) Watts 4500 1307 1.53 4800 1384 1.62 5100 1571 1.84 5700 2054 2.41 6000 2329 2.73 6300 2628 3.08 6600 2951 3.46 1023 6900 1000 3298 3.87 1059 7200 1038 3672...
  • Page 29 Table 15 — Fan Performance — 580F210275 (Low Heat Units)* AIRFLOW (Cfm) Bhp Watts Rpm 5,500 2.27 1908 6,000 2.72 2287 6,500 3.22 2710 7,000 3.78 3177 7,500 4.39 3690 1038 8,000 1038 5.06 4251 1093 8,500 1096 5.78 4859 1148 9,000 1154...
  • Page 30 Table 17 — Fan Performance — 580F240275 (Low Heat Units)* AIRFLOW (Cfm) Watts 6,000 2607 3.09 6,500 3030 3.59 7,000 3488 4.14 1001 7,500 3982 4.72 1055 8,000 1056 4512 5.35 1111 8,500 1116 5077 6.02 1167 9,000 1175 5678 6.74 1224 9,500...
  • Page 31 Table 18 — Fan Performance — 580F240360 (High Heat Units)* AIRFLOW (Cfm) Watts 6,000 2752 3.26 6,500 3201 3.80 7,000 3687 4.37 1049 7,500 1054 4211 5.00 1109 8,000 1117 4773 5.66 1168 8,500 1180 5373 6.37 1229 9,000 1244 6011 7.13 1290...
  • Page 32 Using fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 5. Use of a field-supplied motor may affect wire size. Contact your Bryant representative for details. — — Watts Watts 4.76...
  • Page 33 UNIT 580F Table 22 — Accessory/FIOP Static Pressure (in. wg) — 580F180-300 COMPONENT EconoMi$erIV Perfect Humidity™ Dehumidification LEGEND FIOP — Factory-Installed Option UNIT 580F 180† †† †† 180** †† †† 210† †† †† 1095 210** †† †† 1287 240† †† ††...

  • Page 34: Operating Sequence

    XIII. OPERATING SEQUENCE A. Cooling, Units Without Economizer When thermostat calls for cooling, terminals G and Y1 are energized. The indoor (evaporator) fan contactor (IFC), com- pressor contactor no. 1 (C1) and outdoor-fan contactor (OFC) are energized, and evaporator-fan motor, compressor no. 1, and both condenser fans start.

  • Page 35: Evaporator Fan Performance Adjustment

    CERAMIC BAFFLE CLIP HEAT EXCHANGER TUBES NOTE: One baffle and clip will be in each upper tube of the heat exchanger. Fig. 37 — Removing Heat Exchanger Ceramic Baffles and Clips E. Condenser Coil Clean condenser coil annually and as required by location and outdoor-air conditions.

  • Page 36: Belt Tension Adjustment

    Fig. 38 — Evaporator-Fan Pulley and Adjustment NOTE: A 3 -in. bolt and threaded plate are included in the installer’s packet. They should be added to the motor support channel below the motor mounting plate to aid in raising the motor. The plate part number is 50DP503842.

  • Page 37: Gas Valve Adjustment

    NOTE: Dimensions are in inches. Fig. 40 — Condenser Fan Adjustment, 580F180, 210, 300 NOTE: Dimensions are in inches. Fig. 41 — Condenser Fan Adjustment, 580F240 BOTH CIRCUITS ALL OUTDOOR FANS MUST BE OPERATING ADD CHARGE IF ABOVE CURVE REDUCE CHARGE IF BELOW CURVE LIQUID PRESSURE AT LIQUID VALVE (PSIG) Fig.
  • Page 38 46 for typical wiring diagrams. XV. REPLACEMENT PARTS A complete list of replacement parts may be obtained from any Bryant distributor upon request. XVI. DIAGNOSTIC IGC CONTROL LEDs The unit control boards have LEDs for diagnostic purposes. Refer to Troubleshooting section on page 43.
  • Page 39 DETAIL "C" DETAIL "C" 580F180360 (High Heat) AND 580F210275-300275 (Low Heat) DETAIL "C" 580F180275 (Low Heat) 580F210360-300360 (High Heat) Fig. 44 — Spark Gap Adjustment — —...
  • Page 40 Fig. 45 — Typical Wiring Schematic (580F240, 208/230 V Shown) — —...
  • Page 41 Fig. 46 — Typical Component Arrangement (580F240 Shown) — —...
  • Page 42 LEGEND AND NOTES FOR FIG. 45 AND 46 — Adjustable, Heat Anticipator — Contactor, Compressor — Capacitor — Circuit Breaker — Cooling Compensator — Crankcase Heater — Compressor Lockout COMP — Compressor Motor — Control Relay — Damper Motor — Dummy Terminal EQUIP —...

  • Page 43: Troubleshooting

    A functional view of the EconoMi$erIV is shown in Fig. 48. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$erIV simulator program is avail- able from Bryant to help with EconoMi$erIV training and troubleshooting. A. EconoMi$erIV Preparation This procedure is used to prepare the EconoMi$erIV for troubleshooting.
  • Page 44 G. EconoMi$erIV Troubleshooting Completion This procedure is used to return the EconoMi$erIV 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 45 PROBLEM Compressor and Power failure. Condenser Fan Fuse blown or circuit breaker tripped. Will Not Start. Defective thermostat, contactor, transformer, or control relay. Insufficient line voltage. Incorrect or faulty wiring. Thermostat setting too high. Compressor Will Not Start Faulty wiring or loose connections in compressor circuit. but Condenser Fan Runs.
  • Page 46 LEGEND IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO” position. Fig. 47 — IGC Control (Heating and Cooling) — —...
  • Page 47 INPUTS Enthalpy* Demand Control Ventilation (DCV) Outdoor Below set High (DCV LED Off) (Free Cooling LED Off) (Free Cooling LED On) Above set High (DCV LED On) (Free Cooling LED Off) (Free Cooling LED On) *For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point.

  • Page 48: Index

    Air quality limits Altitude compensation Burner section Burner spark gap Charging chart, refrigerant Clearance sensor Configuration Settings 22, 23 Combustion blower wheel Compressor Lockout 18, 38 Lubrication Mounting Rotation Concentric duct Condensate drain Cleaning Location 11, 12 Condenser coil Cleaning Condenser fan Adjustment 36, 37...

  • Page 49: Service Training

    Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Installation Overview A large selection of product, theory, and skills programs are available, using popular video-based formats and materials.
  • Page 50 Copyright 2006 Bryant Heating & Cooling Systems Printed in U.S.A. CATALOG NO. 04-53580003-01...

  • Page 52: Start-Up Checklist

    CIRCUIT NO. 1 REFRIGERANT DISCHARGE CIRCUIT NO. 1 VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 37. GENERAL ECONOMI$ERIV MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS Copyright 2006 Bryant Heating & Cooling Systems START-UP CHECKLIST SERIAL NO.: TECHNICIAN: L1-L2 L2-L3...

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Durapac 580f180Durapac 580f210Durapac 580f240Durapac 580f300

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