Bryant 541A Users Manual
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2015-02-02
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installation, start-up and service instructions 575B/575C/541A Sizes 072-180 6 to 15 Tons AIR-COOLED SPLIT SYSTEM HEAT PUMP Cancels: II 575B-72-3 II 575B-72-4 9/15/04 INSTALLATION CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 I. COMPLETE PRE-INSTALLATION CHECKS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 I. Complete Pre-Installation Checks . . . . . . . . . . . . . . 1 II. Rig and Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1 III. Complete Refrigerant Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 IV. Complete Electrical Connections. . . . . . . . . . . . . . . 9 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,16 Remove unit packaging except for the top skid assembly, which should be left in place until after the unit is rigged into its final location. START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-18 SEQUENCE OF OPERATION. . . . . . . . . . . . . . . . . . . . . .18-20 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-24 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,26 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2 SAFETY CONSIDERATIONS Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start-up, and service this equipment. Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should be performed by trained service personnel. When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment. Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby when brazing. Use care in handling, rigging, and setting bulky equipment. WARNING: Before installing or servicing system, always turn off main power to system and install lockout tag on disconnect. There may be more than one disconnect switch. Electrical shock can cause personal injury. GENERAL The split system heat pump units described in this book are designed for use with the 524A-H indoor packaged air handler sections only. A. Uncrate Unit B. Inspect Shipment File claim with shipping company if shipment is damaged or incomplete. C. Consider System Requirements • Consult local building codes and National Electrical Code (NEC) for special installation requirements. • Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1-3 for unit dimensions. Figure 4 shows typical component locations for 541A180 units. • Locate unit so that outdoor coil airflow is unrestricted on all sides and above. • Unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points. See Table 1 for unit operating weights. II. RIG AND MOUNT UNIT CAUTION: Be sure unit panels are securely in place prior to rigging. Be careful rigging, handling, and installing unit. Improper unit location can cause system malfunction and material damage. Inspect base rails for any shipping damage and make sure they are fastened securely to unit before rigging. A. Rigging These units are designed for overhead rigging. Refer to rigging label for preferred rigging method. Spreader bars are not required if top crating is left on unit. All panels must be in place when rigging. As further protection for coil faces, plywood sheets may be placed against sides of unit, behind cables. Run cables to a central suspension point so that angle from the horizontal is not less than 45 degrees. Raise and set unit down carefully. If it is necessary to roll the unit into position, mount the unit on field-supplied rails placed lengthwise under the unit, using a minimum of 3 rollers. Apply force to the rails, not the unit. If the unit is to be skidded into position, place it on a large pad and drag it by the pad. Do not apply any force to the unit. Raise from above to lift unit from the rails or pad when unit is in final position. After unit in position, remove all shipping materials and top crating. B. Locate Unit For service access and unrestricted airflow, provide clearance on each end and side of unit. Position unit so that there is unrestricted airflow above unit. C. Mount Unit The unit may be mounted on a solid, level concrete pad, on accessory mounting legs, or on field-supplied raised supports at each mounting position. (Note that mounting hardware is field supplied.) Bolt unit securely to pad or supports after unit is in position and is level. Be sure to mount unit level to ensure proper oil return to compressors. Mounting holes on unit can be used to secure unit to vibration isolators, if required. NOTE: Before mounting unit, remove holddown brackets and release skid. If conditions or local codes require unit to be fastened to pad, use the mounting holes in the base rails. A CONTROL BOX B FRONT 7/8 4 PLACES 19 3/8 27 35 Line & Low Voltage Wiring Entrances 5-3/4 38-1/2 1-1/2 24 1/2 24 9-3/4 10 C 2-1/8 1-1/8 4 7/8 33 2-1/2 4-1/4 D 1-1/2 1-1/2 REAR BOTTOM 33 35 38-1/2 33 1-1/2 TOP 1-1/2 FRONT NOTES: 1. All dimensions are in inches. 2. Recommended clearance for proper airflow (local codes or jurisdictions may prevail): Top — 60 in. Sides — 24 in. on 3 sides, one side may be 6 in. (Control box side should have 24-in. clearance for service access.) 3. Corner Weights (lb): A = 86 B = 84 C = 92 D = 90 Fig. 1 — 575B072 Unit Dimensions —2 — —3— Fig. 2 — 575C090,120 Unit Dimensions WEIGHT DISTRIBUTION UNIT 541A 180 WEIGHT — lb (kg) Total Support Point Operating 1 2 3 4 Weight 803 (364) 158 243 244 158 (72) (110) (111) (72) NOTE: Recommended service clearances are as follows (local codes or jurisdictions may prevail): Side (compressor) — 31/2 ft (1067 mm) Side (opposite compressor) — 3 ft (914 mm) Ends — 2 ft (616 mm) Top — 5 ft (1524 mm) Fig. 3 — 541A180 Unit Dimensions —4 — 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 28 27 16 26 17 25 1 2 3 4 5 6 7 8 9 10 — — — — — — — — — — 24 Defrost Board/Time Guard II Control Fuse Fan No. 1 Compressor Lockout (CLO) Device Outdoor-Fan Relay Outdoor-Fan Contactor Compressor Contactor Fan Motor Capacitors Circuit Breaker Fan No. 2 23 22 21 LEGEND 11 — Power Terminal Block 12 — Control Terminal Block 13 — Compressor Lockout (CLO2 for Crankcase Heater) 14 — Control Relay (CR3) 15 — Liquid Line Solenoid 16 — Control Relay (CR2) 17 — No Dump Relay (NDR) 18 — Oil Pressure Switch 19 — Fusible Plug (hidden) 20 19 20 21 22 23 24 25 26 27 28 Fig. 4 — Component Locations — 541A180 Shown —5— — — — — — — — — — 18 High-Pressure Switch Compressor Capacity Control Solenoid Filter Drier Muffler Oil Solenoid Reversing Valve Accumulator Coil Table 1 — Physical Data — 575B072, 575C090,120 and 541A180 Units UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHTS (lb) Aluminum-Fin Coils (standard) Copper-Fin Coils (optional) REFRIGERANT* Operating Charge, Typical (lb)† Shipping Charge (lb) COMPRESSOR Qty...Model Oil Charge (oz) No. Cylinders Speed (rpm) OUTDOOR FANS Qty...Rpm Diameter (in.) Nominal Hp Nominal Airflow (cfm total) Watts (total) OUTDOOR COILS (Qty) Face Area (sq ft total) Rows...Fins/in. Storage Capacity (lb)** CONTROLS Pressurestat Settings (psig) High Pressure Open Close Low Pressure Open Close PIPING CONNECTIONS (in. ODM) Vapor Liquid 575B072 6 575C090 7.5 345 N/A 464 565 20 1 20 9 Scroll 1...ZR_94 90 N/A 3500 1...SR_75 88 575C120 10 506 607 R-22 22 9 1...ZR125 110 541A180 15 803 945 37 3 Semi-hermetic reciprocating 1...06DF537†† 128 6 1750 1…1100 26 3/ 4 6300 750 1 24 2…18 17.3 2…1100 22 1/ 4 6500 570 2 29.2 2…17 34.2 2…1075 26 1/ 2 11,000 1460 1 29.2 3…15 40.1 420 300 428 ± 10 320 ± 20 395 ± 20 295 ± 20 5 20 7±3 22 ± 5 7±3 22 ± 5 11 / 8 5/ 8 11/8 1/ 2 *Unit is factory supplied with holding charge only. †Typical operating charge with 25 ft of interconnecting pipe. **Storage capacity of condenser coil with 80% full of liquid at 95 F. ††Equipped with an electric solenoid unloader, capacity steps are 100% and 67%. —6 — 13 / 8 1/2 15 / 8 5/8 unit to outdoor unit before opening the liquid and vapor lines at the outdoor unit. For specific filter driers see Table 4. III. COMPLETE REFRIGERANT PIPING CONNECTIONS Refrigerant lines must be carefully designed and constructed to ensure equipment reliability and efficiency. Line length, pressure drop, compressor oil return, and vertical separation are several of the design criteria that must be evaluated. See Table 2. D. Liquid Line Piping Procedure Pipe the system liquid line as follows: WARNING: Unit is pressurized with a holding charge of refrigerant. Recover R-22 holding charge before removing runaround liquid piping loop. Failure to recover holding charge before removing piping loop could result in equipment damage and personal injury. IMPORTANT: Do not bury refrigerant piping underground. IMPORTANT: Piping must be properly sized and installed for the system to operate efficiently. A. Check Vertical Separation 1. Open service valves in sequence: a. Discharge service valve on compressor. b. Suction service valve on compressor. c. Liquid line valve. If there is any vertical separation between the indoor and outdoor units, check to ensure that the separation is within allowable limits. Relocate equipment if necessary. See Table 3. B. Refrigerant Line Sizing Consider the length of the piping required between the outdoor and indoor units. The maximum allowable line length is 100 ft. See Table 3. Refrigerant suction piping should be insulated. IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver. IMPORTANT: For 575C090,120 applications with liquid lift greater than 20 ft, use 5/8-in. liquid line. Maximum lift is 60 ft. 2. Remove 1/4-in. flare cap from liquid valve Schrader port. 3. Attach refrigerant recovery device and recover holding charge. 4. Remove runaround loop (581A180 only). 5. Connect system liquid line from liquid connection of outdoor unit (575B,C, 541A) to indoor unit (524A-H) liquid line connections. Select proper field-supplied bi-flow filter driers and install in the liquid line. See Fig. 5. Install a field-supplied liquid moisture indicator between the filter drier(s) and the liquid connections on the indoor unit. Braze or silver alloy solder all connections. Pass nitrogen or other inert gas through piping while making connections to prevent formation of copper oxide. (Copper oxides are extremely active under high temperature and pressure. Failure to prevent collection of copper oxides may result in system component failures.) Table 2 — Refrigerant Piping Sizes 575B072 1/ 2 LENGTH OF PIPING ft 26-60 61-100 Line Size (in. OD) V L V L V 5/ 8 5/ 8 11/8 11/8 11/8 575C090 3/ 8 11/8 1/ 575C120 1/ 2 13/8 1/ 541A180 5/ 8 15/8 3/ 0-25 OUTDOOR UNIT L 2 11/8 1/ 2 13/8 1/ 4 15/8 3/ MAXIMUM LIQUID LINE (in. OD)* 5/ 8 2 11/8 5/ 8 2 13/8 5/ 8 4 15/8 3/ 4 *If there is a vertical separation between indoor and outdoor units, see Table 3 — Maximum Vertical Separation. LEGEND L — Liquid Line V — Vapor Line NOTES: 1. Pipe sizes are based on a 2 F loss for liquid and vapor lines. 2. Pipe sizes are based on the maximum linear length, shown for each column, plus a 50% allowance for fittings. 3. Charge units with R-22 refrigerant in accordance with unit installation instructions. 4. Maximum line length must not exceed 100 ft. 5. Do not bury refrigerant piping. E. Liquid Line Solenoid Valve Addition of a liquid solenoid valve (LLSV) is required (except for 541A180 units that already have LLSV factory-installed). The LLSV must be a bi-flow type suited for use in heat pump systems. Refer to Table 4. Wire the solenoid valve in parallel with the compressor contactor coil. The LLSV must be installed at the outdoor unit with the flow arrow pointed toward the outdoor unit (in-flow direction for the Heating mode). Table 3 — Maximum Vertical Separation* OUTDOOR UNIT 575B 575C 541A 072 090 120 180 INDOOR UNIT 524A-H 090 090 120 180 DISTANCE FT Outdoor Unit Above 524A-H 50 60 60 80 *Vertical distance between indoor and outdoor units. C. Install Filter Drier(s) and Moisture Indicator(s) Every unit should have a filter drier and liquid-moisture indicator (sight glass). In some applications, depending on space and convenience requirements, it may be desirable to install 2 filter driers and sight glasses. One filter drier and sight glass may be installed at A locations in Fig. 5. If desired, 2 filter driers and sight glasses may be installed at B locations in Fig. 5. Select the filter drier for maximum unit capacity and minimum pressure drop. Complete the refrigerant piping from indoor LEGEND TXV — Thermostatic Expansion Valve Fig. 5 — Location of Sight Glass(es) and Filter Driers —7— Table 4 — Refrigerant Specialties Part Numbers LIQUID LINE SIZE 1/ ″ 2 5/ ″ 8 3/ ″ 8 1/ ″ 2 1/ ″ 2 5/ ″ 8 3/ ″ 4 UNIT 575B072 575C090 575C120 541A180 LIQUID LINE SOLENOID VALVE (LLSV) 200RB GS-1928 5T4 200RB GS-1929 5T5 200RB GS-1928 5T4† 200RB GS-1928 5T4 200RB GS-1928 5T4 ** ** LLSV COIL SIGHT GLASS FILTER DRIER AMG-24/50-60 AMG-24/50-60 AMG-24/50-60 AMG-24/50-60 AMG-24/50-60 ** ** AMI1TT4 AMI1TT5 AMI1TT3 AMI1TT4 AMI1TT4 AMI1TT5 AMI1TT5 * * P504-8083S P504-8084S P504-8164S P504-8085S Qty 2 P504-8085S Qty 2 *A filter drier is shipped loose with the 575B072 units. †Bushings required. **Factory Installed. F. Provide Safety Relief A fusible plug is located on the compressor crankcase or in the liquid line. See Fig. 6. Do not cap this plug. If local code requires additional safety devices, install them as directed. Head Pressure Control (541A180 only) Fan cycling for head pressure control is a standard offering but is functional on the cooling cycle only. Number 2 fan cycles as a function of liquid pressure. Fan cycling pressure switch cycles the fan off at 160 ± 10 psig as pressure decreases and cycles back on at 255 ± 10 psig. Switch is automatically bypassed in heating cycle. Table 5 shows minimum outdoor air temperature for full cooling capacity. Fig. 6 — Location of Fusible Plug — 541A180 Unit G. Vapor Line Piping Procedure Connect system vapor line to the vapor line stub on the outdoor unit and the vapor stubs on the indoor unit. At the indoor unit, construct vapor piping branches as shown in Fig. 7 for good mixing of the refrigerant leaving the indoor coil during cooling. This will ensure proper TXV (thermostatic expansion valve) bulb sensing. Where vapor line is exposed to outdoor air, line must be insulated. See Table 6 for insulation requirements. Table 5 — Minimum Outdoor Air Operating Temperature UNIT 575B 575C 541A 072 090 120 180 MINIMUM OUTDOOR TEMP — F* % COMPRESSOR Standard Head Pressure CAPACITY Unit Control† 0 0 100 35 –20 35 –20 100 23 –20 67 36 –20 *Applies to Cooling mode of operation only. †Wind baffles (field-supplied and field-installed) are recommended for all units with low ambient head pressure control. Refer to Low Ambient Control Installation Instructions (shipped with accessory) for details. LEGEND TXV — Thermostatic Expansion Valve Table 6 — Insulation for Vapor Line Exposed to Outdoor Conditions LENGTH OF EXPOSED VAPOR LINE* ft 10 Fig. 7 — Vapor Line Branch Piping Details INSULATION THICKNESS† in. 3/ 8 25 1/ 2 35 3/ 4 50 3/ 4 *Recommended vapor line insulation for piping exposed to outdoor conditions to prevent loss of heating during heating cycle. When vapor line goes through interior spaces, insulation should be selected to prevent condensation on cooling cycle. Heating capacity should be reduced 1000 Btuh if over 35 ft of vapor line with 3/4 in. insulation is exposed to outdoor conditions. †Closed cell foam insulation with a thermal conductivity of: 0.28 Btu • in./ft2 • h • °F. —8 — IV. COMPLETE ELECTRICAL CONNECTIONS A. Power Supply Electrical characteristics of available power supply must agree with nameplate rating. Supply voltage must be within tolerances shown in Table 7. Phase imbalance must not exceed 2%. Operation of unit on improper supply voltage or with excessive phase imbalance constitutes abuse and is not covered by Bryant warranty. IMPORTANT: Operation of unit on improper power supply voltage or with excessive phase imbalance constitutes abuse and is not covered by Bryant warranty. D. General Wiring Notes (See Fig. 8-13) 1. A crankcase heater is wired in the control circuit so it is always operable as long as power supply disconnect is on, even if any safety device is open or unit stop/ start switch is off. 2. The power-circuit field supply disconnect should never be open except when unit is being serviced or is to be down for a prolonged period. When operation is resumed, crankcase heater should be energized for 24 hours before start-up. If system is to be shut down for a prolonged period, it is recommended that the suction and discharge valves be closed to prevent an excessive accumulation of refrigerant in the compressor oil. 3. Terminals for field power supply are suitable for copper, copper-clad aluminum, or aluminum conductors. 4. Bryant recommends an indoor airflow switch (field supplied) be installed and interlocked with the outdoor unit. This prevents the outdoor unit from operating if indoor airflow fails (broken fan belt, etc.). Operation of the compressor in vacuum can damage bearing surfaces. Install indoor airflow switch in a convenient location at the indoor supply air duct and wire per Fig. 14. 5. If the system is equipped with an accessory electric heater, refer to the 524A-H installation instructions and tables. Per local code requirements, provide an adequate fused disconnect switch within sight of unit and out of reach of children. Provision the switch for locking open (off) to prevent power from being turned on while unit is being serviced. The disconnect switch, fuses, and field wiring must comply with local requirements. Refer to Table 7 for unit electrical data. B. Power Wiring All power wiring must comply with applicable local requirements. Run power wires from disconnect switch through unit power opening and connect to terminal block inside the unit control box. Unit must be grounded. C. 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 percentage of voltage imbalance: % Voltage Imbalance: max voltage deviation from average voltage = 100 x average voltage Example: Supply voltage is 460-3-60. AB = 452 v BC = 464 v AC = 455 v 452 + 464 + 455 Average Voltage = 3 1371 = 3 = 457 (AB) 457 – 452 = 5 v (BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v Maximum deviation is 7 v. Determine percent of 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. WARNING: Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code), ANSI/NFPA (American National Standards Institute/National Fire Protection Association), and local electrical codes. Failure to follow this warning could result in the installer being liable for personal injury of others. E. Control Circuit Wiring Control voltage is 24 v. See unit label diagram for field supplied wiring details. Route control wires through opening in unit to connection in unit control box. Control Transformer Wiring On 208/230V units, check the transformer primary wiring connections. See Fig. 8 or refer to unit label diagram. For 575B,C Unit — If unit will be operating at 208-3-60 power, remove black wire (BLK) from the transformer primary connection labeled “230” and move it to the connection labeled “208”. See Fig. 8. For 541A Unit — Transformers no. 1 and 2 are wired for a 230-v unit. If a 208/230-v unit is to be run with a 208-v power supply, the transformers 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 result in damage to the transformer. —9— Duplex 575C120, 541A180 with 524A-H240 or 524A-H300 In order to properly connect two heat pump condensing units to a single 524A-H packaged air handler, it is necessary to add field-supplied Fan Coil Relay Board(s), P/N 33ZCRLYBRD. Relay board(s) no. 1 and no. 2 should be installed in the control box of condensing unit. IMPORTANT: The common (COM) terminals from the fan coil relay board(s) must be connected to the ‘C’ terminal in condensing unit ‘A’. Route thermostat cable or equivalent single leads of no. 18 AWG (American Wire Gage) colored wire from subbase terminals through conduit in unit to low-voltage connections as shown on unit wiring diagram and Fig. 12 and 13. Fig. 8 — Wiring Diagram — 575C090,120 — Control Transformer NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 51 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 to the thermostat and will require a junction box and a splice at the thermostat. Table 7 — Electrical Data UNIT 575B 072 090 575C 120 541A FLA LRA MCA MOCP NEC RLA 180 — — — — — — FACTORYINSTALLED OPTION NOMINAL VOLTAGE (V-Ph-Hz) NONE VOLTAGE RANGE* COMPRESSOR FAN MOTORS POWER SUPPLY Min Max RLA LRA FLA MCA MOCP 208/230-3-60 460-3-60 575-3-60 187 414 517 253 506 633 18.9 9.5 7.6 146 73 58 5.1 2.6 1.2 208/230-3-60 187 254 29.0 190 1.5 28.7 14.5 10.7 39.0 43.8 19.8 21.9 45.0 50.0 23.0 25.0 18.0 20.0 87.5 40.7 33.0 45 20 15 60 60 30 30 60 70 30 30 25 25 125 60 50 NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET 460-3-60 418 506 15.0 95 0.7 208/230-3-60 187 254 34.0 225 1.5 460-3-60 418 506 17.0 114 0.7 575-3-60 523 632 14.0 80 0.7 NONE 208/230-3-60 460-3-60 575-3-60 187 414 518 253 528 660 63.6 29.3 23.8 266 120 96 4.3 2.3 1.8 LEGEND Full Load Amps Locked Rotor Amps Minimum Circuit Amps Maximum Overcurrent Protection National Electrical Code Rated Load Amps NOTES: 1. The MCA and MOCP values are calculated in accordance with the NEC, Article 440. 2. Motor RLA and LRA values are established in accordance with Underwriters’ Laboratories (UL), Standard 1995. 3. The 575-v units are UL, Canada-listed only. 4. Convenience outlet is available as either a factory-installed option or a field-installed accessory and is 115-v, 1 ph, 60 Hz. *Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed limits. —10— FAN DF LP/HP PS RV SEN TSTAT DEFROST Y-RV CONTROL BK RV BK COIL RV BL BL CC Y PS2 PS1 Y BK BK DF R C LP/HP SEN O Y W R-RV DEFROST HEAT COMPRESSOR HEAT/COOL Y O BL FROM TSTAT NOTES: 1. All electrical work must be done in conformance with the National Electrical Code (NFPA No. 70) and in conformance with local codes and authorities having jurisdiction. 2. For use with copper conductors only. COMMON 24 VAC R LEGEND Defrost Relay Low or High-Pressure Switch (Optional) Pressure Switch Reversing Valve Outdoor Coil Temperature Sensor Thermostat Line Voltage Factory Low Voltage Factory Low Voltage Field COLOR CODE BK Black BL Blue O Orange R Red W White Y Yellow LP/HP W — — — — — — CAUTION: Not suitable for use on systems exceeding 150 volts to ground. Fig. 9 — Wiring Diagram — 575B072; 208/230-3-60 Units THERMOSTAT CONNECTION BOARD (TB) R 1 Y 2 O 3 E 4 W2 5 G IFC LLSV C 6 LEGEND IFC — Indoor Fan Contactor LLSV — Liquid Line Solenoid Valve TB — Terminal Block Field Wiring NOTES: 1. For thermostat and subbase part no. see price pages. 2. Use copper conductors only. 7 TO ELECTRIC HEATER ACCESSORY, IF EQUIPPED 8 Fig. 10 — Wiring Diagram — 575C090,120; 230-3-60 Units —11— EQUIP GND HC IFC IFM NEC TB — — — — — — — LEGEND Equipment Ground Heater Contactor Indoor Fan Contactor Indoor Fan Motor National Electrical Code Terminal Block Fig. 11 — Wiring Diagram — 541A180 Unit With Standard Thermostat and Electric Heat —12— TB1 DISCONNECT FIELD POWER SUPPLY 3-Ph ONLY HC1 L1 L2 HTR1 HC1 L3 EQUIP GND CIRCUIT BREAKER (5 HP AND LARGER) IFC 11 12 13 524A-H240 TERMINAL BLOCK TB1 FIELD POWER R WIRING 21 BLK 22 BLK 23 BLK 1 2 3 IFM UNIT WIRING 524A-H HEAT ACCESSORY Y1 Y2 HEAT PUMP “A” W1 W1 W2 G WHT C1 IFC C2 C WHT W2 C TB2 R CR R X RELAY BOARD (33ZCRLYBRD) Y1 Y1 Y2 Y2 W1 W1 G W2 W2 G C CR O G3/(Y) COM G C TSTAT X HEAT PUMP “B” CR EQUIP GND HC HTR IFC IFM TB TSTAT — — — — — — — — — FAN G2/(W) LEGEND Control Relay (Field-Supplied) Equipment Ground Heating Contactor Electric Heater Indoor-Fan Contactor Indoor-Fan Motor Terminal Block Thermostat Factory Wiring TB2 R Y1 Y2 W1 W2 Field Control Wiring G NOTE: Use copper conductors only. C X Fig. 12 — Wiring Diagram — Duplex 575C120 With 524A-H240 and Electric Heat —13— (VALVE) HI(COOL) MED(HEAT) LO DISCONNECT FIELD POWER SUPPLY 3-Ph ONLY TB1 HC1 L1 L2 HTR1 HC1 L3 EQUIP GND CIRCUIT BREAKER (5 HP AND LARGER) IFC 11 12 13 524A-H300 TERMINAL BLOCK TB1 FIELD POWER R WIRING 21 BLK 22 BLK 23 BLK 1 2 3 IFM UNIT WIRING 524A-H HEAT ACCESSORY Y1 Y2 HEAT PUMP A 541A180 W1 W1 W2 G WHT C1 IFC C2 C WHT W2 C TB2 R RELAY BOARD (33ZCRLYBRD) R X Y1 G Y2 G2/(W) W1 W2 G3/(Y) G COM C RELAY BOARD (33ZCRLYBRD) B W1 FAN A2 (VALVE) Y1 HI(COOL) Y2 MED(HEAT) Q LO C G FAN G2/(W) CR G3/(Y) COM (VALVE) HI(COOL) MED(HEAT) LO P X X TSTAT* 1 2 CR EQUIP GND HC HTR IFC IFM TB TSTAT — — — — — — — — — HEAT PUMP B 575C120 LEGEND Control Relay (Field-Supplied) Equipment Ground Heating Contactor Electric Heater Indoor-Fan Contactor Indoor-Fan Motor Terminal Block Thermostat Factory Wiring TB2 CR R Y1 Y2 W1 CR W2 G Field Control Wiring C *Do not configure TSTAT for heat pump. NOTE: Use copper conductors only. X Fig. 13 — Wiring Diagram — Duplex 575C120 and 541A180 With 524A-H300 and Electric Heat LEGEND AFS — Airflow Switch (Sail Switch) CR — Control Relay DB — Defrost Board Factory Wiring Field Control Wiring NOTES: 1. Locate YEL wire between Y on DB and terminal 5 of CR3 and cut. 2. Splice airflow switch (AFS) (field supplied) contact wires (field provided) to two ends of cut YEL wire as depicted. Fig. 14 — Typical Field Wiring for Airflow Switch — 541A180/524A-H —14— PRE-START-UP IMPORTANT: Before beginning Pre-Start-Up or Start-Up, review Start-Up Checklist at the back of this book. The checklist assures proper start-up of the system and provides a record of unit condition, application requirements, system information, and operation at initial start-up. SNUBBER WASHER SELF-LOCKING BOLT NEOPRENE SNUBBER COMPRESSOR FOOT CAUTION: Do not attempt to start the heat pump system, even momentarily, until the following steps have been completed. Compressor damage may result. Fig. 15A — Compressor Mounting — 575B072 and 575C090,120 Units I. PRELIMINARY CHECKS 1. Check all air handler and other equipment auxiliary components. Consult manufacturer’s instructions regarding any other equipment attached to unit. If unit has field-installed accessories, be sure all are properly installed and correctly wired. If used, airflow switch must be properly installed. See Fig. 14 for typical field wiring. 2. As shipped, compressor is held down by 4 bolts. After unit is installed, loosen each bolt and locknut until flat washer or snubber can be moved with finger pressure. Be sure compressor floats freely on the mounting springs (541A units only). See Fig. 15A and 15B for compressor mounting. 3. Check tightness of all electrical connections. 4. Electrical power source must agree with nameplate rating. 5. Turn on crankcase heater for 24 hours before starting the unit to be sure all refrigerant is out of the oil. To energize crankcase heater, perform the following steps: a. Set the space thermostat system switch to OFF, or adjust the temperature so there is no demand for cooling. b. Close the field disconnect. Fig. 15B — Compressor Mounting — 541A180 Units 150 PSI MAX DRY NITROGEN c. Leave the compressor circuit breaker off. The crankcase heater is now energized. LIQUID LINE SOLENOID VALVE SUCTION LINE 6. Leak test the field refrigerant piping, connections and joints, and indoor coil. To perform leak test, complete the following steps: a. Pressurize refrigerant piping; do not exceed 150 psi. b. Using soap bubbles and/or an electronic leak detector, test refrigerant piping, connections and joints, and the indoor coil. See Fig. 16. OUTDOOR UNIT TXV LIQUID LINE SOAP → Fig. 16 — Recommended Process for Checking for Leaks c. Check for leaks. Evacuate and dehydrate entire refrigerant system. 7. 541A180 only — compressor oil level should be visible in sight glass. Adjust the oil level as required. No oil should be removed unless the crankcase heater has been energized for at least 24 hours. See Start-Up section, Preliminary Oil Charge. NOTE: The 575B, 575C units do not have a compressor oil level sight glass. These units are factory charged with the required amount of oil. If required, use the following oil for replacement: For 575B units use Zerol 150, part number P903-2001. For 575C units use RCD, part number P903-0101. 8. Backseat (open) compressor suction and discharge valves. Now close valves one turn to allow refrigerant pressure to reach test gages. INDOOR COIL II. PRELIMINARY CHARGE —15— CAUTION: The 575C090 and 575C120 units contain a 9 lb charge of refrigerant. Add remainder of preliminary charge and allow pressure to equalize before starting compressor. Failure to do so WILL cause the compressor to overheat in a few minutes, possibly causing permanent compressor damage. The amount of refrigerant added must be at least 80% of the operating charge listed in the Physical Data table (Table 1). Before starting the unit, charge liquid refrigerant into the high side of the system through the liquid service valve. Allow high and low side pressures to equalize before starting compressor. If pressures do not equalize readily, charge vapor on low side of system to assure charge in the evaporator. Refer to GTAC II, Module 5, Charging, Recovery, Recycling, and Reclamation for liquid charging procedures. III. LIQUID LINE SOLENOID To minimize refrigerant migration to the compressor during the heat pump OFF cycle, the 575B,C unit must have a bi-flow liquid line solenoid valve (field supplied). The valve opens when the compressor is energized, and closes when the compressor is deenergized. This reduces compressor flooded starts, thus significantly increasing compressor life. IV. ACCUMULATOR The unit accumulator controls the rate of liquid refrigerant to the compressor during heat pump operation. The 541A accumulator features a unique method for returning oil to the compressor. The oil return mechanism is external to the accumulator. The mixture of oil and refrigerant is metered to the compressor by a brass orifice which is removable and cleanable. The oil return mechanism also contains a solenoid valve that opens when the compressor is ON and closes when the compressor is OFF. This keeps the liquid refrigerant stored in the accumulator from draining to the compressor during the heat pump OFF cycle, which further protects the compressor against flooded starts. becomes excessive, and automatically resets when the internal temperature drops to a safe level. This overload usually resets within 60 minutes (or longer). If the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester. III. ADVANCED SCROLL TEMPERATURE PROTECTION (ASTP) Advanced Scroll Temperature Protection (ASTP) is a form of internal discharge temperature protection that unloads the scroll compressor when the internal temperature reaches approximately 300 F. At this temperature, an internal bimetal disk valve opens and causes the scroll elements to separate, which stops compression. Suction and discharge pressures balance while the motor continues to run. The longer the compressor runs unloaded, the longer it must cool before the bi-metal disk resets. See Fig. 17. To manually reset ASTP, the compressor should be stopped and allowed to cool. If the compressor is not stopped, the motor will run until the motor protector trips, which occurs up to 90 minutes later. Advanced Scroll Temperature Protection will reset automatically before the motor protector resets, which may take up to 2 hours. A label located above the terminal box identifies Copeland Scroll compressor models (ZR94, 108 and 125) that contain this technology. See Fig. 18. START-UP Recommended Cooling Time (Minutes) CAUTION: Compressor crankcase heater must be on for 24 hours before start-up. After the heater has been on for 24 hours, the unit can be started. CAUTION: Prior to starting compressor, a preliminary charge of refrigerant must be added to avoid possible compressor damage. I. COMPRESSOR ROTATION (575B,C Units) 120 110 100 90 80 70 60 50 40 30 20 10 0 0 On 3-phase units with scroll compressors, it is important to be certain compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction: 1. Connect service gages to suction and discharge pressure fittings. 2. Energize the compressor. 3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up. If the suction pressure does not drop and the discharge pressure does not rise to normal levels: 1. Note that the condenser fan is probably also rotating in the wrong direction. 2. Turn off power to the unit, tag disconnect. 10 20 30 40 50 60 70 80 90 Compressor Unloaded Run Time (Minutes) *Times are approximate. NOTE: Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times. Fig. 17 — Recommended Minimum Cool-Down Time After Compressor is Stopped* 3. Reverse any two of the unit power leads. 4. Reapply power to the compressor, verify correct pressures. The suction and discharge pressure levels should now move to their normal start-up levels. II. COMPRESSOR OVERLOAD This overload interrupts power to the compressor when either the current or internal motor winding temperature —16— Fig. 18 — Advanced Scroll Temperature Protection Label IV. COMPRESSOR LOCKOUT DEVICE The compressor lockout (CLO) device prevents the compressor from starting or running in a high pressure, loss-ofcharge or freezestat open situation. Reset the CLO device by setting the thermostat to eliminate cooling demand and return it to the original set point. If the system shuts down again for the same fault, determine the possible cause before attempting to reset the CLO device. V. PRELIMINARY OIL CHARGE (541A) The compressor is factory charged with oil (see Table 1). When oil is checked at start-up, it may be necessary to add or remove oil to bring it to the proper level. Add oil only if necessary to bring oil into view in sight glass. Use only Bryant-approved compressor oil. One recommended oil level adjustment method is as follows: A. Add Oil Close suction service valve and pump down crankcase to 2 psig. Wait a few minutes and repeat until pressure remains steady at 2 psig. Remove oil fill plug above the sight glass, add oil through plug hole, and replace plug. Run compressor for 20 minutes and check oil level. NOTE: Use only Bryant-approved compressor oil. Approved sources are: Refer to Charging Charts Fig. 19A-19C and Table 8. Do not exceed maximum refrigerant charge. Vary refrigerant until the conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the units to the correct subcooling for the various operating conditions. Accurate pressure gage and temperature sensing device are required. Connect the pressure gage to the service port on the liquid line service valve. Mount the temperature sensing device on the liquid line, close to the liquid line service valve and insulate it so that outdoor ambient temperature does not affect the reading. Indoor airflow must be within the normal operating range of the unit. Operate unit a minimum of 15 minutes. Ensure pressure and temperature readings have stabilized. Plot liquid pressure and temperature on chart and add or reduce charge to meet curve. Adjust charge to conform with charging chart, using the liquid pressure and temperature to read chart. If the sight glass is cloudy, check refrigerant charge again. Ensure all fans are operating. Also ensure maximum allowable liquid lift has not been exceeded. If charged per chart and if the sight glass is still cloudy, check for a plugged filter drier or a partially closed solenoid valve. Replace or repair, as needed. Petroleum Specialties, Inc.. . . . . . . . . . . . . . . . . . . Cryol 150A Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capella WF-32 Witco Chemical Co.. . . . . . . . . . . . . . . . . . . . . . . . .Suniso 3GS Do not use oil that has been drained out, or oil that has been exposed to atmosphere. VIII. CHECK HEATING CYCLE OPERATION Place thermostat selector switch at HEAT and reset the space set point above ambient temperature so that a call for heating is ensured. Compressor will start within 5 minutes. Observe system operation. B. Remove Oil Pump down compressor to 2 psig. Loosen the 1/4-in. pipe plug at the compressor base and allow the oil to seep out past the threads of the plug. Retighten plug when level is correct. IX. CHECK COMPRESSOR OIL LEVEL (541A) After adjusting the refrigerant charge, allow the system to run fully loaded for 20 minutes. Running oil level should be within view in the crankcase sight glass. Stop compressor at the field power supply disconnect and check the crankcase oil level. Add oil only if necessary to bring the oil into view in the sight glass. If oil is added, run the system for an additional 10 minutes, then stop and check oil level. If the level remains low, check the piping system for proper design for oil return; also check the system for leaks. NOTE: The crankcase is slightly pressurized. Do not remove the plug, or the entire oil charge will be lost. Small amounts of oil can be removed through the oil pump discharge connection while the compressor is running. VI. START UNIT The field disconnect is closed, the fan circuit breaker is closed, and the space thermostat is set above ambient so that there is no demand for cooling. Only the crankcase heater will be energized. Next, close the compressor circuit breaker and then reset space thermostat below ambient so that a call for cooling is ensured. If the initial check shows too much oil (too high in the sight glass) remove oil to proper level. See Preliminary Oil Charge section for proper procedure for adding and removing oil. When the above checks are complete, repeat the procedure with the unit operating at minimum load conditions. Unload the compressor by disconnecting the field-control circuit lead at TB2 Y2 . NOTE: Do not use circuit breaker to start and stop the compressor except in an emergency. Reconnect the field-control circuit lead when checks are complete. After starting, there is a delay of at least 3 seconds before compressor starts. X. FINAL CHECKS VII. ADJUST REFRIGERANT CHARGE Ensure all safety controls are operating, control panel covers are on, and the service panels are in place. CAUTION: Never charge liquid into the lowpressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating. Table 8 — Maximum Refrigerant Charge UNIT 575B 575C CAUTION: Charge unit on cooling cycle only. If unit is charged on heating cycle, overcharging may occur. 541A —17— 072 090 120 180 R-22 (lb) 27.0 34.2 34.2 62.0 SEQUENCE OF OPERATION I. 575B072 UNITS When power is supplied to unit, the transformer (TRAN) and crankcase heater (CCH) are energized. A. Cooling On a call for cooling, the thermostat completes the following circuits: R-G, R-Y, and R-O. If the compressor recycle delay of 3 minutes is complete, the compressor and outdoor fan start. The reversing valve is energized for cooling and the indoorfan motor starts. When the thermostat is satisfied, the circuits are opened, and the compressor, outdoor-fan motor, and indoor-fan motor stop. The reversing valve is deenergized. B. Heating On a call for heating, the thermostat completes the following circuits: R-G and R-Y. If the compressor recycle delay of 3 minutes is complete, the compressor and outdoor fan start. The indoor-fan motor will also start. If room temperature continues to fall, the thermostat completes circuit R-W. If the optional electric heat package is used, the heat relay is energized, and the electric heaters are energized. 60 140 54 130 49 43 38 32 27 21 LIQUID TEMPERATURE AT LIQUID VALVE (F) LIQUID TEMPERATURE AT LIQUID VALVE (C) Fig. 19A — 575B072 Charging Chart When the thermostat is satisfied, the circuits are opened, and the compressor, outdoor-fan motor, heaters, and indoorfan motor stop. ADD CHARGE IF ABOVE CURVE 120 C. Defrost Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for frost (30, 50, and 90 minutes). Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat (DFT) is closed (below 28 F). 110 100 90 80 Defrost mode is identical to Cooling mode, except outdoor-fan motor (OFM) stops and a bank of supplemental electric heat turns on to warm air supplying the conditioned space. Defrost mode is terminated when the DFT reaches 65 F. 70 REDUCE CHARGE IF BELOW CURVE 16 60 10 50 50 100 344 689 150 200 250 300 LIQUID PRESSURE AT LIQUID VALVE (PSIG) 1034 2069 1379 1724 LIQUID PRESSURE AT LIQUID VALVE (Kilopascals) Fig. 19B — 575C090,120 Charging Chart 350 2414 400 D. Air Circulation When the fan switch is at FAN ON, the indoor-air fans operate continuously to provide ventilation. The thermostat operates the other components as described above. E. Emergency Heat Cycle If the compressor is inoperative due to a tripped safety device, the second stage of the thermostat automatically energizes the indoor-air fan and the electric resistance heaters (if equipped). II. 575C090,120 UNITS When power is supplied to unit, the transformer (TRAN) is energized. The crankcase heater is also energized. A. Cooling With the thermostat subbase in the cooling position, and when the space temperature comes within 2° F of the cooling set point, the thermostat makes circuit R-O. This energizes the reversing valve solenoid (RVS) and places the unit in standby condition for cooling. As the space temperature continues to rise, the second stage of the thermostat makes, closing circuit R-Y. When compressor time delay (5 ± 2 minutes) is completed, a circuit is made to contactor (C), starting the compressor (COMP) and outdoor-fan motor (OFM). Circuit R-G is made at the same time, energizing the indoor-fan contactor (IFC) and starting the indoor-fan motor (IFM) after one-second delay. Fig. 19C — 541A180 Charging Chart —18— When the thermostat is satisfied, contacts open, deenergizing C. The COMP, IFM, and OFM stop. When the thermostat is satisfied, the contacts open, deenergizing first the Heat Pump B and then Heat Pump A. B. Heating On a call for heat, thermostat makes circuits R-Y and R-G. When compressor time delay (5 ± 2 minutes) is completed, a circuit is made to C, starting COMP and OFM. Circuit R-G also energizes IFC and starts IFM after a 1-second delay. Heating When the thermostat calls for heating, the circuit from R to Y1 is completed. If the time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of Heat Pump A and Heat Pump B. At the same time the circuit is completed from R to G, starting the indoor-fan motor. If the second stage of heating is required, the circuit from R to W2 will be completed and the electric resistance heaters will be energized. When the thermostat is satisfied, the contacts open, deenergizing Heat Pump A and Heat Pump B. III. 541A180 UNITS A. Heating Place thermostat selector at HEAT and set temperature selector above room ambient. B. Cooling Place thermostat selector at COOL and set temperature selector below room ambient. When thermostat calls for unit operation (either heating or cooling), the indoor-fan motor starts immediately. The outdoor-fan motors and compressor start within 3 seconds to 5 minutes depending on when unit was last shut off by thermostat, because unit contains a compressor time delay circuit. When first-stage cooling is required, thermostat (TC1) closes, causing the heat pump to start with an unloaded compressor. When TC2 closes, demanding additional cooling, the compressor loads to full load operation. During heating, compressor is always fully loaded. When TH1 demands first-stage heating, the heat pump starts within 3 seconds to 5 minutes depending on when unit was last shut off by thermostat, because unit contains a compressor time delay circuit. (The defrost board has speed terminals to shorten this cycle.) When TH2 of the thermostat closes, auxiliary heat supply (electric strip heat) is energized in 1 or 2 stages depending on number of stages available and whether outdoor thermostats are closed. Defrost is achieved by reversal from heating to cooling cycle and deenergization of outdoor-fan motors, allowing hot refrigerant gas to defrost outdoor coil. Defrost is achieved with a timer set to initiate defrost every 30, 50, or 90 minutes (factory set at 30 minutes). Defrost is initiated when refrigerant temperature leaving the outdoor coil is measured below 27 F, (typically when the outdoor ambient temperature is below 45 F as sensed by the defrost thermostat [DFT]). Defrost is terminated when: The refrigerant temperature rises to 80 F at the DFT location on the liquid line; or the refrigerant pressure rises to 280 psig at the HPS2 location on the liquid line; or the defrost timer completes the 10-minute cycle. IV. DUPLEX UNITS A. Duplex 575C120 Units with 524A-H240 (See Fig. 12) Cooling When the thermostat is set for cooling, and the space temperature comes within 2° F of the cooling set point, the thermostat completes the circuit from R to O and the reversing valves in both units are energized. If the space temperature continues to rise, the circuit from R to Y1 is completed. If the time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of Heat Pump A. At the same time the circuit is completed from R to G, starting the indoor-fan motor. If the space temperature continues to rise, the circuit is completed from R to Y2 and the Cooling mode is initiated in Heat Pump B in a similar manner. B. Duplex 575C120 and 541A180 Units With 524A-H300 (See Fig. 13) Cooling When the thermostat calls for cooling, the circuit from R to Y1 is completed. If the time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of Heat Pump A (541A180). At the same time the circuit is completed from R to G, starting the indoorfan motor. If the space temperature continues to rise, the circuit is completed from R to Y2 and the Cooling mode is initiated in Heat Pump B (575C120). When the thermostat is satisfied, the contacts open, deenergizing first the Heat Pump B and then Heat Pump A. Heating When the thermostat calls for heating, the circuit from R to W1 is completed. If the time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of Heat Pump A and Heat Pump B. At the same time the circuit is completed from R to G, starting the indoor-fan motor. If the second stage of heating is required, the circuit from R to W2 will be completed and the electric resistance heaters will be energized. When the thermostat is satisfied, the contacts open, deenergizing Heat Pump A and Heat Pump B. C. Safeties The high-pressure switch, loss-of-charge switch, oil pressure safety switch, and compressor overtemperature safety are located in a CLO circuit that prevents heat pump operation if these safety devices are activated. A light at the thermostat energizes when CLO circuit is affected. The lockout system can be reset by adjusting the thermostat to open the contacts (down for Heating mode, up for Cooling mode), deenergizing the CLO circuitry. Compressor overcurrent protection is achieved with a circuit breaker which requires manual resetting at the outdoor unit control box. The unit is equipped with an oil pressure safety switch that protects the compressor if oil pressure does not develop on start-up or is lost during operation. The oil pressure switch is of the manual reset type and therefore must be reset at the outdoor unit. DO NOT RESET MORE THAN ONCE. If oil pressure switch trips, determine cause and correct. DO NOT JUMPER OIL PRESSURE SAFETY SWITCH. To reset the oil pressure switch: 1. Disconnect power to the unit. —19— 2. Press the RESET button on the oil pressure switch. 3. Reconnect power to the unit. 6. Remove or disconnect crankcase heater from compressor base. Unit is equipped with a no-dump reversing valve circuit. When unit is in Cooling mode, reversing valve remains in cooling position until a call for heating is requested by thermostat. When unit is in Heating mode, reversing valve remains in heating position until there is a call for cooling. The crankcase heater is in a lockout circuit. If crankcase heater is defective, compressor is locked off. Heat pump remains off until corrective action is taken. The lockout circuit cannot be reactivated by adjusting the thermostat. To reset the crankcase heater lockout, disconnect and then reconnect power to unit. 7. Remove compressor from unit. 8. On 541A180 unit remove compressor holddown bolts and lift compressor off mounting plate. 9. Clean system. Add new liquid line filter drier. 10. Install new compressor on compressor mounting plate and position in unit. Connect suction and discharge lines to compressor. Secure mounting plate with compressor to unit. Ensure that compressor holddown bolts are in place. Connect wiring. Install crankcase heater. D. Check Operation Ensure operation of all safety controls. Replace all service panels. Be sure that control panel cover is closed tightly. V. RESTART Manual reset of the 24-v control circuit is necessary if unit shutdown is caused by automatic reset devices (including IP [internal compressor overcurrent protection], HPS [highpressure switch], and LCS [loss-of-charge switch]) or if shutdown is caused by manual reset devices (including OPS [oil pressure switch] and compressor circuit breaker protection). To restart the unit when IP, HPS, or LCS has tripped (after device has reset automatically), open and then close the thermostat contacts. Opening and then closing thermostat contacts interrupts and restores 24-v power to the compressor lockout (CLO), which resets the circuit. It is necessary to manually reset the compressor circuit breaker and OPS at the unit if either of these safeties should shut down the unit. IMPORTANT: If OPS trips, it must be reset first before making and breaking the thermostat contacts to reset CLO. If this procedure is not followed, the CLO cannot reset. VI. CAUSES OF COMPLETE UNIT SHUTDOWN: • interruption of supplied power • open compressor overtemperature protection (IP) • compressor electrical overload protection (CB) • open high-pressure or loss-of-charge safety switches • open oil pressure switch • open crankcase heater lockout (CLO2) • open control circuit fuse (FU1 or FU2) • open discharge gas thermostat (575C only) 11. Evacuate and recharge unit. 12. Restore unit power. II. 575C090,120 COOLING MODE OPERATION (See Fig. 20) 1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing valve and is directed to the vapor headers of both outdoor coils. 2. At the outdoor coil vapor header, the high pressure, high temperature refrigerant vapor flows up to check valve “A” that blocks the flow. All the refrigerant is then directed to flow into the coil circuits. 3. Subcooled refrigerant liquid leaves the coil circuits through the side outlet on the liquid headers. The liquid refrigerant from each coil flows through check valves “B” which are open, enters the liquid line and goes to the indoor coil. 4. The liquid refrigerant is expanded and evaporated in the indoor coil resulting in low pressure vapor. This low pressure vapor returns to the outdoor unit through the system vapor line, reversing valve, and accumulator, reentering the compressor at the suction connection. III. 575C090,120 HEATING MODE OPERATION (See Fig. 21) 1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing valve and is directed through the system vapor line to the indoor coil. Refrigerant is condensed and subcooled in the indoor coil and returns to the outdoor unit through the system liquid line. SERVICE I. COMPRESSOR REMOVAL See Table 1 for compressor information. Follow safety codes and wear safety glasses and work gloves. 1. Shut off power to unit. Remove unit access panel. 2. Recover refrigerant from system using refrigerant recovery methods, and in accordance with local and national standards. 3. Disconnect compressor wiring at compressor terminal box. 4. Disconnect refrigerant lines from compressor. 5. Remove screws from compressor mounting plate. CAUTION: Excessive movement of copper lines at compressor may cause higher levels of vibration when unit is restored to service. —20— 2. Check valve “B” blocks the flow of liquid and the liquid refrigerant must flow through the filter driers, through check valve “C”, and into the liquid header assembly. 3. The liquid refrigerant is expanded as it passes through the fixed orifice metering devices into outdoor coil circuits. The refrigerant evaporates as it passes through the coil circuits resulting in low pressure vapor. 4. The low pressure vapor leaves the coil circuits and enters the vapor headers, check valves “A” are open, and returns to the compressor through the vapor line, reversing valve, and accumulator, reentering the compressor at the suction connection. IV. 541A180 COOLING MODE OPERATION (See Fig. 22) 1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing valve and is directed to the outdoor coil vapor header. 3. The liquid refrigerant is expanded as it passes through the capillary tubes into outdoor coil circuits. The refrigerant evaporates as it passes through the coil circuits resulting in low pressure vapor. 2. At the outdoor coil vapor header, the high pressure, high temperature refrigerant vapor flows up to check valve “A” that blocks the flow. All the refrigerant is then directed to flow into the coil circuits. 4. The low pressure vapor leaves the coil circuits and enters the vapor header, check valve “A” is open, and returns to the compressor through the vapor line, reversing valve, and accumulator, reentering the compressor at the suction connection. 3. Subcooled refrigerant liquid leaves the coil circuits entering the portion of the vapor header which is above check valve “A”. Check valve “C” is closed, therefore, the liquid refrigerant passes through check valve “B,” which is open, and enters the liquid line and goes to the indoor coil. 4. The liquid refrigerant is expanded and evaporated in the indoor coil resulting in low pressure vapor. This low pressure vapor returns to the outdoor unit through the system vapor line, reversing valve, and accumulator, reentering the compressor at the suction connection. V. 541A180 HEATING MODE OPERATION (See Fig. 23) 1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing valve and is directed through the system vapor line to the indoor coil. Refrigerant is condensed and subcooled in the indoor coil and returns to the outdoor unit through the system liquid line. 2. Check valve “B” blocks the flow of liquid and the refrigerant is then directed to flow through check valve “C” (which is open), through the filter drier, and into the liquid header assembly. VI. CRANKCASE HEATER The crankcase heater prevents refrigerant migration and compressor oil dilution during shutdown when compressor is not operating. Close both compressor service valves when crankcase heater is deenergized for more than 6 hours. VII. OUTDOOR UNIT FANS Each fan is supported by a formed-wire mount bolted to the fan deck and covered with a wire guard. On the 541A180, the exposed end of the motor shaft is covered with a rubber boot. In case a fan motor must be repaired or replaced, be sure the rubber boot is put back on when the fan is reinstalled and be sure the fan guard is in place before starting the unit. VIII. LUBRICATION Fan motors have permanently sealed bearings. No further lubrication is required. COMPRESSOR REVERSING VALVE VAPOR LINE BALL VALVE ACCUMULATOR FROM INDOOR UNIT CK VALVE B CK VALVE A CK VALVE C FILTER DRIER FILTER DRIER LIQUID LINE FIXED ORIFICE METERING DEVICE BALL VALVE Fig. 20 — 575C090,120 Cooling Mode (Size 090 Shown) —21— TO INDOOR UNIT COMPRESSOR REVERSING VALVE VAPOR LINE TO INDOOR UNIT BALL VALVE ACCUMULATOR CK VALVE B CK VALVE A CK VALVE C FILTER DRIER FILTER DRIER LIQUID LINE FIXED ORIFICE METERING DEVICE FROM INDOOR UNIT BALL VALVE Fig. 21 — 575C090,120 Heating Mode (Size 090 Shown) REVERSING VALVE REFRIGERANT MIXTURE MUFFLER FROM INDOOR COIL COMPR TO INDOOR COIL ACCUMULATOR LIQUID LLSV GAS AND OIL ANGLE VALVE WITH SCHRADER PORT CK VALVE B CK VALVE A HOT GAS FILTER DRIER CK VALVE C COIL RETURN BEND END Fig. 22 — 541A180 Cooling Mode —22— REVERSING VALVE REFRIGERANT MIXTURE MUFFLER TO INDOOR COIL COMPR FROM INDOOR COIL ACCUMULATOR LIQUID LLSV GAS AND OIL ANGLE VALVE WITH SCHRADER PORT CK VALVE B CK VALVE A HOT GAS FILTER DRIER CK VALVE C COIL RETURN BEND END Fig. 23 — 541A180 Heating Mode IX. COIL CLEANING AND MAINTENANCE 5. Clean the remaining surfaces in the normal manner. This section discusses the cleaning and the maintenance of standard coils and E-Coated coils. Routine cleaning of coil surfaces is essential to minimize contamination build-up and remove harmful residue. Inspect coils monthly and clean as required. 6. Reposition outer coil sections. Reinstall clips which secure tube sheets, and replace top cover and rear corner posts. 7. Restore unit power. A. Cleaning Standard Coils Standard coils can be cleaned with a vacuum cleaner, washed out with low velocity water, blown out with compressed air, or brushed (do not use wire brush). Fan motors are dripproof but not waterproof. Do not use acid cleaners. Clean coil annually or as required by location or outdoor air conditions. Inspect coil monthly and clean as required. Fins are not continuous through coil sections. Dirt and debris may pass through first section and become trapped, restricting airflow. Use a flashlight to determine if dirt or debris has collected between coil sections. Clean coils as follows: 1. Turn off unit power. 2. Remove screws holding rear corner posts and top cover in place. Pivot top cover up 12 to 18 in. and support with a board or other adequate rigid support. See Fig. 24. 3. Remove clips securing tube sheets together at the return bend end of the coil. Carefully spread the ends of the coil rows apart by moving the outer sections. See Fig. 25. 4. Using a water hose or other suitable equipment, flush down between the sections of coil to remove dirt and debris. B. Cleaning and Maintaining E-Coated Coils Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residue will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil. Remove Surface Loaded Fibers Debris such as dirt and fibers on the surface of the coil should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft brush may be used. The cleaning tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins. NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface debris must be completely removed prior to using low velocity clean water rinse. Periodic Clean Water Rinse A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning is recommended. —23— The following field supplied equipment is required for coil cleaning: • 21/2 gallon garden sprayer • water rinse with low velocity spray nozzle Environmentally Sound Coil Cleaner Application Instructions Perform the following procedure to clean the coil. NOTE: Wear proper eye protection such as safety glasses during mixing and application. 1. Remove all surface debris and dirt from the coil with a vacuum cleaner. 2. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins. 3. Mix Environmentally Sound Coil Cleaner in a 21/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100 F. CAUTION: DO NOT USE water in excess of 130 F. Enzymes in coil cleaner will be destroyed and coil cleaner will not be effective. Fig. 24 — Pivot and Support Top Cover 4. Thoroughly apply Environmentally Sound Coil Cleaner solution to all coil surfaces including finned area, tube sheets, and coil headers. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage. Ensure cleaner thoroughly penetrates deep into finned areas. Interior and exterior finned areas must be thoroughly cleaned. 5. Allow finned surfaces to remain wet with cleaning solution for 10 minutes. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved. 6. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle. Fig. 25 — Coil Cleaning (Typical) CAUTION: Do not use bleach, harsh chemicals, or acid cleaners on outdoor or indoor coils of any kind. These types of cleaners are difficult to rinse, and they promote rapid corrosion of the fin collar — copper tube connection. Only use the Environmentally Sound Coil Cleaner. Never use high pressure air or liquids to clean coils. High pressures damage coils and increase the airside pressure drop. To promote unit integrity, follow cleaning and maintenance procedures in this document. Routine Cleaning of E-Coated Coil Surfaces Monthly cleaning with Environmentally Sound Coil Cleaner is essential to extend the life of coils. It is recommended that all coils including standard aluminum, pre-coated, copper/copper, or E-coated coils be cleaned with the Environmentally Sound Coil Cleaner as described below. Coil cleaning should be part of the regularly scheduled maintenance procedures of the unit to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment. Environmentally Sound Coil Cleaner is non-bacterial, biodegradable and will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected. X. REPLACEMENT PARTS A complete list of replacement parts is available from your Bryant dealer. —24— —25— TROUBLESHOOTING CHART — HEATING CYCLE LEGEND CCH — Crankcase Heater N.C. — Normally Closed Copyright 2004 Bryant Heating & Cooling Systems Printed in U.S.A. CATALOG NO. 5357-506 TROUBLESHOOTING CHART — COOLING CYCLE CCH — TXV — LEGEND Crankcase Heater Thermostatic Expansion Valve START-UP CHECKLIST I. PRELIMINARY INFORMATION OUTDOOR UNIT: MODEL NO. _______________________________ SERIAL NO.: __________________________________ INDOOR UNIT: MODEL NO. _________________________________ SERIAL NO.: __________________________________ ADDITIONAL ACCESSORIES __________________________________________________________________________________ II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? (Y/N)____________ IF SO, WHERE: ________________________________________________________________________________________________ _______________________________________________________________________________________________________________ WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) _____________ CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? (Y/N) _____________ HAS THE GROUND WIRE BEEN CONNECTED? (Y/N) ____________ HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (Y/N) ___________ ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (Y/N) ___________ HAVE COMPRESSOR HOLDDOWN BOLTS BEEN LOOSENED (Washers are snug, but not tight)? (Y/N) _______________ CONTROLS ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED? (Y/N) _______________ ARE ALL WIRING TERMINALS (including main power supply) TIGHT? (Y/N) ______________ HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS? (Y/N) ______________ INDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE? (Y/N) ____________ ARE PROPER AIR FILTERS IN PLACE? (Y/N) ______________ HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT? (Y/N) ____________ DO THE FAN BELTS HAVE PROPER TENSION? (Y/N) ________________ HAS CORRECT FAN ROTATION BEEN CONFIRMED? (Y/N)________________ PIPING HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR UNIT, INDOOR UNIT, TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS WITH A LEAK DETECTOR? (Y/N) ________________ LOCATE, REPAIR, AND REPORT ANY LEAKS. _________________________________________________________________ HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)? (Y/N)___________ HAS LIQUID LINE SERVICE VALVE BEEN OPENED? (Y/N)___________ IS THE OIL LEVEL IN COMPRESSOR CRANKCASE VISIBLE IN THE COMPRESSOR SIGHT GLASS? (Y/N) _______________ CHECK VOLTAGE IMBALANCE LINE-TO-LINE VOLTS: AB ___________ V AC___________ V BC ___________V (AB + AC + BC)/3 = AVERAGE VOLTAGE = ________________V MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =_______________V VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) = _______________ % IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM! CALL LOCAL POWER COMPANY FOR ASSISTANCE. CL-1 III. START-UP OIL PRESSURE SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING OUTDOOR AIR LEAVING OUTDOOR AIR TEMP INDOOR ENTERING-AIR DB (dry bulb) TEMP INDOOR ENTERING-AIR WB (wet bulb) TEMP INDOOR LEAVING-AIR DB TEMP INDOOR LEAVING-AIR WB TEMP COMPRESSOR AMPS (L1/L2/L3) COOLING __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ _______ / _______ / _______ HEATING __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ _______ / _______ / _______ CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES; ARE THE SIGHT GLASSES SHOWING OIL LEVEL IN VIEW? (Y/N) CUT ALONG DOTTED LINE CHECK INDOOR FAN SPEED AND RECORD. _______________ CHECK OUTDOOR FAN SPEED AND RECORD. ________________ AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS: NOTES: ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ ______________________________________________________________________________________________________________ CUT ALONG DOTTED LINE ______________________________________________________________________________________________________________ Copyright 2004 Bryant Heating & Cooling Systems Printed in U.S.A. 10-05A CL-2 CATALOG NO. 5357-506
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