Bryant DURAPAC PLUS 581A Installation And Service Instructions Manual
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Bryant DURAPAC PLUS 581A Installation And Service Instructions Manual

Bryant DURAPAC PLUS 581A Installation And Service Instructions Manual

Durapac plus series single package rooftop electric cooling/gas heating units
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
I. Step 1 - Provide Unit Support. . . . . . . . . . . . . . . . . 1
II. Step 2 - Remove Shipping Rails. . . . . . . . . . . . . . . 2
III. Step 3 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . 2
IV. Step 4 - Field Fabricate Ductwork . . . . . . . . . . . . . 9
VII. Step 7 - Trap Condensate Drain . . . . . . . . . . . . . . 10
VIII. Step 8 - Install Gas Piping . . . . . . . . . . . . . . . . . . 10
X. Step 10 - Install Outdoor-Air Hood. . . . . . . . . . . . 12
XII. Step 12 - Non-Fused Disconnect . . . . . . . . . . . . . 16
XIII. Step 13 - Install All Accessories . . . . . . . . . . . . . 16
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-36
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36-46
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .47-51
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 main power switch
to unit. Electrical shock could cause personal injury.
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
ELEC TRIC COOLING/GAS HEATING UNITS
Cancels: II 581A-210-1
WARNING:
Page
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 temperature operat-
ing 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 in accordance with
instructions shipped with this accessory. See Fig. 1. Install
insulation, cant strips, roofing, and counter flashing as
shown. Ductwork can be installed to roof curb before unit is
set in place. Ductwork must be attached to curb and not to
the unit. Curb must be level. This is necessary to permit unit
drain to function properly. Unit leveling tolerance is ±
per linear ft in any direction. Refer to Accessory Roof Curb
Installation Instructions for additional information as
required. When accessory roof curb is used, unit may be
installed on class A, B, or C roof covering material. Bryant
roof curb accessories are for flat roofs or slab mounting.
Dura Pac Plus Series
Sizes 210-300
18 to 25 Tons
INSTALLATION
581A
II 581A-210-2
10/1/05
1
/
in.
16

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  • Page 1: Table Of Contents

    Refer to Accessory Roof Curb Installation Instructions for additional information as required. When accessory roof curb is used, unit may be installed on class A, B, or C roof covering material. Bryant roof curb accessories are for flat roofs or slab mounting. 581A...

  • Page 2: Ii. Step 2 — Remove Shipping Rails

    IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 1. Improperly applied gasket can also result in air leaks and poor unit performance. Do not slide unit to position on roof curb.
  • Page 3 — —...

  • Page 4: Center Of Gravity

    SHIPPING RAILS CENTER OF GRAVITY UNIT SIZE MAX WEIGHT (in.) 581A (lb) 3358 63.9 34.0 3380 63.9 34.5 3769 67.8 35.0 Fig. 2 — Shipping Rail Removal 30.5 30.5 35.0 Fig. 3 — Rigging Details — —...
  • Page 5 — —...
  • Page 6 UNIT 581A NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Al/Al* COMPRESSOR Quantity Number of Refrigerant Circuits Oil (ounces) Ckt A...Ckt B...Ckt C REFRIGERANT TYPE Expansion Device Operating Charge (lb) Circuit A Circuit B Circuit C CONDENSER FAN Nominal Cfm (Total, all fans) Quantity...Diameter (in.) Motor Hp...Rpm Watts Input (Total)

  • Page 7: Low Range

    Table 2 — Fan Motor and Drive Data — Vertical Supply/Return 581A LOW RANGE Motor Hp Motor Nominal Rpm Maximum Continuous Bhp Maximum Continuous Watts Motor Frame Size Motor Shaft Diameter (in.) Fan Rpm Range Motor Pulley Min. Pitch Diameter (in.) Motor Pulley Max.
  • Page 8 Table 3 — Fan Motor and Drive Data — Horizontal Supply/Return 581A LOW RANGE Motor Hp Motor Nominal Rpm Maximum Continuous Bhp Maximum Continuous Watts Motor Frame Size Motor Shaft Diameter (in.) Fan Rpm Range Motor Pulley Min. Pitch Diameter (in.) Motor Pulley Max.

  • Page 9: Iv. Step 4 — Field Fabricate Ductwork

    ALIGNMENT HOLE (IN BASE RAIL) EDGE FLANGE Fig. 5 — Alignment Hole Details SUPPLY RETURN OPENING OPENING CURB CURB RETURN SUPPLY OPENING OPENING ALIGNMENT HOLES FOR CURB-BOTH SIDES ROOF CURB Fig. 6 — Alignment Hole Location IV. STEP 4 — FIELD FABRICATE DUCTWORK On vertical units, secure all ducts to roof curb and building structure.

  • Page 10: Vii. Step 7 — Trap Condensate Drain

    NOTE: Dimensions A, A′, B, and B′ are obtained from field-supplied ceiling diffuser. Shaded areas indicate block-off pans. Fig. 9 — Concentric Duct Details VI. STEP 6 — INSTALL FLUE HOOD AND INLET HOOD Flue hood (smaller hood), inlet hood (larger hood), and screens are shipped inside the unit in the fan section.

  • Page 11: Ix. Step 9 — Make Electrical Connections

    B. Field Control Wiring Unit must be controlled with a Bryant-approved accessory thermostat. Install thermostat 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 12: Step 10 - Install Outdoor-Air Hood

    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 THERMOSTAT ASSEMBLY REMOVABLE JUMPER TB2- Fig. 16 — Field Control Thermostat Wiring Set heat anticipator settings as follows: STAGE 1 VOLTAGE...
  • Page 13 Table 4A — Electrical Data — Units Without Convenience Outlet COMPRESSOR VOLTAGE NOMINAL 581A RANGE VOLTAGE No. 1 No. 2 UNIT (3 Ph, SIZE Max RLA LRA RLA LRA RLA LRA Qty 60 Hz) 208/230 16.7 16.7 208/230 22.4 22.4 10.7 10.7 208/230...
  • Page 14 Table 4B — Electrical Data — Units With Optional Convenience Outlet COMPRESSOR VOLTAGE NOMINAL 581A RANGE VOLTAGE No. 1 No. 2 UNIT (3 Ph, SIZE Max RLA LRA RLA LRA RLA 60 Hz) 208/230 16.7 16.7 208/230 22.4 22.4 10.7 10.7 208/230 47.1...
  • Page 15 TOP HOOD SECTION SEAL STRIP LOCATION BOTTOM HOOD SECTION FILTER RETAINER NOTE: Units with manual damper only use one filter. Fig. 19 — Outdoor-Air Hood Assembled SEAL STRIP HOOD SIDE FILTER GUIDE FILTER MANUAL DAMPER (IF EQUIPPED) Fig. 18 — Outdoor-Air Hood Details MOVEABLE DAMPER AIR FILTER POSITION Fig.

  • Page 16: Xiii. Step 13 — Install All Accessories

    XIII. STEP 13 — INSTALL ALL ACCESSORIES After all of the factory-installed options have been adjusted, install all field-installed accessories. Refer to the accessory installation instructions included with each accessory. Con- sult the Bryant Price Pages for accessory package numbers for particular applications. — —...

  • Page 17: 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 the servic- ing refrigerant system. 2. Do not operate the compressor or provide any electric power to the unit unless the compressor terminal cover is in place and secured.

  • Page 18: Condenser Fans And Motors

    VIII. CONDENSER FANS AND MOTORS Condenser fans and motors are factory set. Refer to Condenser-Fan Adjustment section (page 39) as required. IX. RETURN-AIR FILTERS Check that correct filters are installed in filter tracks (see Table 1). Do not operate unit without return-air filters. NOTE: For units with 4-in.
  • Page 19 Table 6 — Fan Performance — 581A210 Medium Heat Vertical Discharge Units* AIRFLOW (Cfm) Watts 3500 0.70 4000 0.92 4500 1029 1.18 5000 1297 1.49 5500 1606 1.85 6000 1961 2.26 6500 2363 2.72 7000 2815 3.24 7500 3320 3.82 8000 3879 4.46...
  • Page 20 Table 7 — Fan Performance — 581A210 High Heat Vertical Discharge Units* AIRFLOW (Cfm) Watts 3500 0.70 4000 0.92 4500 1029 1.18 5000 1297 1.49 5500 1606 1.85 6000 1961 2.26 6500 2363 2.72 7000 2815 3.24 7500 3320 3.82 8000 3879 4.46...
  • Page 21 Table 9 — Fan Performance — 581A240 Medium Heat Vertical Discharge Units* AIRFLOW (Cfm) Watts 5,000 1329 1.53 5,500 1648 1.90 6,000 2013 2.32 6,500 2428 2.79 7,000 2895 3.33 7,500 3415 3.93 8,000 3992 4.59 8,500 4628 5.32 9,000 5325 6.12 1037...
  • Page 22 Table 11 — Fan Performance — 581A300 Low Heat Vertical Discharge Units* AIRFLOW (Cfm) Watts 6,500 2,468 2.84 7,000 2,942 3.38 7,500 3,468 3.99 8,000 4,045 4.65 8,500 4,677 5.38 9,000 5,364 6.17 1042 9,500 1033 6,108 7.03 1090 10,000 1079 6,911 7.95...
  • Page 23 Using the fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor fail- ure. Unit warranty will not be affected. 5. Use of a field-supplied motor may affect wire size. Contact the Bryant representative for details. — — Watts...
  • Page 24 Table 14 — Fan Performance — 581A210 Low Heat Horizontal Discharge Units* AIRFLOW (Cfm) Watts 3,500 1064 1.22 4,000 1402 1.61 4,500 1802 2.07 5,000 2264 2.60 5,500 2794 3.21 6,000 1003 3047 3.50 6,500 1079 3812 4.38 7,000 1155 4697 5.40 7,500...
  • Page 25 Table 16 — Fan Performance — 581A210 High Heat Horizontal Discharge Units* AIRFLOW (Cfm) Watts 3,500 1105 1.27 4,000 1454 1.67 4,500 1866 2.15 5,000 2343 2.69 5,500 2889 3.32 6,000 1019 3177 3.65 6,500 1096 3973 4.57 7,000 1173 4894 5.63 7,500...
  • Page 26 Table 18 — Fan Performance — 581A240 Medium Heat Horizontal Discharge Units* AIRFLOW (Cfm) Watts 3,500 1123 1.29 4,000 1479 1.70 4,500 1897 2.18 5,000 2383 2.74 5,500 2937 3.38 6,000 1029 3249 3.74 6,500 1106 4061 4.67 7,000 1184 5003 5.75 7,500...
  • Page 27 Table 20 — Fan Performance — 581A300 Low Heat Horizontal Discharge Units* AIRFLOW (Cfm) Watts 6,500 2,658 3.06 7,000 3,208 3.69 7,500 3,827 4.40 8,000 4,518 5.20 8,500 1012 5,284 6.08 1034 9,000 1069 6,127 7.05 1090 9,500 1127 7,050 8.11 1146 10,000...
  • Page 28 Table 22 — Fan Performance — 581A300 High Heat Horizontal Discharge Units* AIRFLOW (Cfm) Watts 6,500 2,730 3.14 7,000 3,294 3.79 7,500 3,929 4.52 8,000 4,637 5.33 8,500 1029 5,421 6.24 1052 9,000 1087 6,285 7.23 1108 9,500 1145 7,231 8.32 1165 10,000...
  • Page 29 COOLING 581A UNIT GAS HEAT MInimum Maximum SIZE High Heat (8 Cell) 5,400 9,000 Medium Heat (8 Cell) Low Heat (5 Cell) High Heat (8 Cell) 5,500 10,000 Medium Heat (8 Cell) Low Heat (5 Cell) High Heat (8 Cell) 6,000 11,500 Medium Heat (8 Cell)

  • Page 30: Optional Economi$Er

    Table 26 — Accessory/FIOP Static Pressure (in. wg)* COMPONENT 4,000 4,500 5,000 5,500 6,000 6,500 7,000 7,500 8,000 8,500 9,000 9,500 10,000 10,500 EconoMi$er IV 0.02 0.03 0.04 0.05 LEGEND FIOP — Factory-Installed Option *The static pressure must be added to the external static pressure. The sum and the evaporator entering-air cfm should then be used in conjunction with the Fan Performance tables to determine blower rpm and watts.
  • Page 31 DAMPER ACTUATOR OUTDOOR AIR TEMPERATURE SENSOR ECONOMIZER BLOCK OFF Fig. 23 — EconoMi$er IV Component Locations (Exploded View) SAT LOCATION Fig. 24 — Supply-Air Temperature Sensor Location ECONOMI$ER IV WITH OUTDOOR AIR APPLICATION Outdoor Air Dry Bulb None. The outdoor air dry bulb sensor is factory installed. Differential Dry Bulb Single Enthalpy Differential Enthalpy...
  • Page 32 Differential Dry Bulb Control For differential dry bulb control the standard outdoor dry bulb sensor is used in conjunction with an additional acces- sory dry bulb sensor (part number CRTEMPSN002A00). The accessory sensor must be mounted in the return airstream. Wiring is provided in the EconoMi$er IV wiring harness.
  • Page 33 CONTROL CONTROL POINT CURVE APPROX. °F (°C) AT 50% RH 73 (23) 70 (21) 67 (19) 63 (17) APPROXIMATE DRY BULB TEMPERATURE— °F (°C) Fig. 28 — EconoMi$er IV Controller Potentiometer and LED Locations (29) (32) (27) (24) (21) (18) (16) (13) (10)
  • Page 34 Minimum Position Control There is a minimum damper position potentiometer on the EconoMi$er IV controller. See Fig. 28. The minimum damper position maintains the minimum airflow into the building during the occupied period. When using demand ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compounds) ventilation requirements.

  • Page 35: Operating Sequence

    See Table 29. Use setting 1 or 2 for Bryant equipment. See Table 29. 1. Press Clear and Mode buttons. Hold at least 5 sec- onds until the sensor enters the Edit mode.

  • Page 36: Service

    B. Heating, Units Without Economizer NOTE: The 581A210-300 units have 2 stages of electric heat. When the thermostat calls for heating, power is sent to W on the IGC (integrated gas unit controller) board. An LED (light-emitting diode) on the IGC board will be on during normal operation.
  • Page 37 Remove Surface Loaded Fibers Surface loaded fibers or dirt should be removed with a vac- uum cleaner. If a vacuum cleaner is not available, a soft non- metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.

  • Page 38: Evaporator Fan Service And Replacement

    F. Flue Gas Passageways The flue collector box and heat exchanger cells may be inspected by removing heat section access panel (Fig. 4), flue box cover, and main burner assembly (Fig. 30). Refer to Main Burners section on page 41 for burner removal sequence. If cleaning is required, clean tubes with a wire brush.

  • Page 39: Evaporator Fan Performance Adjustment

    IV. EVAPORATOR FAN PERFORMANCE ADJUSTMENT (Fig. 32 and 33) Fan motor pulleys are factory set for speed shown in Table 1. To change fan speeds: 1. Shut off unit power supply. 2. Loosen nuts on the 4 carriage bolts in the mounting base.

  • Page 40: Power Failure

    VII. POWER FAILURE Dampers have a spring return. In event of power failure, dampers will return to fully closed position until power is restored. Do not manually operate damper motor. VIII. REFRIGERANT CHARGE Amount of refrigerant charge is listed on unit nameplate and in Table 1.

  • Page 41: Main Burners

    8. Once desired pressure is established, set unit setting for no call for heat, turn off main gas valve, remove pressure-measuring device, and replace plug and screw cap. X. MAIN BURNERS For most applications, main burners are factory set and should require no adjustment.

  • Page 42: Relief Devices

    XV. REPLACEMENT PARTS A complete list of replacement parts may be obtained from any Bryant distributor upon request. XVI. DIAGNOSTIC LEDs The IGC control board has a LED for diagnostic purposes. The IGC error codes are shown in Table 33.
  • Page 43 Fig. 40 — Low Voltage Control Schematic Fig. 41 — Power Schematic and Fig. 42 — Component Arrangement _ _ .A — Circuit A — Adjustable Heat Anticipator — Ambient Limit — Auxiliary Contact _ _ .B — Circuit B _ _ .C —...
  • Page 44 Fig. 40 — Low Voltage Control Schematic — —...
  • Page 45 Fig. 41 — Power Schematic — —...
  • Page 46 — —...

  • Page 47: Unit Troubleshooting

    TROUBLESHOOTING I. UNIT TROUBLESHOOTING Refer to Tables 34-36 and Fig. 43. PROBLEM Compressor and Condenser Power failure. Fan Will Not Start. Fuse blown or circuit breaker tripped. Defective thermostat, contactor, transformer, or control relay. Insufficient line voltage. Incorrect or faulty wiring. Thermostat setting too high.
  • Page 48 PROBLEM Burners Will Not Ignite. Misaligned spark electrodes. 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. Broken thermostat wires. Inadequate Heating.
  • Page 49 LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO” position. Fig. 43 — IGC Control (Heating and Cooling) — —...

  • Page 50: Economi$Er Iv Troubleshooting

    A functional view of the EconoMi$er IV is shown in Fig. 44. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$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 51: Troubleshooting

    4. Remove the jumper across T and T1. The actuator should drive fully closed. 5. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting. G. EconoMi$er IV Troubleshooting Completion This procedure is used to return the EconoMi$er IV to opera- tion.
  • Page 52 Copyright 2005 Bryant Heating & Cooling Systems Printed in U.S.A. CATALOG NO. 04-53581005-01...

  • Page 56: Pre-Start-Up

    REFRIGERANT DISCHARGE CIRCUIT A CIRCUIT B CIRCUIT C VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 40 GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS Copyright 2005 Bryant Heating & Cooling Systems START-UP CHECKLIST SERIAL NO.: ______________________________________________ TECHNICIAN:_____________________________________________ L2-L3 L3-L1...

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