Bryant DURAPAC PLUS 581B manual

Cancels : II 581B-3 6-6 II 581B-36 -7 10/1/05 installatio n, star t-up and ser vic e ins truction s SINGLE P A CK A GE R OOFT OP GAS HEA TING/ELECTRI C COOL ING UNITS 581B Dura Pa c Plus Series Siz es 03 6-07 2 3 to 6 T ons CONTENTS Pag e SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 INST ALLA TION . . . . . . . . . . .[...]

— 2 — II. STEP 2 — FIELD F ABRICA TE DUCTW ORK On v erti cal u nits , secu re al l du cts to ro of cu rb a nd b uildi ng structure. Do not connect duc twork t o unit. Fo r h o r i z o n t a l applications , field-supplied flange s should be attache d to horizontal dis charge openings and all ductwork s ecured to the flanges. Insulate and w ea[...]

— 3 — ROOF CURB ACCES SOR Y A UNIT SIZE CRRFCURB001A01 1 ′ -2 ″ [356] 581B 036-072 CRRFCURB002A01 2 ′ -0 ″ [610] NO TES: 1. Roof cur b accessor y is shipped disa ssembled. 2. Insul ated pane ls. 3. Dimensions in [ ] are in millimeters. 4. Roof curb: gal vanized steel. 5. Att ach du ctw ork to curb (f lang es of duct re st on curb ). 6. [...]

— 4 — IV . STEP 4 — RIG AND PLA CE UNIT Inspect unit for transpor tation damage. Fi le any claim with transportation agency . Kee p unit upright and do not drop. Sprea der ba rs are n ot req uire d if top crati ng is le ft on un it. Roll ers ma y be us ed to mov e unit ac ross a r oof . Level by using unit frame as a referen ce. See T able 1 [...]

— 5 — Size gas supply piping fo r 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connecti on. Support gas piping as shown in the table in F ig . 9. F or exam- ple , a 3 / 4 -in. gas pipe must have one field-fabricated support beam e ver y 8 ft . Th er ef or e , an 18- ft long ga s pi pe wo uld h a v e a mini mum [...]

— 6 — T ab le 1 — Ph ysica l Data — 581B 036-072 LEGEND *Single p hase/th ree p hase. †Ind ic ates aut omati c r eset. **60,00 0 and 72,000 Btuh heat i nput units have 2 burne rs. 90,000 and 120,000 Bt uh heat input unit s have 3 b urne rs. 115,000 Btuh hea t input uni ts and 150,0 00 Btuh Heat inp ut units have 3 burners. ††An L P ki[...]

— 7 — T a ble 1 — Physi cal D ata — 581B 036-0 72 ( cont ) L EGEND *Single p hase/th ree p hase. †Ind ic ates aut omati c r eset. **60,00 0 and 72,000 Btuh heat i nput units have 2 burne rs. 90,000 and 120,000 Bt uh heat input unit s have 3 b urne rs. 115,000 Btuh hea t input uni ts and 150,0 00 Btuh Heat inp ut units have 3 burners. †?[...]

— 8 — Fig. 7 — Ba se Unit Dim ensions — 58 1B036-0 72[...]

— 9 — VII. STEP 7 — MAKE ELECTRICAL CONNECTIONS A. Field P ower Supply All u nits e xcept 208/2 30-v units are factor y wired for th e voltag e shown on the namepl ate. If the 208/ 230-v u nit is to be connected to a 208-v power supply , the transform er must be rewired by movi ng th e bla c k wire fro m the 230 -v term ina l on the transfor [...]

— 10 — RACEW A Y LOW V OL T AGE CONNECTIONS INTEGRA TED GAS UNIT CONTROLLER (IGC) HOLE IN END P ANEL (HIDDEN) Fig. 10 — P ower Wirin g Connections LEGEND C— Contactor COMP S — Compressors EQUI P — Equipment GND — Ground IFC — Indoor (Evaporator) F an Contactor NEC — National Electrical Code TB — T er minal Block LEGEND NOT E: Un[...]

— 11 — T abl e 2A — Electr ical Data — Sta ndar d Motor Uni ts Withou t Electrica l Con venie nce Outlet T able 2B — Electri cal Data — Standar d Motor Unit s With Ele ctrical Con venience O utlet LEGEND *The values l isted in this ta ble do not include power exhaust. S ee table at r ight for pow er exh aus t requ ir ement s . †Used t[...]

— 12 — T able 2 C — Electrica l Data — High-Stati c Motor Units Wi thout Elec trical Con venience Outlet T able 2D — Electrical Data — High-Static Mo tor Units With Electrica l Con veni ence Outlet LEGEND *The values l isted in this ta ble do not include power exhaust. S ee table at r ight for pow er exh aus t requ ir ement s . †Used [...]

— 13 — VIII. STEP 8 — ADJUST F ACT OR Y-INST ALLED OPTIONS A. Disconnect Switc h The optio nal disco nnect swit ch is non-fus ed. The s witch ha s the capab i lity o f b eing lo cked in pla ce for sa f ety pur poses. B. P erfect Hum idity™ Dehumid ification Syste m P erfect Humidity system operation ca n be controlled by field installation [...]

— 14 — C. Con venience Outlet An option al conv enienc e outle t provide s power for roofto p use . F or maintenan ce personn el safety , the convenie nce out- let power is off w hen the unit disco nnect is off . Adjacent unit outlets may be use d for se rvice tools. An optional “Hot Out- let” is ava ilabl e from the f actory a s a spec i a[...]

— 15 — E. Optional EconoMi$e r IV See F ig . 21 for Econo Mi$e r IV com pon ent loc ati ons . NO TE: These instructions are for i nstalling the optional EconoMi$er IV only . Refer to the acce ssory EconoMi$ er IV instal la tion ins tructio ns when field in stalli ng an EconoM i$ er IV accessory . 1. T o remove the e xisting unit filter access p[...]

— 16 — IMPORT ANT : If the power exhaust ac cessory is to be installed on the unit, the hood shipped w ith the unit will not be used and must be discarded. Save the aluminum filt er for use in the power ex haust hoo d assembly . 3. The in door coil access panel wil l be used as the to p of the hood. Remove the s crews along the sides an d bot- [...]

— 17 — FOR OCCUP ANCY CONTROL REPLACE JUMPER WITH FIELD-SUPPLIED TIME CLOCK LEGEND DCV — Demand Controlled V entilation IA Q — I ndoor Air Quali ty LA — Low Ambient Lockout Device OA T — Outdoo r-Air T emperat ure PO T — Potentiometer RA T — Return-Air T emperature P otentiome ter Defaults Settings: P ower Exhaust Middle Minimum P o[...]

— 18 — T able 3 — Suppl y Air Sensor T emperature /Resistan ce V alues G. EconoMi$ er IV Contr ol Mo des Determine the EconoMi$er IV control mode before set up of the control. Some modes of operatio n may r equire different sensors. R e fe r t o T ab le 4. The Econ oMi$e r IV is sup plied f rom th e fac- tory with a supply ai r temper ature s[...]

— 19 — Outdoor Enthalpy Changeover F or en thalpy control, accessory enthalpy sensor (part num- ber HH57 AC078) is requir ed. Repla ce the standa rd outdo or dry bul b temp erat ure sen sor wit h th e acce ssory enthalp y senso r in the same mou n ting lo ca tio n . Se e Fig. 21. When the outdoo r air ent halpy rises ab ove the outdo or enth al[...]

— 20 — CONTROL CURVE A B C D CONTROL POINT APPROX. °F (°C) A T 50% RH 73 (23) 70 (21) 67 (19) 63 (17) 1 2 1 4 1 6 1 8 2 0 2 2 2 4 26 28 30 32 3 4 3 6 3 8 40 42 4 4 46 9 0 1 0 0 80 70 60 50 4 0 3 0 20 1 0 E NT HA LP Y — B TU P E R PO U N D DR Y A IR 85 (29) 90 (32) 95 (35) 100 (38) 105 (41) 11 0 (43) 35 (2) 35 (2) 40 (4) 40 (4) 105 (41) 11 0[...]

— 21 — T o control t he min imum damp er positi on re motely , remo ve the fact ory-ins talled jumper on the P and P 1 termina ls on the EconoMi$er IV controller . W ire the field-supplie d poten- tiome ter t o the P an d P1 ter minals on th e Econo Mi$ er IV controll er . See F ig . 36. Dampe r Mov eme nt Damper movement from full open to full[...]

— 22 — Table 5 — CO 2 Sensor Standard Settings LEGEND ppm — Parts P er Million IX. STEP 9 — ADJU ST EV APORA TOR-F AN SPEED Adjust evaporator-fan speed to meet jobsi te condition s . T a bles 6A and 6B s h ow fan rp m at motor pulley settings fo r stan da rd a nd al t er na t e mo t o rs . T ables 7 an d 8 s ho w ev ap ora- tor fan motor [...]

— 23 — T able 7 — Ev aporator -Fa n Motor Data — St andar d Motor LEGEND Bhp — Brake Horsepo wer *Extensive motor and electrical testing on these units ensures that the full horsepower and wat ts range of the motors can be utilized wit h con- fidence. Using the f an motors up t o the ratings shown in this table will not result in n uisanc[...]

— 24 — T ab le 8 — Ev aporato r-F an Moto r Data — High-St atic Mot ors LEGEND Bhp — Brake Horsepo wer *Extensive motor and electrical testing on these units ensures that the full horsepower and wat ts range of the motors can be utilized wit h con- fidence. Using the f an motors up t o the ratings shown in this table will not result in n [...]

— 25 — T able 12 — F an P erf orma nce 581B 036 — V ertical Dischar ge Uni ts; High-Stati c Motor (Be lt Drive)* LEGEND *Motor drive r ange: 1075 to 1455 rpm. All other rpms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.40. 3. See page 33 f or general f an perfo[...]

— 26 — T able 14 — F an P erf orma nce 581B 048 — V ertical Dischar ge Uni ts; High-Stati c Motor (Be lt Drive)* LEGEND *Motor dr iv e range: 1075 to 1455 rpm. All other r pms require f ield- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.40. 3. See page 33 f or general f an pe[...]

— 27 — T ab le 16 — F an P erformanc e 581B06 0, Three -Phase — V ertical Dischar ge Un its; Standar d Motor (Bel t Drive)* LEGEND *Motor drive r ange: 1035 to 1460 rpm. All other rpms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.40. 3. See page 33 f or general[...]

— 28 — T able 18 — F an P e rf ormance 581B072 — V ertical Dischar ge Unit s; Standar d Motor (B elt Drive )* LEGEND *Motor dr iv e range: 1119 to 1585 rpm. All other r pms require f ield- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.40. 3. See page 33 f or general f an perfo[...]

— 29 — T able 20 — F an Perf ormance 581B036 — Horizonta l Disc harge Uni ts; Standar d Motor (Belt Driv e)* LEGEND *Motor drive range: 680 to 1044 rpm. All other r pms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 1.20. 3. See page 33 f or general f an performanc[...]

— 30 — T able 22 — F a n P erf ormance 581B048 — Horizonta l Disc harge Uni ts; Standar d Motor (Belt Drive)* LEGEND *Motor drive range: 770 to 1185 rpm. All other r pms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 1.20. 3. See page 33 f or general f an performan[...]

— 31 — T able 24 — F an Perf orman ce 581B0 60, Sing le-Phase — Horizonta l Disch arge Units ; Standar d Motor (Bel t Drive)* LEGEND *Motor drive r ange: 1035 to 1460 rpm. All other rpms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 1.30. 3. See page 33 f or gener[...]

— 32 — T able 26 — F an P erf orman ce 581 B060 — Horiz ontal Dis char ge Units; Hig h-Static Motor (Belt Drive )* LEGEND *Motor dr iv e range: 1300 to 1685 rpm. All other r pms require f ield- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.90. 3. See page 33 f or general f an [...]

— 33 — T able 28 — F an P erf orman ce 581 B072 — Horiz ontal Dis char ge Units; Hig h-Static Motor (Belt Drive )* LEGEND *Motor drive r ange: 1300 to 1686 rpm. All other rpms require field- supplied drive. NO TES: 1. Boldface indicates field-supplied drive is required. 2. Maximum continuous bhp is 2.90. 3. See below f or gener al f an perf[...]

— 34 — PRE-ST ART -UP Procee d as follows to in spect and pr epare the unit for initial start -up : 1. Remo ve all acce ss pane ls . 2. Read a nd fo llow in stru ction s on al l W ARNING , CA U- TION , and INFORMATION l abels attached to , or shipped with, unit. 3. Ma ke the fol lowi n g insp ect ions : a. Inspect for shipping and handling dama[...]

— 35 — 3. Reverse any two of the u nit pow er leads . 4. Ree nergize to the compre ssor . Ch eck pres sures. The suc tion a nd disch arge pressu re leve ls sho uld now move to their normal start-up levels. NO TE: Wh en the com pressor i s rotati ng in the w rong dire c- tion, the unit wi ll ma ke an eleva ted l evel o f nois e and will not pr o[...]

— 36 — A. T o Shut Off Unit Set system selector switch at off position. Re setting heating selector lever b elow room temp erature will te mporarily shu t unit off until space temperature fall s below t hermo stat set ting. XIII. SAFETY RELIEF A soft-solder joint at the s uction servi ce Schrader port provi des pres sure reli ef unde r abnorma [...]

— 37 — Hot Gas Re heat Mode When the h umidi ty level s in the s pace requ ire hum idity con- trol, a hot g as s ol eno id valve (specific t o hot gas reheat m ode only) will op en to b ypass a port ion o f hot g as re frigera nt around the conden ser co il (see F ig . 43). This hot gas will mix wi th liquid refrigerant leaving the con- denser [...]

— 38 — SER VICE I. CLEANING Inspect unit inter ior at the beginning of heatin g and cool ing season and as o perating condit ions re quire . A. Evaporator Coi l 1. Tu rn un it pow er o ff , tag disc on nect. Remo ve ev apo ra- tor coil acc ess p an el. 2. If economiz er or two-positio n damper is installed, remove economi zer by disconnectin g [...]

— 39 — A. No Charge Use s tanda rd ev acua ting techn ique s. Afte r evacu ati ng sy s- tem to 500 microns, weigh in the specified amount of refrig- erant. (Refe r to T able 1 an d unit info rma tion plate.) B. Low Char ge Cooling Using Cool ing Charg ing Charts , Fig. 48-51, vary refri gerant until the conditi ons of the char ts are met. Note [...]

— 40 — Fig. 48 — C ooling C harg ing Chart, Standar d 581 B036 Fig. 49 — Cooli ng Char ging Chart, Standar d 581B048 Fig. 50 — C ooling Ch argin g Chart, Standar d 581 B060 Fig. 51 — Cooli ng Char ging Chart, Standar d 581B072[...]

— 41 — NOT E : When using the charging cha rts, it is important that only the subcoo ling/reheat de hu- midification co il liquid line solenoid va lve be en ergized. The subcooli ng/reheat dehum idifica- tion co il liquid line solenoid va lve MUST be e nergize d to use the chargi ng charts and the outdoor mo tor speed co ntroller j umpered to r[...]

— 42 — E. T o Use Coolin g Charging Charts, Units With Pe rfect Humidity™ D ehumidifica tion Syst em Refer to charts (Fig. 52-55) to determin e the proper leaving conden ser pressu re and t emperatur e. Example (Fig . 52): Leaving Condenser Pressure . . . . . . . . . . . . . . . . . . . .250 psig Leaving Condenser T emperature . . . . . . . .[...]

— 43 — INDUCED- DRAFT MOT OR MOUNTING PLA TE INDUCED- DRAFT MO TOR MANIFOLD PRESSURE TA P VESTIBULE PLA TE FLUE EXHA UST ROLLOUT SWITCH BLO WER HOUSING GAS VA LV E BURNER SECTION Fig. 56 — Bu rner Section Details Fig . 57 — Burn er T ray D etai ls Fig. 58 — Spar k Ga p Adj ustm ent LO W HEA T UNITS 60,000 BTU H INPUT 581B0360 60N 581B0480[...]

— 44 — Fig. 59 — T ypical Wiring Sc hematic and Compo nent Arrangeme nt (208/230-3 -60 Sho wn) LEG END OFM — Outdoor ( Conden ser) Fan Motor OLR — Overload Rela y P— Plug PL — Plug Assembly QT — Quadrup le T ermin al RS — Rollout Switch SA T — Supp ly Air T empe rature Se nsor TRAN — T ransf or mer Field Splice Marked Wire T e[...]

— 45 — TROUBLESHOO TING I. UNIT TROUBLESHOO TING Refe r to T ables 32- 3 6. T able 32 — L ED Error Co de Service Analysis IMPORT ANT : Refer to heating troub leshooting f or additional heating section troubleshooting inf ormation. LE GEND SYMPT OM CA USE REME D Y Hard ware F ailure (LED OF F) Loss of power t o control module (IGC). Check 5 am[...]

— 46 — T ab le 33 — Heatin g Service Ana lys is T ab le 34 — Per fect H umidity™ Adap tive Dehum idificati on System Sub cooling M ode Service A nalys is T ab le 35 — P erfect Humidity Dehumidifi cation Sy stem Hot Ga s Reheat Mode Servic e Anal ysis PRO BLEM CA USE REMED Y Burner s Will Not Ignite Misaligne d spark electrod es. Chec k [...]

— 47 — T ab le 36 — Coolin g Service Anal ysis PROBLEM CA USE REMED Y Compressor and Condenser Fan Will Not St art P ower f ailure. Call pow er company . Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker . Defectiv e thermost at, contactor , transf ormer , or control rela y . Replace component. Insufficient line vol[...]

— 48 — II. ECONOMI$ER IV TR OUBLESHOO TING See T abl e 37 fo r Econo Mi$er IV lo gic . A func tional view of the EconoM i$er IV is s hown in Fig. 60. Typical set tings , sensor ranges , and jumper positions ar e also s hown. An Econo Mi$er I V simu lato r pr ogram is a vail- a b l e f r o m B r y a n t t o h e l p w i t h E c o n o M i $ e r I [...]

— 49 — G. EconoMi$ er IV T roubl eshootin g Completion This p ro c edur e i s u sed t o re t ur n t h e E c o noM i$ er I V to op e r a- tion. No troubl esho oting o r test in g is done by performing the follow in g proc edur e . 1. Disconnec t power at TR and TR1. 2. Set enthalpy potenti ome ter to previous setting . 3. Set DCV maximum po siti[...]

Copyright 2 005 Br yant He ating & C ooling Systems Pr inted in U.S.A. CA T ALOG N O. 04-53581002 -01 INDEX Access panel s 15 Altitude compensation 35 Barometric f low capacity 17 Burner ignition 42 Burner rac k 43 Burner section 43 Burner spark gap 43 Char ging chart, re frigera nt 40, 41 Clearance 4 CO 2 sensor Configuration 21 Settings 20, 2[...]

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Copyright 2 005 Br yant He ating & Coo ling Sy stems Printed in U.S .A. CL-1 CA T ALOG NO. 04-53581002- 01 CUT ALONG DO TTED LINE CUT ALONG DO TTED LINE ST A R T -UP CHECKLIST (Remov e and Sto re in Job File) I. PRELIMINAR Y INFORMA TION MODEL NO .: _________________________________ SERIAL NO .: ________________________________________ DAT E: _[...]