Bryant 558G, Installation, Start-Up And Service Instructions Manual

Page 1: ...ions should be performed by trained service personnel When working on air conditioning equipment observe pre cautions 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 pe...

Page 2: ...k when removing old unit B Alternate Unit Support When the preferred curb or adapter cannot be used support unit with sleepers using unit curb or adapter support area If sleepers cannot be used support long sides of unit refer to Fig 2 and 3 with 3 equally spaced 4 in x 4 in pads on each side Unit may sag if supported by corners only II RIG AND PLACE UNIT Inspect unit for transportation damage Fil...

Page 3: ... Fig 2 Base Unit Dimensions 580G240 360 NOTES 1 Weights include economizer STD 2 Center of gravity 3 Do not locate adjacent units with flue discharge facing economizer inlet Min clearances to be Adjacent Units 158 09 Top of Units No Overhang Condenser Coil 48 09 Economizer Side 68 09 Heat Side 48 09 Filter Access Side 108 09 For Removal of Evapo rator Coil 4 For smaller service and operational cle...

Page 4: ...257 Fig 3 Base Unit Dimensions 580H240 360 NOTES 1 Weights include economizer STD 2 Center of gravity 3 Do not locate adjacent units with flue discharge facing economizer inlet Min clearances to be Adjacent Units 158 09 Top of Units No Overhang Condenser Coil 48 09 Economizer Side 68 09 Heat Side 48 09 Filter Access Side 108 09 For Removal of Evapora tor Coil 4 For smaller service and operational ...

Page 5: ...32 lb 14 5 kg for domestic crating Add 312 lb 142 kg for export crating Add 220 lb 100 kg for copper condenser coil Add 250 lb 113 kg for power exhaust UNIT 580G H WEIGHT A B C lb kg in mm in mm in mm 240 350 4176 1894 87 68 2227 72 4 1839 42 4 1072 240 525 4256 1930 73 3 1862 42 7 1085 300 350 4262 1933 69 6 1768 44 0 1118 324 350 360 350 300 525 4342 1969 70 1 1781 44 3 1125 324 525 360 525 Fig ...

Page 6: ...9 1 8 7 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 115 16 Belt Quantity Type Belt Length in 1 BX59 62 2 BX51 54 2 5VX530 53 1 BX59 62 1 5VX590 59 2 5VX530 53 2 BX52 55 2 5VX500 50 2 5VX530 53 2 BX51 54 2 5VX530 53 2 5VX530 53 Pulley Center Line Distance in 16 0 18 7 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 Factory Speed Setting rpm 717 924 1096 773 96...

Page 7: ...d overhangs B Roof Mount Check building codes for weight distribution requirements III FIELD FABRICATE DUCTWORK Secure all ducts to building structure Use flexible duct con nectors between unit and ducts as required Insulate and weath erproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with applicable codes Ducts passing through an unconditioned sp...

Page 8: ... indoor air quality guidelines VII 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 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 10 WARNING Do not pressu...

Page 9: ...ional disconnect per NEC and local codes requirements of adequate size Table 3 When ever external electrical sources are used unit must be elec trically grounded in accordance with local codes or in absence of local codes with NEC ANSI C1 latest year All field wiring must comply with NEC and local code requirements C Field Power Supply Unit is factory wired for voltage shown on nameplate See Table...

Page 10: ...on R Relay D Diode SIO Serial Input Output LED Light Emitting Diode SW Switch N C Normally Closed T Terminal N O Normally Open Where X is the unit control software version number 1 or 2 Fig 11 Control Board Diagram 10 ...

Page 11: ...price pages according to the installation instructions in cluded with the accessory or these instructions Locate ther mostat assembly on a solid wall in the conditioned space to sense average temperature Route thermostat cable or equivalent single leads of no 18 AWG American Wire Gage colored wire from subbase terminals to low voltage connections as shown on unit label wiring diagram and in Fig 15...

Page 12: ... 632 16 0 91 16 0 91 2 1 2 4 7 5 9 0 0 50 49 8 60 12 6 23 6 0 50 62 4 70 10 11 0 0 50 51 8 60 12 6 23 6 0 50 64 4 80 15 17 0 0 50 57 8 70 12 6 23 6 0 50 70 4 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...

Page 13: ...25 575 518 632 20 5 96 20 5 96 2 1 2 4 10 11 0 0 50 61 9 80 12 6 23 6 0 50 74 5 90 15 17 0 0 50 67 9 80 12 6 23 6 0 50 80 5 100 20 22 0 0 50 72 9 90 12 6 23 6 0 50 85 5 100 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 Outdo...

Page 14: ...vided to hood top d Apply black seal strip to mounting flanges cover holes of hood sides See Fig 18 NOTE Each hood assembly has a slotted side that should be adjacent to the other hood when mounted to the unit e Apply black seal strip to hood top mounting flange Seal strip of hood top mounting flange must press against seal strip of hood side mounting flanges See Fig 19 f Add gray foam strip provi...

Page 15: ...s HOOD TOP HOOD SIDE Fig 19 Add Seal Strip to Hood Top Mounting Flange CROSS MEMBER GRAY FOAM STRIP Fig 20 Adding Foam Strip to Cross Member HOOD SIDE SLOTTED HOOD TOP Fig 21 Adding Foam Strip to Hood Side BLOCKOFF BAFFLE GRAY FOAM STRIP Fig 22 Adding Foam Strip To Blockoff Baffle 15 ...

Page 16: ... is in the full open position Next the indoor fan contactor will energize The outdoor air damper will remain at 0 for 30 seconds It will then move to the 10 position for another 30 seconds This will be repeated at every 10 increment for 30 seconds until the damper reaches 100 open Close DIP switch no 4 during the 30 seconds immediately after the desired outdoor air mini mum damper position The 30 ...

Page 17: ...m of the right hand economizer hood 3 Remove the factory installed 620 ohm jumper be tween terminals SR and on the enthalpy control located inside the outdoor air hood 4 Connect the violet wire from the enthalpy sensor kit to the terminal on the enthalpy control Connect the blue wire from the enthalpy sensor kit to the SR terminal on the terminal control 5 Turn the enthalpy control set point poten...

Page 18: ...ycle Control are also disabled An OAT failure alarm will also be issued X POWER EXHAUST BAROMETRIC RELIEF DAMPER HOOD All electrical connections have been made and adjusted at the factory The power exhaust blowers and barometric relief damp ers are shipped assembled and tilted back into the unit for shipping Brackets and extra screws are shipped in shrink wrap around the dampers If ordered each un...

Page 19: ...e location shown in Fig 32 Connect sensor leads to the violet and grey control signal leads on the Motormaster III control Signal Selection Switch Remove the cover of the Motor master III control Set the switch to accept the thermistor sensor input signal Set the frequency to match the unit power supply 60 Hz Motormaster III Control The recommended mounting location is in the indoor fan section mo...

Page 20: ...a Make sure that condenser fan blades are correctly positioned in fan orifices Blades should clear fan motor and fan orifice ring b Make sure that return air filters and outdoor air inlet screens are in place c Make sure that the condensate trap is filled with water to ensure proper drainage d Make sure that all tools and miscellaneous loose parts have been removed 5 Loosen the compressor holddown...

Page 21: ...r proper cooling control operation as follows Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan motor and evapora tor blower motors start Observe that cooling cycle shuts down when control setting is satisfied B Cooling Sequence of Operation On power up the control module will activate the initializ...

Page 22: ...eating control is performed through the IGC boards The base module board serves only to initiate and terminate heating operation The base module board is powered by 24 vac When the ther mostat or room sensor calls for heating power is sent from the base module board to W on each of the IGC boards A light emitting diode LED on the IGC board will be on dur ing normal operation A check is made to ens...

Page 23: ...ded Do not use the unit 24 v power supply to power the sensor Once installed the sensor must be enabled The sensor is con figured with default values which may be changed through network access software To work properly the IAQ sensor high and low reference points for the sensor that is used must match the configured values The expansion board reacts to a 4 to 20 mA signal from the IAQ sensor The ...

Page 24: ... board the indoor fan will operate for an additional 30 seconds after deenergizing the circuit Setting of the outdoor air damper position is performed in con junction with a shortened version of the field test Open DIP switch no 4 and then no 6 The outdoor air damper will close The control allows 90 seconds for the damper to close in case it is in the full open position Next the indoor fan contact...

Page 25: ...he pilot valve opens to the preset position When power is supplied to terminals 1 and 2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 5 in wg To adjust regulator 1 Set thermostat at setting for no call for heat 2 Turn field supplied main gas valve to OFF position 3 Remove 1 8 in pipe plug from manifold Install a water manometer pressure meas...

Page 26: ...m Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 4 000 759 3 97 796 4 42 831 4 87 865 5 34 897 5 81 929 6 30 959 6 79 988 7 28 5 000 780 4 53 816 4 99 851 5 45 884 5 93 916 6 41 946 6 90 976 7 40 1005 7 91 6 000 805 5 23 840 5 70 874 6 18 906 6 67 937 7 16 968 7 66 997 8 17 1025 8 69 7 000 834 6 09 868 6 57 901 7 07 932 7 56 962 8 07 992 8 58 1020 9 10 1048 9 63 8 000 866 7 10 899 7 60 930 8 11 961 8 62 990 ...

Page 27: ...4 80 5380 11 700 0 04 4 83 5420 LEGEND Bhp Brake Horsepower ESP External Static Pressure in wg Watts Input Watts to Motor Table 10 Motor Limitations STANDARD EFFICIENCY MOTORS Nominal Hp Maximum Bhp Maximum Amps Maximum Watts Motor Efficiency 230 460 575 5 5 9 14 6 5 030 87 5 5 9 7 9 6 0 5 030 87 5 7 5 8 7 22 0 7 334 88 5 9 5 12 0 10 0 8 008 88 5 10 10 2 28 0 8 502 89 5 11 8 14 6 12 0 9 836 89 5 1...

Page 28: ... the saturated condensing temperature For outdoor temperatures down to 20 F it maintains condensing temperature at 100 F CARE AND MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic mainte nance must be performed on this equipment This combina tion heating cooling unit should be inspected at least once each year by a qualified s...

Page 29: ...he filters E Main Burners At the beginning of each heating season inspect for deterio ration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary Refer to Main Burners sections on page 28 Check spark gap See Fig 40 F Flue Gas Passageways The flue collector box and heat exchanger cells may be inspected by removing gas section access panel Fig 2 and 3 f...

Page 30: ...stment NOTES 1 Torque setscrews on blower wheel to 70 in lbs 2 in lbs 2 Torque setscrew on propeller fan to 15 in lbs 2 in lbs 3 Dimensions are in inches Fig 41 Typical Gas Heating Section Fig 42 Gas Heat Section Details 30 ...

Page 31: ... mounting hex bolts and secure in place by inserting a prop 9 Remove the nuts from the motor mounting hex bolts and remove motor 10 Reverse above steps to install new motor V POWER FAILURE Dampers have a spring return In event of power failure damp ers will return to fully closed position until power is restored VI REFRIGERANT CHARGE Amount of refrigerant charge is listed on unit nameplate and in ...

Page 32: ...d Contact Application Engineering C Condenser Fan Motor Protection Each condenser fan motor is internally protected against overtemperature D High and Low Pressure Switches If either switch trips or if the compressor overtemperature switch activates that refrigerant circuit will be automa tically locked out To reset manually move the thermostat setting E Freeze Protection Thermostat FPT Freeze pro...

Page 33: ...ontrol board The red light is used to check unit operation and alarms A constant pulse is normal unit operation A series of quick blinks indicates an alarm Refer to Table 12 for a description of alarms The yellow and green LEDs have no significance on 580G H units LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Fig 44 Typical Refrigerant Circuiting 33 ...

Page 34: ...rors then replace sensor 7 HF 03 DIP Switch 2 is Open Close DIP switch 2 8 HF 12 DIP Switch 1 is Open Close DIP switch 1 9 SE 05 Loss of Communications with Expansion Board Communications between the expansion board and the control board have been interrupted Ensure that an expansion board is installed and wired using the wire harness supplied with the expansion module If an expansion board is not...

Page 35: ... 1 Relay DO 24 vac T30 29 Heat 2 Relay DO 24 vac T31 32 CV Power Exhaust 1 Modulating Pwr Exht DO 115 vac T33 32 CV Power Exhaust 2 DO 115 vac T34 35 Condenser Fan DO 115 vac T36 35 OFC2 DO 115 vac T37 38 T39 38 K1 Indoor Fan Relay DO HV K2 Compr 1 DO HV K3 Compr 2 DO HV LEGEND AO Analog Output CV Constant Volume DI Direct Input DO Direct Output HV High Voltage KV Kilo Ohms OAT Outdoor Air Thermis...

Page 36: ...LEGEND IDM Induced Draft Motor IGC Integrated Gas Controller NOTE Thermostat Fan Switch in the AUTO position Fig 45 IGC Control Heating and Cooling 36 ...

Page 37: ...eaker IFM Indoor Fan Motor IFR Indoor Fan Relay IGC Integrated Gas Unit Controller IP Internal Protector L Light LPS Low Pressure Switch LS Limit Switch MGV Main Gas Valve NC Normally Closed NEC National Electrical Code NO Normally Open OAT Outdoor Air Thermostat OD Outside Diameter OFC Outdoor Fan Contactor OFM Outdoor Fan Motor PEC Power Exhaust Contactor PEM Power Exhaust Motor PES Power Exhaus...

Page 38: ...ny of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent 5 Compressors and or fan motors are thermally protected 6 Three phase motors are protected against primary single phasing conditions TABLE A The Following Compressors Have Two Parallel Wires Run From TB1 to the Compressors Compressor Model Voltage Wire Quantity 06D 537 208 230 3 60 2 TABLE ...

Page 39: ...than 156 FLA for CB1 and CB2 All others are 140 4 If any of the original wire furnished must be replaced it must be replaced with Type 90 C wire or its equivalent 5 Compressors and or fan motors are thermally protected 6 Three phase motors are protected against primary single phasing conditions Fig 48 Power Schematic 580G H240 360 575 3 60 39 ...

Page 40: ...NOTE Red wire and violet wire are spliced together at the factory The brown wire has a wire nut added at the factory Fig 49 24 V Control Schematic 580G H240 360 40 ...

Page 41: ...Fig 50 Component Arrangement 580G H240 360 41 ...

Page 42: ...tion Overview Maintenance Operating Sequence A large selection of product theory and skills programs is available All programs include a video cassette and or slides and a companion booklet Use these for self teaching or to conduct full training sessions For a free Service Training Material Catalog STM call 1 800 962 9212 Ordering instructions are included Copyright 1997 Carrier Corporation CATALO...

Page 43: ...TOLERANCES M CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING ORIFICE AND VERIFY SETSCREW IS TIGHT M VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED M VERIFY THAT SUCTION DISCHARGE AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 COMPRESSOR AMPS COMPRESSOR NO 1 L1 L2 L3 COMPRESSOR NO 2 L1 L2 L3 SUPPLY FAN AMPS EXHAU...

Page 44: ... PERFORMANCE TABLES HIGH PRESSURE SWITCH SETTING PSIG LOW PRESSURE SWITCH SETTING PSIG MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in FILTER QUANTITY FILTER SIZES in ADDITIONAL NOTES CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE Copyright 1997 Carrier Corporation CATALOG NO 5358 000 ...