Bryant PURON 581J User Manual

581J

SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT

SIZES 07, 08, 09 & 12 with PURONR(R--410A) REFIRGERANT

Installation Instructions

NOTE: Read the entire instruction manual before starting

the installation

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 2....................

INSTALLATION 7...............................

Jobsite Survey 7................................

Step 1 -- Plan for Unit Location 7..................

Roof Mount 7...............................

Step 2 -- Plan for Sequence of Unit Installation 8......

Curb--Mount Installation 8.....................

Pad--Mount Installation 8......................

Frame--Mount Installation 8....................

Step 3 -- Inspect Unit 8...........................

Step 4 -- Provide Unit Support 8...................

Roof Curb Mount 8..........................

Slab Mount (Horizontal Units Only) 8...........

Alternate Unit Support

(In Lieu of Curb or Slab Mount) 8..............

Step 5 -- Field Fabricate Ductwork 11...............

Step 6 -- Rig and Place Unit 11....................

Positioning on Curb 12.......................

Step 7 -- Convert to Horizontal & Connect Ductwork 12...

Step 8 -- Install Outside Air Hood 12...............

Economizer and Two Position Damper Hood

Package Removal and Setup — Factory Option 12..

Economizer Hood and Two--Position Hood 13.....

Step 9 -- Install Flue Hood 13.....................

Step 10 -- Install Gas Piping 13....................

Factory--Option Thru--Base Connections

(Gas Connections) 14.........................

Step 11 -- Install External Condensate Trap and Line 16..

Step 12 -- Make Electrical Connections 17...........

Field Power Supply 17........................

Units with Factory--Installed Disconnect 17.......

Units without Factory--Installed Disconnect 17....

All Units 17................................

Convenience Outlets 18.......................

Factory--Option Thru--Base Connections

(Electrical Connections) 19....................

Units without Thru--Base Connections 19.........

Field Control Wiring 19.......................

Thermostat 19...............................

Unit without Thru--Base Connection Kit 20.......

Heat Anticipator Settings 20...................

Perfect Humidityt Control Connections 21........

Perfect Humidity -- Space RH Controller 21.......

RTU Open Control System 23...................

Supply Air Temperature (SAT) Sensor 26.........

Outdoor Air Temperature (OAT) Sensor 26.......

EconoMi$er2 27.............................

Field Connections 27..........................

Space Temperature (SPT) Sensors 27............

Indoor Air Quality (CO

Outdoor Air Quality Sensor 28.................

Smoke Detector/Fire Shutdown (FSD) 29.........

Space Humidity Sensor or Humidistat 29.........

Connecting Discrete Inputs 30..................

Communication Wiring -- Protocols 31............

General 31.................................

Local Access 32..............................

RTU Open Troubleshooting 32.................

Outdoor Air Enthalpy Control 33.................

Differential Enthalpy Control 33................

Return Air Enthalpy Sensor 34.................

Smoke Detectors 34...........................

System 34..................................

Controller 34...............................

Sensor Module 34...........................

Smoke Detector Locations 35....................

Supply Air 35...............................

Return Air without Economizer 35..............

Return Air with Economizer 35.................

Step 13 -- Adjust Factory--Installed Options 40........

Step 14 -- Install Accessories 40...................

)Sensor 28.............

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal injury or death.

Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1)

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for special requirements. It is important to recognize safety information. This is the

safety--alert symbol unit and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

. When you see this symbol on the

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

Puronr (R--410A) refrigerant systems operate at higher pressures than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could cause personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Ware safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death.

Disconnect gas piping from unit when leak testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than 0.5 psig (3450 Pa) will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig (3450 Pa), it must be replaced before use. When pressure testing field--supplied gas piping at pressures of 0.5 psig (3450 Pa) or less, a unit connected to such piping must be isolated by closing the manual gas valve.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning equipment.

CAUTION

Vertical Connections / Economizer

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Horizontal Connections / Economizer

Fig. 1 -- Unit Dimensional Drawing — Sizes 07--09

C11110

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C11111

Fig. 1 -- Unit Dimensional Drawing — Sizes 07--09 (cont.)

Vertical Connections / Economizer

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Horizontal Connections / Economizer

Fig. 2 -- Unit Dimensional Drawing — Size 12

C11112

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C11113

Fig. 2 -- Unit Dimensional Drawing — Size 12 (cont.)

INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 3.

18” (457)

42" (1067)

Required bottom condensate drain connection. Otherwise, 36” (914mm) for condensate connection.

Fig. 3 -- Service Clearance Dimensional Drawing

NOTE: Consider also the effect of adjacent units.

18" (457)

C10145

Be sure that the unit is installed such that snow will not block the combustion intake or flute outlet.

Unit may be installed directly on wood flooring or on Class A, B, or C roof--covering material when roof curb is used.

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) and NFPA (National Fire Protection Association) 54 TIA----54----84----1. In Canada, installation must be in accordance with the CAN1----B149 installation codes for gas burning appliances.

Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Locate mechanical draft system flue assembly at least 4 ft (1.2 m) from any opening through which combustion products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent unit’s fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code). When unit is located adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.

Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements. Refer to Step 11 — Install External Condensate Trap and Line – for required trap dimensions.

Roof Mount —

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

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Table 1 – Operating Weights

581J*

Base Unit 765 (347) 925 (419.5) 925 (419.5) 1099 (499)

Economizer

Vertical 50 (23) 80 (36) 80 (36) 80 (36)

Horizontal 80 (36) 105 (48) 105 (48) 105 (48)

Powered Outlet 32 (15) 32 (15) 32 (15) 32 (15)

Perfect Humidity™ System 41 (19) 70 (32) 70 (32) 75 (34)

Curb

14--- in/356 mm 110 (50) 133 (65) 133 (65) 133 (65)

24--- in/610 mm 145 (66) 174 (79) 174 (79) 174 (79)

07 08 09 12

UNITS LB (KG)

Step 2 — Plan for Sequence of Unit Installation

The support method used for this unit will dictate different sequences for the steps of unit installation. For example, on curb--mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps.

Curb--Mounted Installation —

Install curb Install field--fabricated ductwork inside curb Install accessory thru--base service connection package

(affects curb and unit) (refer to accessory installation instructions for details)

Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 11 for details)

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Rig and place unit Install outdoor air hood Install flue hood Install gas piping Install condensate line trap and piping Make electrical connections Install other accessories

Pad--Mounted Installation —

Prepare pad and unit supports Check and tighten the bottom condensate drain

connection plug Rig and place unit Convert unit to side duct connection arrangement Install field--fabricated ductwork at unit duct openings Install outdoor air hood Install flue hood Install gas piping Install condensate line trap and piping Make electrical connections Install other accessories

Frame--Mounted Installation —

Frame--mounted applications generally follow the sequence for a curb installation. Adapt as required to suit specific installation plan.

Step 3 — Inspect Unit

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

Step 4 — Provide Unit Support

Roof Curb Mount —

Accessory roof curb details and dimensions are shown in Fig. 4 and Fig. 5. Assemble and install accessory roof curb in accordance with instructions shipped with the curb.

NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 4 and Fig. 5. Improperly applied gasket can also result in air leaks and poor unit performance.

Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are show in Fig. 6. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and

not to the unit. The accessory thru--the--base power and gas connection package must be installed before the unit is set on the roof curb. If field--installed thru--the--roof

curb gas connections are desired, use factory--supplied pipe coupling and gas plate assembly to mount the thru--the--roof curb connection to the roof curb. Gas connections and power connections to the unit must be field installed after the unit is installed on the roof curb.

If electric and control wiring is to be routed through the basepan, attach the accessory thru--the--base service connections to the basepan in accordance with the accessory installation instructions.

Slab Mount (Horizontal Units Only) —

Provide a level concrete slab that extends a minimum of 6 in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

Alternate Unit Support (InLieuofCurborSlabMount)—

A non--combustible sleeper rail can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4--in. x 4--in. (102 mm x 102 mm) pads on each side.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

ROOFCURB ACCESSORY

CRRFCURB003A01

CRRFCURB004A01

1’ - 2” [356]

2’ - 0” [610]

UNIT SIZE

581J*07-09

581J

Fig. 4 -- Roof Curb Details — Sizes 07--09

C11081

581J*12

581J

ROOFCURB ACCESSORY

CRRFCURB003A02

CRRFCURB004A02

1’ - 2” [356]

2’ - 0” [610]

UNIT SIZE

581J*12

Fig. 5 -- Roof Curb Details — Size 12

C11082

A minimum clearance is not required around ductwork.

MAXIMUM ALLOWABLE

DIFFERENCE IN. (MM)

A-B

0.5” (13)

B-C

1.0” (25)

A-C

1.0” (25)

C06110

Fig. 6 -- Unit Leveling Tolerances

Step 5 — Field Fabricate Ductwork

Cabinet return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or

0.45 in. wg (112 Pa) without economizer. For vertical ducted applications, secure all ducts to roof curb

and building structure. Do not connect ductwork to unit. Fabricate supply ductwork so that the cross sectional

dimensions are equal to or greater than the unit supply duct opening dimensions for the first 18 in. (458 mm) of duct length from the unit basepan.

Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

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

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in damage to roofing materials.

Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.

Step 6 — Rig and Place Unit

Keep unit upright and do not drop. Spreader bars are not required if top crating is left on unit. Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 1 and Fig. 7 for additional information.

Lifting holes are provided in base rails as shown in Fig. 7. Refer to rigging instructions on unit.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck.

CAUTION

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If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

UNIT

581J*07 1200 545 88.0 2235 44.0 1120 41.5 1055

581J*08 1420 645 88.0 2235 44.0 1120 49.5 1255

581J*09 1420 645 88.0 2235 44.0 1120 49.5 1255

581J*12 1665 757 88.0 2235 32.0 815 49.5 1255

NOTES:

1. SPREADER BARS REQUIRED — Top damage will occur if spreader bars are not used.

2. Dimensions in ( ) are in millimeters.

3. Hook rigging shackles through holes in base rail, as shown in detail “A.” Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

MAX WEIGHT

LB KG IN MM IN MM IN MM

Fig. 7 -- Rigging Details

Before setting the unit onto the curb, recheck gasketing on curb.

C06005

DIMENSIONS

A B C

PositioningonCurb—

Position unit on roof curb so that the following clearances are maintained:

/4in. (6.4 mm) clearance between the roof curb and the base rail inside the front and back, 0.0 in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately equal to Fig. 4 and Fig. 5, section C--C.

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48 inches (1220 mm).

Flue gas can deteriorate building materials. Orient unit such

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that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48 in. (1220 mm) from an adjacent building or combustible material.

NOTE: Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to 18 in. (460 mm).

After unit is in position, remove rigging skids and shipping materials.

Step 7 — Convert to Horizontal and Connect Ductwork (when required)

Unit is shipped in the vertical duct configuration. Unit without factory--installed economizer or return air smoke detector option may be field--converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers and remove covers. Using the same screws, install covers on vertical duct openings with the insulation--side down. Seals around duct openings must be tight. See Fig. 8.

Do not cover or obscure visibility to the unit’s informative data plate when insulating horizontal ductwork.

Step 8 — Install Outside Air Hood

Economizer and Two Position Damper Hood Package Removal and Setup -- Factory Option

1. The hood is shipped in knock--down form and must be field assembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, attached to a metal support tray using plastic stretch wrap, and shipped in the return air compartment behind the indoor coil access panel. The hood assembly’s metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

2. To gain access to the hood, remove the filter access panel. (See Fig. 9.)

FILTER ACCESS PANEL

INDOOR COIL ACCESS PANEL

C10146

Fig. 9 -- Typical Access Panel Locations

3. Locate the (2) screws holding the metal tray to the basepan and remove. Locate and cut the (2) plastic tie--wraps securing the assembly to the damper. (See Fig. 10) Be careful to not damage any wiring or cut tie--wraps securing any wiring.

Fig. 8 -- Horizontal Conversion Panels

C06108

Field--supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes.

Hood Parts

Plastic Tie Wrap Qty (2)

Screws for Metal Tray Qty (2)

C08639

Fig. 10 -- Economizer and Two--Position Damper

Hood Parts Location

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