Bryant 180A User Manual
180A, 187A
Evolutionr Line Air Conditioners
with Puron Refrigerant
2 to 5 Nominal Tons (Sizes 024 to 060)
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
Unless otherwise noted, information in these installation
instructions pertain to both 180A and 187A series units.
Information that is unique to the 180A series will be identified as
such; likewise information that is unique to the 187A series will
also be identified.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
current editions of the National Electrical Code (NEC) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code
CSA 22.1.
!
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand these signal words; DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
!
Indoor Thermostat Control Options
Model
187A Ye s Ye s
180A Ye s Ye s *
* Units containing circuit board HK38EA015 or newer.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out and
tag switch with a suitable warning label.
.
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury,
death and/or equipment damage.
Puron refrigerant systems operate at higher pressures than
standard R--22 systems. Do not use R--22 service equipment
or components on Puron equipment.
!
WARNING
WARNING
Evolution
Control
Standard 2 - --stage
Thermostat
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when handling
parts.
INSTALLATION RECOMMENDATI ONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
1. Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.
2. Ensure that vapor and liquid tube diameters are appropriate
for unit capacity.
3. Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends.
4. Leave some slack between structure and unit to absorb vibration.
5. When passing refrigerant tubes through the wall, seal opening with RTV or other pliable silicon --based caulk. (See Fig.
1.)
6. Avoid direct tubing contact with water pipes, duct work,
floor joists, wall studs, floors, and walls.
7. Do not suspend refrigerant tubing from joists and studs with
a rigid wire or strap which comes in direct contact with
tubing (See Fig. 1.)
8. Ensure that tubing insulation is pliable and completely surrounds vapor tube.
180A / 187A
9. When necessary, use hanger straps which are 1 in. wide and
conform to shape of tubing insulation. (See Fig. 1.)
10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
When outdoor unit is connected to factory--approved indoor unit,
outdoor unit contains system refrigerant charge for operation with
ARI rated indoor unit when connected by 15 ft (4.57 m) of
field--supplied or factory accessory tubing. For proper unit
operation, check refrigerant charge using charging information
located on control box cover and/or in the Check Charge section of
this instruction.
IMPORTANT: Maximum liquid--line size is 3/8--in. OD for all
residential applications including long line applications.
IMPORTANT: Always install the factory--supplied liquid--line
filter drier. If replacing the filter drier, refer to Product Data Digest
for appropriate part number. Obtain replacement filter driers from
your distributor or branch.
can be no deviation. Consult the Application Guideline and
Service Manual – Air Conditioners and Heat Pumps Using Puron
Refrigerant to obtain required unit changes for specific applications
andforR--22retrofit.
Check Equipment and Job Site
Unpack Unit
Move to final location. Remove carton taking care not to damage
unit.
Inspect Equipment
File claim with shipping company prior to installation if shipment
is damaged or incomplete. Locate unit rating plate on unit corner
panel. It contains information needed to properly install unit.
Check rating plate to be sure unit matches job specifications.
Install on a Solid, Level Mounting Pad
If conditions or local codes require the unit be attached to pad, tie
down bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig. 2
to determine base pan size and knockout hole location.
For hurricane tie downs, contact distributor for details and PE
Certified (Professional Engineer), if required.
On rooftop applications, mount on level platform or frame. Place
unit above a load-- bearing wall and isolate unit and tubing set
Consult local codes governing rooftop applications.
Roof mounted units exposed to winds above 5 mph may require
wind baffles. Consult the Application Guideline and Service
Manual -- Residential Split System Air Conditioners and Heat
Pumps Using Puron Refrigerant for wind baffle construction.
INSTALLATION
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL
CAULK
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
1” (25.4 mm) MIN.
Fig. 1 -- Connecting Tube Installation
Specifications for this unit in residential new construction market
require the outdoor unit, indoor unit, refrigerant tubing sets,
metering device, and filter drier listed in presale literature. There
INDOOR WALL
SUSPENSION
LIQUID TUBE
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
LIQUID TUBE
A94026
UNIT BASE PAN
DIMENSIONS
in. (mm)
36---1/2 x 40
(927.1x1016)
TIEDOWN KNOCKOUT LOCATIONS
A B C
11---5/8
(295.3)
in. (mm)
6---13/16
(173.0)
28---3/4
(730.3)
A05177
Fig. 2 -- Clearance Requirements
NOTE: Unit must be level to within ±2_, ±3/8 in./ft. (9.53
mm/m) per compressor manufacturer specifications.
Clearance Requirements
When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 24 in. (610 mm)
clearance to service end of unit and 48 in. (1219.2 mm) above unit.
For proper airflow, a 6 in. (152.4 mm) clearance on 1 side of unit
and 12 in. (304.8 mm) on all remaining sides must be maintained.
Maintain a distance of 24 in. (609.6 mm) between units. Position
so water, snow, or ice from roof or eaves cannot fall directly on
unit.
2
On rooftop applications, locate unit at least 6 in. (152.4 mm) above
roof surface.
Operating Ambient
The minimum outdoor operating ambient in cooling mode is
55_F/12.78_C without low ambient cooling enabled, and the
maximum outdoor operating ambient in cooling mode is
125_F/51.67_C. On Evolution communicating systems only, for
both 180A and 187A models, low ambient cooling is available to
0_F/--17.78_C.
Make Piping Connections
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
If ANY refrigerant tubing is buried, provide a 6 in. (152.4
mm) vertical rise at service valve. Refrigerant tubing lengths
up to 36 in. (914.4 mm) may be buried without further
special consideration. Do not bury lines longer than 36 in.
(914.4 mm).
!
WARNING
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could result in personal
injury or death.
Relieve pressure and recover all refrigerant before system
repair or final unit disposal Use all service ports and open
all flow--control devices, including solenoid valves.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not leave system open to atmosphere any longer than
minimum required for installation. POE oil in compressor is
extremely susceptible to moisture absorption. Always keep
ends of tubing sealed during installation.
Table 1 – Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (in.)
UNIT SIZE
187A024 3/8 3/8 5/8 5/8
187A036 3/8 3/8 3/4 3/4
187A048 3/8 3/8 7/8 7/8
187A060 3/8 3/8 7/8 1 --- 1 / 8
Connection
Diameter
Outdoor units may be connected to indoor section using
field--supplied refrigerant grade tubing of correct size and
condition. For tubing requirements beyond 80 ft (24.38 m),
substantial capacity and performance losses can occur. Following
the recommendations in the Residential Piping and Longline
Guideline will reduce these losses. Refer to Table 1 for field tubing
diameters. Refer to Table 2 for accessory requirements.
There are no buried--line applications greater than 36 in. (914.4
mm).
If refrigerant tubes or indoor coil are exposed to atmosphere, they
must be evacuated to 500 microns to eliminate contamination and
moisture in the system.
Outdoor Unit Connected to Factory Approved Indoor
Unit:
Outdoor unit contains correct system refrigerant charge for
operation with factory approved ARI rated indoor unit with highest
sales volume when connected by 15 ft (4.57 m) of field-- supplied
or factory-- accessory tubing, and factory supplied filter drier.
Check refrigerant charge for maximum efficiency.
LIQUID RATED VAPOR*
Tube
Diameter
Connection
Diameter
Tube
Diameter
180A / 187A
180A024
180A036
180A048
180A060 3/8 3/8 7/8 1 --- 1 / 8
* Units are rated with 25 f t. (7.6 m) of lineset. See Product Data sheet for performance data when using different size and length linesets.
Notes:
1. Do not apply capillary tube or fixed orifice indoor coils to these units.
2. For Tubing Set lengths between 80 and 200 ft. (24.38 and 60.96 m) horizontal or 20 ft. (6.10 m) vertical differential ( 250 ft./76.2 m Total Equivalent Length),
refer to the Residential Piping and Longline Guideline.
the environmentally sound refrigerant
3/8 3/8 7/8 7/8
ISO 9001:2000
REGISTERED
This produc t has been designed and manuf actured to
meet Energy St ar® criteria for energy effici ency when
matched with appropriate coil components. However,
proper refri gerant char ge and proper air flow ar e critic al
to achieve rated capacity and efficiency. Installation of
this product should follow all manufacturing refrigerant
charging and air flow instructions. Failure to confirm
proper charge and air flow may reduce energy
efficiency and shorten equipment life.
3
Table 2 – Accessory Usage
REQUIRED FOR
Accessory
Compressor Start Assist Capacitor and
Puron Balance Port Hard Shut --- off TXV
* For Tubing Set lengths between 80 and 200 f t. (24.38 and 60.96 m) horizontal or 20 ft. (6.10 m) vertical differential (250 ft./76.2 m Total Equivalent Length),
refer to the Residential Piping and Long Line Guideline for Air Conditioners and Heat Pumps using Puron® Refrigerant.
{ Required on all indoor units. Standard on all new Puron fan coils and furnace coils.
} Information is specific to 187A and 180A models.
Accumulator No No No
Relay}
Crankcase Heater Standard
Evaporator Freeze Protection
Liquid Line Solenoid Valve No
Low--- ambient Control
Winter Start Control
Support Feet Recommended No Recommended
L O W --- A M B I E N T C O O L I N G
APPLICATIONS
(Below 55°F/12.8_C)
Standard on 187A models.
Not required for 180A models.
Standard with Evolution Control
(Low Ambient not allowed with non ---
communicating Thermostat)
Standard with Evolution Control (Low
Ambient not allowed with non ---com-
municating thermostat)
Ye s {
Standard with Evolution Control (Low
Ambient not allowed with Non---Com-
municating Thermostat)
REQUIRED FOR LONG LINE
APPLICATIONS*
Standard on 187A models.
Not required for 180A models.
Standard
No No
No
No No
Ye s { Yes {
No No
REQUIRED FOR SEA COAST
APPLICATIONS
(Within 2 mile s/3.22 km)
Standard on 187A models.
Not required for 180A models.
Standard
180A / 187A
Install Liquid--Line Filter Drier Indoor
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
Installation of filter drier in liquid line is required.
Refer to Fig. 3 and install filter drier as follows:
1. Braze 5 in. (127 mm) liquid tube to the indoor coil.
2. Wrap filter drier with damp cloth.
3. Braze filter drier to above 5 in. (127 mm) liquid tube. Flow
arrow must point towards indoor coil.
4. Connect and braze liquid refrigerant tube to the filter drier.
CAUTION
Refrigerant Tubing Connection Outdoor
Connect vapor tube to fitting on outdoor unit vapor service valves
(see Table 1.) Connect and braze the 3/8 in. coupling (provided
with the filter drier) to the liquid service valve and connect and
braze the liquid tubing to the other end of this coupling. Use
refrigerant grade tubing.
Sweat Connection
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
S Use a brazing shield
S Wrap service valves with wet cloth or heat sink material.
CAUTION
No
Fig. 3 -- Liquid Line Filter Drier
A05178
Use refrigerant grade tubing. Service valves are closed from factory
and ready for brazing. After wrapping service valve with a wet
cloth, braze sweat connections using industry accepted methods
and materials. Consult local code requirements. Refrigerant tubing
and indoor coil are now ready for leak testing. This check should
include all field and factory joints.
Evacuate Refrigerant Tubing and Indoor Coil
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Never use the system compressor as a vacuum pump.
CAUTION
4
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used. See Service Manual for
triple evacuation method. Always break a vacuum with dry
nitrogen._
Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum method
is the most positive way of assuring a system is free of air and
liquid water. (See Fig. 4)
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
Fig. 4 -- Deep Vacuum Graph
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
A95424
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, making sure wire ties on feeder tubes are
secure and tight.
Make Electrical Connections
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not supply power to unit with compressor terminal
box cover removed.
Be sure field wiring complies with local and national fire, safety,
and electrical codes, and voltage to system is within limits shown
on unit rating plate. Contact local power company for correction of
improper voltage. See unit rating plate for recommended circuit
protection device.
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating plate. Do not
install unit in system where voltage may fluctuate above or below
permissible limits.
NOTE: Use copper wire only between disconnect switch and unit.
NOTE: Install branch circuit disconnect of adequate size per NEC
to handle unit starting current. Locate disconnect within sight from
and readily accessible from unit, per Section 440--14 of NEC.
Route Ground and Power Wires
Remove access panel to gain access to unit wiring. Extend wires
from disconnect through power wiring hole provided and into unit
control box.
WARNING
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur. The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes.
WARNING
Connect Ground and Power Wires
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 5.
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
FIELD POWER
WIRING
FIELD GROUND
WIRING
Fig. 5 -- Line Power Connections
GROUND LUG
CONTACTOR
A91056
Connect Control Wiring
Route low--voltage control wires through control wiring grommet
and connect leads to control board.
For Evolution, connect to ABCD only. For standard
non--communicating thermostats, connect to standard thermostat
connections R, C, Y1 and Y2.
Use No. 18 AWG color--coded, insulated (35_C minimum) wire
for all installations.
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
Use furnace transformer or fan coil transformer for control power,
24--v/40--va minimum. The outdoor unit requires a minimum of
27va/24 vac control power.
Final Wiring Checks
IMPORTANT: Check factory wiring and field wire connections
to ensure terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal, etc.
CompressorCrankcaseHeater
Furnish power to crankcase heater a minimum of 24 hr before
starting unit. To furnish power to heater only, set thermostat to
OFF and close electrical disconnect to outdoor unit.
NOTE: On 187A models, starting the compressor without a
minimum of 12 hours of crankcase heat prior to initial start--up
may result in a compressor chattering noise and possible damage to
the compressor.
Install Accessories
Refer to the individual instructions packaged with kits or
accessories when installing.
180A / 187A
5
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