Bryant 581J 17-28 Series Service And Maintenance Instructions Download Page 1 | Manualshive

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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53581021-01

Printed in U.S.A.

Form SM581J-17-28-02

Pg 1

12-19

Replaces: SM581J-17-28-01

Service and Maintenance Instructions

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . .1

UNIT ARRANGEMENT AND ACCESS . . . . . . . . . . . . . .2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SUPPLY FAN (BLOWER) SECTION . . . . . . . . . . . . . . . .4

Supply Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TWO-SPEED INDOOR FAN MOTOR SYSTEM:

2-SPEED FAN WITH VARIABLE FREQUENCY

DRIVE (VFD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Two-Speed Indoor Fan Motor System. . . . . . . . . . . . . . . . .5

Identifying Factory Option . . . . . . . . . . . . . . . . . . . . . . . . . .6

Unit Installation with 2-Speed Indoor Fan Motor Option.6
ADDITIONAL VFD INSTALLATION AND

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .6

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Replacing the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Changing Fan Wheel Speed by Changing Pulleys . . . . . . .7
CONDENSER COIL SERVICE . . . . . . . . . . . . . . . . . . . . .7

Round Tube Plate Fin (RTPF) Condenser Coil . . . . . . . . .7

Recommended Condenser Coil Maintenance and

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

EVAPORATOR COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Coil Maintenance and Cleaning Recommendation . . . . . .8

Evaporator Coil Metering Devices. . . . . . . . . . . . . . . . . . . .9
Refrigerant System Pressure Access Ports . . . . . . . . . . . . .9

PERFECT HUMIDITY ADAPTIVE DEHUMIDIFICA-

TION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Perfect Humidity Modes . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Perfect Humidity System Components . . . . . . . . . . . . . . .10
Subcooler/Reheat Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Operating Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
THERMOSTATIC EXPANSION VALVE (TXV). . . . . .15

TXV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Replacing TXV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Refrigerant System Pressure Access Ports . . . . . . . . . . . .16

PURON® (R-410A) REFRIGERANT. . . . . . . . . . . . . . . .16

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
COOLING CHARGING CHARTS. . . . . . . . . . . . . . . . . .18

COMPRESSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Replacing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . .22

Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Adjusting the Condenser-Fan. . . . . . . . . . . . . . . . . . . . . . .22
TROUBLESHOOTING COOLING SYSTEM . . . . . . . .22

Troubleshooting Cooling System . . . . . . . . . . . . . . . . . . . .22

CONVENIENCE OUTLETS . . . . . . . . . . . . . . . . . . . . . . .24
Non-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Unit-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Wet in Use Convenience Outlet Cover. . . . . . . . . . . . . . . .24
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

GFCI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Fuse On Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Using Unit-Mounted Convenience Outlets . . . . . . . . . . . . 25

Installing a Weatherproof Cover . . . . . . . . . . . . . . . . . . . . 25

SMOKE DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Smoke Detector Locations . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIOP Smoke Detector Wiring and Response . . . . . . . . . . 28

Sensor and Controller Tests . . . . . . . . . . . . . . . . . . . . . . . . 29
Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Normal State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Alarm State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . 31
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Supply (Indoor) Fan Motor Protection . . . . . . . . . . . . . . . 31

Control Circuit, 24-v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
RTU-OPEN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . 32

GAS HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 32

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuel Types and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Flue Gas Passageways. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Combustion-Air Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Burners and Igniters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ECONOMI$ER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 44
EconoMi$er IV Standard Sensors . . . . . . . . . . . . . . . . . . . 48

EconoMi$er® X (Factory Option). . . . . . . . . . . . . . . . . . . 54

PRE-START-UP/START-UP . . . . . . . . . . . . . . . . . . . . . . 67
START-UP, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Additional Installation/Inspection . . . . . . . . . . . . . . . . . . . 67

FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . 69

APPENDIX A — MODEL NUMBER

NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

APPENDIX B — PHYSICAL DATA . . . . . . . . . . . . . . . . 71
APPENDIX C — FAN PERFORMANCE . . . . . . . . . . . . 75

APPENDIX D — WIRING DIAGRAMS . . . . . . . . . . . . . 83

APPENDIX E — MOTORMASTER SENSOR

LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and electrical components. Only

trained and qualified service personnel should install, repair, or

service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of

cleaning coils and filters and replacing filters. All other operations

should be performed by trained service personnel. When working

on air-conditioning equipment, observe precautions in the litera-

Preferred Series™

581J*17-28

Gas Heat/Electric Cooling

with Puron

®

(R-410A) Refrigerant

1
2
3
...
»

Summary of Contents for 581J 17-28 Series

Page 1: ...stem 22 CONVENIENCE OUTLETS 24 Non Powered Type 24 Unit Powered Type 24 Wet in Use Convenience Outlet Cover 24 Duty Cycle 24 GFCI Maintenance 24 Fuse On Powered Type 25 Using Unit Mounted Convenience Outlets 25 Installing a Weatherproof Cover 25 SMOKE DETECTORS 25 System 25 Controller 25 Sensor 26 Smoke Detector Locations 26 FIOP Smoke Detector Wiring and Response 28 Sensor and Controller Tests 29...

Page 2: ...NG FIRE EXPLOSION HAZARD Failure to follow this warning could result in death serious personal injury and or property damage Never use non certified refrigerants in this product Non certi fied refrigerants could contain contaminates that could lead to unsafe operating conditions Use ONLY refrigerants that con form to AHRI Standard 700 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may r...

Page 3: ...iodically re placed or cleaned Return Air Filters Return air filters are disposable fiberglass media type Access to the filters is through the vertical panel to the right of the control box Filters are situated on slide out racks for easy inspection and repair See Fig 1 Removing the Return Air Filters 1 Remove the return air filter and indoor coil access panel See Fig 1 2 Reach inside and remove t...

Page 4: ...ting Fig 5 Checking Blower Motor Belt Tension ADJUSTING THE BELT TENSION Use the following steps to adjust the V belt tension See Fig 4 1 Loosen the four motor mounting nuts that attach the motor to the blower rail 2 Loosen the two jackbolt locking nuts beneath the motor mounting plate Turn the jackbolt locking nut counter clockwise to loosen 3 Turn the jack bolts counterclockwise to loosen and cl...

Page 5: ... not exceed maximum fan speed in the product data or motor amperage as listed on the unit rating plate 5 Set movable flange at nearest keyway or flat of pulley hub and tighten setscrew to torque specifications Torque pul ley set screw to 72 5 in lb 8 14 0 56 Nm ALIGNING THE FAN AND MOTOR PULLEYS 1 Loosen fan pulley setscrews 2 Slide fan pulley along fan shaft Make angular alignment by loosening mo...

Page 6: ...Remove four bolts four flat washers four lock washers and four nuts attaching the motor mounting plate to the unit Discard all lock washers 9 Remove motor and motor mounting bracket from unit 10 Remove four bolts flat washers lock washers and single external tooth lock washer attaching motor to the motor mounting plate Discard all lock washers and external tooth lock washer 11 Lift motor from moto...

Page 7: ...open 0 2 change in pulley diameter per turn open 2 9 0 2 3 1 in pulley diameter when pulley closed one turn from full open CONDENSER COIL SERVICE Round Tube Plate Fin RTPF Condenser Coil The condenser coil is fabricated with round copper hairpins tubing and plate fins of various materials and coatings see Appendix A to identify the materials provided in this unit The coil can be one row or composi...

Page 8: ...uld be removed with a vacuum cleaner If a vacuum cleaner is not available a soft non metallic bristle brush can be used In either case the tool should be applied in the direction of the fins Coil surfaces can be easily damaged Applying the tool across the fin edges can cause the edges to be easily bent over damaging the coating of a protected coil NOTE Use of a water stream such as a garden hose a...

Page 9: ...icate a plugged or a missing orifice Refrigerant System Pressure Access Ports There are two access ports in the system on the suction tube near the compressor and on the discharge tube near the compressor These are brass fittings with black plastic caps The hose connec tion fittings are standard 1 4 in SAE male flare couplings The brass fittings are two piece High Flow valves with a recep tacle ba...

Page 10: ...te at a low SHR of 0 0 to 0 2 With no cooling requirement calling for dehumidification the Perfect Humidity adaptive dehumidification system will turn on both compressors and open the two hot gas bypass valves allowing refrigerant flow to the Perfect Humidity coil to reheat the unit s supply air to a neu tral temperature As the hot bypassed refrigerant liquid gas or two phase mixture passes throug...

Page 11: ...ircuits will operate in Re heat2 mode Both solenoids are energized in both circuits See Fig 17 Hot Gas Reheat Schematic for system refrigerant flow When there is both cooling demand thermostat Y1 demand and dehumidification demand circuit 1 will operate in Reheat1 mode Subcooling Fig 16 and circuit will operated in Reheat2 mode Reheat Fig 17 In Reheat1 mode the 3 way solenoid valve is energized op...

Page 12: ...tem CONDENSER COIL EVAPORATOR COIL COMPRESSOR OUTDOOR AIR INDOOR AIR RH2 x VALVE RH1 x VALVE TXV VALVE CLOSED VALVE OPEN VALVE 3 WAY VALVE PERFECT HUMIDITY COIL CONDENSER COIL PERFECT HUMIDITY COIL EVAPORATOR COIL COMPRESSOR OUTDOOR AIR INDOOR AIR RH2 x VALVE RH1 x VALVE TXV VALVE CLOSED VALVE OPEN VALVE 3 WAY VALVE ...

Page 13: ... ON G OFF OFF ON R OFF OFF OFF OFF ON X OFF Normal Heat 1 OFF OFF ON G OFF OFF ON R OFF OFF OFF OFF OFF ON ON Reheat Dehumidify ON ON ON G ON ON OFF ON R ON R ON OFF OFF ON ON Subcool Cir1 Reheat Cir2 Cool1 and Cool2 Subcool Dehumidify ON ON ON G ON ON OFF OFF ON R ON ON OFF ON ON Subcool Cir1 and Cir2 Cool1 and Cool2 Subcool Dehumidify ON ON ON G ON ON OFF OFF OFF OFF OFF ON X ON Heat Override He...

Page 14: ...er RDV Valve Operation NOTE Normally Closed When De energized No 24V signal to input terminals Check using Cool Reheat1 Valve Test Service Test HMZR RHV A or RHV B using ComfortLink Scrolling Marquee Check MBB relay output Check wiring Check transformer and circuit breaker or fuses Solenoid coil burnout Check continuous over voltage is less than 10 Check under voltage is less than 15 Check for mis...

Page 15: ...ure at the outlet of the evaporator coil is transferred through the external equalizer tube to the underside of the diaphragm 3 The needle valve on the pin carrier is spring loaded exert ing pressure on the underside of the diaphragm Therefore the bulb pressure equals the evaporator pressure at the outlet of the coil plus the spring pressure If the evapora tor load increases the temperature increa...

Page 16: ...torque do not over tighten PURON R 410A REFRIGERANT This unit is designed for use with Puron R 410A refrigerant Do not use any other refrigerant in this system Puron R 410A refrigerant is provided in pink rose colored cyl inders These cylinders are available with and without dip tubes Cylinders with dip tubes will have a label indicating this feature For a cylinder with a dip tube place the cylind...

Page 17: ...63 F 17 C Circuit B Outdoor Temperature 85 F 29 C Suction Pressure 120 psig 827 kPa Suction Temperature should be 58 F 14 C USING THE COOLING CHARGING CHARTS Take the outdoor ambient temperature and read the suction pres sure gage Refer to chart to determine what suction temperature should be If suction temperature is high add refrigerant If suction temperature is low carefully recover some of the...

Page 18: ...18 COOLING CHARGING CHARTS Fig 21 Cooling Charging Chart 15 Ton ...

Page 19: ...19 Fig 22 Cooling Charging Chart 17 5 Ton ...

Page 20: ...20 Fig 23 Cooling Charging Chart 20 Ton ...

Page 21: ...21 Fig 24 Cooling Charging Chart 25 Ton ...

Page 22: ... the filter drier 1 Using Puron R 410A gage set recover all refrigerant from system 2 Use tubing cutter to remove filter drier from line NOTE Do not use a torch to remove old filter drier The heat from the torch will allow contaminants into the air and into the open re frigeration system 3 Sweat a new replacement filter drier into refrigerant line 4 Re charge refrigerant system Adjusting the Conde...

Page 23: ...lter Replace air filter Unit undersized for load Decrease load or replace with larger unit Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Leaking valves in compressor Replace compressor Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Excessive Head Pressure Dirty air f...

Page 24: ...oading for continuous duty loads such as electric heat ers for overnight use Observe a 50 limit on circuit loading above 8 amps i e limit loads exceeding 8 amps to 30 minutes of operation every hour The primary leads to the convenience outlet transformer are not factory connected Selection of primary power source is a custom er option If local codes permit the transformer primary leads can be conn...

Page 25: ...l closing and latching Fig 28 Weatherproof Cover Installation SMOKE DETECTORS Smoke detectors are available as factory installed options on 581J models Smoke detectors can be specified for supply air only for return air with or without economizer or in combination of supply air and return air Return air smoke detectors are arranged for ver tical return configurations only All components necessary ...

Page 26: ...ire alarm control panel etc The sensor uses a photoelectric light scattering principle process called differential sensing preventing gradual environmental changes from triggering false alarms A rapid change in environ mental conditions such as smoke from a fire causes the sensor to signal an alarm state but dust and debris accumulated over time does not Fig 30 Smoke Detector Sensor For installati...

Page 27: ...See installation steps Fig 32 Typical Return Air Smoke Detector Location without Economizer RETURN AIR WITH ECONOMIZER The sampling tube is inserted through the side plates of the econo mizer housing placing it across the return air opening on the unit basepan See Fig 33 The holes in the sampling tube face down ward into the return air stream The sampling tube is connected through tubing to the re...

Page 28: ...ating are terminated as described above HIGHLIGHT D On smoke alarm condition the smoke detector NO Alarm contact will close supplying 24 v power to GRA conductor HIGHLIGHT E GRAlead at Smoke Alarm input on LCTB provides 24 v signal to FIOP DDC control RTU OPEN The 24 v signal is conveyed to the RTU OPEN J1 10 input termi nal This signal initiates the FSD sequence by the RTU OPEN control FSD status...

Page 29: ...ding it against the sensor housing again for approxi mately 2 seconds until the sensor s Alarm LED turns off REMOTE STATION TEST The remote station alarm test checks a test reset station s ability to initiate and indicate an alarm state SD TRK4 REMOTE ALARM TEST PROCEDURE 1 Turn the key switch to the RESET TEST position for seven seconds 2 Verify that the test reset station s Alarm LED turns on 3 ...

Page 30: ... high impedance multiple fan shutdown control line is pulled to ground Trouble state The SuperDuct duct smoke detector enters the trouble state un der the following conditions A sensor s cover is removed and 20 minutes pass before it is properly secured A sensor s environmental compensation limit is reached 100 dirty A wiring fault between a sensor and the controller is detected An internal sensor...

Page 31: ...r 2 Verify that power is applied to the controller s supply input terminals If power is not present replace or repair wiring as required REMOTE TEST RESET STATION S TROUBLE LED DOES NOT FLASH WHEN PERFORMING A DIRTY TEST BUT THE CONTROLLER S TROUBLE LED DOES 1 Verify that the remote test station is wired as shown in Fig 35 Repair or replace loose or missing wiring 2 Configure the sensor dirty test...

Page 32: ...an economizer open mode or a leak devel ops in the duct system that allows a bypass back to unit return opening CONDENSER FAN MOTOR PROTECTION The condenser fan motor is internally protected against over temperature Control Circuit 24 v The control circuit is protected against overcurrent conditions by a circuit breaker mounted on control transformer TRAN Reset is manual RTU OPEN CONTROL SYSTEM Fo...

Page 33: ...m to the heat exchanger system Contact your fuel supplier if this condition is suspected Fig 41 LP Low Pressure Switch installed for 581J D Fig 42 LP Supply Line Low Pressure Switch Wiring Flue Gas Passageways To inspect the flue collector box and upper areas of the heat exchanger 1 Remove the combustion blower wheel and motor assem bly according to directions in Combustion Air Blower sec tion See...

Page 34: ...ply line 2 Turn the gas valve ON OFF knob to the OFF position 3 Shut off power to unit and install lockout tag 4 Disconnect gas piping at unit gas valve 5 Remove wires connected to gas valve Mark each wire to assist in re connecting power to the gas valve BURNER ASSEMBLY GAS VALVE INDUCER FAN MOTOR ASSEMBLY VESTIBULE PLATE SUPPORT INSULATION ASSEMBLY HEATER TUBE ASSEMBLY SEAL STRIPS SPONGE RUBBER ...

Page 35: ... mm to 3 60 mm and spaced 0 18 in 4 60 mm from the end of the burner See Fig 49 5 If factory orifice has been removed check that each orifice is tight at its threads into the manifold pipe and that orifice projection does not exceed maximum valve See Fig 44 6 Reinstall burners on the rack in the same locations as they were installed at the factory The outside crossover flame regions of the outermo...

Page 36: ...36 Fig 47 Unit Control Box IGC Location IGC Board IGC Board Side view Front view ...

Page 37: ...rrupted When a break in power occurs the IGC will be reset resulting in a loss of fault history and the indoor evaporator fan ON OFF times will be reset The LED error code can be observed through the viewport During servicing refer to the label on the control box cover or Table 13 for an explanation of LED error code descriptions A 3 second pause exists between LED error code flashes If more than ...

Page 38: ...113 0 1130 34 LH32RF111 0 1110 35 LH32RF110 0 1100 36 LH32RF105 0 1065 37 LH32RF104 0 1040 38 LH32RF102 0 1015 39 LH32RF103 0 0995 40 LH32RF098 0 0980 41 LH32RF096 0 0960 42 LH32RF094 0 0935 43 LH32RF089 0 0890 44 LH32RF086 0 0860 45 LH32RF082 0 0820 46 LH32RF080 0 0810 47 LH32RF079 0 0785 48 LH32RF076 0 0760 49 LH32RF073 0 0730 50 LH32RF070 0 0700 51 LH32RF067 0 0670 52 LH32RF065 0 0635 53 LH32RF...

Page 39: ...39 Fig 50 Integrated Gas Control IGC Board RED LED STATUS ...

Page 40: ...r gas section analog input J1 1 3 FS T1 Flame sensor gas section switch input W Heat stage 1 LCTB 24 vac J2 2 RS Rollout switch gas section switch input J2 5 6 LS Limit switch fan section switch input J2 7 8 CS Centrifugal switch not used switch input J2 9 10 OUTPUTS L1 CM Induced draft combustion motor gas section line VAC IFO Indoor fan control box relay J2 1 GV Gas valve heat stage 1 gas sectio...

Page 41: ...00 3658 372 114 400 372 161 200 372 208 000 13 000 3962 392 105 600 392 148 800 392 192 000 14 000 4267 392 96 800 392 136 400 392 176 000 KIT NO XX1 CRNGELEV001A00 XX2 CRNGELEV002A00 XX3 CRLPELEV005A00 XX4 CRLPELEV006A00 XX5 CRLPKIT9001A00 KIT NO Table 17 Altitude Compensation 17 30 for Propane Gas PROPANE GAS NOMINAL HEAT INPUT ELEVATION 220k BTUH 310k BTUH 400k BTUH Feet Meters Orifice Size Inp...

Page 42: ... valve Water in gas line Drain water and install drip leg to trap water No power to furnace Check power supply fuses wiring and circuit breaker No 24 v power supply to control circuit Check transformer Transformers with internal overcurrent protection require a cool down period before resetting Miswired or loose connections Check all wiring and wire nut connections Burned out heat anticipator in t...

Page 43: ...er reset for LED reset 4 consecutive limit switch faults within a single call for heat See Limit Switch Fault 5 Flashes Ignition Fault No gas heating Heat call W Off Power reset for LED reset Unit unsuccessfully attempted ignition for 15 minutes Check igniter and flame sensor electrode spacing gaps etc Check flame sense and igniter wiring Check gas valve operation and gas supply 6 Flashes Induced ...

Page 44: ... 55 EconoMi er 2 Component Locations IMPORTANT Any economizer that meets the economizer requirements as laid out in California s Title 24 mandatory section 120 2 fault detection and diagnostics and or pre scriptive section 140 4 life cycle tests damper leakage 5 year warranty sensor accuracy etc will have a label on the economizer Any economizer without this label does not meet California s Title ...

Page 45: ...45 Fig 56 RTU Open Overlay for Economizer Wiring ...

Page 46: ...46 Fig 57 VFD Overlay for W2770 Controller Wiring ...

Page 47: ...osition Fig 58 EconoMi er IV Wiring NOTES 1 Switch on actuator must be in run position for economizer to operate 2 50HJ540573 actuator consists of the 50HJ540567 actuator and a harness with 500 ohm resistor Fig 59 EconoMi er2 with 4 to 20 mA Control Wiring FOR OCCUPANCY CONTROL REPLACE JUMPER WITH FIELD SUPPLIED TIME CLOCK 8 7 LEGEND DCV Demand Controlled Ventilation IAQ Indoor Air Quality LA Low ...

Page 48: ... when the EconoMi er IV can be used for free cooling The sensor is facto ry installed on the EconoMi er IV in the outdoor airstream See Fig 61 The operating range of temperature measurement is 40 F to 100 F 4 C to 38 C See Fig 62 SUPPLY AIR TEMPERATURE SAT SENSOR The supply air temperature sensor is a 3 K thermistor located at the inlet of the indoor fan See Fig 61 This sensor is factory in stalle...

Page 49: ...ature is compared to an adjustable set point selected on the control If the outdoor air temperature is above the setpoint the EconoMi er IV system will adjust the out side air dampers to minimum position If the outdoor air tempera ture is below the setpoint the position of the outside air dampers will be controlled to provided free cooling using outdoor air When in this mode the LED next to the fr...

Page 50: ...004A00 one in the outside air duct and one in the return air duct The EconoMi er IV controller compares the outdoor air en thalpy to the return air enthalpy to determine EconoMi er IV use The controller selects the lower enthalpy air return or outdoor for cooling For example when the outdoor air has a lower enthalpy than the return air the EconoMi er IV opens to bring in outdoor air for free cooli...

Page 51: ...eturn air temperatures To determine the minimum position setting perform the following procedure 1 Calculate the appropriate mixed air temperature using the following formula TO Outdoor Air Temperature OA Percent of Outdoor Air TR Return Air Temperature RA Percent of Return Air TM Mixed Air Temperature As an example if local codes require 10 outdoor air during oc cupied conditions outdoor air temp...

Page 52: ...termine the maximum setting of the CO2 sensor For example an 1100 ppm setpoint relates to a 15 cfm per person design Use the 1100 ppm curve on Fig 68 to find the point when the CO2 sensor output will be 6 7 volts Line up the point on the graph with the left side of the chart to determine that the range configuration for the CO2 sensor should be 1800 ppm The EconoMi er IV control ler will output th...

Page 53: ... IV settings and wiring to normal after completing troubleshooting DCV DEMAND CONTROLLED VENTILATION AND POWER EXHAUST To check DCV and Power Exhaust 1 Make sure EconoMi er IV preparation procedure has been performed 2 Ensure terminals AQ and AQ1 are open The LED for both DCV and Exhaust should be off The actuator should be fully closed 3 Connect a 9 v battery to AQ positive node and AQ1 negative ...

Page 54: ...ensor which is powered by and communicates on the S Bus Up to three sensors may be configured with the W7220 economizer module CO2 Sensor optional The CO2 sensor can be added for Demand Controlled Ventilation DCV SPECIFICATIONS W7220 Economizer Module The module is designed for use with 2 to 10 vdc or bus communi cating actuator The module includes terminals for CO2 sensor Mixed Air sensor and an ...

Page 55: ...01 Rev G HJW10 www energy ca gov Certified FDD Product California Title 24 Part 6 Table 23 Economizer Module Left Hand Terminal Blocks LABEL TYPE DESCRIPTION Top Left Terminal Block MAT MAT 20k NTC and COM Mixed Air Temperature Sensor Polarity Insensitive Connection OAT OAT 20k NTC and COM Outdoor Air Temperature Sensor Polarity Insensitive Connection S BUS S BUS S BUS Sylk Bus Enthalpy Control Se...

Page 56: ...enu items and to change parame ter and configuration settings To use the keypad when working with menus Press the Up arrow button to move to the previous menu Press the Down arrow button to move to the next menu Press the Enter button to display the first item in the currently displayed menu Press the Menu Up Exit button to exit a menu s item and return to the list of menus Fig 74 W7220 Controller...

Page 57: ...ATUS ECON AVAIL NO YES NO FIRST STAGE COOLING DEMAND Y1 IN YES economizing available the system can use outside air for free cooling when required ECONOMIZING NO YES NO FIRST STAGE COOLING RELAY OUTPUT YES outside air being used for first stage cooling OCCUPIED NO YES NO OCCUPIED YES OCC signal received from space thermostat or unitary controller YES 24 vac on terminal OCC NO 0 vac on terminal OCC...

Page 58: ...eating that is active FAN SPEED N A LOW or HIGH SUPPLY FAN SPEED Displays speed setting of fan on a 2 speed fan unit W HEAT IN N A ON OFF HEAT DEMAND STATUS Displays status of heat demand on a 2 speed fan unit SETPOINTS MAT SET 53 F 12 C 38 F to 70 F 3 C to 21 C increment by 1 F SUPPLY AIR SETPOINT The economizer will modulate the OA damper to maintain the mixed air temperature at the set point LO...

Page 59: ... Display order MM DD YY Setting order DD MM then YY UNITS DEG F F or C Sets economizer controller in degrees Fahrenheit or Celsius EQUIPMENT CONV CONV or HP CONV conventional HP O B Enable Heat Pump mode Use AUX2 I for Heat Pump input from thermostat or controller AUX2 IN W Shutdown SD Heat W1 HP O HP B In CONV mode SD Enables configuration of shutdown default W Informs controller that system is i...

Page 60: ...sor OA H CAL 0 RH 10 RH OUTSIDE AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor RA T CAL 0 0 F 2 5 F RETURN AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor RA H CAL 0 RH 10 RH RETURN AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor DA T CAL 0 0...

Page 61: ...or has failed or become disconnected check wiring then replace sensor if the alarm continues OA SYLK H ERR N A N A RA SYLK T ERR N A N A RETURN AIR S BUS SENSOR ERROR Return air enthalpy sensor has failed or become disconnected check wiring then replace sensor if the alarm continues RA SYLK H ERR N A N A DA SYLK T ERR N A N A DISCHARGE AIR S BUS SENSOR ERROR Discharge air sensor has failed or beco...

Page 62: ...f MIN POS Closed On On High 24 v On 24 v On MIN POS Closed Yes Off Off High 0 v Off 0 v Off MIN POS Closed On Off High 0 v Off 0 v Off MIN POS to Full Open Closed to Full Open On On High 24 v On 0 v Off MIN POS to Full Open Closed to Full Open Table 30 Dry Bulb Operation with DCV CO2 Sensor 1 Speed Fan DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OC...

Page 63: ... Off Off High 0 v Off 0 v Off MIN POS Closed On Off High 0 v Off 0 v Off MIN POS to Full Open Closed to Full Open On On High 24 v On 0 v Off MIN POS to Full Open Closed to Full Open Table 32 Enthalpy Operation with DCV CO2 Sensor 1 Speed Fan DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 set No Off Off High 0 v Off 0 v Of...

Page 64: ...I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 Set No OFF OFF LOW 0v Off 0v Off VENTMIN Closed ON OFF LOW 24v On 0v Off VENTMIN Closed ON ON HIGH 24v On 24v On VENTMIN Closed Yes OFF OFF LOW 0v Off 0v Off VENTMIN Closed ON OFF LOW 0v Off 0v Off VENTMIN to Full Open Closed to Full Open ON ON HIGH 24v On 0v Off VENTMIN to Full Open Closed to Full Open Above CO2 Set No OFF OFF LOW 0v Off 0v...

Page 65: ...tus to determine the speed of the supply fan and controls the OA damper to the required posi tion see Table 37 The W heating mode is not controlled by the W7220 but it re quires the status to know where to position the OA damper for minimum position for the fan speed The 2 speed fan delay is available when the system is pro grammed for 2 speed fan in the System Setup menu item The 2 speed fan dela...

Page 66: ...e item RUN appears 3 Press the Enter button to start the test The unit pauses and then displays IN PROGRESS When the test is complete DONE appears 4 When all desired parameters have been tested press the Menu Up button to end the test The Checkout tests can all be performed at the time of installation or at any time during the operation of the system as a test that the system is operable TROUBLESH...

Page 67: ...s especially important when field accessories have been added to the unit The factory pre configures options in stalled at the factory There may also be additional installation steps or inspection required during the start up process Additional Installation Inspection Inspect the field installed accessories for proper installation mak ing note of which ones do or do not require configuration chang...

Page 68: ...ng ef fect then lower the thermostat setting below the room temperature and verify that the burners and evaporator fan turn off Refer to Tables 16 and 17 for the correct orifice to use at high altitudes HEATING 1 Purge gas supply line of air by opening union ahead of the gas valve If gas odor is detected tighten union and wait 5 minutes before proceeding 2 Turn on electrical supply and manual gas ...

Page 69: ... a minimum of 10 minutes has elapsed since the last call for heating The evaporator fan off delay can also be modified Once the call for heating has ended there is a 10 minute period during which the modification can occur If the limit switch trips during this period the evaporator fan off delay will increase by 15 seconds A maximum of 9 trips can occur extending the evaporator fan off delay to 18...

Page 70: ...t Power Exhaust Low Leak w CO W7212 or W7220 Q Motorized 2 Position Damper P Manual Outdoor Air Damper U Temp Econo Baro Relief Ultra Low Leak W7220 V Temp Econo Cent Power Exhaust Ultra Low Leak W7220 W Enthalpy Econo Baro Relief Ultra Low Leak W7220 X Enthalpy Econo Cent Power Exhaust Ultra Low Leak W7220 Indoor Fan Options 1 Standard Static Option Vertical 2 Medium Static Option Vertical 3 High...

Page 71: ...2 822 Max blower Shaft RPM 1200 1200 1200 1200 Motor frame size 56 56 56 56 Fan qty Type 2 Centrifugal 2 Centrifugal 2 Centrifugal 2 Centrifugal Fan diameter in 15 x 15 15 x 15 15 x 15 15 x 15 MEDIUM STATIC Motor qty Belt qty Driver type 1 1 Belt 1 1 Belt 1 1 Belt 1 1 Belt Nominal nameplate H P 3 7 3 7 5 25 5 25 Max BHP 3 7 3 7 4 9 4 9 RPM range 679 863 679 863 713 879 713 879 Max blower Shaft RPM...

Page 72: ...me size 56 56 Fan qty Type 2 Centrifugal 2 Centrifugal Fan diameter in 18 x 15 15 x 11 18 x 15 15 x 11 HIGH STATIC HIGH EFFICIENCY Motor qty Belt qty Driver type 1 1 Belt 1 1 Belt Nominal nameplate H P 5 0 5 0 Max BHP 6 5 6 9 7 0 8 3 6 5 6 9 7 0 8 3 RPM range 835 1021 835 1021 Max blower Shaft RPM 1100 1100 Motor frame size 184T 184T Fan qty Type 2 Centrifugal 2 Centrifugal Fan diameter in 18 x 15...

Page 73: ... BHP RPM range Max blower Shaft RPM Motor frame size Fan qty Type Fan diameter in STANDARD STATIC HIGH EFFICIENCY Motor qty Belt qty Driver type 1 1 Belt 1 1 Belt Nominal nameplate H P 5 0 5 0 Max BHP 6 5 6 9 7 0 8 3 6 5 6 9 7 0 8 3 RPM range 690 863 690 863 Max blower Shaft RPM 1200 1200 Motor frame size 184T 184T Fan qty Type 2 Centrifugal 2 Centrifugal Fan diameter in 15 x 15 15 x 15 MEDIUM STA...

Page 74: ...7 5 7 5 7 5 Max BHP 10 5 11 9 11 9 11 10 5 11 9 11 9 11 10 5 11 9 11 9 11 10 5 11 9 11 9 11 RPM range 941 1100 941 1100 906 1100 906 1100 Max blower Shaft RPM 1100 1100 1100 1100 Motor frame size 213T 213T 213T 213T Fan qty Type 2 Centrifugal 2 Centrifugal 2 Centrifugal 2 Centrifugal Fan diameter in 18 x 15 15 x 11 18 x 15 15 x 11 18 x 15 15 x 11 18 x 15 15 x 11 Cond Coil Circuit A Coil type RTPF ...

Page 75: ...4 780 RPM 3 7 BHP max High static 746 912 RPM 4 9 BHP max Table D 581J 17 Vertical Supply 15 Tons CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 0 2 0 4 0 6 0 8 1 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 4500 494 0 77 583 1 09 662 1 43 732 1 80 796 2 19 4900 522 0 93 605 1 27 681 1 64 750 2 03 813 2 44 5250 547 1 10 626 1 45 700 1 84 766 2 24 828 2 67 5650 577 1 32 651 1 68 721 2 09 786 2 51 846 2 ...

Page 76: ...8 836 5 23 883 6 01 7000 714 3 67 769 4 38 820 5 14 868 5 92 913 6 74 7450 753 4 33 805 5 08 854 5 87 900 6 69 944 7 54 7900 792 5 06 841 5 85 888 6 68 933 7 54 8300 827 5 78 874 6 61 920 7 47 8750 867 6 69 912 7 55 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 5250 848 4 99 893 5 72 934 6 47 974 7 25 1012 8 05 5700 875 5 56 918 6 33 959 7...

Page 77: ...17 7450 718 2 70 775 3 14 832 3 62 887 4 13 940 4 67 7900 755 3 16 809 3 62 863 4 12 915 4 65 966 5 21 8300 787 3 62 839 4 09 891 4 61 941 5 16 990 5 73 8750 825 4 18 874 4 68 923 5 22 971 5 78 1018 6 38 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 5250 885 3 11 939 3 57 990 4 05 1038 4 54 1084 5 04 5700 905 3 47 958 3 95 1008 4 45 1055 4...

Page 78: ...39 954 6 10 998 6 81 8500 843 4 73 896 5 45 945 6 18 991 6 93 1034 7 68 9000 886 5 52 937 6 28 984 7 06 1029 7 84 1071 8 63 9500 929 6 40 978 7 21 1024 8 02 1067 8 84 10000 973 7 38 1020 8 22 1064 9 08 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 6000 907 4 68 949 5 27 990 5 88 1028 6 50 1064 7 13 6500 939 5 29 981 5 92 1020 6 56 1058 7 2...

Page 79: ...1 4 55 1011 5 03 1059 5 51 9500 893 4 20 947 4 69 998 5 19 1046 5 69 1092 6 19 10000 934 4 85 986 5 36 1035 5 88 1082 6 40 1126 6 93 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 6000 928 2 92 978 3 28 1025 3 65 1071 4 03 1114 4 42 6500 955 3 31 1003 3 69 1050 4 09 1094 4 49 1137 4 89 7000 983 3 75 1030 4 15 1075 4 56 1119 4 98 1161 5 41 7...

Page 80: ...8 991 6 93 1034 7 68 9000 886 5 52 937 6 28 984 7 06 1029 7 84 1071 8 63 9500 929 6 40 978 7 21 1024 8 02 1067 8 84 10000 973 7 38 1020 8 22 1064 9 08 10500 1017 8 45 1062 9 33 11000 1061 9 63 11500 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 7500 1005 6 72 1046 7 42 1084 8 13 8000 1040 7 54 1079 8 28 8500 1075 8 45 9000 9500 10000 10500...

Page 81: ...0 1088 5 67 1131 6 15 1173 6 64 9400 1129 6 56 1172 7 07 10000 1169 7 47 10650 11250 11900 12500 Standard static 717 911 RPM 4 9 Max BHP Medium static 913 1116 RPM Voltage 208v 230v 460v 575v Max BHP 6 5 6 9 7 0 8 3 High static 941 1176 RPM Voltage 208v 230v 460v 575v Max BHP 10 5 11 9 11 9 11 0 Table K Pulley Adjustment Vertical Fan RPM at Motor Pulley Settings MODEL SIZE MOTOR DRIVE COMBO MOTOR ...

Page 82: ...ated by EPACT include any general purpose T frame three digit 143 and larger single speed foot mounted polyphase squirrel cage induction motors of NEMA National Electrical Manufacturers Association design A and B manufactured for use in the United States Ranging from 1 to 200 Hp these continuous duty motors operate on 230 and 460 volt 60 Hz power If a motor does not fit into these specifications t...

Page 83: ...0HE500752 L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE502184 F page 91 20 208 230 3 60 50HE500889 L page 85 50HE502186 D page 89 460 3 60 50HE500752 L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE502184 F page 91 24 208 230 3 60 50HE500889 L page 85 50HE502186 D page 89 460 3 60 50HE500752 L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE50218...

Page 84: ...84 Fig B 581J 17 28 Control Diagram 208 230 3 60 460 575 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 85: ...85 Fig C 581J 17 28 Power Diagram 208 230 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 86: ...86 Fig D 581J 17 28 Power Diagram 460 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 87: ...87 Fig E 581J 17 28 Power Diagram 575 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 88: ...88 Fig F 581J 17 28 Control Diagram with Perfect Humidity System APPENDIX D WIRING DIAGRAMS ...

Page 89: ...89 Fig G 581J 17 28 Power Diagram 208 230 3 60 with Perfect Humidity System APPENDIX D WIRING DIAGRAMS ...

Page 90: ...90 Fig H 581J 17 28 Power Diagram 460 3 60 with Perfect Humidity System APPENDIX D WIRING DIAGRAMS ...

Page 91: ...91 Fig I 581J 17 28 Power Diagram 575 3 60 with Perfect Humidity System APPENDIX D WIRING DIAGRAMS ...

Page 92: ...92 Fig J RTU OPEN Wiring Diagram APPENDIX D WIRING DIAGRAMS ...

Page 93: ...93 Fig K RTU OPEN Wiring Diagram with Perfect Humidity System APPENDIX D WIRING DIAGRAMS ...

Page 94: ... obligations Catalog No 04 53581021 01 Printed in U S A Form SM581J 17 28 02 Pg 94 12 19 Replaces SM581J 17 28 01 2019 Bryant Heating Cooling Systems Fig L MotorMaster Sensor Locations for Size 17 20 and 24 Units Fig M MotorMaster Sensor Locations Size 28 Units SENSOR LOCATION SENSOR LOCATION APPENDIX E MOTORMASTER SENSOR LOCATIONS ...

Page 95: ...ecessary Y N _____ Verify gas pressure to unit gas valve is within specified range Y N _____ Check gas piping for leaks Y N _____ Check that indoor air filters are clean and in place Y N _____ Check that outdoor air inlet screens are in place Y N _____ Verify that unit is level Y N _____ Check fan wheels and propeller for location in housing orifice and verify setscrew is tight Y N _____ Verify th...

Page 96: ...o make the observations listed for this start up STEPS 1 Check CTB for jumper 5 6 7 Jumper 5 6 7 must be cut and open Y N _____ 2 Open humidistat contacts Y N _____ 3 Start unit In cooling Close Y1 Y N _____ OBSERVE AND RECORD A Suction pressure _______________ PSIG B Discharge pressure _______________ PSIG C Entering air temperature _______________ F D Liquid line temperature at outlet or reheat ...

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