Bryant 580J*04--12 - Manual

Page 2 - must; WARNING; UNIT ARRANGEMENT AND ACCESS; General; Routine Maintenance

2 ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death.Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock and rotating equipment could cause injury. ! WARNING ELECTRICAL OPERATION HAZARD Fai...

Page 4 - ELECTRICAL SHOCK HAZARD; Belt

4 Re--install by placing the frame in its track, rotating the retainer back down and tighten all screws. SUPPLY FAN (BLOWER) SECTION ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause personal injury or death.Before performing service or maintenance operations on the fan system, shut...

Page 5 - COOLING; UNIT OPERATION AND SAFETY HAZARD; Condenser Coil; Remove Surface Loaded Fibers

5 C07075 Fig. 6 -- Supply--Fan Pulley Adjustment Bearings This fan system uses bearings featuring concentric split locking collars. The collars are tightened through a cap screw bridging the split portion of the collar. The cap screw has a Torx T25 socket head. To tighten the locking collar: Hold th...

Page 7 - Evaporator Coil

7 UNIT DAMAGE HAZARD Failure to follow this caution may result in accelerated corrosion of unit parts.Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind. These cleaners can be very difficult to rinse out of the coil and can acc...

Page 8 - PURON; Refrigerant Charge; No Charge

8 1/2-20 UNF RH 30 0.596 .47 5/8” HEX SEAT CORE WASHER DEPRESSOR PER ARI 720 +.01/-.035 FROM FACE OF BODY 7/16-20 UNF RH O-RING 45 torqued into the seat. Appropriate handling is required to not scratch or dent the surface. 1/2" HEX This surface provides a metal to metal seal when o o (Part No. E...

Page 9 - COOLING CHARGING CHARTS

9 COOLING CHARGING CHARTS C08203 C08204 Fig. 12 -- Cooling Charging Charts 580J

Page 13 - Compressor; CAUTION; Filter Drier; Troubleshooting Cooling System

13 Compressor Lubrication The compressor is charged with the correct amount of oil at the factory. UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to components.The compressor is in a Puron R refrigerant system and uses a polyolester (POE) oil. This oil is extremely hygroscopi...

Page 14 - Table 1 – Cooling Service Analysis

14 Table 1 – Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and Condenser Fan Will Not Start. Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, or control relay. Replace component. ...

Page 15 - CONVENIENCE OUTLETS; ELECTRICAL OPERATION HAZARD

15 CONVENIENCE OUTLETS ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death.Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if ...

Page 16 - SMOKE DETECTORS; System

16 SMOKE DETECTORS Smoke detectors are available as factory--installed options on 580J models. Smoke detectors may be specified for Supply Air only or for Return Air without or with economizer or in combination of Supply Air and Return Air. Return Air smoke detectors are arranged for vertical return...

Page 17 - Smoke Detector Locations; Location; Completing Installation of Return Air Smoke; Screws

17 such as smoke from a fire, causes the sensor to signal an alarm state but dust and debris accumulated over time does not. For installations using two sensors, the duct smoke detector does not differentiate which sensor signals an alarm or trouble condition. Smoke Detector Locations Supply Air — T...

Page 18 - FIOP Smoke Detector Wiring and Response

18 tion of the flexible tubing to the sampling tube is the same. C08127 Fig. 22 -- Return Air Sensor Operating Position FIOP Smoke Detector Wiring and Response All units: FIOP smoke detector is configured to automatically shut down all unit operations when smoke condition is detected. See Fig. 23, S...

Page 19 - SENSOR AND CONTROLLER TESTS; Sensor Alarm Test; Controller Alarm Test; Dirty Controller Test; Dirty Sensor Test

19 SENSOR AND CONTROLLER TESTS Sensor Alarm Test The sensor alarm test checks a sensor’s ability to signal an alarm state. This test requires that you use a field provided SD--MAG test magnet. OPERATIONAL TEST HAZARD Failure to follow this caution may result in personnel and authority concern.This t...

Page 20 - Changing the Dirt Sensor Test; To Configure the Dirty Sensor Test Operation; Remote Station Test; Remote Test/Reset Station Dirty Sensor Test; OPERATIONAL TEST HAZARD; OPERATIONAL TEST HAZARD; Detector Cleaning; Cleaning the Smoke Detector

20 Changing the Dirt Sensor Test By default, sensor dirty test results are indicated by: S The sensor’s Dirty LED flashing. S The controller’s Trouble LED flashing. S The controller’s supervision relay contacts toggle. The operation of a sensor’s dirty test can be changed so that the controller’s su...

Page 21 - Table 3 – Detector Indicators; Indicators; Normal State

21 Table 3 – Detector Indicators CONTROL OR INDICATOR DESCRIPTION Magnetic test/reset switch Resets the sensor when it is in the alarm or trouble state. Activates or tests the sensor when it is in the normal state. Alarm LED Indicates the sensor is in the alarm state. Trouble LED Indicates the senso...

Page 22 - Troubleshooting; PROTECTIVE DEVICES; Compressor Protection

22 NOTE : All troubles are latched by the duct smoke detector. The trouble condition must be cleared and thenthe duct smoke detector must be reset in order to restore itto the normal state. Resetting Alarm and Trouble Condition Trips: Manual reset is required to restore smoke detector systems to Nor...

Page 23 - GAS HEATING SYSTEM; Table 4 – Natural Gas Supply Line Pressure Ranges

23 Control Circuit, 24--V The control circuit is protected against overcurrent conditions by a circuit breaker mounted on control transformer TRAN. Reset is manual. GAS HEATING SYSTEM 580J unit heating systems are referenced here according to unit Gas Heat Option (defined in the unit model number Po...

Page 24 - Flue Gas Passageways

24 Table 6 – Liquid Propane Supply Line Pressure Ranges 580J SIZE GAS HEAT OPT HEAT LEVEL MIN MAX All A, C All 11.0 in. wg (2740 Pa) 13.0 in. wg (3240 Pa) All B All NA NA Manifold pressure for LP fuel use must be adjusted to specified range. Follow instructions in the accessory kit to make initial r...

Page 25 - Burners and Igniters; EQUIPMENT DAMAGE HAZARD; Main Burners; Orifice; Cleaning and Adjustment

25 Heater TubeAssembly Seal Strips, Sponge Rubber RegulatorGasket Regulator Retainer SupportInsulationAssembly Wind Cap Assembly(shown inverted,as shipped) Burner Assembly Inducer Fan-MotorAssembly C08227 Fig. 31 -- Heat Exchanger Assembly Burners and Igniters EQUIPMENT DAMAGE HAZARD Failure to foll...

Page 26 - IMPORTANT; Burner Ignition

26 6. Reinstall burners on rack in the same locations as factory--installed. (The outside crossover flame re- gions of the outermost burners are pinched off to pre- vent excessive gas flow from the side of the burner assembly. If the pinched crossovers are installed between two burners, the flame wi...

Page 28 - Table 8 – LED Error Code Description*; Orifice Replacement; Single Stage

28 Table 8 – LED Error Code Description* LED INDICATION ERROR CODE DESCRIPTION ON Normal Operation OFF Hardware Failure 1 Flash { Evaporator Fan On/Off Delay Modified 2 Flashes Limit Switch Fault 3 Flashes Flame Sense Fault 4 Flashes 4 Consecutive Limit Switch Faults 5 Flashes Ignition Lockout Fault...

Page 29 - Table 9 – IGC Connections

29 Red LED-Status C08452 Fig. 38 -- Integrated Gas Control (IGC) Board Table 9 – IGC Connections TERMINAL LABEL POINT DESCRIPTION SENSOR LOCATION TYPE OF I/O CONNECTION PIN NUMBER INPUTS RT, C Input power from TRAN 1 control box 24 VAC — SS Speed sensor gas section analog input J1, 1-3 FS, T1 Flame ...

Page 30 - Table 10 – Orifice Sizes

30 Table 10 – Orifice Sizes ORIFICE DRILL SIZE BRYANT PART NUMBER DRILL DIA. (in.) #30 LH32RF129 0.1285 1/8 LH32RF125 0.1250 #31 LH32RF120 0.1200 #32 LH32RF116 0.1160 #33 LH32RF113 0.1130 #34 LH32RF111 0.1110 #35 LH32RF110 0.1100 #36 LH32RF105 0.1065 #37 LH32RF104 0.1040 #38 LH32RF102 0.1015 #39 LH3...

Page 31 - Units; Minimum heating entering air temperature; Troubleshooting Heating System

31 Table 11 (cont.) -- Altitude Compensation* (A08--A12) ELEVATION ft (m) 125,000 BTUH Nominal 250,000 BTUH Nominal 180,000, 224,000 BTUH Nominal NG Orifice Size LP Orifice Size NG Orifice Size LP Orifice Size NG Orifice Size LP Orifice Size 0 --- 2000 (610) 31 1 49 3 †30 46 3 31 1 48 3 2000 (610) 3...

Page 32 - Table 13 – Heating Service Analysis; PROBLEM

32 Table 13 – Heating Service Analysis PROBLEM CAUSE REMEDY Burners Will Not Ignite. Misaligned spark electrodes. 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 d...

Page 33 - Table 14 – IGC Board LED Alarm Codes; ECONOMIZER SYSTEMS; The 580J units may be equipped with a factory--installed

33 Table 14 – IGC Board LED Alarm Codes LED FLASH CODE DESCRIPTION ACTION TAKEN BY CONTROL RESET METHOD PROBABLE CAUSE On Normal Operation — — — Off Hardware Failure No gas heating. — Loss of power to the IGC. Check 5 amp fuse on IGC, power to unit, 24V circuit breaker, transformer, and wiring to th...

Page 35 - Table 15 – EconoMi$er IV Input/Output Logic

35 4 3 5 2 8 6 7 1 10 11 9 12 PINK VIOLET BLACK BLUE YELL O W NOTE 1 NOTE 3 RUN 500 OHMRESISTOR 50HJ540573 ACTUATOR ASSEMBLY RED WHITE ECONOMISER2 PLUG DIRECT DRIVE ACTUATOR 4-20mA SIGNAL OAT SENSOR 4-20 mApositioninput signal 24 VAC TRANSFORMERGROUND NOTES: 1. Switch on actuator must be in run posi...

Page 37 - Setpoints

37 SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION SUPPLY AIR TEMPERATURE SENSOR C06033 Fig. 44 -- Supply Air Sensor Location The temperature sensor looks like an eyelet terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture. Outdoor Air Lockout Senso...

Page 38 - Mounting Location

38 provided in the EconoMi$er IV wiring harness. (See Fig. 38.) ECONOMI$ERIV ECONOMI$ERIVCONTROLLER GROMMET RETURN AIRSENSOR RETURN DUCT(FIELD-PROVIDED) C07085 Fig. 48 -- Return Air Temperature or Enthalpy Sensor Mounting Location In this mode of operation, the outdoor-air temperature is compared to...

Page 39 - Sensor Maximum Range Settings

39 TR1 24 Vac COM TR 24 Va c HOT 1 2 3 4 5 EF EF1 + _ P1 T1 P T N EXH 2V 10V EXH Set Set 2V 10V 2V 10V DCV DCV Free Cool B C A D SO+ SR+ SR SO AQ1 AQ DCV Min Pos Open Max N1 C06038 Fig. 50 -- EonoMi$er IV Control Indoor Air Quality (IAQ) Sensor Input The IAQ input can be used for demand control vent...

Page 40 - CO

40 5. Carefully adjust the minimum position potentiometer until the measured mixed air temperature matches the calculated value. 6. Reconnect the supply air sensor to terminals T and T1. Remote control of the EconoMi$er IV damper is desirable when requiring additional temporary ventilation. If a fie...

Page 42 - WIRING DIAGRAMS; PERSONAL INJURY HAZARD

42 when the potentiometer is approximately 9--v. The ac- tuator should drive fully closed. 6. Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds after the Exhaust LED turns on. 7. Return EconoMi$er IV settings and wiring to n...

Page 43 - NOTE

43 b. Inspect for oil at all refrigerant tubing connec- tions and on unit base. Detecting oil generally indicates a refrigerant leak. Leak--test all refri- gerant tubing connections using electronic leak detector, halide torch, or liquid--soap solution. c. Inspect all field--wiring and factory--wiri...

Page 44 - Heating; OPERATING SEQUENCES; Cooling, Unit Without Economizer

44 setting below the room temperature and verify that the burners and evaporator fan turn off. Refer to Table 11 and Table 12 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 ...

Page 45 - FASTENER TORQUE VALUES; Table 18 – Torque Values

45 During free cooling operation, a supply air temperature (SAT) above 50 _ F will cause the dampers to modulate between Minimum Position setpoint and 100% open. With SAT from 50 _ F to 45 _ F, the dampers will maintain at the Minimum Position setting. With SAT below 45 _ F, the outside air dampers ...

Page 48 - APPENDIX I. MODEL NUMBER SIGNIFICANCE; Model Number Nomenclature

48 APPENDIX I. MODEL NUMBER SIGNIFICANCE Model Number Nomenclature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 5 8 0 J E 0 6 A 0 7 2 A 1 A 0 A A -- ____________ ______ ________ ______ Unit Type 580J = Std Eff gas heat RTU Design Revision Voltage --- = First Revision E = 460 --- 3 --- 60J = 208/230 ...

Page 49 - APPENDIX II. PHYSICAL DATA

49 APPENDIX II. PHYSICAL DATA Physical Data (Cooling) 3 -- 6 TONS -- Standard Refrigeration System 580J*04 580J*05 580J*06 580J*07 Refrigeration System # Circuits / # Comp. / Type 1 / 1 / Scroll 1 / 1 / Scroll 1 / 1 / Scroll 1 / 1 / Scroll Puron (R410A) charge A/B (lbs) 5.6 8.5 10.7 14.1 Oil A/B (oz...

Page 53 - APPENDIX III. FAN PERFORMANCE; General Fan Performance Notes:; pressure caused by any FIOPs or accessories.

53 APPENDIX III. FAN PERFORMANCE General Fan Performance Notes: 1. Interpolation is permissible. Do not extrapolate.2. External static pressure is the static pressure difference between the return duct and the supply duct plus the static pressure caused by any FIOPs or accessories. 3. Tabular data a...

Page 54 - Phase

54 APPENDIX III. FAN PERFORMANCE (cont.) 580J*04 1 Phase 3 Ton Horizontal Supply 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 Field --- Supplied Drive 1 Standard Static Option Medium Static Option 900 553 0.14 681 0.22 782 0.32 870 0.42 ...

Page 55 - Phase

55 APPENDIX III. FAN PERFORMANCE (cont.) 580J*04 3 Phase 3 Ton Horizontal Supply 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 Field --- Supplied Drive 1 Standard Static Option Medium Static Option 900 553 0.14 681 0.22 782 0.32 870 0.42 ...

Page 61 - PHASE

61 APPENDIX III. FAN PERFORMANCE (cont.) 580J*08 3 PHASE 7.5 TON HORIZONTAL SUPPLY 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 Standard Static Option Medium Static Option 2250 505 0.52 586 0.73 657 0.97 722 1.22 782 1.50 2438 533 0.62 6...

Page 64 - Pulley Adjustment

64 APPENDIX III. FAN PERFORMANCE (cont.) Pulley Adjustment UNIT MOTOR/DRIVE COMBO MOTOR PULLEY TURNS OPEN 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 04 1p ha se Standard Static 854 825 795 766 736 707 678 648 619 589 560 Medium Static 1175 1135 1094 1054 1013 973 932 892 851 811 770 High Static ---...

Page 65 - APPENDIX IV. ELECTRICAL DATA

65 APPENDIX IV. ELECTRICAL DATA 580J*04 3 TONS V --- Ph --- Hz VOLTAGE COMP (ea) OFM (ea) IFM RANGE RLA LRA WATTS FLA TYPE Max WATTS Max AMP Draw EFF at Full Load FLA MIN MAX 208 --- 1 --- 60 187 253 16.6 79 325 1.5 Std Static 1000 5.1 70% 4.9 Med Static 1000 5.1 70% 4.9 230 --- 1 --- 60 187 253 16....

Page 70 - APPENDIX V. WIRING DIAGRAM LIST; Wiring Diagrams; SIZE

70 APPENDIX V. WIRING DIAGRAM LIST Wiring Diagrams 580J SIZE VOLTAGE CONTROL POWER 04 208/230 --- 1 --- 60 48TM500213.05 48TM500749.08 208/230 --- 3 --- 60 48TM500213.05 48TM500748.08 460 --- 3 --- 60 48TM500213.05 48TM500748.08 575 --- 3 --- 60 48TM500213.05 48TM500215.08 05 208/230 --- 1 --- 60 48...

Page 71 - APPENDIX VI. MOTORMASTER SENSOR LOCATIONS

71 APPENDIX VI. MOTORMASTER SENSOR LOCATIONS C08259 Fig. 54 -- 580J*04(A, B, C) Outdoor Circuiting C08260 Fig. 55 -- 580J*05/06(A, B, C) Outdoor Circuiting C08261 Fig. 56 -- 580J*07(A, C) Outdoor Circuiting C08262 Fig. 57 -- 580J*08(A, C) Outdoor Circuiting 580J

Page 73 - PRELIMINARY INFORMATION; ELECTRICAL

73 START-UP CHECKLIST (Remove and Store in Job File) I. PRELIMINARY INFORMATION MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: BUILDING LOCATION: II. PRE-START-UP (insert checkmark in box as each item is completed) j VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT j VERIFY THAT CONDENSATE ...

Bryant 580J*04--12 - Manual

Table of Contents:

Summary

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