Bryant DURAPAC 580F manual

Cancels: II 580F-1 80-2 II 580F -180-3 3/15/06 installation , start-up and service instructio ns SINGLE P A CKA GE ROOFT OP GAS HEA TING/ELECTR IC COOLIN G UNITS 580F Dura Pa c Series Siz es 18 0-30 0 15 to 25 T ons CONTENTS Pag e SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 INST ALLA TION . . . . . . . . . . . . . . .[...]

— 2 — Fig. 1A — Roof Cur b Details — 580F180- 240 PKG. NO. REF . CURB HEIGHT DESCRIPTION CRRFCURB010A00 1 ′− 2 ″ (305 ) Sta ndar d Cur b 14 ″ High CRRFCURB011A00 2 ′ -0 ″ (610) Standa rd Curb for Units Requi ri ng High I nstallati on CRRFCURB012A00 2 ′ -0 ″ (610) Side S upply an d Retur n C urb for High Installatio n[...]

— 3 — Fig. 1B — Ro of Curb De tails — 5 80F300 A A[...]

— 4 — IMPORT ANT : The ga sketin g of t he unit to the roof curb o r adapter ro of curb is crit ical for a waterti ght se al. Inst all gasket wi th the ro of curb or adap ter as s hown in Fig. 1A and 1B . Improperly applied gasket ca n also result i n air leaks and poor un it performance . B. Alternate Unit Support When the c urb o r adapte r c[...]

— 5 — NOTES: 1. Dimensions in ( ) are in millimeters. 2. Refer to Fig. 4-6 for unit operating weights. 3. Remove boards at ends of unit and runners prior to rigging. 4. Rig by insert ing hooks into unit base rails as sho wn. Use corner post from packaging to protect coil from damage. Use bumper boards f or spreader bars on all units . 5. Weight[...]

— 6 — Fig. 4 — Bas e Unit Dime nsions — 580F180, 2 10 NO TES: 1. Refer to p rint for roo f curb accessory dimensions. 2. Dimensions in [ ] ar e in millimeter s. 3. Center of g ravity . 4. Direction o f airflow . 5. Ductwork to be att ached to accesso ry roof curb only . 6. Minimum c l earance: • Rea r: 7 ′ -0 ″ (2134) f or coil remov [...]

— 7 — Fig. 5 — Bas e Unit Dimensions — 580 F240 NOTES: 1. Refe r to print f or ro of curb accessory dimens ions. 2. Dimensions in [ ] are in millimeters. 3. Center of g ravity . 4. Direction of airflow . 5. Ductwork to be attached to accessory roof curb only . 6. Minimum clearance : • Rear: 7 ′ -0 ″ (2134) f or coil remova l. This dim[...]

— 8 — Fig. 6 — Base Unit Dimensions — 580F300 NOTES: 1. Ref er to pri nt f or ro of c urb acc essory dime nsions. 2. D imens ions in ( ) are in millim eters. 3. Center of Gravity . 4. Direct io n of air flo w. 5. Ductwork to be attached to accessory roof curb only . 6. Mini mum clea ra nce: •R e a r : 7 ′ -0 ″ (21 34) for co il remova[...]

— 9 — T able 1 — Ph ysical Data LEGEND *The ZRU140KC compressor is a tandem c ompre ssor, consisting of a ZR72KC (25% total capacity) and a ZR68KC ( 24% total capacit y). †Circuit 1 uses the lower por tion of the condenser coil and lower por tion of the ev aporator coils; and Circuit 2 uses the upper portion of both coils . **Pulley has 6 t[...]

— 10 — T able 1 — Ph ysical Data (cont) LEGEND *The ZRU140KC compressor is a tandem compress or , consisting of a ZR 72KC (25% total capac- ity) and a ZR68K C (24% total capac ity). †Circuit 1 uses the lower por tion of the condens er coil and lower por tion of the ev apo rator coils; and Circuit 2 uses the upper portion of both coils . **P[...]

— 11 — III. STEP 3 — FIEL D F ABRICA TE DUCTW O RK Se cure all duc ts to buildi ng stru ctur e. Us e fl exi bl e duc t con- nector s betwee n unit and ducts as requir ed. Insulat e and weatherp roof all e xternal du ctwork, joints, and roof openings with co unte r flash ing and m asti c i n acc ord an ce wi t h appl ica- ble c odes. Ducts pa [...]

— 12 — VII. STEP 7 — ORIFI CE CHANGE This un it is fact ory a ssembled for hea ting ope ratio n using natural gas at an ele vation fro m sea le vel to 2000 ft. This unit uses ori fice type LH32RFn nn, where “nnn” i ndicates th e orifice size based on drill size diamet er in thou sands of an inch. A. High Ele vation (Abo ve 2000 ft) Use ac[...]

— 13 — VIII. STEP 8 — INST ALL GAS PIPING Unit is equip ped for use with natural g as. I nstallation must confo rm with lo cal bui lding codes or , in the absen ce of local codes , with the National Fuel Gas Code , ANSI Z223.1. Install field-suppl ied manual gas shutoff valve with a 1 / 8 -in. NPT pressure tap for test gage connection at u ni[...]

— 14 — 4. Tighten the Allen bolt to lock the shaft into posi tion. 5. Clos e the cont rol bo x door . 6. Attach the handle to the external access door with the tw o screw s provi ded. Wh en the hand le is in th e ON pos ition, t he hand le will be vertical. When the ha ndle is in the O FF posit ion, the hand le wil l be horizontal. 7. Tu rn the[...]

— 15 — T able 5 — El ectrical Da ta LEGEND *Fuse or HACR circuit breaker. NO TES: 1. In compliance with NEC requirements for multimotor and combination load equipm ent (refer to NEC Ar ticles 4 30 an d 440 ), the overcurre nt pr otective device for the unit shall be fuse or HACR bre aker . C anadi an uni ts may be fuse or circ uit brea ker . [...]

— 16 — IMPORT ANT : If the unit is equip ped wit h the opt iona l EconoMi$ erIV compon ent, mo ve the outdo or - air temp era- ture sensor prior to installing the outdoor-air hood. See the Optional Eco noMi$ er IV sect ion for mo re inform at ion. NO TE: The hood t op panel, upper and lower filter ret ainers , hood drain pan, baffl e (size 300 [...]

— 17 — Motor Mount — T o ensure pr oper fan height, repl ace the existing motor m ount with the new m otor mount provided with acc essory . T ransformer (460-v Units Only) — On 460-v unit s , a trans- former is req uired . The tr ansf ormer is pr ovided with the accesso ry and must be fiel d-install ed. Motormaster ® I Con trol — Recomme[...]

— 18 — XIII. STEP 13 — ADJUST F A CT ORY-INST ALLED OPTIONS A. Optional EconoMi$e r IV See Fig. 25 and 26 for Econ oMi$e rIV com ponent l ocation s. NO TE: These instructions are for in stalling the optional EconoMi$erIV only . Refer to the accessory EconoMi$erIV or EconoMi$er2 installat ion instructions when field inst alling an EconoMi$erIV[...]

— 19 — T able 10 — Suppl y Air Sensor T emperature/ Resistan ce V alues C. EconoMi$ erIV Contr ol Modes Determine the EconoMi$erIV control mode before set up of the control. Some modes of operatio n may require different sensors. Ref er to T ab le 11. The EconoMi $erIV is suppli ed from the fac- tory with a supply air temperature s ensor , a [...]

— 20 — T able 11 — EconoM i$erIV Sen sor Usage *CRENTDIF 004A00 and C RTEMPSN002A00 accessor ies are used on m any different b ase units. As such, these kits may contain p ar ts tha t will not be needed for installation. †CGCDXSE N004A0 0 is an access or y CO 2 sen sor. **CGCDXASP001A00 is an accessory aspirator bo x required f or duct-moun[...]

— 21 — for cooling . F or example , when the outdoor air has a lower enthalpy than the return air and is below the set point, the EconoMi$erI V opens to bring in outdo or air for free c ooling . Replace the standard outside air dry bulb temperature sen- sor wi th th e ac ces sory en th alpy se nso r in th e same moun ting location. See Fig . 25[...]

— 22 — T o determine the minim um position setting, perform the follow in g procedure: 1. Calcu late th e appr opriat e mix ed-air temper ature using t he foll owing formu l a: T O = Outdoor-Air T empera t u re OA = Pe rcent of Outdoo r Ai r T R = Return-A ir T e mpera ture RA = P ercent of Re turn Air T M = Mixed-Air T emp erat ure As an e xam[...]

— 23 — percent of outsi de-air enteri ng the buildi ng for a given dam per posit ion. F or best r esult s there shoul d be at least a 1 0 degre e difference i n outsi de and return-air temperatur es. T O = Outdoor-Air T empera t u re OA = Pe rcent of Outdoo r Ai r T R = Return-A ir T e mpera ture RA = P ercent of Re turn Air T M = Mixed-Air T e[...]

— 24 — XIV . STEP 14 — INST ALL HUMIDIST A T FOR OPTIONAL PERFECT HUMIDITY™ DEHUM IDIFICA TION P ACKA GE P erfect Humidity dehumidification package operation can b e cont rolled by fiel d install ation of a Bryant-a pproved humid istat. T o instal l the humidis tat perform the following proced ure: 1. Loca te hu midi stat on a so lid in ter[...]

— 25 — Fig. 36 — Perfec t Humi dity ™ Deh umid ifi cati on Package Ope ra tion D iagra m (Sin gle C ircuit Shown)[...]

— 26 — ST ART -UP Use th e follow ing in format ion and S tart-Up C heck list on page CL-1 to check out unit PRIOR to start-up . I. UNIT PREP ARA TION Check t hat unit has be en instal led in ac cordan c e wi th thes e instal lation instru ctions an d all appl icable codes . II. COMPRESSOR MOUNTING C ompres sors a re in ternal ly spri ng mou nt[...]

— 27 — T able 13 — F an Per f ormance — 580F1 80275 (Lo w Heat Units)* LEG END *Standard low-medium static drive range is 873 to 1021 rpm. Alter nate high-static drive range is 1025 to 1200. Other rpms req uire a field- supplied drive. Refer to page 32 for general F an Perf or mance Da ta notes. NO TE: M aximum continuous bhp f or the stand[...]

— 28 — T able 14 — Fan P erforman ce — 580F18 0360 (High Heat Unit s)* LEG END *Standard low-medium static drive range is 873 to 1021 rpm . Alternate high-static drive range is 1025 to 1200. Other rpms req uire a field- supplied drive. Refer to page 32 for general F an Perf or mance Da ta notes. NO TE: M aximum continuous bhp f or the stand[...]

— 29 — T able 15 — F an Per f ormance — 580F2 10275 (Lo w Heat Units)* LEGEND *Standard low-medium static drive range is 910 to 1095 rpm. Alter nate high-static drive range is 1069 to 1287. Other rpms req uire a field- supplied drive. Refer to page 32 for general F an Perf or mance Da ta notes. NO TE: M aximum continuous bhp is 5.90. The ma[...]

— 30 — T able 17 — F an Per f ormance — 580F2 40275 (Lo w Heat Units)* LEG END *Standard low-medium static driv e range i s 1002 to 1151 rpm . Alternate high-static drive range is 1193 to 1369. Other rpms req uire a field- supplied drive. Refer to page 32 for general F an Perf or mance Da ta notes. NO TE: M aximum continuous bhp for the sta[...]

— 31 — T able 18 — Fan P erforman ce — 580F24 0360 (High Heat Unit s)* LEG END *Standard low-medium static driv e range i s 1002 to 1151 rpm . Alternate high-static drive range is 1193 to 1369. Other rpms req uire a field- supplied drive. Refer to page 32 for general F an Perf or mance Da ta notes. NO TE: Maximum continuous bhp for the stan[...]

— 32 — T able 19 — F an Per f ormance — 580F3 00275 (Lo w Heat Units)* LEGEND *Standard low-mediu m static driv e rang e is 1066 to 1283 rpm. Alternate high-st atic driv e r ange is 1 332 t o 1550. O ther rpms require a field- supplied dri ve. Ref er to this page fo r general F an Per f ormance Data note s. NO TE: Maximum con t inu ous bhp [...]

— 33 — T able 21 — Air Qu antity Limits T able 22 — Accesso ry/FIOP Static Press ure (in. wg) — 580F18 0-300 LEGEND NO TES: The static pressure must be added to exter nal static pressure. The sum and the evaporat or entering-air cf m should then be us ed in conjunction with the Fan P erformance table to deter mine blower rpm, bhp, and w a[...]

— 34 — XIII. OPERA TING SEQUENCE A. Coolin g, Units Wi thout Econo mizer When therm ostat call s for co oling , termina ls G and Y1 are energized. The indoor (evaporator) fan contactor (IFC), com- pre ssor co ntac tor no . 1 (C1 ) and ou tdo or -fa n co nta cto r (O FC) are energize d, a nd eva porat or -fan motor , compre sso r no. 1, and both[...]

— 35 — E. Condenser Coil Clean c onden ser coil annua lly and as re quired b y location and outdo or -air conditions . Inspect coil monthly — clea n as requir ed. F . Condensate Drain Check and clean each year at star t of coolin g season . In winter , keep drains and t raps dry . G. Filter s Clean or repl ace at s tart of ea ch heat ing and [...]

— 36 — 5. Remo ve the be lt dri ve. 6. Remove jac k ing bolt and tapped jack ing bolt plat e. 7. Remove the 2 screws that secure the motor mounti ng plate to the motor support c hannel. 8. Remove th e 3 screw s from the en d of the mo tor sup- port channel that interfere with the motor slide pa th. 9. Slide out the motor and mo tor mounting pla[...]

— 37 — C. T o Use the Cooling Charging Chart Use the ab ove tem perat ure an d pre ssure re adings, and find the intersec tion point on the co ol i ng ch argi ng ch art. If in te r- sectio n point on cha rt is a bove li ne , add re frigeran t . If int er- sec tion p oint on ch art is below line, ca refully recov er some of the charge. Recheck s[...]

— 38 — B. Cleaning and Adjustment 1. Remo ve burne r rack from unit as descr ibed in Main Burner Removal section on page 3 7 . 2. Inspect burner s, and if dirty , remove burn ers from rack. 3. Using a soft brush, clean burne rs and crossover port as re quir ed . 4. Adjus t spark gap. S ee F ig . 44. 5. Reins tall burners o n rac k. 6. Reins tal[...]

— 39 — SEE DET AIL "C" SEE DET AIL "C" SEE DET AIL "C" 580F1802 75 (Low Heat) 580F1803 60 (High Heat) AND 580F2102 75-300275 (Lo w Heat) 580F21036 0-300360 (High Heat) Fig. 44 — Sp ark Gap Adjus tment[...]

— 40 — Fig. 45 — Ty pical Wiring Sch ematic (580 F240, 208/230 V Sho wn)[...]

— 41 — Fig. 46 — T ypical Component Arrangement (580F240 Shown)[...]

— 42 — LEGEND AND NOTES FOR FIG. 45 AND 46 PL — Plug Assembly PRI — Prim ar y QT — Quadr uple T erminal RA T — Return Air T emperature Sensor RS — Rollout Swit ch SN — Senso r SW — Switch TB — T er m inal Bloc k TC — Thermost at Cooling TH — Therm ostat Heating TRAN — T ransformer T er minal (Mar ked) T er minal (Unmar ked[...]

— 43 — TROUBLESHOO TING I. UNIT TR OUBLESHOOTI N G Refe r to T ables 26- 2 8 an d Fig. 47. II. ECONOMI$ERI V TROUBLSHO O TING See T able 2 9 for Econo Mi$er IV lo gic. A function al view o f the EconoM i$erIV is shown in Fig . 48. Typical set tings , sensor ranges , and jumper position s are also sh own. An Econo Mi$erI V simulator pr ogra m is[...]

— 44 — G. EconoMi$ erIV T roub lesho oting Completio n This proce du re is us ed to r eturn the Eco noMi $erI V to o pera - tion. No troubl eshootin g or testing is don e by performi ng t he follow in g procedure . 1. Disconne ct power at TR and TR 1. 2. Set enth alpy potenti ome ter to previous setting . 3. Set DCV maximum positi on potentiome[...]

— 45 — T able 28 — Cooling Service Ana lysis LE GEND TXV — Ther mostatic Expansion V alve PROBLEM C A U SE REM ED Y Compressor and Condenser Fan Will Not Start. P ower failure . Call power company . Fuse blo wn or circuit breaker tripped. Replace fuse or reset circuit breaker . Defectiv e thermost at, contactor , transf or m er , or c ontro[...]

— 46 — Fig. 47 — IG C Contr ol (Heatin g and Cooling) LEGEND IGC — Integrated Gas Unit Controller NO TE : Thermostat F an Switch in the “A UTO” position.[...]

— 47 — T able 29 — EconoM i$erIV In put/Output Lo gic *For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point. †P ower at N terminal deter mines Occupied/Unoccupied set ting: 24 v ac (Occupied), no power (Unoccupied). **Modulation is based on the supply air sensor signal. ††Modulation is based on the DCV[...]

— 48 — INDEX Air quali ty limits 33 Altitude compe nsati on 12 Burner section 12 Burner spark gap 39 Char ging chart, re frigerant 37 Clearance 6-8 CO 2 sensor Configuration 23 Settings 22, 23 Combustion blower wheel 34 Compressor Lockout 18, 38 Lubrication 35 Mounting 26 Rotation 26 Concentric duct 11 Condensate drain Cleaning 35 Location 11 ,[...]

— 49 — SER VICE TRAINING P ackaged Service Training prog rams are an ex cellent w ay to inc rease your knowle dge of the eq uipment discussed i n this manu al, inc l uding: • Uni t F a mili ariza ti on • Maint en ance • Installation Ov erview • Operating S equenc e A large selection of product, theory , and skills pro grams are availabl[...]

Copyright 2 006 Br yant He ating & Cooling System s Printe d in U.S.A. CA T A LOG NO. 04-5358 0003-01[...]

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Copyright 2 006 Br yant He ating & C ooling Systems P rint ed in U.S.A. CL-1 CA T ALOG N O. 04-53580003- 01 CUT ALONG DO TTED LINE CUT ALONG DO TTED LINE ST ART -UP CHECKLIST I. PRE-ST AR T -UP VERIFY THAT ALL P ACKI NG MATERIALS HA VE BEEN REMOVED FROM UNIT VERIFY INSTALLA TION OF INDOOR F AN MO TOR ADJUSTMENT BOL T AND PLATE VERIFY INSTALLA T[...]