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Bryant 581A Air Conditioner User Manual

1. EQUIP GND CAP3 BOTTOM CAP2 MIDDLE CAP1 TOP EG I GAS SECTION FIELD POWER WIRING FIELD CONTROL WIRING OFM1 2 3 BLU PL1 R BLK 1 1 YEL DISCONNECT PER NEC I 3 5 1 mum am EH Gm COMP 10 6 2 GRN 1 amp 2 3 11 7 3 5 151 2 8 4 D ar LPS FPT HPS CH e t 182 182 182 182 3 OD 52 HS 3 ECONOMIZER OPTION ACCESSORY TR TR1 DM 0 93 50 OAT fiat CU 4 RESISTOR il RESISTOR 4 2 3 4 T1 5 Pif Fig 39 Typical Component Arrangement 581A180 Shown 34 TROUBLESHOOTING Refer to Tables 18 and 19 for troubleshooting details Table 18 Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and condenser fan will Call power company not start Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer Replace component or control relay Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly Thermostat setting too high Lower thermostat setting below room temperature Compressor will not start but Faulty wiring or loose co
2. Watts Bhp Rpm Watts Bhp _ Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 9 Fan Performance 581A180360 High Heat Units AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM cel 06 08 d 710 LRpm Watts Bhp Watts Bhp Rpm Watts Bhp Watts Bhp Watts Bhp_ AT UY d ge CD NUT T ID Oo AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 14 16 18 gt 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts CFM AVAILABLE EXTERNAL STATIC PRESSURE in wg __ __ 22 _ __ 2 _ _ 26 __ ee En ee Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Watts
3. CFM CFM LEGEND Bhp Brake Horsepower Factory Installed Option Watts Input Watts to Motor Standard low medium static drive range is 834 to 1064 rpm Alternate high static drive range is 1161 to 1426 Other roms require a field supplied drive NOTES 1 Maximum continuous bhp for the standard motor is 3 13 The maxi mum continuous watts is 2700 Do not adjust motor rom such that motor maximum bhp and or watts is exceeded at the maximum operating cfm 02 2 204 _ J406 _ 590 10 Rpm Watts Bhp Rpm Wes Bhp Rpm Watts Bhp Watts Bhp Watts Bhp_ AVAILABLE EXTERNAL STATIC PRESSURE wg 211 14 Rpm Watts Bhp Rpm Watts Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bnp 2 Static pressure losses i e must be added to external static pressure before entering Fan Performance table 3 Interpolation is permissible Do not extrapolate 4 Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information 5 Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure
4. Connect service gages to suction and discharge pres sure fittings 2 Energize the compressor 3 The suction pressure should drop and the discharge pressure should rise as is normal on any start up If the suction pressure does not drop and the discharge pres sure does not rise to normal levels l Notethat the evaporator fan is probably also rotating in the wrong direction 2 Turn off power to the unit 3 Reverse any two of the incoming power leads 4 Turn on power to the compressor The suction and discharge pressure levels should now move to their normal start up levels 4 NOTE When compressors are rotating in the wrong direc tion the unit will have increased noise levels and will not provide heating and cooling After a few minutes of reverse operation the scroll compres sor internal overload protection will open which will acti vate the unit s lockout and requires a manual reset Reset is accomplished by turning the thermostat on and off VI INTERNAL WIRING Check all electrical connections in unit control boxes tighten as required Vil CRANKCASE HEATER S Crankcase heater s is energized as long as there is power to the unit and the compressor is not operating IMPORTANT Unit power must be on for 24 hours prior to start up Otherwise damage to compressor may result Vill EVAPORATOR FAN Fan belt and variable pulleys are factory installed Remove tape from the fan pulley See Table
5. Ht t mz 1m 10 129 1257 125 193 n Approximate fan rpm shown TIndicates standard drive package Indicates alternate drive package TTDue to belt and pulley style pulley cannot be set to this number of turns open E NEM 203 0 3 5 0 2 tc D ep tr n O 04 gt I 0 3500 4000 4500 5000 Fig 27 Fan Performance Using Accessory Power Exhaust GAS HEAT Verify gas pressures before turning on heat as follows l Turn off manual gas stop 2 Connect pressure gage to supply gas pressure tap see Fig 13 3 Connect pressure gage to manifold pressure tap on gas valve 4 Turn on manual gas stop and set thermostat to HEAT position After the unit has run for several minutes verify that incoming pressure is 5 5 in wg or greater and that the manifold pressure is 3 3 in wg If manifold pressure must be adjusted refer to Gas Valve Adjustment section on page 29 5 After unit has been in operation for 5 minutes check temperature rise across the heat exchangers See unit informative plate for correct rise limits of the heat supplied Air quantities may need to be adjusted to bring the actual riseto within the allowable limits XIV BASE UNIT OPERATION A Cooling Units Without Economizer When thermostat calls for cooling terminals G and Y 1 are energized The indoor evaporator fan contactor IFC and compresso
6. i 5 EL a a a So e y 2 4 07 4 1 6 5 167 Nx 77 RUE e md Nome dcum om ce m 102 466 1 7 T n VIEW Z Z 4 m POWER EXHAUST y RIGHT 0 3 BAROMETRIC RELIEF j 7 SINE 76 ACCESSORY ONLY 4 ut 3 8 467 0 10 1 41 V 260 HL lt BENE 0 3 E 1 3 5 8 amp 1 3 8 DIA CONCENTRIC a 76 b 0 4 0 2 7 8 92 amp 35 FIELD POWER Q c3 mm 73 7 8 DIA K 0 CONTROL Mm n INDOOR COIL 0 3 7 8 22 1 1 4 DIA HOLE 8 ALTERNATE RETURN 98 1 1 2 DIA GAS ENTRY 3 4 NPT 32 102 3 4 FPT DRAIN CONNECTION 1722 187 E SUPP 310 SUPPLIED 27 FAR SIDE ONLY s 0 2 yg be SECTION Fig 4 Base Unit Dimensions 581 155 and 180 ECONOMIZER STD UNIT WEIGHT WEIGHT UNIT 581A240 550 LBS 250 KG 1 3 8 DIA DRAIN HOLE 1900 Ibs 862 kg 110 165 50 kg TYP 4 PLCS 443 LBS 201 KG NOTES uc E NUM 7 mee 1 Refer to print for roof curb accessory dimensions 1 7 13 16 em 1 4 5 1671 4 9 16 0 3 18 16 9 1 5 16 0 5 15 16 2 Dimensions in are in millimeters 0 B 1 8 REAR 504 415 421 e 33 151 aR 2 3 e Center of Gravity ES 0 4 5716 m 109 4 Direction of airflow zo 5 Ductwork to be attached to accessory roof curb only
7. power supply 60 Hz Motormaster Control Recommended mounting location is beneath the control box mounted tothe partition that sep arates the control box section from the indoor section NOTE If unit power is supplied through the roof curb and basepan of the unit mount the Motormaster 111 control on the corner post adjacent to the conduit running from the basepan to the bottom of the control box START UP Use the following information and Start Up Checklist on page CL 1 to check out unit PRIOR to start up UNIT PREPARATION Check that unit has been installed in accordance with these installation instructions and all applicable codes Il SERVICE VALVES Ensure that the liquid line service valve is open Damage to the compressor could result if it is left closed COMPRESSOR MOUNTING Compressors are internally spring mounted Do not loosen or remove compressor holddown bolts IV REFRIGERANT SERVICE PORTS Each refrigerant system has a total of 3 Schrader type ser vice gage ports One port is located on the suction line one on the compressor discharge line and one on the liquid line In addition Schrader type valves are located underneath the low pressure switches Be sure that caps on the ports are tight V COMPRESSOR ROTATION It is important to be certain the compressors are rotating in the proper direction To determine whether or not compres sors are rotating in the proper direction l
8. roof curb Al Aluminum Circuit 1 uses the lower portion of condenser coil and lower portion of evaporator coils and Bhp Brake Horsepower Circuit 2 uses the upper portion of both coils Copper tPulley has 6 turns Due to belt and pulley moveable pulley cannot be set to 0 to 1 turns open Thermostatic Expansion Valve Rollout switch is manual reset Ill STEP 3 FIELD FABRICATE DUCTWORK On vertical units secure all ducts to roof curb and building structure Do not connect ductwork to unit Use flexible duct connectors between unit and ducts as required Adequately insulate and weatherproof all ductwork located outdoors joints and roof openings with counter flashing and mastic accordance with applicable codes Insulate ducts passing through unconditioned space and use vapor barrier in accor dance with the latest issue of SMACNA Sheet Metal and Air Conditioning Contractors National Association and ACCA Air Conditioning Contractors of America minimum instal lation standards for heating and air conditioning systems Ducts passing through an unconditioned space must be insu lated and covered with a vapor barrier A minimum clearance to combustibles of 1 in for the first 24 in of ductwork is required for all units with electric heat Cabinet return air static shall not exceed 0 35 in wg with economizer or 0 45 in wg without economizer IV STEP 4 MAKE UNIT DUCT CONNECTIONS Unit is sh
9. Elecrical Code requirements of adequate size Table 2 All field wiring must comply with NEC and local require ments Insulate low voltage wires for highest voltage con tained within conduit when low voltage control wires are run in the same conduit as high voltage wires INDOOR MOTOR ACCESS FILTER ACCESS 3 4 DRAIN 1 3 8 DRAIN HOLE Fig 11 Condensate Drain Details 581A155 Shown 3 4 FPT DRAIN CONNECTION HALF COUPLING 2 IN FIELD SUPPLIED NIPPLE BASE RAIL 8 1 2 IN FIELD SUPPLIED NIPPLE Fig 12 Condensate Drain Piping Details MANUAL SHUTOFF FIELD SUPPLIED GAS 4 SUPPLY PRESSURE TAP 1 8 NPT PLUG SEDIMENT TRAP Fig 13 Field Gas Piping Route power and ground lines through control box end panel or unit basepan see Fig 4 and 5 to connections as shown on unit wiring diagram and Fig 14 NCAUTION The correct power phasing is critical in the operation of the scroll compressors An incorrect phasing will cause the compressor to rotate in the wrong direction This may lead to premature compres sor failure WARNING The unit must be electrically grounded in accordance with local codes and NEC ANSI NFPA 70 National Fire Protection Association Field wiring must conform to temperature limitations for type T wire All field wiring must comply with NEC and local
10. Nominal Cfm Quantity Diameter in Motor Hp Rpm Watts Input Total EVAPORATOR COIL Rows Fins in Total Face Area sq ft EVAPORATOR FAN Quantity Size in Type Drive Nominal Cfm Std Motor Hp Opt Motor Hp Motor Nominal Rpm Std Maximum Continuous Bhp Opt Maximum Continuous Bhp Motor Frame Size Fan Rpm Range Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Dia Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Nominal Fan Shaft Diameter in Belt Quantity Type Length in Pulley Center Line Distance in Speed Change per Full Turn of Movable Pulley Flange Rpm Movable Pulley Maximum Full Turns From Closed Position Factory Speed Factory Speed Setting Rpm FURNACE SECTION Rollout Switch Cutout Temp F Il Burner Orifice Diameter in drill size Natural Gas Thermostat Heat Anticipator Setting Stage 1 amps Stage 2 amps Gas Input Btuh Stage 1 Stage 2 Efficiency Steady State Temperature Rise Range Manifold Pressure in wg Natural Gas Gas Valve Quantity Gas Valve Pressure Range in wg psig Field Gas Connection Size in FPT HIGH PRESSURE SWITCH psig Cutout Reset Auto LOW PRESSURE SWITCH psig Cutout Reset Auto FREEZE PROTECTION THERMOSTAT F Opens Closes Low Medium Static High Static Low Medium Static High Static Low Medium Static High Static Low Medium Static High Static Low Medium Static High Stat
11. STD UNIT ECONO CORNER CORNER CORNER CORNER UNIT WEIGHT MIZER A B C D DIMC 581A WEIGHT ft in Lb Kg Kg Lb Kg Lb Kg ftin mm mm ftin mm 1725 199 470 213 1051 1800 218 228 3 2 961 3 6 1070 1 10 1 3 8 DIA DRAIN HOLE o gt CORNER D i CORNER A 1 Refer to print for roof curb accessory dimensions 4 PLCS 2121 eae 0 3 7 8 6 11 1 2 2 Dimensions in are in millimeters 99 z 17 7 13 16 1 4 5 16 1 4 9 16 m 0 3 15 16 0 5 15 16 i 0 8 1 8 504 415 421 108 d d 151 d Center of Gravity 206 T 33 5 07 4 5 16 109 4 Direction of airflow 5 Ductwork to be attached to accessory roof curb only 6 Minimum clearance e Rear 7 0 2134 for coil removal This dimension can be reduced 2 B 15 15 to 4 ft O in 1219 if conditions permit coil removal from the top SUPPLY Tom 2 00 4 ft 0 in 1219 to combustible surfaces all four sides includes between OUTDOOR AIR 50 DIA units SECTION TP Hane pose Left side 4 0 in 1219 for proper condenser coil
12. Unit warranty will not be affected 6 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details 15 Table 4 Fan Performance 5814155225 Low Heat Units with Optional Indoor Fan Motor AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM 1 04 06 V 08 d 10 LRpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Watts Bhp Rpm Watts Bhp_ COON Too o NR AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM LEGEND 2 Bhp Brake Horsepower FIOP Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 834 to 1064 rpm Alternate high static drive range is 1161 to 1426 Other roms require a field supplied drive 5 1 Maximum continuous bhp for the optional motor is 4 38 The maxi mum continuous watts is 3775 Do not adjust motor rpm such that motor maximum bhp and or watts is exceeded at the maximum 6 operating cfm ___ 14 16 1 8 20 S Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Watts Bhp Rpm Watts Bhp _ Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13
13. above by using an ammeter to determine the exact setting for stages 1 and 2 Failure to make a proper heat anticipator adjustment may result in improper operation discomfort to the occupants of the conditioned space and inefficient energy utilization however the required setting may be changed slightly to pro vide a greater degree of comfort for a particular installation Refer to Accessory Remote Control Panel instructions if required STEP 9 MAKE OUTDOOR AIR INLET ADJUSTMENTS A Manual Outdoor Air Damper All units except those equipped with a factory installed economizer have a manual outdoor air damper to provide ventilation air Damper can be preset to admit up to 2596 outdoor air into return air compartment To adjust loosen securing screws and move damper to desired setting Retighten screws to secure damper Fig 16 B Optional Economizer Economizer Motor Control Module See Fig 17 19 The economizer control location is shown Fig 17 For maxi mum benefit of outdoor air set economizer motor control module to the D setting Fig 18 The economizer motor control module is located on the economizer motor See Fig 19 THERMOSTAT ASSEMBLY Fig 15 Field Control Thermostat Wiring Table 2 Electrical Data NOMINAL VOLTAGE COMPRESSOR POWER COMBUSTION POWER Wr Pera EXHAUST FANMOTOR SUPPLY j RLA LRA Qty Hp Hp FLA FLA LRA FLA MCA MOCP 57 7
14. baffle details Use 20 gage galvanized sheet metal or similar corrosion resistant metal for baffles Use field supplied screws to attach baffles to unit Screws should in diameter and long Drill required screw holes for mounting baffles CAUTION To avoid damage to the refrigerant coils and electrical components use recommended screw sizes only Use care when drilling holes LOCATION HAIRPIN END NOTES 1 All sensors are located on the eighth hairpin up from the bottom 2 Field installed tubing insulation is required to be installed over the TXV thermostatic expansion valve bulb and capillary tube for proper operation at low ambients Tubing insulation is only required on the portion of suction line located between indoor and outdoor section Fig 26 Motormaster and Motormaster Sensor Locations Replace Outdoor M otor Replace outdoor fan motor no 1 with motor included in accessory kit Existing motor is not Motormaster 111 compati ble Install Motormaster 111 Controls Only one Motormaster 111 control is required per unit Sensor Install the sensor for thermistor input control in the location shown in Fig 26 Connect sensor leads to the purple and grey control signal leads the M otormaster 111 control Signal Selection Switch Remove the cover of the Motor master control Set the switch to accept the thermistor sensor input signal Set the frequency to match the unit
15. bhp for the standard motor is 6 13 The maxi mum continuous watts is 5180 Do not adjust motor rom such that motor maximum bhp and or watts is exceeded at the maximum 6 operating cfm __ __ 22 24 5 _ __ 3 728 90 22 Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Watts Bhp Watts Bhp _ Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 6 Fan Performance 581A240270 Low Heat Units AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM NANOROWO 4 5 5 6 7 7 8 9 ___ 022 _ 1 08 49 __ Watts Bhp Rpm Watts Bhp Bhp Bhp Watts Bhp _ AVAILABLE EXTERNAL STATIC
16. im 0 MOTOR PULLEY SN 10 5 N HI dfi MOTOR PLATE WY rae N N N Ls N EN SEE NOTE b M JACKING PLATE MOTOR SUPPORT HANNEL BOLT 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 The adjustment bolt is 16 x 1 in LG Fig 32 581A180 and 240 Evaporator Fan Motor Section 6 Remove jacking bolt and tapped jacking bolt plate 7 Remove the 2 screws that secure the motor mounting plate to the motor support channel 8 Remove the 3 screws from the end of the motor sup port channel that interfere with the motor slide path 9 Slide out the motor and motor mounting plate 10 Disconnect wiring connections and remove the 4 mounting bolts 11 Remove the motor 12 Toinstall the new motor reverse Steps 1 11 V BELT TENSION ADJUSTMENT To adjust belt tension l Loosen fan motor bolts 2 Size155 Units Move motor mounting plate up or down for proper belt tension 1 5 in deflection with one finger Size 180 and 240 Units Turn motor jacking bolt to move motor mounting plate up or down for proper belt tension 3 5 in deflec tion at midspan with one finger 9 b force Tighten nuts Adjust bolts and nut on mounting plate to secure motor in fixed position VI CONDENSER FAN ADJUSTMENT
17. information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 8 Fan Performance 581A155300 High Heat Units with Optional Indoor Fan Motor AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM 1 04 06 0 LRpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Watts Bhp Rpm Watts Bhp_ AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 27 1 42 1 59 1 77 1 97 2 18 2 41 2 65 2 91 3 18 CFM 2 27 2 43 2 62 2 81 3 02 3 25 3 49 3 75 4 03 4 32 LEGEND 2 Bhp Brake Horsepower Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 834 to 1064 rpm Alternate high static drive range is 1161 to 1426 Other roms require a field supplied drive 5 1 Maximum continuous bhp for the optional motor is 4 38 The maxi mum continuous watts is 3775 Do not adjust motor rpm such that motor maximum bhp and or watts is exceeded at the maximum 6 operating cfm p 12 _ A 16 1 8 gt gt 020 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp
18. mount assembly back past original position toward evaporator coil 8 Remove motor mounting nuts D and E both sides 9 Lift motor up through top of unit 10 Reverse above procedure to reinstall motor 11 Check and adjust belt tension as necessary B 581A180 and 240 Units See Fig 32 The 581A 180 240 units use fan motor mounting sys tem that features a slide out motor mounting plate To replace or service the motor slide out the bracket 1 Remove the evaporator fan access panel and the heating control access panel 2 Removethe center post located between the evapora tor fan and heating control access panels and all screws securing it 3 Loosen nuts on the 2 carriage bolts in the motor mounting base 4 Using jacking bolt under motor base raise motor to top of slide and remove belt Secure motor in this position by tightening the nuts on the carriage bolts 5 Remove the belt drive a PANT S STRAIGHTEDGE MUST i BE PARALLEL T WITH BELT ENSURE PROPER CLEARANCE BETWEEN BELT S AND FAN SUPPORT NOTCH PULLEY gt MOVABLE FLANGES PULLEY MOTOR AND FAN SHAFTS MUST BE PARALLEL SETSCREWS FIXED FLANGES SINGLE GROOVE Fig 30 Evaporator Fan Alignment and Adjustment SEN A MOTOR UNIT TOP PANEL FAN SCROLL SIDE PLATES DRAIN CONNECTION Fig 31 581A155 Evaporator Fan Motor Adjustment FAN PULLEY CENTER POST BELT Q n r
19. numbers sig nifies a single pole double throw contact An underlined number signifies a normally closed contact A plain no line number signifies a normally open contact FROM WIRE DIAGRAM SHEET 1 FROM WIRE I AGRAM SHEET 1 SSS ECONOMIZER OPTION AC DQe Joo Terminal Marked Terminal Unmarked Terminal Block Splice Splice Marked Splice Field Supplied Factory Wiring Field Control Wiring Field Power Wiring Accessory or Optional Wiring To Indicate Common Potential Only Not To Represent Wiring CESSORY TR BRN BLK P1 TRI a 100 3 BLK BLK RESISTOR RESISTOR m BLU YEL 2 CLS 3 WHT 4 ADJUSTMENT A MINIMUM POSITION T PNK Fig 38 Typical Wiring Schematic 581A180 208 230 V Shown 3J MINIMUM 24 VAC MIXED AIR SENSOR POSITION 20 22 OFC QT YEL 4 YEL YEL Fo BRN BRN BLK FUT IPs Hi uud YEL YEL OFM1 YEL rte 2 YEL 21 ve 2 fee sk BLK BLU Lo BRN 3 CAP3 3 YEL OFM3 C1 DU1 o BLK BLK BLK a BLU IDM mr EO BLK YEL 62 01 BLK cn2 CH1 BLK 6X5 BLK e e C2 DU1 BLK CH2 BLK BLK S
20. of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 7 Fan Performance 5814155300 High Heat Units with Standard Indoor Fan Motor AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM w C2 ci I Oo T 1 1 1 1 2 2 2 2 AVAILABLE EXTERNAL STATIC PRESSURE wg CFM LEGEND 2 Bhp Brake Horsepower FIOP Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 834 to 1064 rpm Alternate high static drive range is 1161 to 1426 Other roms require a field supplied drive 5 NOTES 1 Maximum continuous bhp for the standard motor is 3 13 The maxi mum continuous watts is 2700 Do not adjust motor rpm such that motor maximum bhp and or watts is exceeded at the maximum 6 operating cfm 9 02 0 09 LRpm Watts Bhp Hpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp _ 1212 14 16 418 20 Watts Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp _ Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure
21. requirements Transformer 1 1 wired for 230 v unit If 208 230 v unit is to be run with 208 v power supply the transformer must be rewired as follows 1 Remove cap from red 208 v wire 2 Remove cap from orange 230 v spliced wire 3 Replace orange wire with red wire 4 Recap both wires IMPORTANT BE CERTAIN UNUSED WIRES ARE CAPPED Failure to do so may damage the transformers Operating voltage to compressor must be within voltage range indicated on unit nameplate On 3 phase units volt ages between phases must be balanced within 2 Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components Such operation would invalidate any warranty B Field Control Wiring Theunit must have a separate electrical service with a field supplied waterproof fused disconnect switch mounted at or within sight from the unit Refer to the unit rating plate for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing Be sure disconnect switch does not obstruct unit rating plate The field supplied disconnect switchbox may be mounted on the unit over the high voltage inlet hole in the control corner panel FIELD 70707 POWER wo Ht la 4 0 EQUIP GND l NOTE The maximum wire size for TB1 is 2 0 LEGEND EQUIP E
22. there is main power to the unit and the compressor is not energized IMPORTANT After prolonged shutdown or servicing ener gize the crankcase heaters for 24 hours before starting the compressors Compressor L ockout If any of the safeties high pressure low pressure freeze protection thermostat compressor internal thermostat trip or if there is loss of power to the compressors the cooling lockout CLO will lock the compressors off To reset manu ally move the thermostat setting B Evaporator Fan Motor Protection On size 155 units an internal protector with auto reset is Included in the indoor fan motor as a protection against overcurrent On size 180 and 240 units a manual reset calibrated trip magnetic circuit breaker protects against overcurrent Do not bypass connections or increase the size of the breaker to correct trouble Determine the cause and correct it before resetting the breaker REGULATOR ADJUSTMENT SCHEW REMOVE COVER PILOT ADJUSTMENT SCREW REMOVE COVER Fig 36 Gas Valve 29 C Condenser Fan Motor Protection Each condenser fan motor is internally protected against overtemperature D High and Low Pressure Switches If either switch trips or if the compressor overtemperature switch activates that refrigerant circuit will be automati cally locked out by the CLO To reset manually move the thermostat setting E Freeze Protection Thermostat FPT An FPT is locat
23. utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 11 Air Quantity Limits MINIMUM CFM 3600 4500 6000 MAXIMUM CFM 6 000 7 900 10 000 Table 12 Evaporator Fan Motor Specifications NOMINAL MAX MAX MAX vortace wars EFF Bip Bw _ 2 9 208 2700 85 8 3 13 2 34 230 2700 85 8 3 13 2 34 460 2 00 85 8 3 13 2 34 208 3775 85 8 4 38 3 27 230 3 75 85 8 4 38 3 27 460 3775 85 8 4 38 3 27 208 0180 87 596 6 13 4 57 230 5180 87 5 6 13 4 57 460 5180 87 5 6 13 4 57 208 7915 88 5 9 47 7 06 230 8640 88 5 10 33 7 71 8640 88 5 10 33 7 71 155 Standard Motor 155 Optional Motor 9 46 8 6 4 3 10 5 10 5 4 8 15 8 15 8 6 000 7 200 9 000 10 000 NOTES 1 The factory assembled horizontal adapter substantially improves fan performance See Fig 27 2 The static pressure must be added to external static pressure The sum and the evaporator entering air cfm should then be used in con junction with the Fan Performance table to determine blower rpm bhp and watts LEGEND bhp Brake Horsepower FIOP Factory Installed Option Table 14 Fan RPM at Motor Pulley Setting 9 3 mi 27 3 359 me s 52 5 H tt
24. 0 7 pee p D e Be Be Standard IFM 42 0 30 29 35 2 22 0 30 31 40 11 0 0 57 61 61 80 80 os 208020 x s per m D ue 505 Optional 0 30 30 35 IFM 4 8 EE 15 8 0 57 82 82 110 110 208 230 fos te 110 110 25 0 0 57 124 124 150 150 208 230 be be Ss LS 129 129 150190 ee De Dee Pe Pe oe Pe SE LEGEND EXAMPLE Supply voltage is 460 3 60 A B C i 460 79 0 30 41 50 2 3 3 0 30 43 50 FLA Full Load Amps AB 452 v HACR Heating Air Conditioning and Refrigeration BC 464 v IFM Indoor Evaporator Fan Motor AC 455 v LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection NEC National Electrical Code 9 Average Voltage epee OFM Outdoor Condenser Fan Motor Listed Lister 3 RLA Rated Load Amps 1371 Fuse or HACR circuit breaker 457 In compliance with NEC requirements for multimotor and combination load equipment refer Determine maximum deviation from average voltage to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or 457 452 5v HACR breaker Canadian units may be fuse or circuit breaker e 464 457 7 2 Unbalanced 3 Phase Supply Voltage ye 457 455 MM Never operate a motor where a phase imbalance in supply voltage is greate
25. 6 Minimum clearance 3 2 6 15 50 DIA HOLE e Rear 7 ft 0 in 2134 for coil removal This dimension can be reduced to 042 16 TYPICAL i ER 786 2 31 4 ft 0 in 1219 if conditions permit coil removal from the top e 4ft 0 in 1219 to combustible surfaces all four sides includes between units e Left side 4 0 in 1219 for proper condenser coil airflow RETURN Sar aug 1 174 DIA HOLE e Front 4 0 in 1219 for control box access oca AIR 1825 Right side 4 0 in 1219 for proper operation of damper and power 1707 537 TYPICAL 4 CORNERS exhaust if so equipped 1753 e 6 0 in 1829 to assure proper condenser fan operation 2 1487 Bottom 14 in 356 to combustible surfaces when not using curb 52787 e Control box side 3 ft 0 in 914 to ungrounded surfaces non combustible e Control box side 3 ft 6 in 1067 to block or concrete walls or other diu eR grounded surfaces 662 POWER EXHAUST Local codes or jurisdiction may prevail BAROMETIC RELIEF 7 With the exception of clearance for the condenser coil and the damper power ACCESSORY ONLY exhaust as stated in Note no 6 a removable fence or barricade requires no clearance rene aver 8 Dimensions are from outside of corner post Allow 0 ft 46 in 8 on each 274 e 20 7 3 47 283 side for top cover drip edge 197 a 3 amp 7 8 DIA CONCENTRIC OUTDOOR 3 us BRE 76 amp 22 FIELD PO
26. A 581A155 and 180 Units Fig 33 l Shut off unit power supply 2 Remove access panel s dosest to the fan to be adjusted 3 Loosen fan hub setscrews 4 Adjust fan height on shaft using a straightedge placed across the fan orifice 5 Tighten setscrews and replace panel s 6 Turn on unit power E B 581A240 Units Fig 34 l Shut off unit power supply 2 Remove fan top grille assembly and loosen fan hub SCrews 3 Adjust fan height on unit using a straightedge placed across the fan orifice 0 0 0 25 NOTE Dimension is in inches Fig 33 Condenser Fan Adjustment 581A155 and 180 SHIELD NOTE Dimension is in inches Fig 34 Condenser Fan Adjustment 581A240 4 Tighten setscrews and replace rubber hubcap to pre vent hub from rusting to motor shaft 5 Fill hub recess with permagum if rubber hubcap is missing Vil ECONOMIZER ADJUSTMENT See Tables 16 and 17 for checkout and outdoor air tempera ture simulation Make certain the outdoor air damper is fully dosed and the return air damper is fully open before completing the following steps 1 Turn on power to the unit 2 Turn the thermostat fan switch to the ON position The damper will goto the vent position 3 Adjust the vent position with the minimum damper position adjustment on the economizer motor control module See Fig 18 4 Set the system selector switch to COOL position and set the cooling temperatur
27. Bhp Rpm Watts Bhp _ LEGEND 2 Bhp Brake Horsepower FIOP Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 873 to 1021 rpm Alternate high static drive range is 1025 to 1200 Other roms require a field supplied drive 5 NOTES 1 Maximum continuous bhp for the standard motor is 6 13 The maxi mum continuous watts is 5180 Do not adjust motor rom such that motor maximum bhp and or watts is exceeded at the maximum 6 operating cfm Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 10 Fan Performance 5814240360 High Heat Units AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM 0 5 7 0 8 ___ 022 004 1 19 Rpm Watts Bhp Rpm W
28. EE NOTE 5 YEL YEL CH2 TB2 RoT ORN BLK YEL R TRANI RED BRN IFC Ca 24 5 BRN TB2 RED GRN YEL IGC C2 9 10 TRANI YEL FLAME_SEN YEL I GRN YEL a_ C TRAN GROUNDED THRU STANDOFF BRN BRN C TRANI Bt CFC ern C 6c 13 ETD TA HPS1 LPSI 1 M er PL1 5 PL1 8 Q e VIO Ci cr c2 BRN C2 1 2 3 V0 29 eo vI0 e VIO e YEL BLU BRN WHT T BRK W ATI PRI 1 5 1 WHT CLO1 NOTE 6 CT BRK WAATA FIELD THERMOSTAT ORN NOTE 3 PRI gt 1 511 BRN bi HPS2 LPS2 ORN GENER die cia Ci c2 c2 BRN IFC 5 6 7 PL1 6 YEL gt gt gt PNK CLO2 NOTE 6 PL1 9 WHT PNK BRN PL1 1 BRN a TO ECONOMIZER OPTION ACCESSORY BLK TO ECONOMIZER OPTION ACCESSORY SS BLY L PNK Fig 38 Typical Wiring Schematic 581 180 208 230 V Unit Shown cont 33 CONTROL BOX D 2 3 OO CD 2 5 QO CLO 1 CLO 2 ECD 42 d3 00 G2 o e e e e ODU2 DUIO YEL 2 COM 0RN4 230 TRANI RED 208 e BLK1 4680 A
29. OF UNIT 5 Roof curb 16 ga VA03 56 stl Installation 2 El E NOTE To prevent the hazard of stagnant water build up in the drain Side Supply pan of the indoor section unit can only be pitched as shown and Return CRRFCURBO12A00 Curb for High Installation SUPPLY RETURN 2 OPENING OPENING CURB CURB 6 2 3 16 5 9 CONDENSER 1885 1753 COM RE SEG REF SUPPLY OPENING END CONDENSATE DRAIN CONDENSER KEEP THIS AREA CLEAR FOR 1 7 PONER GAS ENTRY FOR GAS FIRED ROOFTOPS END B 0 1 4 IS SON NON pev zi 1 li 107 5 3 16 EIL _ _ SEED EIN LE 132 1 Haigh eh Ke 305 ATTACH DUCT TO ROOF CURB 1 1 15 16 349 1 7 13 16 504 1 3 16 17 10 3 4 310 578 MITERED CORNERS ONLY UNIT LEVELING TOLERANCES XFrom edge of unit to horizontal INSULATED PANEL FOR SIDE SUPPLY AND RETURN CCRRFCURBO12A00 ONLY NAIL GASKET GHT SUPPLIED WITH CURB TABLE COUNTER FLASHING FIELD SUPPLIED ROOFING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL FIELD SUPPLIED DUCT FIELD SUPPLIED 5 6 1676 CCRRFCURBO12A00 ONLY SCG GQ 4 CORNERS UNIT OPENINGS 5 N j 7 13716 CRRFCURBO12A00 ONLY 504 E hr jest ar 5 16 0 B 178 155 RIGID INSULATION SU
30. PPLY RETURN FIELD SUPPLIED 02 7 ETURN 5 7 1 16 1885 1703 i OPTIONAL us SIDE SUPPLY 4 0 2 1 2 CRRFCURBO12A00 ONLYO 64 CCRRFCURBO12A00 ONLY SECTION A A Fig 1 Roof Curb Details EVAPORATOR FAN MOTOR 581A155 EVAPORATOR FAN MOTOR 581A180 240 2596 VENT AIR ECONOMIZER HOOD AIR IN TRANSITION CRRFCURBO12A00 DUCT OR HORIZONTAL ADAPTER ROOF CURB CRRFCURBO13A00 HORIZONTAL SUPPLY CURB NOTE For preassembled horizontal adapter roof curb part no CRRFCURBO13A00 the accessory kit includes a factory designed high static regain transition duct For horizontal curb part no CRRFCURBO 12A00 a field supplied transition duct is required Fig 2 Horizontal Adapter Roof Curbs and Roof Curbs IMPORTANT Curb or adapter roof curb must belevel This is necessary to permit unit drain to function properly Unit lev eling toleranceis 1 in per linear ft in any direction Refer to Accessory Roof Curb or Horizontal Supply Roof Curb Installation Instructions for additional information as required When accessory roof curb or horizontal supply roof curb is used unit may be installed on dass A B or C roof covering material IMPORTANT The gasketing of the unit to the roof curb or adapter roof curb is critical for a watertight seal Install gas ket with the roof curb or adapter as shown in Fig 1 mprop erly applied gasket can also result in ai
31. PRESSURE in wg CFM 6 000 6 500 7 000 7 500 8 000 8 500 9 000 9 500 10 000 LEGEND 2 Bhp Brake Horsepower FIOP Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 1002 to 1151 rpm Alternate high static drive range is 1193 to 1369 Other rpms require a field supplied drive 9 NOTES 1 Maximum continuous bhp for the standard motor is 9 47 for 208 v units and 10 33 for 230 and 460 v units The maximum continuous watts is 7915 for 208 v units and 8640 for 230 and 460 v units 6 Do not adjust motor rpm such that motor maximum bhp and or watts is exceeded at the maximum operating cfm 18 _ 242 _ 03 _ 2 _ 99 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use
32. R FANS MUST BE OPERATING LIQUID TEMPERATURE AT LIQUID VALVE DEG F 50 100 150 200 250 300 350 400 LIQUID PRESSURE AT LIQUID VALVE PSIG Fig 35 Cooling Charging Chart X GAS VALVE ADJUSTMENT A Natural Gas The gas valve opens and doses in response to the thermostat or limit control When power is supplied to valve terminals D1 and C2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 3 in wg To adjust regulator 1 Set thermostat at setting for no call for heat 2 Turn main gas valveto OFF position 3 Remove s in pipe plug from manifold or gas valve pressure tap connection Install a suitable pressure measuring device 4 Set main gas valveto ON position Set thermostat at setting to call for heat 6 Remove screw cap covering regulator adjustment screw See Fig 36 7 Turn adjustment screw clockwise to increase pres sure or counterclockwise to decrease pressure 8 Once desired pressure is established set thermostat setting for no call for heat turn off main gas valve remove pressure measuring device and replace s in pipe plug and screw cap MAIN BURNERS For all applications main burners are factory set and should require no adjustment ud A Main Burner Removal l Shu
33. RIFICE AND VERIFY SETSCREWIS TIGHT O VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SCROLL COMPRESSOR IS ROTATING IN THE CORRECT DIRECTION O VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED 24 HOURS BEFORE START UP ll START UP ELECTRICAL SUPPLY VOLTAGE L1412 243 131 COMPRESSOR AMPS COMPRESSOR NO 1 1 12 13 COMPRESSOR NO 2 11 12 J 13 SUPPLY FAN AMPS EXHAUST FAN AMPS ____ TEMPERATURES OUTDOOR AIR TEMPERATURE DB Dry Bulb RETURN AIR TEMPERATURE FDB _____ Wet Bulb COOLING SUPPLY AIR GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE WG GAS MANIFOLD PRESSURE STAGE NO 1 IN WG STAGENO 2 IN WG REFRIGERANT SUCTION CIRCUITNO 1 PSIG CIRCUITNO 2 PSIG REFRIGERANT DISCHARGE CIRCUITNO 1 PSIG CIRCUITNO 2 PSIG O VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 29 GENERAL O ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS OB REQUIREMENTS Copyright 1999 Bryant Heating amp Cooling Systems CL 1 CATALOG NO 5358 101 CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
34. UT SWITCH OUTDOOR FAN STOP IF IDM IS TURNING AT CORRECT SPEED AT LEAST 2400 RPM HALL IMMEDIATELY EFFECT SENSOR SENDS CORRECT SIGNAL TO TERMINAL J1 ON IGC 8 FLASHES HARDWARE OR 30 SECOND OFF DELAY SOFTWARE FAULT FOR INDOOR FAN 5 FLASHES IGNITION LOCKOUT No ignition within 15 minutes 6 FLASHES INDUCED DRAFT MOTOR FAULT No signal from the Hall Effect Sensor for 60 seconds IF LIMIT SWITCH AND ROLLOUT SWITCH ARE CLOSED SAFETY LOGIC WILL INITIATE IGNITION SEQUENCE IGC HIGH VOLTAGE TRANSFORMER CREATES A 10 000 VOLT SPARK FOR 5 SECONDS p CAS VALVE AND SCARE No 2 MCROAMPS FOR 2 SECONDS Yes AFTER 45 SECONDS OR LESS THE TIMING HAS BEEN REDUCED DUE TO LIMIT SWITCH TRIPS WILL ENERGIZE BLOWER RELAY IGC SAFETY LOGIC OPENS GAS VALVE FOR 5 SECONDS SUBTRACT 5 SECONDS OR ANOTHER 5 SECONDS FROM INDOOR FAN ON TIME DELAY IGNITION LOCKOUT 5 FLASHES OF LED No LEGEND IDM Induced Draft Motor IGC Integrated Gas Unit Controller NOTE Thermostat Fan Switch in the AUTO position 45 SECOND BLOWER SHUTOFF DELAY DELAY EXTENDED BY 5 SECONDS FOR EACH LIMIT SWITCH TRIP MAXIMUM DELAY 3 MINUTES Fig 40 IGC Control Heating and Cooling PACKAGED SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equip ment discussed in this manual induding Unit Familiariz
35. WER COIL 2 DIA K Q 07 554 k 022 22 0 2 51 G27 dl 05 14 35 18 errr 51 5 11 3 87 303 1813 ECONOMIZER OPENING Gm ES 3 1 3 87 DIA CONCENTRIC 185 KG nodu C6 35 1 CONTROL BOX 0 3 261 2 1 TOP FILTERS 25 ALR OR 25 DAMPER OPENIN 0 3 3747 57 ACCESS FAR SIDE ro 10 5 167 ECONOMIZER HOOD ENING 97 2 1 5 87 Er 17 1 5 167 339 pu LEFT SIDE 2 3 M 1 4 162 17 6 5 16 0 3 7 16 466 1200 4 VIEW 2 2 rus POWER EXHAUST uem du SIDE 6 3 8 XS 508 467 07 10 EN ax 260 d 5 87 amp 1 3 87 DIA CONCENTRIC K o AH ne ue E 76 Lee 0 2 7 8 92 amp 35 FIELD POWER 0 3 1 5 73 7 8 DIA CONTROL 75 INDOOR COIL 0 3 7 8 e 22 t 1 47 DIA HOLE 7 4 ALTERNATE RETURN 98 4 1 2 DIA GAS ENTRY 3 4 NPT 32 152 3 47 DRAIN CONNECTION 123 45 38 FIELD 27 FAR SIDE ONLY 5 6 SUPPLIED 54 1676 SECTION A A Fig 5 Base Unit Dimensions 581A240 Table 1 Physical Data UNIT 581A 5 2140 NOMINAL CAPACITY tons po 1 5 Xu ong OPERATING WEIGHT Ib Economizer Roof Curbt COMPRESSOR Quantity Number of Refrigerant Circuits Crankcase Heater Watts Oil oz Ckt 1 Ckt 2 REFRIGERANT TYPE Expansion Device Operating Charge Ib oz Circuit 1 Circuit 2 CONDENSER COIL Rows Fins in Total Face Area sq ft CONDENSER FAN
36. airflow y e RETURN e Front 4 0 in 1219 for control box access i de Right side 4 0 in 1219 for proper operation of damper and power 5 7 3 16 exhaust if so equipped SECUS 1 4 DI e 6 ft 0 in 1829 to assure proper condenser fan operation Bottom 14 in 356 to combustible surfaces when not using curb TYPICAL 4 CORNERS e Control box side 0 in 914 to ungrounded surfaces non combustible e Control box side 3 ft 6 in 1067 to block or concrete walls or other grounded surfaces POWER EXHAUST Local codes or jurisdiction may prevail BAROMETRIC RELIEF 7 With the exception of clearance for the condenser coil and the damper ACCESSORY ONLY power exhaust as stated in Note no 6 a removable fence or barricade i 4 be des end requires no clearance 07 10 13 16 5 7 8 Dimensions are from outside of corner post Allow 0 ft 8 on each 274 T side for top cover drip edge A E 2 GU g 7 8 DIA CONCENTRIC B0 2 DIA is abs amp 22 FIELD POWER 51 THRU CURB GAS CO 127 exl 158 715 07 4 128 5 11 3 8 303 CORNER B 79 1813 ECONOMIZER OPENING CORNER C 3 amp 1 3 8 DIA CONCENTRIC prag 76 35 THRU CURB POWER BOX 787 i 28 3 4 TOP FILTERS 5 25 DAMPER OPENING a 2411 5 8 _ ACCESS FAR SIDE 8 17 10 5 16 651 567 Sm AN Ly s _ _ _ _ LA LA 8 T 2 17 1 5 16 5 3 4
37. ation Maintenance e Installation Overview Operating Sequence A large selection of product theory and skills programs are available using popular video based for mats and materials All include video and or slides plus companion book Classroom Service Training which indudes hands on experience with the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training Copyright 1999 Bryant Heating amp Cooling Systems CATALOG NO 5358 101 START UP CHECKLIST MODEL NO SERIAL NO DATE TECHNICIAN l PRE START UP O VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT O VERIFY INSTALLATION OF INDOOR FAN MOTOR ADJUSTMENT BOLT 155 OR ADJUSTMENT BOLT AND PLATE 180 240 ONLY O OPEN LIQUID LINE SERVICE VALVE VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF EXHAUST HOOD VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT VERIFY GAS PRESSURE TO UNIT GAS VALVE IS WITHIN SPECIFIED RANGE CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR AIR FILTER IS CLEAN AND IN PLACE CHECK THAT OUTDOOR AIR INLET SCREEN IS IN PLACE O VERIFY THAT UNIT IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING O
38. atts Bhp Rpm Watts Bhp Watts Bhp Watts Bhp _ O E OTIO AVAILABLE EXTERNAL STATIC PRESSURE in wg crm 22 6 000 6 500 7 000 7 500 8 000 8 500 9 000 9 500 10 000 LEGEND 2 Bhp Brake Horsepower Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 1002 to 1151 rpm Alternate high static drive range is 1193 to 1369 Other roms require a field supplied drive 9 NOTES 1 Maximum continuous bhp for the standard motor is 9 47 for 208 v units and 10 33 for 230 and 460 v units The maximum continuous watts is 7915 for 208 and 575 v units and 8640 for 230 and 460 v 6 units Do not adjust motor rpm such that motor maximum bhp and or watts is exceeded at the maximum operating cfm plos 2 94 co 526 3 21 Bpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Static pressure losses i e economizer must be added to external static pressure before entering Fan Performance table Interpolation is permissible Do not extrapolate 4 Fan performance is based on wet coils clean filters and casing losses See Table 13 for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be
39. 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 doth for unbrazing operations Have fire extinguishers available for all brazing operations NWARNING Before performing service or mainte nance operations on unit turn off mail power switch to unit electrical shock could cause personal injury Cancels 581A 155 2 581A 155 3 6 15 99 N WARNING l 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 Donot 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 l DO NOT try tolight 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 f you cannot reach your gas supplier call the fire department NWARNING Disconnect gas piping from unit when pressure testing at pressure greater than 0 5 psig Pressures greater than 0 5 psig will cau
40. e Fig 10 ___ ae 2 5 8 v 6 2 MAX amp MAX BAFFLE OTE Dimensions A A B and are obtained from field supplied ceiling diffuser Shaded areas indicate block off pans Fig 8 Concentric Duct Details 8 x N lal RE N P N NXN i x INLET WIND LOUVERS BAFFLE P 5 BS SSES L Cc S555 CL Fn 2 SE HSE COMBUSTION Nem FAN HOUSING S55 INSIDE FLUE SCREEN WIND BAFFLE MOUNTING HOLES Fig 9 Flue Hood Location INDUCED DRAFT OTOR MAIN BURNER HEAT EXCHANGER SECTION COMBUSTION FAN HOUSING SECTION Fig 10 Combustion Fan Housing Location VI STEP 6 TRAP CONDENSATE DRAIN See Fig 4 5 and 11 fore drain location Plug is provided in drain hole and must be removed when unit is operating One 3 in half coupling is provided inside unit evaporator section for condensate drain connection An 81 gt x 4 in diameter nipple and a 2 in x in diameter pipe nipple are coupled to standard in diameter elbow to provide a straight path down through holes in unit base rails see Fig 11 and 12 A trap at least 4 inches deep must be used Vil STEP 7 INSTALL GAS PIPING The gas suppl
41. e selector to its lowest setting NOTE The Cooling mode may also be simulated by removing the thermostat wires from terminals Y1 and Y 2 and installing a jumper between terminals and Y1 Refer to unit label diagram for terminal locations Table 16 Economizer Checkout Procedures TEST PROCEDURE RESULTS Disconnect power at TR and Disconnect jumper between P and P1 See Fig 18 Jumper TH to 1 Jumper T1 to T Disconnect outdoor air thermostat connections from So and Factory installed 800 ohm resistor should remain connected to Sp and E Reconnect power to terminals TR and TR1 1 LED light emitting diode should be off 2 Motor is in closed position TEST PROCEDURE RESULTS Disconnect factory installed resistor from terminals Sg 1 LED should be 2 Motor drives toward open Table 17 High and Low Outdoor Air Simulation TEST PROCEDURE RESULTS Reconnect factory installed 800 ohm resistor between terminals SR and Connect 1200 ohm checkout resistor between terminals SO and Turn set point potentiometer to position A Low outdoor air test results 1 LED light emitting diode should be on 2 Motor drives toward open D Turn set point potentiometer to position D E Disconnect 1200 ohm checkout resistor High outdoor air test results 1 LED should be off 2 Motor drives toward closed 5 Set the outdoor air thermostat OAT locat
42. eaning frequency To inspect blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel assembly by removing screws holding motor mounting plate to top of com bustion fan housing Fig 28 The motor and wheel assembly will slide up and out of the fan housing Remove the blower wheel from the motor shaft and clean with a detergent or sol vent Replace motor and wheel assembly INTEGRATED GAS IGC LED CONTROL BOX INDUCED DRAFT MOTOR ACCESS PANEL UNIT CONTROLLER VIEW HIDDEN PORT COMBUSTION MAIN BURNER FLUE BOX MAIN GAS FIELD GAS FAN HOUSING SECTION COVER VALVE CONNECTION Fig 28 Typical Gas Heating Section CERAMIC BAFFLE CLIP HEAT EXCHANGER TUBES NOTE One baffle and clip will be in each upper tube of the heat exchanger Fig 29 Removing Heat Exchanger Ceramic Baffles and Clips 25 Il LUBRICATION A Compressors E ach compressor is charged with the correct amount of oil at the factory Conventional white oil Sontex 200LT is used White oil is compatible with 3GS oil and 3GS oil may be used if the addition of oil is required See compressor name plate for original oil charge A complete recharge should be four ounces less than the original oil charge When a com pressor is exchanged in the field it is possible that a major portion of the oil from the replaced compressor may stil
43. ed in the economizer section of the unit See Fig 17 to 75 F 6 If the outdoor temperature is below 75 F the econo mizer will control the mixed air with the mixed air sensor If the outdoor air is above 75 place a jumper around the contacts of the OAT 7 Jumper terminal T to terminal T1 on the module see Fig 18 The economizer will go to the full open posi tion The outdoor air damper will go to the full open position and the return air damper will go to the full closed position 8 Adjust mechanical linkage if necessary for correct positioning If may be necessary to remove the filters to adjust the linkage 9 Remove the jumper from around the contacts of the OAT if installed in Step 6 Remove the jumper from terminals T and 1 installed in Step 7 10 If the Cooling mode was si mulated to operate the unit in Step 4 remove the jumper and reconnect the ther mostat wires to terminals Y 1 and Y2 Vill POWER FAILURE Dampers have a spring return In event of power failure dampers will return to fully dosed position until power is restored Do not manually operate damper motor IX REFRIGERANT CHARGE Amount of refrigerant charge is listed on unit nameplate and in Table 1 Refer to Carrier 11 Module 5 Charging Recovery Recycling and Reclamation section for charging methods and procedures Unit panels must be in place when unit is operating during charging procedure NOTE Do not use recycled refrig
44. ed on the top and bottom of the evaporator coil They detect frost build up and turn off the compressor allowing the coil to clear Once the frost has melted the com pressor can be reenergized by resetting the compressor lockout XIV RELIEF DEVICES All units have relief devices to protect against damage from excessive pressures i e fire These devices protect the high and low side XV CONTROL CIRCUIT 24 V This control circuit is protected against overcurrent by a 3 2 amp circuit breaker Breaker can be reset If it trips determine cause of trouble before resetting XVI REPLACEMENT PARTS A complete list of replacement parts may be obtained from any Carrier distributor upon request XVII DIAGNOSTIC LEDS IGC control board has a LED for diagnostic purposes ThelGC error codes are shown in Table 15 SEE DETAIL M e N SER SEE prn 581A180360 AND 5814240360 SPARK GAP 120 TO 140 SPARK GAP 181 DETAIL Fig 37 Spark Gap Adjustment p AHA BKR W AT BR NOTES LEGEND Fig 38 Typical Wiring Schematic and Fig 39 Typical Component Arrangement Adjustable Heat Anticipator Breaks with Amp Turns Burner Relay Contactor Compressor Capacitor Circuit Breaker Cooling Compensator Crankcase Heater Compressor Lockout Compressor Lockout Switch Compressor Motor Control Relay Current Transformer Damper Motor Dummy Terminal Equipment F
45. ed vent position Do not manually operate econo mizer motor since damageto motor will result X STEP 10 INSTALL OUTDOOR AIR HOOD The outdoor air hood is common to 2596 air ventilation and economizer f economizer is used all electrical connections have been made and adjusted at the factory Assemble and install hood in the field NOTE The hood top panel upper and lower filter retainers hood drain pan baffle sizes 180 and 240 and filter support bracket are secured opposite the condenser end of the unit The screens hood side panels remaining section of filter support bracket seal strip and other hardware are in a package located inside the return air filter access panel Fig 20 l Attach seal strip to upper filter retainer SeeFig 21 2 Assemble hood top panel side panels upper filter retainer and drain pan see Fig 22 OUTDOOR AIR HOOD AND MOUNTING BRACKETS RETURN AIR FILTER ACCESS PANEL Fig 20 Outdoor Air Hood Component Location HOOD COMPONENTS 3 Secure lower filter retainer and long section of filter support bracket to unit See Fig 22 Leave screws loose on 180 and 240 units 4 Slide baffle sizes 180 and 240 behind lower filter retainer and tighten screws 5 Loosen sheet metal screws for top panel of base unit located above outdoor air inlet opening and remove screws for hood side panels located on the sides of the outdoor air inlet opening 6 Match notches in hood to
46. erant as it may contain contaminants A No Charge Use standard evacuating techniques After evacuating sys tem weigh in the specified amount of refrigerant refer to Table 1 B Low Charge Cooling Using appropriate cooling charging chart see Fig 35 add or remove refrigerant until conditions of the chart are met Note that charging chart is different from those normally used An accurate pressure gage and temperature sensing device is required Charging is accomplished by ensuring the proper amount of liquid sub cooling Measure liquid line pressure at the liquid line service valve using pressure gage Connect temperature sensing device to the liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading C To Use the Cooling Charging Chart Use the above temperature and pressure readings and find the intersection point on the cooling charging chart If inter section point on chart is above line add refrigerant If inter section point on chart is below line carefully recover some of the charge Recheck suction pressure as charge is adjusted NOTE Indoor air CFM must be within normal operating range of unit All outdoor fans must be operating The TXV thermostatic expansion valve is set to maintain between 15 and 20 degrees of superheat at the compressors The valves are factory set and should not require re adjustment 28 BOTH CIRCUITS ALL OUTDOO
47. erminal S on the return air enthalpy sensor to the economizer con trol module terminal Sp 10 Turn changeover set point dial clockwise past the D setting or the control will not operate on a differen tial See Fig 18 11 Reinstall economizer hood if removed IMPORTANT Be sure all seal strips and RTV sealant are intact A watertight seal to inside of unit must be maintained STEP 11 INSTALL ALL ACCESSORIES After all the factory installed options have been adjusted install all field installed accessories Refer to the accessory installation instructions included with each accessory A Motormaster Control Installation 581A155 and 180 Only Install Field Fabricated Wind Baffles Wind baffles must be field fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures See Fig 25 for baffle details Use 20 gage galvanized sheet metal or similar corrosion resistant metal for baffles Use field supplied screws to attach baffles to unit Screws should be in diameter and g in long Drill required screw holes for mounting baffles NCAUTION To avoid damage to the refrigerant coils and electrical components use recommended screw sizes only Use care when drilling holes Install Motormaster Controls Only one Motormaster control is required per unit The Motormaster control must be used in conjunction with the Accessory 0 F Low Ambient Kit purchased separatel
48. essor no 1 is energized and mechanical cooling is integrated with econo mizer cooling the outdoor air temperature drops below 50 F a cooling lockout switch prevents the compressors from running When supply air temperature drops below a fixed set point the economizer damper modulates to maintain the tempera ture at the fixed set point D Freeze Protection Thermostats A freeze protection thermostat is located on the top and bot tom of the evaporator coil It detects frost build up and locks out the compressors allowing the coil to clear Once frost has melted the compressors can be reenergized by resetting the compressor lockout E Heating Units With Economizer Outdoor air damper stays at VENT position while evapora tor fan is operating Refer to Heating Units without E cono mizer section on page 24 for heating sequence of operation SERVICE NWARNING Before performing service or mainte nance operations on unit turn off main power switch to unit Electrical shock could cause personal injury CLEANING Inspect unit interior at beginning of each heating and cooling season and as operating conditions require Remove unit top panel and or side panels for access to unit interior A Evaporator Coil Clean as required with commercial coil deaner Wash both sides of coil and flush with dean water B Condenser Coil Clean condenser coil annually and as required by location and outdoor air conditions Inspect co
49. fan auto 45 seconds after ignition occurs the indoor fan motor will be energized and the outdoor air dampers will open to their minimum posi tion If for some reason the overtemperature limit opens prior to the start of the indoor fan blower on the next attempt the 45 second delay will be shortened to 5 seconds less than the time from initiation of heat to when the limit tripped Gas will not be interrupted to the burners and heat ing will continue Once modified the fan on delay will not change back to 45 seconds unless power is reset to the control When additional heat is required W2 doses and initiates power to the second stage of the main gas valve When the thermostat is satisfied W1 and W2 open and the gas valve doses interrupting the flow of gas to the main burners If the call for W1 lasted less than 1 minute the heating cyde will not terminate until 1 minute after W1 became active If the unit is controlled through a room thermostat set for fan auto the indoor fan motor will continue to operate for an additional 45 seconds then stop and the outdoor air damp ers will dose If the overtemperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive on the next cycle the time will be extended by 15 seconds The maximum delay is 3 minutes Once modi fied the fan off delay will not change back to 45 seconds unless power is reset to the control A LED indicator is provided on the IGC to
50. for accessory FIOP static pressure information Extensive motor and drive testing on these units ensures that the full bhp and watts range of the motor can be utilized with confidence Using your 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 Use of a field supplied motor may affect wiring size Contact your Bryant representative for details Table 5 Fan Performance 5814180270 Low Heat Units AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM 00 2 5041 1 06 0 1 _ 2 LRpm Watts Bhp Rpm Watts Rpm Watts Bhp Rpm Watts Bhp pm Watts Bhp_ A RO O1 00000 gt 5 5 gt NOM 0101004 AVAILABLE EXTERNAL STATIC PRESSURE wg 12 1 14 16 118 20 Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp CFM AVAILABLE EXTERNAL STATIC PRESSURE in wg CFM LEGEND 2 Bhp Brake Horsepower FIOP Factory Installed Option 3 Watts Input Watts to Motor 4 Standard low medium static drive range is 873 to 1021 rpm Alternate high static drive range is 1025 to 1200 Other roms require a field supplied drive 5 NOTES 1 Maximum continuous
51. ic Low Medium Static High Static 4 15 Propeller Type 022 5 1050 1100 Cross Hatched g in Copper Tubes Aluminum Lanced or Copper Plate Fins Face Split 4 15 1161 1426 Ball 1550 3 1 4 1 3 7 4 7 J 6 0 5 2 13 46 1 42 1 42 13 5 15 5 58 67 3 5 978 190 0 1285 30 0 136 29 0 98 0 8 0 44 0 44 172 000 230 000 225 000 300 000 81 15 45 30 60 3 3 1 5 5 13 5 235 487 3 4 15 Centrifugal Type 2 12x 12 Belt 6000 5 1745 6 13 184T 873 1021 1025 1200 Ball 1550 4 9 5 9 4 9 5 9 ee 9 4 8 0 17116 1 BX 50 1 BX 48 13 3 14 8 37 44 3 5 965 190 0 1285 30 0 136 29 0 98 0 8 0 44 0 44 206 000 275 000 270 000 360 000 81 15 45 20 50 3 3 1 5 5 13 5 235 487 3 4 15 2 12 x 12 Belt 8000 1 5 1745 9 47 208 v 10 33 230 and 460 v 213T 1002 1151 1193 1369 Ball 1550 5 4 6 6 5 4 6 6 19 5 9 4 7 9 17 6 1 54 1 50 14 6 15 4 37 44 3 5 190 0 1285 30 0 136 29 0 98 0 8 0 44 0 44 206 000 275 000 270 000 360 000 81 15 45 20 50 3 3 1 5 5 13 5 235 487 3 426 320 27 44 30 55 45 35 OUTDOOR AIR SCREENS Cleanable Quantity Size in 2 20x 25 x 1 1 20 x 20 x 1 RETURN AIR FILTERS Throwaway Quantity Size in 4 20 x 20 x2 4 16 x 20 x2 LEGEND Evaporator coil fin material condenser coil fin material TWeight of 14 in
52. il monthly clean as required C Condensate Drain Check and dean each year at start of cooling season n win ter keep drains and traps dry D Filters Clean or replace at start of each heating and cooling season or more often if operating conditions require Refer to Table 1 for type and size E Outdoor Air Inlet Screens Clean screens with steam or hot water and a mild detergent Do not use throwaway filters in place of screens See Table 1 for quantity and size F Main Burner At the beginning of each heating season inspect for deterio ration or blockage due to corrosion or other causes Observe the main burner flames Refer to Main Burners section on page 29 G Flue Gas Passageways The flue collector box and heat exchanger cells may be inspected by removing heat exchanger access panel Fig 4 and 5 flue box cover and main burner assembly Fig 28 Refer to Main Burners section on page 29 for burner removal sequence If cleaning is required remove heat exchanger baf fles and dean tubes with a wire brush Use caution with ceramic heat exchanger baffles When installing retaining dip be sure the center leg of the clip extends inward toward baffle See Fig 29 H Combustion Air Blower Clean periodically to assure proper airflow and heating effi ciency Inspect blower wheel every fall and periodically dur ing heating season For the first heating season inspect blower wheel bi monthly to determine proper cl
53. installation start up and Service instructions 581A Sizes 155 240 SINGLE PACKAGE ROOF TOP ELECTRIC COOLING GAS HEATING UNITS CONTENTS Page SAFETY CONSIDERATIONS l INSTALLATION 1 14 Step 1 Provide Unit Support 1 ll Step 2 Rig and Place Unit 3 lll Step 3 Field Fabricate Ductwork 7 IV Step 4 Make Unit Duct Connections 7 V Step 5 Install Flue Hood and Wind ate tae athe Sees A 7 VI Step 6 Trap Condensate Drain 8 Vil Step 7 Install Gas Piping 8 Vill Step 8 Make Electrical Connections 8 IX Step 9 Make Outdoor Air Inlet Adjustments 9 X Step 10 Install Outdoor Air Hood 11 Step 11 Install All Accessories 13 START UP 14 25 SERVICE 54 25 25 25 34 5 35 37 START UP 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 deaning
54. ipped for thru the bottom duct connections Duct work openings are shown in Fig 1 4 and 5 Duc connections are shown in Fig 6 Field fabricated concentric SEE NOTE N NOTE Do not drill in this area damage to basepan may result in water leak Fig 6 Air Distribution Thru the Bottom 5814180 240 Unit Shown AIR IN AIR OUT AIR OUT NOTE Do not drill in this area damage to basepan may result in water leak Fig 7 Concentric Duct Air Distribution 5814180 240 Unit Shown EE m B ductwork may be connected as shown in Fig 7 and 8 Attach all ductwork to roof curb and roof curb basepans Refer to Installation instructions shipped with accessory roof curb for more information NWARNING For vertical supply and return units tools or parts could drop into ductwork and cause an injury Install a 90 degree turn in the return ductwork between the unit and the conditioned space If a 90 degree elbow cannot be installed then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space V STEP 5 INSTALL FLUE HOOD AND WIND BAFFLE Flue hood screen and wind baffle are shipped secured under main control box To install secure flue hood and screen to access panel with screws provided See Fig 9 The wind baffle is then installed over the flue hood NOTE When properly installed flue hood will line up with combustion fan housing Se
55. jumper removed in Step 1 See Fig 18 3 Disconnect the blue wire from the OAT 4 Remove OAT from the outside of the economizer See Fig 17 5 Mount the enthalpy sensor Fig 23 to the econo mizer on the outside of the unit in the same location from which the OAT was removed using the 2 screws provided See Fig 17 6 Reconnect the blue wire removed in Step 3 to the enthalpy sensor terminal 7 Cut the violet wire provided to desired length and terminate with quick connect terminal provided Route the violet wire from the enthalpy sensor termi nal S through the snap bushing and to the econo mizer control module terminal So See Fig 18 8 Set changeover set point to the desired location See Fig 24 NOTE For maximum benefit of outdoor air set the enthalpy control to the A setting At this setting when the relative humidity is 50 and the outdoor air is below 74 F the relay contacts on the sensor will be closed 9 Reinstall economizer hoods if removed IMPORTANT Be sure all seal strips and RTV sealant are intact A watertight seal to inside of unit must be maintained Fig 23 Outdoor Air and Return Air Enthalpy Sensor CONTROL CONTROL POINT CURVE Approx Deg AT 50 RH A 73 68 IN AXA X Le q LL lt BESET BLN 45 50 55 60 55 70 75 80 85 90 95 100105 IIO DRY BULB TEMPERATURE APPROXIMATE RH Relati
56. l be in the system Whilethis will not affect the reliablity of the replacement compressor the extra oil will add rotor drag and increase power usage To remove this excess oil an access valve may be added to the lower portion of the suction lineat the inlet of the compressor The compressor should then be run for 10 minutes shut down and the access valve opened until nooil flows This should berepeated twice to make sure the proper oil level has been achieved B Fan Shaft Bearings For size 155 units bearings are permanently lubricated No field lubrication is required For size 180 and 240 units lubricate bearings at least every 6 months with suitable bearing grease E xtended grease line is provided for far side fan bearing opposite drive side Typical lubricants are given below MANUFACTURER LUBRICANT Texaco Regal AFB 2 Mobil Mobilplex EP No 1 Prestige 42 Multifak 2 Preferred lubricant because it contains rust and oxidation inhibitors C Condenser and Evaporator Fan Motor Bearings The condenser evaporator fan motors have permanently sealed bearings so no field lubrication is necessary Ill EVAPORATOR FAN PERFORMANCE ADJUSTMENT Fig 30 32 Fan motor pulleys factory set for speed shown in Table 1 To change fan speeds l Shut off unit power supply 2 Size155 only Loosen belt by loosening carriage nuts holding motor mount assembly to fan scroll side plates A and B Size 180 240 onl y Lo
57. monitor opera tion The IGC is located by removing the side panel and viewing thelGC through the view port located in the control box access panel See Fig 28 During normal operation the LED is continuously on See Table 15 for error codes Table 15 IGC LED Indications ERROR CODE LED INDICATION Normal Operation On HardwareFailure Off dt Delay 1 Flash Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes ys Mig Lupe ds Limit 4 Flashes Ignition Lockout Fault 5 Flashes Inducer Switch Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode NOTES 1 There is a 3 second pause between error code displays 2 f more than one error code exists all applicable error codes will be displayed in numerical sequence 3 Error codes on the IGC will be lost if power to the unit is interrupted C Cooling Units With Economizer U pon a call for cooling when outdoor ambient is above the changeover control setting the economizer damper moves to VENT position The compressors and evaporator and con denser fans energize and operate as per Cooling Units With out Economizer section on this page U pon a first call for cooling when outdoor ambient is below the changeover control setti ng the evaporator fan starts and the economizer is fully open The compressors remain off Upon a second stage call for cooling compr
58. nnections in Check wiring and repair or replace condenser fan runs compressor circuit Compressor motor burned out seized or Determine cause Replace compressor internal overload open Defective overload Determine cause and replace Compressor locked out Determine cause for safety trip and reset leout e or saty e One leg of 3 phase power dead Replace fuse or reset circuit breaker Compressor cycles other than Refrigerant overcharge or undercharge Recover refrigerant evacuate system and recharge to normally satisfying thermostat nameplate Faully condenser fan molor Compressor operates continuously Excessive head pressure 1 Check TXV bulb mounting and secure tightly to suction line 2 Replace TXV if stuck open or closed Head pressure too low Excessive suction pressure High heat load Check for source and eliminate Faulty TXV 1 Check TXV bulb mounting and secure tightly to suction line 2 Replace TXV if stuck open or closed Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace filter Low refrigerant charge Check for leaks repair and recharge Metering device or low side restricted Remove source of restriction Faulty TXV 1 Check TXV bulb mounting and secure tightly to suction line 2 Replace TXV if stuck open or closed Insufficient evaporator airflow Increase air quantity Check filter and replace if necessary Tempe
59. osen nuts on the 2 carriage bolts in the mounting base Install jacking bolt and plateunder motor base bolt and plate are shipped in installer s packet Using bolt and plate raise motor to top of slide and remove belt Secure motor in this position by tighten ing the nuts on the carriage bolts 3 Loosen movable pulley flange setscrew see Fig 30 4 Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed Increasing fan speed increases load on motor Do not exceed maxi mum speed specified in Table 1 See Table 11 for air quantity limits 5 Set movable flange at nearest keyway of pulley hub and tighten setscrew See Table 1 for speed change for each full turn of pulley flange 6 Replace and tighten belts see Belt Tension Adjust ment section on page 27 To align fan and motor pulleys l Loosen fan pulley setscrews Sunoco Texaco 2 Slide fan pulley along fan shaft 3 Make angular alignment by loosening motor from mounting plate IV EVAPORATOR FAN SERVICE AND REPLACEMENT A 581A155 Units See Fig 31 NOTE To remove belts only follow Steps 1 6 l Remove filter and supply air section panels 2 Remove unit top panel 3 Loosen carriage nuts A and B holding motor mount assembly to fan scroll side plates 4 Loosen screw C 5 Rotate motor mount assembly with motor attached as far as possible away from evaporator coil 6 Remove belt 7 Rotate motor
60. p panel with unit top panel screws Insert hood flange between top panel flange and unit Tighten screws 7 Hold hood side panel flanges flat against unit and install screws removed in Step 5 HOOD TOP PANEL UPPER FILTER RETAINER N SEAL STRIP HOOD DRAIN PAN Fig 21 Seal Strip Location BAFFLE 180 AND 240 SIZES ONLY LOWER FILTER RETAINER HOOD SIDE PANELS 2 HOOD TOP PANEL BAFFLE 180 AND 240 UPPER FILTER RETAINER NOTE The outdoor air hood comes with a baffle which is used on sizes 180 and 240 only Discard baffle for size 155 units Fig 22 Outdoor Air Hood Details 8 Insert outdoor air inlet screens and spacer in channel created by lower filter retainer and filter support bracket 9 Attach remaining short section of filter support bracket A Enthalpy Control Installation NOTE The accessory outdoor air enthalpy sensor must be installed BEFORE the economizer hoods are installed on the unit or hoods will have to be removed 1 Remove and discard the factory installed jumper assembly containing the 800 ohm resistor on the economizer control module between terminals Sp and See Fig 18 2 Remove black wire assembly containing the 620 ohm resistor from between economizer control module ter minal S and the outdoor air thermostat Place this wire assembly containing the 620 ohm resistor between economizer control module terminals Sp and replacing the
61. pplication Replace with proper unit or add additional unit Restricted airflow Clean filter replace filter or remove any restrictions fan speed and temperature rise of unit Adjust as needed Too much outdoor air Poor flame characteristics Incomplete combustion lack of combustion air Check all screws around flue outlets and burner compartment results in Tighten as necessary Aldehyde odors CO sooting flame or floating Cracked heat exchanger flame Overfired unit reduce input change orifices or adjust gas line or manifold pressure Check vent for restriction Clean as necessary Check orifice to burner alignment Burners will not turn off Unit is locked into Heating mode for a one minute Wait until mandatory one minute time period has elapsed or minimum power to unit LEGEND GR Ground Refer to Fig 40 for IGC troubleshooting information 1 FLASH INDOOR FAN DELAY DEFECTIVE MODIFIED HEATING FLASHING OFF IGC BOARD 2 FLASHES OPENING OF LIMIT SWITCH ON 1 BLOWN 5 AMP FUSE 3 FLASHES FLAME SENSOR INDICATES FLAME WITH CLOSED GAS VALVE CALL FOR 2 DEFECTIVE 24V TRANS 3 BROKEN WIRE HEATING W1 FROM BASE CONTROL BOARD ENERGIZES ON IGC 1 MINUTE LOCK ON 4 NO POWER TO UNIT 1 SECOND ON DELAY Fon AN COMBUSTION RELAY ON IGC IS ENERGIZED COOLING DEMAND SATISFIED COMBUSTION RELAY ENERGIZES INDUCED DRAFT MOTOR IDM THROUGH TERMINAL CM ON IGC 7 FLASHES OPENING OF COMPRESSOR AND ROLLO
62. quipment GND Ground NEC National Electrical Code TB Terminal Board Fig 14 Field Power Wiring Connections Connect ground lead to chassis ground connection when using separate ground wire The unit has a terminal block for field power connections Install conduit connectors in side panel power supply knockout openings indicated in Fig 4 and 5 Route power lines through connector to unit control box Install a Bryant approved accessory thermostat assembly according to the installation instructions included with the accessory Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature Route thermostat cable or equivalent single leads of colored wire from subbase terminals through conduit in unit to low voltage connections as shown on unit label wiring diagram and in Fig 15 NOTE For wire runs up to 50 ft use no 18 AWG American Wire Gage insulated wire 35 C minimum For 50 to 75 ft use no 16 AWG insulated wire 35 C minimum For over 75 ft use no 14 AWG insulated wire 35 C Minimum All wire larger than no 18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat Set heat anticipator settings as follows VOLTAGE _ 208 230 08 944 The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance Set the heat anticipator to settings based on the table
63. r contactor no 1 C1 are energized and evapora tor fan motor IFM compressor no 1 and condenser fan start The condenser fan motors run continuously while unit is cooling If the thermostat calls for a second stage of cooling by energizing Y 2 compressor contactor no 2 C2 is ener gized and compressor no 2 starts B Heating Units Without Economizer NOTE The 581A 155 240 units have 2 stages of 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 A check is made to ensure that the rollout switch and limit switch are closed and the induced draft motor is running Theinduced draft motor is then energized and when speed is proven with the hall effect sensor on the motor the ignition activation period begins The burners will ignite within 5 seconds If the burners do not light there is a 22 second delay before another 5 second attempt If the burners still do not light this sequence is repeated for 15 minutes After the 15 min utes have elapsed if the burners still have not lighted heat ing is locked out To reset the control break 24 v power to the thermostat When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches the hall effect sensor as well as the flame sensor If the unit is controlled through a room thermostat set for
64. r leaks and poor unit performance SPREADER BARS DETAIL A at RIGGING HOOK NO NOTES 1 Dimensions in are in millimeters 2 Refer to Fig 4 and 5 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 post from packaging to protect coil from damage Use bumper boards for spreader bars on all units Weights do not include optional economizer Add 110 Ib 50 kg for econo mizer weight Weights given are for aluminum evaporator and condenser coil plate fins Add 75 Ib 34 kg for crating on 581A155 and 180 units Add 135 Ib 61 kg for crating on 581A240 units Add 150 lb 68 kg for copper condenser coil Add 280 lb 127 kg for copper condenser and evaporator coils B Alternate Unit Support When a curb or adapter cannot be used install unit on a noncombustible surface Support unit with sleepers using unit curb support area If sleepers cannot be used support long sides of unit with a minimum of 3 equally spaced 4 in x 4 in pads on each side STEP 2 RIG AND PLACE UNIT Inspect unit for transportation damage File any claim with transportation agency Do not drop unit keep upright Spreader bars are nct required if top crating is left on unit Use spreader bars over unit to prevent sling or cable damage Rollers may be used to move unit across a roof Level by using unit frame as a
65. r than 2 Use AC VS the following formula to determine the percent voltage imbalance Maximum deviation is 7 v Determine percent voltage imbalance Voltage Imbalance 7 max voltage deviation from average voltage Voltage Imbalance 100 x EMO Xe E RR E 457 average voltage 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately 10 2596 ADJUSTABLE AIR DAMPER SECURING SCREWS Fig 16 2596 Outdoor Air Section Details COOLING LOCKOUT SWITCH ECONOMIZER MOTOR ECONOMIZER CONTROL MODULE FILTERS OUTDOOR AIR THERMOSTAT ECONOMIZER DAMPER ASSEMBLY CHANGEOVER SET POINT MINIMUM DAMPER MINIMUM POSITION SETTING LED LIGHTS UP TO INDICATE OUTDOOR AIR IS SUITABLE FOR FREE COOLING LEGEND LED Light Emitting Diode Fig 18 Economizer Motor Control Module Part Number W7459A ECONOMIZER MOTOR eomm Go E Tm ECONOMIZER CONTROL MODULE Fig 19 Economizer Motor Control Module Location Damper Vent Position Setting l Set fan switch at ON position continuous fan opera tion and close night switch if used 2 Set system selector switch at OFF position 3 Turn damper adjustment knob located on control module clockwise slowly until dampers assume desir
66. rature too low in conditioned area Reset thermostat Field installed filter drier restricted Compressor no 2 will not run Proper operation no remedy necessary LEGEND TXV Thermostatic Expansion Valve Table 19 Heating Service Analysis PROBLEM CAUSE REMEDY Burners will not ignite Misaligned spark electrodes Check flame ignition and sensor electrode positioning Adjust as needed No gas at main burners Check gas line for air purge as necessary After purging gas line of air allow gas to dissipate for at least 5 minutes before attempting to relight unit Check gas valve Drain water and install drip leg to trap water Water in gas line No power to furnace Check power supply fuses wiring and circuit breaker Check transformer Transformers with internal overcurrent protection require a cool down period before resetting Check No 24 v power supply to control circuit 24 v circuit breaker reset if necessary Miswired or loose connections Check all wiring and wire nut connections Burned out heat anticipator in thermostat Replace thermostat Broken thermostat wires Run continuity check Replace wires if necessary Inadequate heating Dirty air filter Clean or replace filter as necessary Gas input to unit too low Check gas pressure at manifold Clock gas meter for input If too low increase manifold pressure or replace with correct orifices Unit undersized for a
67. reeze Protection Thermostat Fuse Ground Gas Valve Relay High Pressure Switch Hall Effect Sensor High Voltage Induced Draft Motor Indoor Evaporator Fan Contactor Indoor Evaporator Fan Circuit Breaker Indoor Evaporator Fan Motor Integrated Gas Unit Controller Light Light Emitting Diode Lockout Relay Low Pressure Switch Limit Switch Mixed Air Thermostat Main Gas Valve National Electrical Code Outdoor Air Thermostat Outdoor Condenser Fan Contactor Outdoor Condenser Fan Motor Plug Assembly Quadruple Terminal Relay Rollout Switch Sensor Switch Terminal Block Transformer 1 Compressor and fan motors thermally protected 3 phase motors protected against pri mary single phasing conditions N If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent Jumpers are omitted when unit is equipped with economizer IFCB must trip amps is equal to or less than 140 full load amps On 208 230 v unit TRAN1 is factory wired to ORN lead for 230 v power supply If unit is to run on 208 v power supply TRAN1 must be rewired Disconnect the BLK wire on TRAN and connect wire to 208 v RED wire Insulate 230 v ORN wire 6 The CLO locks out the compressor to prevent short cycling on compressor overload and safety devices Before replacing CLO check these devices 7 Number s indicates the line location of used contacts A bracket over 2
68. refer ence leveling tolerance is 1 6 in per linear ft in any direc tion See Fig 3 for additional information Unit operating weight is shown in Table 1 Four lifting holes are provided in ends of unit base rails as shown in Fig 3 Refer torigging instructions on unit A Positioning Maintain clearance per Fig 4 and 5 around and above unit to provide minimum distance from combustible materials proper airflow and service access Do not install unit in an indoor location Do not locate air inlets near exhaust vents or other sources of contaminated air For proper unit operation adequate combustion and ven tilation air must be provided in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 American National Standards Institute Although unit is weatherproof guard against water from higher level runoff and overhangs Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the building and at least 4 ft from any adjacent build ing When unit is located adjacent to public walkways flue assembl y must be at least 7 ft above grade B Roof Mount Check building codes for weight distribution requirements Unit operating weight is shown in Table 1 Instructions continued on page 8 NCAUTION All panels must be in place when rigging 2121 2121 2121 Fig 3 Rigging Details AE A
69. s 3 10 for Fan Perfor mance Data Be sure that fans rotate in the proper direction See Table 11 for air quantity limits See Table 12 for E vapo rator Fan Motor Specifications See Table 13 for static pres sure information for accessories and options See Table 14 for fan rpm at various motor pulley settings To alter fan perfor mance see E vaporator Fan Performance Adjustment secti on on page 26 NOTE A 31 gt bolt and threaded plate are included in the installer s packet They can be added to the motor support channel below the motor mounting plate to aid in raising the fan motor IX CONDENSER FANS AND MOTORS Condenser fans and motors are factory set Refer to Con denser Fan Adjustment section page 27 as required Be surethat fans rotate in the proper direction X RETURN AIR FILTERS Check that correct filters are installed in filter tracks see Table 1 Do not operate unit without return air filters OUTDOOR AIR INLET SCREENS Outdoor air inlet screens must be in place before operating unit ACCESSORY ECONOMIZER ADJUSTMENT Remove filter access panel Check that outdoor air damper is dosed and return air damper is open E conomizer operation and adjustment are described in Base Unit Operation section on page 24 and in Economizer Adjustment section on page 28 Table 3 Fan Performance 581A155225 Low Heat Units with Standard Indoor Fan Motor AVAILABLE EXTERNAL STATIC PRESSURE in wg
70. se 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 operating limits If limits are exceeded the units will automatically lock the compressor out of operation Manual reset will berequired to restart the compressor INSTALLATION l STEP 1 PROVIDE UNIT SUPPORT A Roof Curb Assemble or install accessory roof curb or horizontal supply roof curb in accordance with instructions shipped with this accessory See Fig 1 and 2 Install insulation cant strips roofing and counter flashing as shown Ductwork can be installed to roof curb or horizontal supply roof curb before unit is set in place Instructions continued on page 3 CURB HEIGHT DESCRIPTION ft in mm 1 2 Standard Curb CRRFCURBO10A00 805 14 High Standard Curb 8 5 10 1 2 n4 NOTES 1 Roof curb accessory is shipped disassembled 2 Insulated panels 1 in thick neoprene coated Ib density Dimensions in are in millimeters 4 O gt Direction of airflow PLAN VIEW OF ROOF CURB CRRFCURBO11A00 E Requiring High OUTLINE
71. t off field supplied manual main gas valve 2 Shut off power tounit 3 Remove unit control box access panel burner section access panel and center post Fig 4 and 5 4 Disconnect gas piping from gas valve inlet 5 Remove wires from gas valve 6 Remove wires from rollout switch 7 Remove sensor wire and ignitor cable from IGC board 8 Remove 2 screws securing manifold bracket to basepan 9 Remove 2 screws that hold the burner support plate flange to the vesti bule plate 10 Lift burner assembly out of unit B Cleaning and Adjustment l Remove burner rack from unit as described in Main Burner Removal section above 2 Inspect burners and if dirty remove burners from rack 3 Using a soft brush dean burners and crossover port as required 4 Adjust spark gap SeeFig 37 5 Reinstall burners on rack 6 Reinstall burner rack as described above FILTER DRIER Replace whenever refrigerant system is exposed to atmosphere XIII PROTECTIVE DEVICES A Compressor Protection Overcurrent E ach compressor has internal line break motor protection Overtemperature Each compressor has an internal protector to protect it against excessively high discharge gas temperatures Crankcase H eater The 581A units are equipped with a 70 watt crankcase heater to prevent absorption of liquid refrigerant by oil in the crankcase when the compressor is idle The crankcase heater is energized whenever
72. ve Humidity Fig 24 Psychrometric Chart for Solid State Enthalpy Control B Differential Enthalpy Control NOTE The accessory outdoor air enthalpy sensor must be installed BEFORE the economizer hoods are installed on the unit or hoods will have to be removed 1 Remove and discard the factory installed jumper assembly containing the 800 ohm resistor on the economizer control module between terminals Sp and See Fig 18 2 Disconnect black wire from economizer control mod ule terminal So and blue wire from the OAT outdoor air thermostat 3 Remove OAT and black wire assembly containing the 620 ohm resistor from the outside of the economizer See Fig 17 4 Mount the outdoor air enthalpy sensor first sensor to the economizer on the outside of the unit in the same location from which the OAT was removed using the 2 screws provided See Fig 17 5 Reconnect the blue wire removed in Step 2 to the enthalpy sensor terminal 6 Cut the violet wire provided to desired length and terminate with quick connect terminal provided Route the violet wire from the enthalpy sensor termi nal S through the snap bushing and to the econo mizer control module terminal So 7 Mount the second enthalpy sensor in the return air duct return air sensor 8 Route the blue wire provided from terminal on the return air enthalpy sensor to the economizer control module terminal 9 Route the violet wire provided from t
73. y The Motormaster device controls outdoor fan no 1 while out door fans no 2 and 3 are sequenced off by the Accessory 0 F Low Ambient Kit Accessory 0 Low Ambient Kit Install the Accessory 0 Low Ambient Kit per instruction supplied with accessory mIL 14 356 MIN CROSS BREAK BAFFLE TOP VIEW 4 25 MN 78 12 0 125 10 254 TYP 1984 3 40 1016 10 254 15 381 TYP 3 4 19 1 25 MIN BAFFLE FRONT VIEW NOTE Dimensions are in mm Fig 25 Wind Baffle Details __ 1 Sensor Assembly Install the sensor assembly in the loca tion shown in Fig 26 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 volt units a trans former is required The transformer is provided with the accessory and must be field installed Motormaster amp Control Recommended mounting location is on the inside of the panel to the left of the control box The control should be mounted on the inside of the panel verti cally with leads protruding from bottom of extrusion B Motormaster Control Installation 581A240 Install Field Fabricated Wind Baffles Wind baffles must be field fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures See Fig 25 for
74. y pipe enters the unit through the 1 in diameter knockout provided The gas connection to the unit is made to the in gas inlet on the gas manifold Unit is equipped for use with natural gas Installation must con form with local building codes or in the absence of local codes with the National Fuel Gas code ANSI Z223 1 Install field supplied manual gas shutoff valve with a t g in NPT pressure tap for test gage connection at unit Field gas piping must include sediment trap and union See Fig 13 Install sediment trap in riser leading to heating section This drip leg functions as a trap for dirt and condensate Install trap where condensate cannot freeze Install this sediment trap by connecting a piping tee to riser leading to heating section so that straight through section of tee is vertical Then connect capped nipple into lower end of tee Extend capped nipple below level of gas controls NWARNING Do not pressure test gas supply while connected to unit Always disconnect union before servicing IMPORTANT Natural gas pressure at unit gas connection must not beless than 5 5 in wg or greater than 13 5 in wg Size gas supply piping for 0 5 in wg maximum pressure drop Do not use supply pipe smaller than unit gas connection Vill STEP 8 MAKE ELECTRICAL CONNECTIONS A Field Power Supply Unit is factory wired for voltage shown on unit nameplate When installing units provide a disconnect per NEC National

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