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Pr e f e r re d ™ Se ri es 5 81 K * 04 -0 6 U l t r a L o w N O x ( 1 4 n g / J )
Sin g le Pa c ka ge Ro o ft op
Gas Heating/Electric Cooling Unit
w ith P ur on
( R - 4 1 0 A) Re fr ig er an t
®
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . . . . . 8
Step 2 - Plan for Sequence of Unit Installation . . . . . . . . 8
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . . . . . . 8
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . . . . . 10
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . 10
(When Required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . . . . . 12
Step 9 - Units with Hinged Panels Only . . . . . . . . . . . . . 13
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . . 13
Step 11 - Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . . 13
(GAS CONNECTIONS)
Step 13 - Make Electrical Connections . . . . . . . . . . . . . 17
• CONVENIENCE OUTLETS
• UNITS WITHOUT THRU-THE-BASE CONNECTIONS
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53581034-01
Installation Instructions
Page
Printed in U.S.A.
Form No. II581K-F-4-6-05 Rev. B
Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . . . . . . 29
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EconomizerONE (Factory Option) . . . . . . . . . . . . . . . . . . 34
RTU Open Controller (Factory Option) . . . . . . . . . . . . . 55
Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Step 14 - Adjust Factory-Installed Options . . . . . . . . . . 56
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . . . . . . 56
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . . . . . . . . . . . 56
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . CL-1
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 literature, tags and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguisher available for all brazing operations.
It is important to recognize safety information. This is the
safety-alert symbol
. When you see this symbol on the unit
and in instructions or manuals, be alert to the potential for
personal injury.
Understand the signal
CAUTION, and NOTE. These words are used with the
safety-alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices,
Pg 1
words
DANGER, WARNING,
3-24
Replaces: II581K-F-4-6-04
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Table of Contents
Related Manuals for Bryant Preferred 581K 04 Series
Summary of Contents for Bryant Preferred 581K 04 Series
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Page 1: Table Of Contents
Pr e f e r re d ™ Se ri es 5 81 K * 04 -0 6 U l t r a L o w N O x ( 1 4 n g / J ) Sin g le Pa c ka ge Ro o ft op Gas Heating/Electric Cooling Unit w ith P ur on ( R - 4 1 0 A) Re fr ig er an t... - Page 2 which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions WARNING which will result in enhanced installation, reliability, or operation. CARBON-MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide DANGER poisoning, if combustion products infiltrate into the ELECTRICAL SHOCK HAZARD...
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Page 3: Model Number Nomenclature And
WARNING CAUTION FIRE HAZARD Do not detach the burner box from the heat exchanger panel. If the burner box must be replaced, refer to the Failure to follow this warning could result in severe Service and Maintenance Instructions for the unit. personal injury and/or property damage. - Page 4 Position: 9 10 11 12 13 14 15 16 17 Example: Unit Type Packaging and Control 581 = Gas Heat RTU A = Standard Packaging, electromechanical Preferred™ Series controls, no intake or exhaust option. Will allow for use of all field-installed economizers, manual or two-position Model damper.
- Page 5 Fig. 2 — 581K*04-06 Ultra Low NOx Unit Dimensional Drawing...
- Page 6 Fig. 2 — 581K*04-06 Ultra Low NOx Unit Dimensional Drawing (cont)
- Page 7 Fig. 2 — 581K*04-06 Ultra Low NOx Unit Dimensional Drawing (cont)
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Page 8: Installation
INSTALLATION Step 2 — Plan for Sequence of Unit Installation The support method used for this unit will dictate different se- Jobsite Survey quences for the steps of unit installation. For example, on curb- Complete the following checks before installation. mounted units, some accessories must be installed on the unit be- Consult local building codes and the NEC (National Elec- fore the unit is placed on the curb. - Page 9 ROOF CURB NOTES: POWER WIRING CONTROL WIRING ACCESSORY CONVENIENCE CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING ACCESSORY # 1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED. FITTING FITTING OUTLET WIRING CONNECTOR 2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY. 14"...
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Page 10: Slab Mount (Horizontal Units Only)
NOTE: The gasketing of the unit to the roof curb is critical for a Insulate and weatherproof all external ductwork, joints, and roof watertight seal. Install gasket supplied with the roof curb as shown openings with counter flashing and mastic in accordance with in Fig. -
Page 11: Step 7 - Convert To Horizontal And Connect Ductwork
Place all seal strips in place before "B" placing unit 36-54 in. Required Detail "A" on roof curb (914-1371 mm) Spreader Bars Duct End "C" Side "A" See Detail "A" NOTE(S): 1. SPREADER BARS ARE REQUIRED. Top damage will occur if spreader bars are not used. 2. -
Page 12: Step 8 - Install Outside Air Hood
Screws Hood Parts Plastic Tie Wrap Qty (2) Duct Covers Sheet Metal Face Up Screws for Metal Tray Qty (2) Basepan Fig. 10 — Economizer Hood Parts Location ECONOMIZER HOOD NOTE: 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 Fig. -
Page 13: Step 9 - Units With Hinged Panels Only
Step 9 — Units with Hinged Panels Only If the unit does not have hinged panels, skip this step and continue to Step 10. Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in Fig. 14 after unit Panel installation. -
Page 14: Factory Option Thru-Base Connections
FACTORY OPTION THRU-BASE CONNECTIONS (GAS Table 3 — Natural Gas Supply Line Pressure Ranges CONNECTIONS) ULTRA LOW NOx UNIT SIZE MIN. MAX. This service connection kit consists of a 1/2 in. electrical UNIT MODEL bulkhead connector and a 3/4 in. electrical bulkhead connector, 5.0 in. - Page 15 and the gasket (located between the “L” bracket and the con- nector plate assembly). NOTE: Take care not to damage the gasket, as it is reused in the 9 in. (229 mm) Minimum following step. Place the gasket over the embossed area in the basepan, align- ing the holes in the gasket to the holes in the basepan.
- Page 16 When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the ab- sence of local building codes, adhere to the following pertinent recommendations: •...
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Page 17: Step 12 - Install External Condensate Trap And Line
Step 12 — Install External Condensate Trap and Step 13 — Make Electrical Connections Line The unit has one 3/4 in. condensate drain connection on the end of WARNING the condensate pan and an alternate connection on the bottom. See Fig. -
Page 18: Units With Factory-Installed Non-Fused
Measure from the tip of the shaft to the top surface of the Units Without Non-Fused Disconnect or HACR Option black pointer; the measurement should be 3.75 to 3.88 in. (95 to 99 mm). Equip Tighten the locking screw to secure the shaft to the NFD. GR Lug Turn the handle to the OFF position with red arrow pointing at OFF. -
Page 19: All Units
ALL UNITS Convenience All field wiring must comply with NEC and all local codes. Size Outlet GFCI PWD-CO Fuse wire based on MCA (Minimum Circuit Amps) on the unit infor- Switch mative plate. See Fig. 26 and the unit label diagram for power wir- ing connections to the unit power terminal blocks and equipment ground. -
Page 20: Factory-Option Thru-The-Base Connections (Electrical Connections)
be connected at the line-side terminals on the unit-mounted non- fused disconnect; this will provide service power to the unit when WARNING the unit disconnect switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when ELECTRICAL OPERATION HAZARD the unit disconnect is open. -
Page 21: Field Control Wiring
Field-supplied and field-installed liquid tight conduit connectors THERMOSTAT and conduit may be attached to the connectors on the basepan. Install a Bryant-approved accessory thermostat according to in- Pull correctly rated high voltage and low voltage through appro- stallation instructions included with the accessory. For complete priate conduits. -
Page 22: Heat Anticipator Settings
control box. The raceway provides the UL-required clearance Raceway between high-voltage and low-voltage wiring. Connect one of the leads from the 2-conductor cable to the HUM terminal on the UCB (Unit Control Board). Connect the other lead to the R terminal on the UCB. See Fig. 37. Unit Control Board Humidistat... - Page 23 Programmable Thermostat Unit Control Board Thermostat Connections O/W2/B S RTN Fig. 38 — Typical Rooftop Unit with Perfect Humidity™ Dehumidification System and Programmable Thermostat...
- Page 24 Fig. 39 — Typical Control Wiring Diagram, Electromechanical with POL224 (581K*04-05 Ultra Low NOx Unit, 208/230-3-60 Shown)
- Page 25 Fig. 40 — Typical Control Wiring Diagram, Electromechanical with POL224 (581K*06 Ultra Low NOx Unit, 208/230-3-60 Shown)
- Page 26 Fig. 41 — Typical Control Wiring Diagram, RTU Open Controller (581K*04-05 Ultra Low NOx Unit, 208/230-3-60 Shown)
- Page 27 Fig. 42 — Typical Control Wiring Diagram, RTU Open Controller (581K*06 Ultra Low NOx Unit, 208/230-3-60 Shown)
- Page 28 A M E R I C A N W I R E G A U G E Fig. 43 — Typical Power Wiring Diagram, Electromechanical Controls (581K*04-06 Ultra Low NOx Unit, 208/230-3-60 Shown)
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Page 29: Integrated Gas Controller
Integrated Gas Controller and limit switch are closed, and that the pressure switch is open. If the check was successful, the induced draft motor is energized. This unit contains an Integrated Gas Controller (IGC) board. The When the pressure in the heat exchanger is low enough to close IGC control board uses a flue gas pressure switch that senses pres- the pressure switch, the ignition activation period begins. - Page 30 UNIT CONTROL BOARD Fig. 46 — Typical IGC Control Wiring Diagram Table 5 — IGC Board LED Alarm Codes a,b,c,d FLASH SYMPTOM CAUSE REMEDY CODE Normal Operation — — Check 5-amp fuse on the ICG, power to unit, 24-v circuit breaker, and transformer. Units Loss of power to control No Power or Hardware Failure without a 24-v circuit breaker have an internal overload in the 24-v transformer.
- Page 31 Pre-purge: Induced draft motor Ignition: Gas valve and Call for heat: starts and runs for 30 seconds at igniter energize for 2 W terminal is energized. ignition speed, Speed 1. seconds. Rectification: Flame sensor activates for 2 seconds after Gas valve and igniter ignition period.
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Page 32: Perfect Humidity Dehumidification System
DEHUM/MECH COOLING (SUBCOOLING) MODE Perfect Humidity Dehumidification System (Optional) This mode increases the latent heat removal and decreases sen- sible cooling compared to normal cooling. This occurs when Units with the factory-installed Perfect Humidity ™ system op- there is a cooling and dehumidification demands. tion are capable of providing multiple modes of improved dehu- midification as a variation of the normal cooling cycle. - Page 33 Indoor Valve Supply Air Condenser Coil Hot Gas Reheat Coil Valve Outdoor Air Expansion Valve Valve (TXV) Compressor Evaporator Coil = Closed Valve = Open Valve Indoor Return Air Fig. 50 — Subcooling Mode – Perfect Humidity System with 2 Stage Cooling, 581K*04-06 Ultra Low NOx Indoor Valve Supply Air...
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Page 34: Economizerone (Factory Option)
EconomizerONE (Factory Option) the harness are made to the C (24 vac common) and R (24 vac power) terminals of the economizer controller. See Fig. 54. ECONOMIZER SETTINGS LED Indication Interface Overview NOTE: If different faulty events occur at the same time, then EconomizerONE sensor/DAC LED lights up following the priority below: Red ... - Page 35 Table 6 — LED Indication FREE SENSOR Power STATUS COOLING DAC LED Yellow Yellow Yellow Commissioning mode Blinking Blinking Blinking Power start up Yellow On Yellow On Yellow On Free cooling is running Green On — — Free cooling is available Green —...
- Page 36 Table 7 — Free Cooling Functions CONTROL MODE SENSORS USED ENABLE FREE COOLING? The outside air dry bulb temperature is compared with the set temperature OA (outside air) temperature sensor Control Mode 1 shutoff setpoint. • Fixed Dry bulb If the outside air dry bulb temperature is below the temperature shutoff MA (Mixed Air) temperature sensor setpoint, then the outside air is used to meet all or part of the cooling demand.
- Page 37 Table 8 — 1 and 2-Stage Cooling Stage I/O Logic Table 11 — Different Fan Speeds with Different Configured Outputs ECONOMIZER COOLING COOLING CONDITION MET STAGE 1 STAGE 2 FAN TYPE 1-SPEED COOLING 2-STAGE COOLING • Spd H (regardless of •...
- Page 38 Table 13 — Different Damper Position Settings with Different Configured Outputs (DCV is Enabled) FAN TYPE 1-STAGE COOLING 2-STAGE COOLING • 2VENTMIN H to 2VENTMAX H (regardless of • 2VENTMIN H to 2VENTMAX H (regardless of 1-SPEED FAN cooling demand, OCC=Yes) cooling demand, OCC=Yes) •...
- Page 39 Exhaust Fan Operation Users can enable this function only from the Climatix mobile ap- ™ plication if the related function is available in the current mobile Up to two exhaust fans can be connected to the economizer application version. controller. Fault Detection and Diagnostics •...
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Page 40: Wiring
WIRING WARNING Failure to follow this caution may result in damage to equipment. Be sure to allow enough time for compressor startup and shutdown between checkout tests so that the compressors do not short-cycle. Mounting Devices Connected to the Economizer Controller Devices like damper actuators, sensors (temperature sensor, humidity sensor, combination temperature and humidity sensor, CO... - Page 41 Table 15 — EconomizerONE Control Wiring Settings LABEL TYPE DESCRIPTION RS485 Modbus A Line A RS485 Modbus B Line B ¬ GND_ISO Earth Ground Type II NTC 10K or 0-10 vdc Mixed or Discharge Air Temperature Sensor Mixed or Discharge Air Temperature Sensor Common Type II NTC 10K or 0-10 vdc Outside Air Temperature Sensor 0-10 vdc or 4-20mA...
- Page 42 Connecting Peripheral Devices to the Economizer Controller See Fig. 59-63 for wiring details. • Outside Air: Connect to the Mixed or Discharge Air Temperature Sensor OAT and COM terminals of the Outside Air Temperature Sensor device. • Return Air (Differential): Return Air Temperature Sensor Connect to the RAT and S-COM...
- Page 43 • Outside Combination Temperature/ Humidity: Connect Combo Temperature and Humidity Sensor to the OAT, COM, and OAH terminals of the device. • Combo Temperature and Humidity Sensor Return Combination Temperature/ Humidity: Connect to the RAT, S-COM, and RAH terminals of the device. Fig.
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Page 44: Setup And Configuration
SETUP AND CONFIGURATION NOTE: Parameters and display menus may display differently/dynamically if different applications are config- ured. See Tables 16-23. IMPORTANT: Before setup and configuration, it is recommend- ed to obtain some location-based values, such as shutoff points, IMPORTANT: Not all operations are available on the local or utilize the location services in the Climatix ™... - Page 45 Table 16 — Status Display PARAMETER DESCRIPTION VALUE 1FREECOOL Indicates whether the system can use outdoor air for free cooling. 1ECON ENAB Indicates whether outdoor air is being used for the first stage of cooling. Indicates whether the space is occupied. If users choose ALWAYS for 6OCC when configuring I/Os, then the parameter value is YES;...
- Page 46 Table 17 — Parameter Settings — Basic PARAMETER DESCRIPTION RANGE DEFAULT Temperature shutoff setpoint can be obtained automatically if a smartphone or tablet with the mobile application installed on it is connected to the 2 TEMP OFF 48...80°F; increment by 1 63°F network provided by a Wi-Fi/WLAN stick plugged into the economizer controller.
- Page 47 Table 18 — Parameter Settings — Advanced PARAMETER DESCRIPTION VALUE/RANGE DEFAULT 3FREEZE POS Anti-freeze protection damper position (closed or minimum). 3SD ACT POS Damper position during shutdown (open or closed). MAT sensor location: • Choose MAT if the sensor is installed before the DX (Direct Expansion) coil. 3DIF T LOC •...
- Page 48 Table 19 — Parameter Settings — I/O Configurations (cont) PARAMETER DESCRIPTION VALUE DEFAULT Choose “COOL 2” if Cooling Stage 2 is available (another compressor is COOL 2 6Y2O COOL 2 connected to the Economizer). Otherwise, choose “NONE”. NONE Auxiliary DO-1. Configurable as: NONE •...
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Page 49: Installing Optional Hh57Lw001 Single
Table 22 — Enter Running State PARAMETER DESCRIPTION 8RUN STATE Change to Running State. Press Enter to confirm the change. 8ENTER RUN? Confirm the change to Running State. Perform factory reset. Press Enter to confirm the reset. (This action resets the controller 8FACTORY DEF password to default: OneBT.) 8DEF CONFIRM? - Page 50 Fig. 64 — HH57LW001 Dimensional, Connection and Switching Information Fig. 65 — HH79NZ039 Dry Bulb and Mixed Air Sensor Wiring Actuator Wiring Harness HH79NZ039 Outside Air Temperature Sensor Outside Air Damper Fig. 67 — California Title 24 Zones Fig. 66 — EconomizerONE Component Locations (CRECOMZR108A00 Shown)
- Page 51 U.S. and Canada I-Codes / ASHRAE Zones Climate Zone 1 Climate Zone 5 and Marine Climate Zone 2 Climate Zone 6 Climate Zone 3 Climate Zone 7 and 8 Climate Zone 4 (Except Marine) Fig. 68 — U.S. and Canada Climate Zones Table 24 —...
- Page 52 Economizers are shipped standard with an HH79NZ039 outside Table 25 — California Title 24 Regional High Limit Dry air dry bulb sensor (see Fig. 65). System default setting (high temp Bulb Temperature Settings limit) is 63°F (17°C) and has a range of 48°F to 80°F (9°C to REQUIRED HIGH LIMIT 27°C).
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Page 53: Checkout
CHECKOUT Status Use the Status menu (refer to Table 16) to check the parameter Inspect all wiring connections at the economizer module’s termi- values for the various devices and sensors configured. nals, and verify compliance with the installation wiring diagrams. For checkout, review the Status of each configured parameter and NOTE: For information about menu navigation and use of the perform the Test Commands tests (refer to Table 21). -
Page 54: Troubleshooting
TROUBLESHOOTING For EconomizerONE troubleshooting issues see Table 27. Table 27 — Operating Issues and Concerns SYMPTOM REASON SOLUTION An alarm is displayed on the Sensor, damper, or the whole working Check sensor, damper, or the whole working system following the detailed alarm information. system may not work properly DAC LED is blinking RED Damper slippage... -
Page 55: Rtu Open Controller (Factory Option)
RTU Open Controller (Factory Option) Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 70, Step 3. For details on operating 581K*04-06 units equipped with the fac- tory-installed RTU Open controller option, refer to the Factory-In- Connect the flexible tube on the sampling inlet to the sam- stalled Option RTU Open Multi-Protocol Controller Controls, pling tube on the basepan. -
Page 56: Step 14 - Adjust Factory-Installed Options
Step 14 — Adjust Factory-Installed Options NOTE: The fan speed set up labels are located on the High Voltage cover in the Control Box. SMOKE DETECTORS Connect a multimeter to the vdc terminals on the UCB. Smoke detector(s) will be connected at the Unit Control Board Set the Range Switch to either A, B, or C per the Switch (UCB), at terminals marked “Smoke Shutdown.”... - Page 57 NOTE: On single phase units, the approximate static pressure of the ductwork must be set for optimal unit efficiency. The unit is factory set for greater than 1.0 in. wg. If the external static pressure is less than 1.0 in. wg, slide switch 1 on the 5-pin DIP to the “ON” position.
- Page 58 ESP in. wg Factory Setting: Calculator 9.0 V 1500 Field Setting: 1625 Record field setting here 10.0 1750 1875 2000 Switch Range: 2125 2250 4.1 - 7.5 2375 6.9 - 8.7 2500 7.7 - 10.0 Field Accessories: Economizer * Overlap in A, B, C switch range designed for maximum field adjustment potential.
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Page 59: Start-Up Checklist
START-UP CHECKLIST FOR 581K*04-06 ULTRA LOW NOx SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT (Remove and use for job file) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this document. - Page 60 PRESSURES Gas Inlet Pressure _____________ in. wg Gas Manifold Pressure STAGE 1 _____________ in. wg STAGE 2 _____________ in. wg Refrigerant Suction _____________ PSIG Refrigerant Discharge _____________ PSIG Verify Refrigerant Charge using Charging Charts. (Y/N) _____ GENERAL Economizer minimum vent and changeover settings to job requirements (if equipped). (Y/N) _____ Verify smoke detector unit shutdown by utilizing magnet test.
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