Bryant DuraPac 580F Series Installation, Start-Up And Service Instructions Manual Download Page 52

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CL-1

CATALOG NO. 04-53580003-01

CUT

TTE

D LI

ONG DO

INE

START-UP CHECKLIST

I. PRE-START-UP

VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

VERIFY INSTALLATION OF INDOOR FAN MOTOR ADJUSTMENT BOLT AND PLATE

VERIFY INSTALLATION OF OUTDOOR-AIR HOOD

VERIFY INSTALLATION OF FLUE HOOD AND WIND BAFFLE

VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS

VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT

CHECK GAS PIPING FOR LEAKS

CHECK THAT FILTERS AND SCREENS ARE CLEAN AND IN PLACE

VERIFY THAT UNIT IS LEVEL

CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW

IS TIGHT

VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED

VERIFY THAT SCROLL COMPRESSOR IS ROTATING IN THE CORRECT DIRECTION

VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED FOR 24 HOURS

II. START-UP

ELECTRICAL

SUPPLY FAN AMPS

EXHAUST FAN AMPS

TEMPERATURES

OUTDOOR-AIR TEMPERATURE

F DB (Dry-Bulb)

RETURN-AIR TEMPERATURE

F DB

F WB (Wet-Bulb)

COOLING SUPPLY AIR

GAS HEAT SUPPLY AIR

PRESSURES

VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 37.

GENERAL

ECONOMI$ERIV MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

SUPPLY VOLTAGE

L1-L2

L2-L3

L3-L1

COMPRESSOR AMPS — COMPRESSOR NO. 1 L1

— COMPRESSOR NO. 2 L1

GAS INLET PRESSURE

IN. WG

GAS MANIFOLD PRESSURE

STAGE NO. 1

IN. WG

STAGE NO. 2

IN. WG

REFRIGERANT SUCTION

CIRCUIT NO. 1

PSIG

CIRCUIT NO. 2

PSIG

REFRIGERANT DISCHARGE

CIRCUIT NO. 1

PSIG

CIRCUIT NO. 2

PSIG

Summary of Contents for DuraPac 580F Series

Page 1: ...TALLATION I STEP 1 PROVIDE UNIT SUPPORT A Roof Curb Assemble or install accessory roof curb or horizontal adapter roof curb in accordance with instructions shipped with this accessory See Fig 1A 1B and 2 Install insulation cant strips roofing and counter flashing as shown Ductwork can be installed to roof curb or horizontal adapter roof curb before unit is set in place Curb or adapter roof curb sh...

Page 2: ...80 240 PKG NO REF CURB HEIGHT DESCRIPTION CRRFCURB010A00 1 2 305 Standard Curb 14 High CRRFCURB011A00 2 0 610 Standard Curb for Units Requiring High Installation CRRFCURB012A00 2 0 610 Side Supply and Return Curb for High Installation ...

Page 3: ... 3 Fig 1B Roof Curb Details 580F300 A A ...

Page 4: ...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 ventila tion 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 wea...

Page 5: ...ards for spreader bars on all units 5 Weights do not include optional EconoMi erIV Add 90 lb 41 kg for EconoMi erIV weight 6 Weights given are for aluminum evaporator and condenser coil plate fins CAUTION All panels must be in place when rigging Fig 3 Rigging Details UNIT 580F MAXIMUM SHIPPING WEIGHT DIMENSIONS A B lb kg ft in mm ft in mm 180 1875 850 6 111 2 2121 4 0 1219 210 1925 873 6 111 2 212...

Page 6: ...oil airflow Front 4 0 1219 for control box access Right side 4 0 1219 for proper operation of damper and power exhaust if so equipped Top 6 0 1829 to assure proper condenser fan operation Bottom 14 356 to combustible surfaces when not using curb Control box side 3 0 914 to ungrounded surfaces non combustible Control box side 3 6 1067 to block or concrete walls or other grounded surfaces Local code...

Page 7: ...l airflow Front 4 0 1219 for control box access Right side 4 0 1219 for proper operation of damper and power exhaust if so equipped Top 6 0 1829 to assure proper condenser fan operation Bottom 14 356 to combustible surfaces when not using curb Control box side 3 0 914 to ungrounded surfaces non combustible Control box side 3 6 1067 to block or concrete walls or other grounded surfaces Local codes ...

Page 8: ...ox access Right side 4 0 1219 for proper operation of damper and power exhaust if so equipped Top 6 0 1829 to assure proper condenser fan operation Bottom 14 356 to combustible surfaces when not using curb Control box side 3 0 914 to ungrounded surfaces non combustible Control box side 3 6 1067 to block or concrete walls or other grounded surfaces Local codes or jurisdiction may prevail 7 With the...

Page 9: ...Cfm 10 500 10 500 14 200 21 000 Quantity Diameter in 3 22 3 22 2 30 6 22 Motor Hp Rpm 1 2 1050 1 2 1050 1 1075 1 2 1050 Watts Input Total 1100 1100 3400 2200 EVAPORATOR COIL Cross Hatched 3 8 in Copper Tubes Aluminum Lanced or Copper Plate Fins Face Split Rows Fins in 4 15 4 15 4 15 4 15 Total Face Area sq ft 17 5 17 5 17 5 17 5 EVAPORATOR FAN Centrifugal Type Quantity Size in 2 12 x 12 2 12 x 12 ...

Page 10: ...0 1285 30 0 136 29 0 1285 30 0 136 29 0 1285 30 0 136 29 0 1285 30 0 136 29 Thermostat Heat Anticipator Setting amps 208 230 v Stage 1 0 98 0 98 0 98 0 98 Stage 2 0 44 0 44 0 44 0 44 460 v Stage 1 0 80 0 80 0 80 0 80 Stage 2 0 44 0 44 0 44 0 44 Gas Input Stage 1 206 000 270 000 206 000 270 000 206 000 270 000 206 000 270 000 Stage 2 275 000 360 000 275 000 360 000 275 000 360 000 275 000 360 000 E...

Page 11: ... box To install secure flue hood to access panel See Fig 10 The wind baffle is then installed over the flue hood NOTE When properly installed flue hood will line up with combustion fan housing See Fig 11 VI STEP 6 TRAP CONDENSATE DRAIN See Fig 12 for drain location One 3 4 in half coupling is pro vided inside unit evaporator section for condensate drain connection An 81 2 in x 3 4 in diameter and ...

Page 12: ...sage for elevations up to 7000 ft For elevations above 7000 ft refer to Table 4 to identify the correct orifice size for the elevation See Table 3 for the number of orifices required for each unit size Purchase these orifices from your local Bryant dealer Follow instructions in accessory Installation Instructions to install the correct orifices Table 4 LP Gas Conversion As the height above sea lev...

Page 13: ...ed 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 16 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 n...

Page 14: ... optional convenience outlet a 115 v GFI ground fault interrupt convenience outlet receptacle is pro vided for field wiring Field wiring should be run through the 7 8 in knockout provided in the basepan near the return air opening LEGEND NOTE The maximum wire size for TB1 is 2 0 Fig 15 Field Power Wiring Connections EQUIP Equipment GND Ground NEC National Electrical Code TB Terminal Board RH RC Y1...

Page 15: ...and EconoMi erIV If EconoMi erIV is factory installed all electrical connections have been made and adjusted at the factory Assemble and install hood in the field UNIT 580F NOMINAL VOLTAGE 3 Ph 60 Hz VOLTAGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION FAN MOTOR POWER SUPPLY No 1 No 1A No 2 Min Max RLA LRA RLA LRA RLA LRA Qty Hp FLA ea Hp FLA FLA LRA FLA MCA MOCP 180 208 230 187 253 32 1 195 ...

Page 16: ...ory installation instructions included with each accessory A Motormaster I Control 20 F Installation 580F180 and 210 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 22 for baffle details Use 20 gage galvanized sheet metal or similar corrosion resistant metal for baffles Use f...

Page 17: ...ent temperatures at which the unit will operate are To operate down to the ambient temperatures listed Motormaster V controls Fig 24 must be added Field fabricated and installed wind baffles are also required for all units see Fig 22 The Motormaster V control permits opera tion of the unit to an ambient temperature of 20 F The con trol regulates the speed of 3 phase fan motors that are compatible ...

Page 18: ...elocated See Fig 25 The operating range of tem perature measurement is 40 to 100 F 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 26 This sensor is factory installed The operating range of temperature measurement is 0 to 158 F See Table 10 for sensor tempera ture resistance values The temperature sensor looks l...

Page 19: ... air dampers will be con trolled to provide free cooling using outdoor air When in this mode the LED next to the free cooling set point potentiome ter will be on The changeover temperature set point is con trolled by the free cooling set point potentiometer located on the control See Fig 28 The scale on the potentiometer is A B C and D See Fig 29 for the corresponding temperature changeover values...

Page 20: ...per must be in place across terminals SR and SR on the EconoMi erIV controller See Fig 25 and 32 Differential Enthalpy Control For differential enthalpy control the EconoMi erIV controller uses two enthalpy sensors HH57AC078 and CRENTDIF004A00 one in the outside air and one in the return airstream on the EconoMi erIV frame The EconoMi erIV controller compares the outdoor air enthalpy to the return...

Page 21: ...er position above which the exhaust fan will be turned on When there is a call for exhaust the EconoMi erIV controller provides a 45 15 sec ond delay before exhaust fan activation to allow the dampers to open This delay allows the damper to reach the appropri ate position to avoid unnecessary fan overload Minimum Position Control There is a minimum damper position potentiometer on the EconoMi erIV...

Page 22: ... terminal TB2 10 When unoccupied mode is desired install a field supplied timeclock function in place of the jumper between terminals TB2 9 and TB2 10 See Fig 27 When the timeclock contacts are closed the EconoMi erIV control will be in occupied mode When the timeclock contacts are open removing the 24 v signal from terminal N the EconoMi erIV will be in unoccupied mode Demand Controlled Ventilati...

Page 23: ...wice The STDSET Menu will appear 3 Use the Up Down button to select the preset number See Table 12 4 Press Enter to lock in the selection 5 Press Mode to exit and resume normal operation The custom settings of the CO2 sensor can be changed any time after the sensor is energized Follow the steps below to change the non standard settings 1 Press Clear and Mode buttons Hold at least 5 sec onds until ...

Page 24: ...ell venti lated area to sense average humidity 2 Route thermostat cable or equivalent single leads of colored wire from humidistat terminals through con duit in unit to the low voltage connection on the 2 pole terminal strip TB3 as shown in Fig 34 and Fig 35 See Fig 36 for operation diagram Fig 35 Typical Perfect Humidity Dehumidification Package Control Box Fig 34 Typical Wiring Perfect Humidity ...

Page 25: ... 25 Fig 36 Perfect Humidity Dehumidification Package Operation Diagram Single Circuit Shown ...

Page 26: ...rt up Otherwise damage to compressor may result VIII EVAPORATOR FAN Fan belt and variable pulleys are factory installed See Tables 13 20 for fan performance data Be sure that fans rotate in the proper direction See Table 21 for air quantity limits See Table 22 for static pressure information for acces sories and options See Table 23 for fan rpm at various motor pulley settings See Tables 24 and 25...

Page 27: ...00 950 3057 3 59 1013 3364 3 95 1072 3675 4 31 1129 3991 4 68 1183 4311 5 06 7200 986 3401 3 99 1047 3717 4 36 1104 4037 4 74 1159 4361 5 11 1211 4689 5 50 7500 1022 3770 4 42 1081 4095 4 80 1136 4423 5 19 1189 4755 5 58 1241 5091 5 97 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 4500 1044 2345 2 75 1...

Page 28: ... 4 52 1190 4163 4 88 6900 1000 3298 3 87 1059 3603 4 23 1115 3912 4 59 1168 4225 4 96 1220 4543 5 33 7200 1038 3672 4 31 1095 3986 4 67 1149 4303 5 05 1201 4625 5 42 1251 4950 5 81 7500 1077 4072 4 78 1131 4394 5 15 1184 4720 5 54 1234 5050 5 92 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 4500 1060 2...

Page 29: ... 1236 5 13 4310 1288 5 50 4622 1313 5 68 4780 1337 5 87 4939 6 500 1219 5 29 4450 1270 5 66 4759 1320 6 03 5073 1344 6 22 5232 1368 6 41 5391 7 000 1258 5 88 4942 1307 6 25 5253 1355 6 62 5569 1378 6 81 5729 1402 7 00 5890 7 500 1299 6 52 5480 1346 6 89 5794 1392 7 27 6113 1415 7 46 6273 1437 7 65 6435 8 000 1341 7 21 6065 1387 7 59 6383 1392 7 97 6704 1453 8 16 6866 1475 8 36 7028 8 500 1385 7 97...

Page 30: ...24 5915 7 02 1272 6154 7 30 1319 6395 7 59 1364 6639 7 88 9 500 1235 6315 7 49 1282 6552 7 77 1327 6791 8 06 1372 7033 8 34 1415 7276 8 63 10 000 1295 6988 8 29 1340 7225 8 57 1383 7465 8 86 1426 7706 9 14 1468 7949 9 43 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 6 000 1141 3829 4 54 1196 4082 4 84 ...

Page 31: ... 6 65 1277 5847 6 94 1323 6088 7 22 1368 6331 7 51 9 000 1244 6011 7 13 1290 6247 7 41 1335 6485 7 69 1380 6726 7 98 1423 6968 8 27 9 500 1308 6687 7 93 1352 6924 8 21 1395 7162 8 50 1437 7402 8 78 1479 7644 9 07 10 000 1372 7401 8 78 1414 7638 9 06 1455 7876 9 34 1496 8117 9 63 1535 8358 9 92 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm ...

Page 32: ...766 1314 7 55 6 243 8 500 1117 5 74 4 750 1169 6 28 5 190 1219 6 83 5645 1268 7 40 6 114 1315 7 98 6 597 1361 8 58 7 094 9 000 1177 6 75 5 583 1226 7 31 6 047 1274 7 89 6524 1320 8 48 7 015 1365 9 09 7 520 1410 9 72 8 037 9 500 1237 7 98 6 511 1284 8 46 6 999 1329 9 07 7499 1374 9 69 8 012 1417 10 33 8 538 1459 10 98 9 076 10 000 1297 9 12 7 450 1342 9 74 8 051 1385 10 37 8574 1428 11 02 9 110 146...

Page 33: ... Energy Policy Act of 1992 EPACT effective October 24 1997 UNIT 580F MINIMUM COOLING CFM MINIMUM HEATING CFM MAXIMUM CFM Low Heat High Heat 180 4500 3800 3800 7 500 210 5400 4750 5450 9 000 240 6000 4750 5450 10 000 300 7000 4750 5450 11 250 COMPONENT CFM 4500 5000 5400 6000 7200 7500 9000 10 000 11 250 EconoMi erIV 0 040 0 050 0 060 0 070 0 090 0 100 0 110 0 120 0 140 Perfect Humidity Dehumidific...

Page 34: ...minimum position of the damper will be increased proportionally As the CO2 level decreases because of the increase in fresh air the outdoor air damper will be proportionally closed Damper position will follow the higher demand condition from DCV mode or free cooling mode Damper movement from full closed to full open or vice versa will take between 11 2 and 21 2 minutes If free cooling can be used ...

Page 35: ...Condenser and Evaporator Fan Motor Bearings The condenser and evaporator fan motors have permanently sealed bearings so no field lubrication is necessary III EVAPORATOR FAN PERFORMANCE ADJUSTMENT Fig 38 and 39 Fan motor pulleys are factory set for speed shown in Table 1 To change fan speeds 1 Shut off unit power supply 2 Loosen nuts on the 2 carriage bolts in the motor mounting base Install jackin...

Page 36: ...sing VII POWER FAILURE Dampers have a spring return In event of power failure dampers will return to fully closed position until power is restored Do not manually operate economizer motor VIII REFRIGERANT CHARGE Amount of refrigerant charge is listed on unit nameplate and in Table 1 Refer to GTAC II Module 5 Charging Recovery Recycling and Reclamation section for charging methods and procedures Un...

Page 37: ... 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 valve to OFF position 3 Remove 1 8 in pipe plug from manifold or gas valve pressure tap connection Install a suitable pressure measuring device 4 Set main gas valve to ON position 5 Set thermostat at set...

Page 38: ...reenergized by resetting the compressor lockout XIII 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 XIV 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 See Fig 45 an...

Page 39: ... 39 SEE DETAIL C SEE DETAIL C SEE DETAIL C 580F180275 Low Heat 580F180360 High Heat AND 580F210275 300275 Low Heat 580F210360 300360 High Heat Fig 44 Spark Gap Adjustment ...

Page 40: ... 40 Fig 45 Typical Wiring Schematic 580F240 208 230 V Shown ...

Page 41: ... 41 Fig 46 Typical Component Arrangement 580F240 Shown ...

Page 42: ...ir Temperature Sensor OCCUP Occupancy Sensor OFC Outdoor Fan Contactor OFM Outdoor Fan Motor LEGEND NOTES 1 Compressor and or fan motor s thermally protected three phase motors protected against primary single phasing conditions 2 If any of the original wire furnished must be replaced it must be replaced with Type 90 C or its equivalent 3 Jumpers are omitted when unit is equipped with economizer 4...

Page 43: ...ubleshooting D DCV Demand Controlled Ventilation and Power Exhaust To check DCV and Power Exhaust 1 Make sure EconoMi erIV 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 node The LED for both DCV and Exhaust should turn on ...

Page 44: ...s 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 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...

Page 45: ...t system Locate restriction and remove Compressor Operates continuously Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Excessive...

Page 46: ... 46 Fig 47 IGC Control Heating and Cooling LEGEND IGC Integrated Gas Unit Controller NOTE Thermostat Fan Switch in the AUTO position ...

Page 47: ...n DCV or fully open supply air signal INPUTS OUTPUTS Demand Control Ventilation DCV Enthalpy Y1 Y2 Compressor N Terminal Outdoor Return Stage 1 Stage 2 Occupied Unoccupied Damper Below set DCV LED Off High Free Cooling LED Off Low On On On On Minimum position Closed On Off On Off Off Off Off Off Low Free Cooling LED On High On On On Off Modulating between min position and full open Modulating betw...

Page 48: ...6 Gas pressure 1 10 Heat anticipator settings 10 13 High pressure switch 10 38 Hinged access doors 38 Horizontal adapter roof curb 4 Humidistat 24 Indoor air quality sensor 21 Integrated gas controller Error codes 46 Liquid propane 10 12 Low pressure switch 10 38 Main burners 34 37 Manual outdoor air damper 15 Motormaster I control 16 17 Motormaster V control 17 18 Mounting Compressor 26 Unit 4 Na...

Page 49: ...d skills programs are available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training which includes 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 CATALO...

Page 51: ......

Page 52: ... VERIFY SETSCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SCROLL COMPRESSOR IS ROTATING IN THE CORRECT DIRECTION VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED FOR 24 HOURS II START UP ELECTRICAL SUPPLY FAN AMPS EXHAUST FAN AMPS TEMPERATURES OUTDOOR AIR TEMPERATURE F DB Dry Bulb RETURN AIR TEMPERATURE F DB F WB Wet Bulb COOLING SUPPLY AIR F GAS HEA...

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