Bryant 580F User Manual

installation, start-up and service instructions

580F DuraPac Series

SINGLE PACKAGE ROOFTOP

GAS HEATING/ELECTRIC COOLING UNITS

Sizes 180-300

15 to 25 Tons

CONTENTS

Page

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

I. Step 1 — Provide Unit Support. . . . . . . . . . . . . . . . . 1 II. Step 2 — Rig and Place Unit. . . . . . . . . . . . . . . . . . . 4 III. Step 3 — Field Fabricate Ductwork . . . . . . . . . . . . 11 IV. Step 4 — Make Unit Duct Connections . . . . . . . . . 11 V. Step 5 — Install Flue Hood and Wind Baffle . . . . . 11 VI. Step 6 — Trap Condensate Drain . . . . . . . . . . . . . . 11 VII. Step 7 — Orifice Change. . . . . . . . . . . . . . . . . . . . . 12 VIII. Step 8 — Install Gas Piping . . . . . . . . . . . . . . . . . . 13 IX. Step 9 — Make Electrical Connections . . . . . . . . . 13

X. Step 10 — Make Outdoor-Air Inlet Adjustments . . 15 XI. Step 11 — Install Outdoor-Air Hood. . . . . . . . . . . . 15 XII. Step 12 — Install All Accessories . . . . . . . . . . . . . 16 XIII. Step 13 — Adjust Factory-Installed Options . . . . . 18

XIV. Step 14 — Install Control Accessory for Optional Perfect Humidity™ Dehumidification Package . . 24

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-34

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-42

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .43-47

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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 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 cloth for unbrazing operations. Have fire extinguishers available for all brazing operations.

WARNING: Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag to disconnect switch. Electrical shock could cause personal injury.

Cancels: II 580F-180-2	II 580F-180-3
	3/15/06

WARNING:

1.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.Do not 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:

1.DO NOT try to light 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.If you cannot reach your gas supplier, call the fire department.

WARNING: Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than 0.5 psig will cause 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 closing 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 be required to restart the compressor.

INSTALLATION

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 should be level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is ± 1/16 in. per linear ft in any direction. Refer to Accessory Roof Curb or Horizontal Adapter Roof Curb Installation Instructions for additional information as required. When accessory roof curb or horizontal adapter roof curb is used, unit may be installed on class A, B, or C roof covering material.

Instructions continued on page 4.

	PKG. NO. REF.	CURB		DESCRIPTION
		HEIGHT
	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

—2—

Fig. 1A — Roof Curb Details — 580F180-240

—3—

A

A

Fig. 1B — Roof Curb Details — 580F300

				FULLY INSULATED
				SUPPLY PLENUM
	3 1/2"		2" X 1/4	1" INSULATION
			SUPPORT TYP.	1 1/2 # DENSITY,
			STITCH WELDED	STICK PINNED & GLUED

14 3/4"

23"

6"

NOTE: CRRFCURB013A00 is a fully factory preassembled horizontal adapter and includes an insulated transition duct. The pressure drop through the adapter curb is negligible.

For horizontal return applications: The power exhaust and barometric relief dampers must be installed in the return air duct.

12" WIDE STANDING SEAM PANELS

	ACCESSORY	CURB	DESCRIPTION
	PACKAGE NO.	HEIGHT
	CRRFCURB013A00	1′-11″	Pre-Assembled, Roof Curb,
		(584)	Horizontal Adapter

Fig. 2 — Horizontal Supply/Return Adapter Installation (580F180-240)

IMPORTANT: The gasketing of the unit to the roof curb or adapter roof curb is critical for a watertight seal. Install gasket with the roof curb or adapter as shown in Fig. 1A and 1B. Improperly applied gasket can also result in air leaks and poor unit performance.

B. Alternate Unit Support

When the 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.

II. STEP 2 — RIG AND PLACE UNIT

Inspect unit for transportation damage. File any claim with transportation agency.

Do not drop unit; keep upright. 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 reference; leveling tolerance is ± 1/16 in. per linear ft in any direction. 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 to rigging instructions on unit.

NOTE: On 580F300 units, the lower forklift braces must be removed prior to setting unit on roof curb.

A. Positioning

Maintain clearance, per Fig. 4-6, 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 ventilation 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 building. When unit is located adjacent to public walkways, flue assembly 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 11.

—4—

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 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.

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.

UNIT	MAXIMUM				DIMENSIONS
	SHIPPING WEIGHT			A			B
580F
	lb	kg	ft-in.		mm	ft-in.		mm
180	1875	850	6-111/2		2121	4-0		1219
210	1925	873	6-111/2		2121	3-2		964
240	2085	923	6-111/2		2121	3-4		1016
300	2445	1109	6-111/2		2121	3-4		1016

Fig. 3 — Rigging Details

—5—

NOTES:

1.	Refer to print for roof curb accessory dimensions.
2.	Dimensions in [ ] are in millimeters.
3.					Center of gravity.
4.						Direction of airflow.
5.						to be attached to accessory roof curb only.
			Ductwork
6.	Minimum clearance:
		•		Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to 4′-0″
		•		(1219) if conditions permit coil removal from the top.
				4′-0″ (1219) to combustible surfaces, all four sides (includes between units).
		•		Left side: 4′-0″ (1219) for proper condenser coil 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 or jurisdiction may prevail.
7.	With the exception of clearance for the condenser coil and the damper/power
	exhaust as stated in Note #6, a removable fence or barricade requires no clear-
	ance.
8.	Dimensions are from outside of corner post. Allow 0′-5/16″ (8) on each side for

top cover drip edge.

—6—

Fig. 4 — Base Unit Dimensions — 580F180, 210

NOTES:

1.	Refer to print for roof curb accessory dimensions.
2.	Dimensions in [ ] are in millimeters.
3.					Center of gravity.
4.						Direction of airflow.
5.						to be attached to accessory roof curb only.
			Ductwork
6.	Minimum clearance:
		•		Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to 4′-0″
		•		(1219) if conditions permit coil removal from the top.
				4′-0″ (1219) to combustible surfaces, all four sides (includes between units).
		•		Left side: 4′-0″ (1219) for proper condenser coil 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 or jurisdiction may prevail.
7.	With the exception of clearance for the condenser coil and the damper/power
	exhaust as stated in Note #6, a removable fence or barricade requires no clear-
	ance.
8.	Dimensions are from outside of corner post. Allow 0′-5/16″ (8) on each side for

top cover drip edge.

—7—

Fig. 5 — Base Unit Dimensions — 580F240

NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in millimeters.

3. Center of Gravity.

4. Direction of airflow.

5. Ductwork to be attached to accessory roof curb only. 6. Minimum clearance:

• Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to 4′-0″ (1219) if conditions permit coil removal from the top.

• 4′-0″ (1219) to combustible surfaces, all four sides (includes between units).

• Left side: 4′-0″ (1219) for proper condenser coil 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 or jurisdiction may prevail.

7. With the exception of clearance for the condenser coil and the damper/power exhaust as stated in Note #6, a removable fence or barricade requires no clearance.

8. Dimensions are from outside of corner post. Allow 0′-5/16 ″ (8) on each side for top cover drip edge.

9. The lower forklift brace must be removed prior to setting unit on roof curb.

—8—

Fig. 6 — Base Unit Dimensions — 580F300

Table 1 — Physical Data

		UNIT 580F		180			210			240		300
NOMINAL CAPACITY (tons)				15			18			20		25
OPERATING WEIGHT				1800			1850			1900		2270
EconoMi$erIV				90			90			90		90
Perfect Humidity™ Dehumidification Package				40			40			40		40
COMPRESSOR/MANUFACTURER							Scroll, Copeland
Quantity...Model (Ckt 1, Ckt 2)				1...ZR94KC,			1...ZR108KC,			1...ZR125KC,		1...ZRU140KC,*
				1...ZR72KC			1...ZR94KC			1...ZR108KC		1...ZR144KC
Capacity Stages (%)
				60, 40			55, 45			55, 45		50, 50
Number of Refrigerant Circuits				2			2			2		2
Oil (oz) (Ckt 1, Ckt 2)				85, 60			106, 81			106,106		136, 106
REFRIGERANT TYPE								R-22
Expansion Device								TXV
Operating Charge (lb-oz)
Circuit 1†				19-8			19-8			19-11		26-13
Circuit 2				13-8			19-2			13-14		25-10
CONDENSER COIL				Cross-Hatched 3/8-in. Copper Tubes, Aluminum Lanced,
Rows...Fins/in.					Aluminum Pre-Coated, or Copper Plate Fins
				4...15			4...15			4...15		3...15 (2 coils)
Total Face Area (sq ft)				21.7			21.7			21.7		43.4
CONDENSER FAN							Propeller Type
Nominal 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
Rows...Fins/in.							Copper Plate Fins, Face Split
				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			2...12 x 12		2...12 x 12
Type Drive				Belt			Belt			Belt		Belt
Nominal Cfm				6000			7200			8000		10,000
Motor Hp				5			5			7.5		10
Motor Nominal Rpm				1745			1745			1745		1740
Maximum Continuous Bhp				6.13			5.90			8.7 [208/230 v]		10.2 [208/230 v]
										9.5 [460 v]		11.8 [460 v]
Motor Frame Size
				184T			184T			213T		215T
Nominal Rpm High/Low				—			—			—		—
Fan Rpm Range			Low-Medium Static	873-1021			910-1095			1002-1151		1066-1283
Motor Bearing Type			High Static	1025-1200			1069-1287			1193-1369		1332-1550
				Ball			Ball			Ball		Ball
Maximum Allowable Rpm				1550			1550			1550		1550
Motor Pulley Pitch Diameter			Low-Medium Static	4.9/5.9			4.9/5.9			5.4/6.6		4.9/5.9
	Min/Max (in.)		High Static	4.9/5.9			4.9/5.9			5.4/6.6		4.9/5.9
Nominal Motor Shaft Diameter (in.)			Low-Medium Static	11/8			11/8			13/8		13/8
Fan Pulley Pitch Diameter (in.)				9.4			9.4			9.4		8.0
Nominal Fan Shaft Diameter (in.)			High Static	8.0			8.0			7.9		6.4
			Low-Medium Static	17/16			17/16			17/16		17/16
Belt, Quantity...Type...Length (in.)				1...BX...50			1...BX...50			1...BX...53		2...BX...50
Pulley Center Line Distance (in.)			High Static	1...BX...48			1...BX...48			1...BX...50		2...BX...47
				13.3-14.8			13.3-14.8			14.6-15.4		14.6-15.4
Speed Change per Full Turn of			Low-Medium Static	37			37			37		36
	Movable Pulley Flange (rpm)		High Static	44			34			44		45
Movable Pulley Maximum Full Turns
	From Closed Position			6**			6††			6**		6††
Factory Pulley Setting				3.5			3.5			3.5		3.5
Factory Speed Setting (rpm)			Low-Medium Static	965			1002			1120		1182
Fan Shaft Diameter at Pulley (in.)			High Static	1134			1178			1328		1470
				17/16			17/16			17/16		17/16
		LEGEND
Bhp	—	Brake Horsepower
TXV	—	Thermostatic Expansion Valve

*The ZRU140KC compressor is a tandem compressor, consisting of a ZR72KC (25% total capacity) and a ZR68KC (24% total capacity).

†Circuit 1 uses the lower portion of the condenser coil and lower portion of the evaporator coils; and Circuit 2 uses the upper portion of both coils.

**Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to 11/2 turns open.

††Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to 1/2 turns open.

***Rollout switch is manual reset.

†††A Liquid Propane kit is available as an accessory.

¶The 580F300 unit requires 2-in. industrial-grade filters capable of handling face velocities up to 625 ft/min (such as American Air Filter no. 5700 or equivalent).

NOTE: The 580F units have a low-pressure switch (standard) located on the suction side.

—9—

Table 1 — Physical Data (cont)

UNIT 580F				180	210	240	300
				(Low Heat/High Heat)	(Low Heat/High Heat)	(Low Heat/High Heat)	(Low Heat/High Heat)
FURNACE SECTION
Rollout Switch Cutout Temp (F)***				190	190	190	190
Burner Orifice Diameter (in. ...drill size)
	Natural Gas		Std	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
Efficiency (Steady-State) (%)				81	81	81	81
Temperature Rise Range				15-45/20-50	15-45/20-50	15-45/20-50	15-45/20-50
Manifold Pressure (in. wg)
	Natural Gas		Std	3.3	3.3	3.3	3.3
	Liquid Propane†††		Alt	3.3	3.3	3.3	3.3
Gas Valve Quantity				1	1	1	1
Gas Valve Pressure Range
	in. wg			5.5-13.5	5.5-13.5	5.5-13.5	5.5-13.5
	psig			0.235-0.487	0.235-0.487	0.235-0.487	0.235-0.487
Field Gas Connection Size (in.-FPT)				3/4	3/4	3/4	3/4
HIGH-PRESSURE SWITCH (psig)
Cutout					426
Reset (Auto)					320
LOW-PRESSURE SWITCH (psig)
Cutout					27
Reset (Auto)					44
FREEZE PROTECTION THERMOSTAT (F)
Opens					30 ± 5
Closes					45 ± 5
OUTDOOR-AIR INLET SCREENS					Cleanable
Quantity...Size (in.)					2...20 x 25 x 1
					1...20 x 20 x 1
RETURN-AIR FILTERS					Throwaway¶
Quantity...Size (in.)					4...20 x 20 x 2
					4...16 x 20 x 2
POWER EXHAUST				1/2 Hp, 208/230-460 v Motor Direct Drive, Propeller-Fan (Factory-Wired for 460 v)
		LEGEND
Bhp	—	Brake Horsepower
TXV	—	Thermostatic Expansion Valve

*The ZRU140KC compressor is a tandem compressor, consisting of a ZR72KC (25% total capacity) and a ZR68KC (24% total capacity).

†Circuit 1 uses the lower portion of the condenser coil and lower portion of the evaporator coils; and Circuit 2 uses the upper portion of both coils.

**Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to 11/2 turns open.

††Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to 1/2 turns open.

***Rollout switch is manual reset.

†††A Liquid Propane kit is available as an accessory.

¶The 580F300 unit requires 2-in. industrial-grade filters capable of handling face velocities up to 625 ft/min (such as American Air Filter no. 5700 or equivalent).

NOTE: The 580F units have a low-pressure switch (standard) located on the suction side.

—10—

III. STEP 3 — FIELD FABRICATE DUCTWORK

Secure all ducts to building structure. Use flexible duct connectors between unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

IV. STEP 4 — MAKE UNIT DUCT CONNECTIONS

Unit is shipped for thru-the-bottom duct connections. Ductwork openings are shown in Fig. 1 and 4-6. Duct connections are shown in Fig. 7. Field-fabricated concentric ductwork may be connected as shown in Fig. 8 and 9. Attach all ductwork to roof curb and roof curb basepans.

NOTE: Do not drill in this area; damage to basepan may result in water leak.

Fig. 7 — Air Distribution — Thru-the-Bottom

V. STEP 5 — INSTALL FLUE HOOD AND WIND BAFFLE

Flue hood and wind baffle are shipped secured under main control 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 provided inside unit evaporator section for condensate drain connection. An 81/2-in. x 3/4-in. diameter and 2-in. x 3/4-in. diameter pipe nipple, coupled to standard 3/4-in. diameter elbows, provide a straight path down through hole in unit base rails (see Fig. 13). A trap at least 4-in. deep must be used.

NOTE: Dimensions A, A′, B, and B′ are obtained from field-supplied ceiling diffuser.

Shaded areas indicate block-off panels.

Fig. 9 — Concentric Duct Details

WIND

BAFFLE

NOTE: Do not drill in this area; damage to basepan may result in water leak.

Fig. 8 — Concentric Duct Air Distribution

Fig. 10 — Flue Hood Location

—11—

INDUCED DRAFT

MOTOR

										HEAT EXCHANGER
COMBUSTION			MAIN BURNER
FAN HOUSING			SECTION							SECTION

Fig. 11 — Combustion Fan Housing Location

3/4" FPT DRAIN	1-3/8"
CONNECTION	DRAIN HOLE

Fig. 12 — Condensate Drain Details (580F180 Shown)

Fig. 13 — Condensate Drain Piping Details

VII. STEP 7 — ORIFICE CHANGE

This unit is factory assembled for heating operation using natural gas at an elevation from sea level to 2000 ft. This unit uses orifice type LH32RFnnn, where “nnn” indicates the orifice size based on drill size diameter in thousands of an inch.

A. High Elevation (Above 2000 ft)

Use accessory high altitude kit when installing this unit at an elevation of 2000 to 7000 ft. For elevations above 7000 ft, refer to Table 2 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 2 — Altitude Compensation*

	ELEVATION (ft)	NATURAL GAS ORIFICE†
		Low Heat	High Heat
	0-1,999	30	29
	2,000	30	29
	3,000	31	30
	4,000	31	30
	5,000	31	30
	6,000	31	30
	7,000	32	31
	8,000	32	31
	9,000	33	31
	10,000	35	32

*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through your Bryant dealer.

Table 3 — Orifice Quantity

	UNIT	ORIFICE QUANTITY
	580F180 Low Heat	5
	580F210 Low Heat,
	580F240 Low Heat,	6
	580F300 Low Heat,
	580F180 High Heat
	580F210 High Heat,
	580F240 High Heat,	7
	580F300 High Heat

B. Conversion To LP (Liquid Propane) Gas

Use accessory LP gas conversion kit when converting this unit for use with LP fuel usage 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*

ELEVATION (ft)	LP GAS ORIFICE†
0-1,999	36
2,000	37
3,000	38
4,000	38
5,000	39
6,000	40
7,000	41
8,000	41
9,000	42
10,000	43

*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through your Bryant dealer.

—12—

VIII. STEP 8 — INSTALL GAS PIPING

Unit is equipped for use with natural gas. Installation must conform 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 1/8-in. NPT pressure tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 14.

WARNING: 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 be less 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.

Fig. 14 — Field Gas Piping

IX. STEP 9 — 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 Electrical Code) requirements of adequate size (Table 5).

All field wiring must comply with NEC and local requirements.

Route power and ground lines through control box end panel or unit basepan (see Fig. 4-6) to connections as shown on unit wiring diagram and Fig. 15.

CAUTION: 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 compressor 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 requirements.

Transformer no. 1 is 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, voltages 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.

B. Field Control Wiring

Install a Bryant-approved accessory thermostat assembly (or light commercial Thermidistat™ device for units equipped with Perfect Humidity™ option) according to the installation instructions included with accessory. Locate thermostat assembly on a solid interior 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 lowvoltage 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 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	W1	W2
208/230	0.98	0.44
460	0.80	0.44

Settings may be changed slightly to provide a greater degree of comfort for a particular installation.

C. Optional Non-Fused Disconnect

On units with the optional non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 17 for wiring for 100 and 200 amp disconnect switches. Units with an MOCP (maximum overcurrent protection) under 100 will use the 100 amp disconnect switch. Units with an MOCP over 100 will use the 200 amp disconnect switch. Refer to the applicable disconnect wiring diagram.

To prevent breakage during shipping, the disconnect handle and shaft are shipped and packaged inside the unit control box. Install the disconnect handle before unit operation. To install the handle and shaft, perform the following procedure:

1.Open the control box door and remove the handle and shaft from shipping location.

2.Loosen the Allen bolt located on the disconnect switch. The bolt is located on the square hole and is used to hold the shaft in place. The shaft cannot be inserted until the Allen bolt is moved.

3.Insert the disconnect shaft into the square hole on the disconnect switch. The end of the shaft is specially cut and the shaft can only be inserted in the correct orientation.

—13—

	LEGEND
EQUIP	— Equipment
GND	— Ground
NEC	— National Electrical Code
TB	— Terminal Board

NOTE: The maximum wire size for TB1 is 2/0.

Fig. 15 — Field Power Wiring Connections

4.Tighten the Allen bolt to lock the shaft into position.

5.Close the control box door.

6.Attach the handle to the external access door with the two screws provided. When the handle is in the ON position, the handle will be vertical. When the handle is in the OFF position, the handle will be horizontal.

7.Turn the handle to the OFF position and close the door. The handle should fit over the end of the shaft when the door is closed.

8.The handle must be in the OFF position to open the control box door.

D. Optional Convenience Outlet

On units with optional convenience outlet, a 115-v GFI (ground fault interrupt) convenience outlet receptacle is provided for field wiring. Field wiring should be run through the 7/8-in. knockout provided in the basepan near the return air opening.

THERMOSTAT ASSEMBLY

REMOVABLE JUMPER
	RH	RC	Y1	Y2	W1		W2	G	C	L	X
	R		Y1	Y2	W1		W2	G	C		X
	RED		BLU	PNK	ORN		VIO	BLK	BRN		WHT
		Fig. 16 — Field Control Thermostat Wiring
								6T3	4T2	2T1 LOAD

5L3 3L2 1L1 LINE

NOTE: The disconnect takes the place of TB-1 as shown on the unit wiring diagram label and the component arrangement label.

Fig. 17 — Optional Non-Fused Disconnect Wiring

—14—

Table 5 — Electrical Data

UNIT	NOMINAL	VOLTAGE			COMPRESSOR							OFM			IFM	POWER		COMBUSTION	POWER
		RANGE		No. 1		No. 1A			No. 2							EXHAUST		FAN MOTOR	SUPPLY
580F	VOLTAGE
	(3 Ph, 60 Hz)	Min	Max	RLA	LRA	RLA	LRA		RLA	LRA	Qty	Hp	FLA (ea)	Hp	FLA	FLA	LRA	FLA	MCA	MOCP*
	208/230	187	253	32.1	195	—	—		20.7	156	3	0.5	1.7	5.0	15.8/15.8	—	—	0.57	82/82	110/110
180																4.6	18.8	0.57	86/86	110/110
	460	414	508	16.4	95	—	—		10	70	3	0.5	0.8	5.0	7.9	—	—	0.30	41	50
																2.3	6.0	0.30	43	50
	208/230	187	253	30.1	225	—	—		28.8	195	3	0.5	1.7	5.0	15.8/15.8	—	—	0.57	87/87	110/110
210																4.6	18.8	0.57	92/92	110/110
	460	414	508	15.5	114	—	—		14.7	95	3	0.5	0.8	5.0	7.9	—	—	0.30	44	50
																2.3	6.0	0.30	47	60
	208/230	187	253	42	239	—	—		33.6	225	2	1	6.6	7.5	25.0/25.0	—	—	0.57	124/124	150/150
240																4.6	18.8	0.57	129/129	150/150
	460	414	508	19.2	125	—	—		17.3	114	2	1	3.3	7.5	13.0	—	—	0.30	61	80
																2.3	6.0	0.30	63	80
	208/230	187.2	253	20.7	156	20.7	156		47.1	245	6	0.5	1.7	10.0	28.0/28.0	—	—	0.57	138/138	175/175
300																4.6	18.8	0.57	143/143	150/175
	460	414	508	10	75	10	75		19.6	125	6	0.5	0.8	10.0	14.6	—	—	0.30	64	80
																2.3	6	0.30	66	80

		LEGEND
FLA	—	Full Load Amps
HACR	—	Heating, Air Conditioning and Refrigeration
IFM	—	Indoor (Evaporator) Fan Motor
LRA	—	Locked Rotor Amps
MCA	—	Minimum Circuit Amps
MOCP —		Maximum Overcurrent Protection
NEC	—	National Electrical Code
OFM	—	Outdoor (Condenser) Fan Motor
RLA	—	Rated Load Amps

*Fuse or HACR circuit breaker.

NOTES:

1.In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

2.Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percent voltage imbalance.

% Voltage Imbalance

= 100 x

max voltage deviation from average voltage average voltage

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v

BC = 464 v

AC = 455 v

	Average Voltage =	452 + 464 + 455
		3

=1371

3

=457

Determine maximum deviation from average voltage. (AB) 457 – 452 = 5 v

(BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

Maximum deviation is 7 v.

Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

7

457

= 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.

X. STEP 10 — MAKE OUTDOOR-AIR INLET ADJUSTMENTS

A. Manual Outdoor-Air Damper

All units (except those equipped with a factory-installed EconoMi$erIV) have a manual outdoor-air damper to provide ventilation air.

Damper can be preset to admit up to 25% outdoor air into return-air compartment. To adjust, loosen securing screws and move damper to desired setting, then retighten screws to secure damper (Fig. 18).

XI. STEP 11 — INSTALL OUTDOOR-AIR HOOD
The outdoor-air hood is common to 25% air ventilation and
EconoMi$erIV. If EconoMi$erIV is factory installed, all
electrical connections have been made and adjusted at the	Fig. 18 — Standard 25% Outdoor-Air Section Details
factory. Assemble and install hood in the field.

—15—

IMPORTANT: If the unit is equipped with the optional EconoMi$erIV component, move the outdoor-air temperature sensor prior to installing the outdoor-air hood. See the Optional EconoMi$erIV section for more information.

NOTE: The hood top panel, upper and lower filter retainers, hood drain pan, baffle (size 300), 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 hardware are in a package located inside the return-air filter access panel (Fig. 19).

1.Attach seal strip to upper filter retainer. See Fig. 20.

2.Assemble hood top panel, side panels, upper filter retainer, and drain pan (see Fig. 21).

3.Secure lower filter retainer and support bracket to unit. See Fig. 21. Leave screws loose on size 300 units.

4.Slide baffle (size 300) 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 top panel to 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.

8.Insert outdoor-air inlet screens and spacer in channel created by lower filter retainer and filter support bracket.

9.Attach remaining section of filter support bracket.

XII. STEP 12 — 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® 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 field-supplied screws to attach baffles to unit. Screws should be 1/4-in. diameter and 5/8-in. 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.

Install Motormaster I Controls

One Motormaster I control is required on size 180 and 210 units. The Motormaster I control must be used in conjunction with the accessory fan motor sequencing kit and winter start kit (purchased separately). The Motormaster I device controls outdoor fan no. 1 while outdoor fans no. 2 and 3 are sequenced off by the accessory fan motor sequencing kit.

Accessory Fan Motor Sequencing Kit — Install the accessory fan motor sequencing kit per instruction supplied with accessory (purchased separately).

Winter Start Time Delay Relay Kit — Install the kit per the instructions supplied with the accessory (purchased separately).

Sensor Assembly — Install the sensor assembly in the location shown in Fig. 23.

Fig. 19 — Outdoor-Air Hood Component Location

Fig. 20 — Seal Strip Location

BAFFLE

LOWER FILTER

RETAINER

FILTER SUPPORT

BRACKET

HOOD SIDE

PANELS (2)

HOOD TOP PANEL

BAFFLE (300 ONLY)

LOWER

FILTER

RETAINER

FILTER SUPPORT

BRACKET

HOOD DRAIN PAN

UPPER FILTER RETAINER

NOTE: The outdoor-air hood comes with a baffle which is used on size 300 units only, discard baffle for size 180-240 units.

Fig. 21 — Outdoor-Air Hood Details

—16—