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installation, start-up and
581A
service instructions
Sizes 155-240
SINGLE PACKAGE ROOFTOP
ELECTRIC COOLING/GAS HEATING UNITS
Cancels: II 581A-155-2 II 581A-155-3
6/15/99
CONTENTS
Page
WARNING:
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
1. Improper installation, adjustment, alteration,
service, or maintenance can cause property
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
damage, personal injury, or loss of life. Refer to
I. Step 1 —
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—2— NOTES: CURB 1. Roof curb accessory is shipped disassembled. PKG. NO. REF. HEIGHT DESCRIPTION 1 2. Insulated panels: 1 in. thick neoprene coated 1 / lb density. 2 ft-in. (mm) 3. Dimensions in ( ) are in millimeters. 1-2 Standard Curb CRRFCURB010A00 (305) 14” High 4. Direction of airflow. Standard Curb 2-0 for Units 5. Roof curb: 16 ga. (VA03-56) stl. CRRFCURB011A00 (610) Requiring High Installation NOTE: To prevent the hazard of stagnant water build-up in the drain pan of the indoor section,
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B. Alternate Unit Support When a 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. Spreader bars are not required if top crating is left on unit. Us
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—4— ECONO- STD UNIT CORNER CORNER CORNER CORNER MIZER DIM A DIM B DIM C UNIT WEIGHT A B C D WEIGHT 581A Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg ft-in. mm ft-in. mm ft-in. mm 155 1725 782 110 50 427 194 390 177 438 199 470 213 3-3 991 3-5 1051 1-10 559 180 1800 816 110 50 417 189 399 181 481 218 503 228 3-2 961 3-6 1070 1-10 559 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 attac
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—5— ECONOMIZER UNIT STD. UNIT WEIGHT WEIGHT 1900 lbs (862 kg) 110 lbs (50 kg) 581A240 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 ft-0 in. (2134) for coil removal. This dimension can be reduced to 4 ft-0 in. (1219) if conditions permit coil removal from the top. • 4 ft-0 in. (1219) to combustible surfac
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Table 1 — Physical Data UNIT 581A 155 180 240 NOMINAL CAPACITY (tons) 12 15 20 OPERATING WEIGHT (lb) Unit Al/Al* 1725 1800 1900 Al/Cu* 1875 1950 2050 Cu/Cu* 2005 2080 2180 Economizer 110 110 110 Roof Curb† 200 200 200 COMPRESSOR Quantity 22 2 Number of Refrigerant Circuits 22 2 Crankcase Heater Watts 70 70 70 Oil (oz) (Ckt 1, Ckt 2) 60,66 85,60 110,110 REFRIGERANT TYPE R-22 Expansion Device TXV Operating Charge (lb oz) Circuit 1** 20.7 19.5 18.5 Circuit 2 11.9 13.45 13.3 3 CONDENSER COIL Cross-H
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III. STEP 3 — FIELD FABRICATE DUCTWORK ductwork may be connected as shown in Fig. 7 and 8. Attach all ductwork to roof curb and roof curb basepans. Refer to On vertical units, secure all ducts to roof curb and building installation instructions shipped with accessory roof curb for structure. Do not connect ductwork to unit. Use flexible duct more information. connectors between unit and ducts as required. Adequately insulate and weatherproof all ductwork located outdoors, joints, and roof openin
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All field wiring must comply with NEC and local require- INDUCED DRAFT MOTOR ments. Insulate low-voltage wires for highest voltage con- tained within conduit when low-voltage control wires are run in the same conduit as high-voltage wires. INDOOR MOTOR ACCESS MAIN BURNER HEAT EXCHANGER COMBUSTION SECTION SECTION FAN HOUSING Fig. 10 — Combustion Fan Housing Location FILTER ACCESS VI. STEP 6 — TRAP CONDENSATE DRAIN See Fig. 4, 5, and 11 fore drain location. Plug is provided in drain hole and must
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Route power and ground lines through control box end panel Connect ground lead to chassis ground connection when or unit basepan (see Fig. 4 and 5) to connections as shown on using separate ground wire. The unit has a terminal block unit wiring diagram and Fig. 14. for field power connections. Install conduit connectors in side panel power supply knockout openings indicated in Fig. 4 and 5. Route power lines through connector to unit control CAUTION: The correct power phasing is critical in
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Table 2 — Electrical Data NOMINAL VOLTAGE COMPRESSOR POWER COMBUSTION POWER OFM IFM UNIT VOLTAGE RANGE EXHAUST FAN MOTOR SUPPLY No. 1 No. 2 581A (3 Ph, 60 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* Hz) 8.8/ — — 0.57 59/59 70/70 208/230 187 253 20.7 156 19.3 123 3 0.5 1.7 2.9 015 8.4 4.6 18.8 0.57 64/63 80/80 (Standard — — 0.30 29 35 IFM) 460 414 508 10 70 10 62 3 0.5 0.8 2.9 4.2 2.3 6.0 0.30 31 40 11.0/ — — 0.57 61/61 80/80 208/230 187 253 20.7 156 19.3 123 3 0.5 1.7
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Fig. 16 — 25% Outdoor-Air Section Details Fig. 19 — Economizer Motor Control Module Location Damper Vent Position Setting 1. Set fan switch at ON position (continuous fan opera- tion) and close night switch if used. 2. Set system selector switch at OFF position. 3. Turn damper adjustment knob located on control module clockwise slowly until dampers assume desired vent position. Do not manually operate econo- mizer motor, since damage to motor will result. X. STEP 10 — INSTALL OUTDOOR-AIR HOOD Th
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3. Secure lower filter retainer and long section of filter 8. Insert outdoor-air inlet screens and spacer in channel support bracket to unit. See Fig. 22. Leave screws created by lower filter retainer and filter support loose on 180 and 240 units. bracket. 4. Slide baffle (sizes 180 and 240) behind lower filter 9. Attach remaining short section of filter support retainer and tighten screws. bracket. 5. Loosen sheet metal screws for top panel of base unit- A. Enthalpy Control Installation located
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11. Reinstall economizer hood if removed. CONTROL CONTROL POINT IMPORTANT: Be sure all seal strips and RTV sealant are CURVE (Approx Deg) AT 50% RH intact. A watertight seal to inside of unit must be A 73 maintained. B 68 C 63 XI. STEP 11 — INSTALL ALL ACCESSORIES D 58 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 Installation (581A155 a
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Sensor Assembly — Install the sensor assembly in the loca- Replace Outdoor Motor tion shown in Fig. 26. Replace outdoor-fan motor no. 1 with motor included in Motor Mount — To ensure proper fan height, replace the accessory kit. Existing motor is not Motormaster III existing motor mount with the new motor mount provided compatible. with accessory. Install Motormaster III Controls Transformer (460-v Units Only) — On 460 volt units, a trans- Only one Motormaster III control is required per unit. f
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NOTE: When compressors are rotating in the wrong direc- mance, see Evaporator Fan Performance Adjustment section tion, the unit will have increased noise levels and will not on page 26. provide heating and cooling. 1 NOTE: A 3 / -in. bolt and threaded plate are included in the 2 After a few minutes of reverse operation, the scroll compres- installer’s packet. They can be added to the motor support sor internal overload protection will open, which will acti- channel below the motor mounting plate
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Table 4 — Fan Performance — 581A155225 (Low Heat Units with Optional Indoor Fan Motor) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) CFM 0.20.4 0.60.8 1.0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 3750 753 942 1.08 838 1091 1.25 945 1298 1.49 1044 1513 1.74 1138 1737 2.00 4000 755 1020 1.17 865 1223 1.41 968 1433 1.65 1063 1652 1.90 1154 1878 2.16 4250 788 1159 1.33 894 1366 1.57 992 1581 1.82 1084 1803 2.07 1172 2032 2.34 4500 822 1311 1.51 923 1522 1.75 10
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Table 5 — Fan Performance — 581A180270 (Low Heat Units) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) CFM 0.2 0.4 0.6 0.8 1.0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 4500 753 1307 1.53 761 1330 1.56 840 1572 1.84 912 1822 2.14 980 2080 2.44 4800 747 1384 1.62 790 1515 1.78 866 1765 2.07 936 2023 2.37 1002 2289 2.68 5100 741 1465 1.72 820 1718 2.01 893 1977 2.32 961 2243 2.63 1025 2516 2.95 5700 810 1911 2.24 882 2182 2.56 950 2459 2.88 1014 2741 3.21 1
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Table 6 — Fan Performance — 581A240270 (Low Heat Units) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) CFM 0.2 0.4 0.6 0.8 1.0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 6,000 824 2607 3.09 894 2844 3.37 961 3085 3.66 1023 3330 3.95 1083 3578 4.24 6,500 881 3030 3.59 947 3266 3.88 1009 3507 4.16 1069 3751 4.45 1126 3998 4.74 7,000 939 3488 4.14 1001 3725 4.42 1060 3965 4.70 1116 4208 4.99 1170 4454 5.28 7,500 998 3982 4.72 1055 4218 5.00 1111 4458 5.29 1165
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Table 7 — Fan Performance — 581A155300 (High Heat Units with Standard Indoor Fan Motor AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) CFM 0.2 0.4 0.6 0.8 1.0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 3750 753 915 1.05 844 1077 1.24 949 1287 1.48 1047 1507 1.73 1139 1735 2.00 4000 764 1006 1.16 872 1211 1.39 972 1425 1.64 1067 1648 1.90 1156 1880 2.16 4250 798 1147 1.32 901 1357 1.56 997 1576 1.81 1089 1803 2.07 1175 2038 2.34 4500 832 1301 1.50 931 1516 1.7
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Table 8 — Fan Performance — 581A155300 (High Heat Units with Optional Indoor Fan Motor) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) CFM 0.20.4 0.60.8 1.0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 3750 753 942 1.08 844 1101 1.27 949 1306 1.50 1047 1520 1.75 1139 1741 2.00 4000 764 1035 1.19 872 1236 1.42 972 1444 1.66 1067 1661 1.91 1156 1885 2.17 4250 798 1177 1.35 901 1382 1.59 997 1594 1.83 1089 1814 2.09 1175 2041 2.35 4500 832 1331 1.53 931 1540 1.77 10
