installation, start-up,
601A
and service instructions
3-PHASE SINGLE-PACKAGED HEAT PUMPS
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................1
INTRODUCTION ..........................................................................2
RECEIVING AND INSTALLATION ..........................................2
Check Equipment......................................................................2
IDENTIFY UNIT ................................................................2
INSPECT SHIPMENT ........................................................2
Provide Unit Support ................................................................2
ROOF CURB.......................................................................2
SLAB MOUNT ...................................................................2
GROUND MOUNT ............................................................2
Provide Clearances....................................................................2
Rig and Place Unit....................................................................2
INSPECTION ......................................................................2
INSTALLATION ................................................................2
Select and Install Ductwork .....................................................5
CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE UNITS.........7
Provide for Condensate Disposal .............................................7
Install Electrical Connections...................................................7
HIGH-VOLTAGE CONNECTIONS..................................9
ROUTING POWER LEADS INTO UNIT ......................14
CONNECTING GROUND LEAD TO GROUND LUG.14
ROUTING CONTROL POWER WIRES (24-V) ............14
SPECIAL PROCEDURES FOR 208-V OPERATION ...14
PRE-START-UP ..........................................................................15
START-UP ...................................................................................15
Check for Refrigerant Leaks ..................................................15
Start-Up Adjustments..............................................................15
CHECKING COOLING AND HEATING
CONTROL OPERATION.................................................15
CHECKING AND ADJUSTING REFRIGERANT
CHARGE ...........................................................................16
REFRIGERANT CHARGE ..............................................16
NO CHARGE....................................................................16
LOW CHARGE COOLING .............................................17
TO USE COOLING CHARGING CHARTS ..................17
INDOOR AIRFLOW AND AIRFLOW ADJUST-
MENTS..............................................................................17
MAINTENANCE.........................................................................18
Air Filter..................................................................................18
Indoor blower and motor........................................................18
OUTDOOR COIL, INDOOR COIL, AND
CONDENSATE DRAIN PAN...............................................19
Outdoor fan .............................................................................19
Electrical controls and wiring ................................................20
Refrigerant circuit ...................................................................20
Indoor airflow .........................................................................20
Metering device ......................................................................20
Liquid line strainers ................................................................22
High Flow Valves...................................................................22
Time-delay relay .....................................................................22
602A
030-060
Cancels: New II 601A-30-1
2-06
C99001
Fig. 1—Model 601A/602A
Loss of charge switch.............................................................22
Check defrost thermostat ........................................................22
Defrost Thermostat .................................................................22
TROUBLESHOOTING ...............................................................22
START-UP CHECKLIST............................................................22
NOTE TO INSTALLER — READ THESE INSTRUCTIONS
CAREFULLY AND COMPLETELY before installing this unit.
Also, make sure the Owner’s Manual and Service Instructions are
left with the unit after installation.
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified personnel should install, repair, or service
air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters. All other operations should be performed
by trained service personnel. When working on air-conditioning
equipment, observe precautions in the literature, tags, and labels
attached to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available for all brazing operations.
—1—
WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion,
fire, electric shock, or other occurrences, which could
cause serious injury or death or damage your property.
Consult a qualified installer or service agency for information or assistance. The qualified installer or agency
must use only factory-authorized kits or accessories when
modifying this product.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the product or in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words — DANGER, WARNING, CAUTION, and NOTE. Danger identifies the most serious hazards,
which will result in severe personal injury or death. Warning
indicates a condition that could cause serious personal injury or
death. Caution is used to identify unsafe practices, which would
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.
1. The power supply (volts, phase, and hertz) must correspond
to that specified on unit rating plate.
2. The electrical supply provided by the utility must be
sufficient to handle load imposed by this unit.
3. This installation must conform with local building codes
and with NEC (National Electrical Code). Refer to provincial and local plumbing or waste water codes and other
applicable local codes.
WARNING: Before performing service or maintenance
operations on system, turn off main power to unit. Turn
off accessory heater power switch if applicable. Electrical
shock could cause severe injury or death.
INTRODUCTION
The 601A and 602A heat pumps are fully self-contained and
designed for outdoor installation (See Fig. 1). Standard units are
shipped in a horizontal-discharge configuration for installation on
a ground-level slab. Units can be converted to downflow (vertical)
discharge configurations for rooftop applications. See Fig. 2 and 3
for unit dimensions.
RECEIVING AND INSTALLATION
I. CHECK EQUIPMENT
A. IDENTIFY UNIT
The unit model number and serial number are stamped on the unit
identification plate. Check this information against shipping papers.
B. INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest Bryant Air Conditioning office if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.
II. PROVIDE UNIT SUPPORT
A. ROOF CURB
Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 5). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a watertight seal. Install gasketing material supplied
with the roof curb. Improperly applied gasketing also can result in
air leaks and poor unit performance.
Curb should be level to within 1/4 in. (See Fig. 6). This is
necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
B. SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of
4 in. thick with 2 in. above grade (See Fig. 7). The slab should
extend approximately 2 in. beyond the casing on all 4 sides of the
unit. Do not secure the unit to the slab except when required by
local codes.
C. GROUND MOUNT
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Place the unit on level ground
prepared with gravel for condensate discharge.
III. PROVIDE CLEARANCES
The required minimum service clearances are shown in Figs. 2 and
3. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 36
in. above the unit top. The maximum horizontal extension of a
partial overhang must not exceed 48 in. For extended overhangs,
provide a minimum clearance of 48 in.
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor-air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab-mounted units
should be at least 4 in. above the highest expected water and runoff
levels. Do not use unit if it has been under water.
IV. RIG AND PLACE UNIT
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.)
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
A. INSPECTION
Prior to initial use, and at monthly intervals, all rigging brackets
and straps should be visually inspected for any damage, evidence
of wear, structural deformation, or cracks. Particular attention
should be paid to excessive wear at hoist hooking points and load
support areas. Brackets or straps showing any kind of wear in these
areas must not be used and should be discarded.
B. INSTALLATION
1. Remove unit from shipping carton. Leave top shipping skid
on the unit as a spreader bar to prevent the rigging straps
from damaging the unit. If the wood skid is not available,
use a spreader bar of sufficient length to protect unit from
damage.
2. Position the lifting bracket assembly around the base of the
unit. Be sure the strap does not twist.
—2—
C00137
UNIT ELECTRICAL CHARACTERISTICS
601A030 208/230-3-60 287 130.2 39.02 (991.1) 19.5 (495.3) 13.7 (348.0) 15.0 (381.0)
601A036 208/230-3-60, 460-3-60 291 132.0 37.02 (940.3) 19.5 (495.3) 13.7 (348.0) 13.0 (330.2)
601A042 208/230-3-60, 460-3-60 323 146.5 37.02 (940.3) 19.7 (500.4) 14.0 (355.6) 13.0 (330.2)
602A030 208/230-3-60 320 145.2 37.02 (940.3) 19.7 (500.4) 14.0 (355.6) 17.6 (447.0)
602A036 208/230-3-60, 460-3-60 328 148.8 37.02 (940.3) 19.7 (500.4) 14.0 (355.6) 16.5 (419.1)
UNIT WEIGHT
Lb Kg X Y Z
UNIT HEIGHT
IN. (MM)
”A”
CENTER OF GRAVITY
IN. (MM)
Fig. 2—601A030-042/602A030-036 Unit Dimensions
—3—
C00136
UNIT ELECTRICAL CHARACTERISTICS
601A048 208/230-3-60, 460-3-60 353 160.1 38.98 (990.2) 19.9 (505.5) 15.7 (398.8) 17.0 (431.8)
601A060 208/230-3-60, 460-3-60 418 189.6 38.98 (990.2) 19.9 (505.5) 15.7 (398.8) 17.0 (431.8)
602A042 208/230-3-60, 460-3-60 350 158.8 40.98 (1040.9) 19.9 (505.5) 15.7 (398.8) 16.6 (421.6)
602A048 208/230-3-60, 460-3-60 315 170.1 40.98 (1040.9) 19.9 (505.5) 15.7 (398.8) 18.0 (457.2)
602A060 208/230-3-60, 460-3-60 428 194.1 42.98 (1091.7) 19.9 (505.5) 15.7 (398.8) 17.6 (447.0)
UNIT WEIGHT
Lb Kg X Y Z
UNIT HEIGHT
IN. (MM)
”A”
CENTER OF GRAVITY
IN. (MM)
Fig. 3—601A048-060/602A042-060 Unit Dimensions
—4—
12
y
43
CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)
Unit 303642
Total Weight 287 291 323 Total Weight 353 418 —
Corner Weight 1 66 67 83 Corner Weight 1 76 90 —
Corner Weight 2 54 55 55 Corner Weight 2 49 58 —
Model 601A
Model 602A
3. Place each of the 4 metal lifting brackets into the rigging
4. Thread lifting bracket strapping around bottom perimeter of
5. Tighten the tension buckle until it is taut. Lifting brackets
6. Attach field-supplied clevis or hook of sufficient strength to
7. Attach the 2 safety straps directly to the clevis or hook at the
8. Position lifting point directly over the unit’s center of
9. Lift unit. When unit is directly over the roof curb, remove
V. SELECT AND INSTALL DUCTWORK
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non-residence type air conditioning and ventilating systems, NFPA
90A or residence type, NFPA 90B and/or local codes and
ordinances.
Corner Weight 3 62 63 78 Corner Weight 3 96 114 —
Corner Weight 4 105 106 107 Corner Weight 4 132 156 —
CORNER WEIGHTS (Small Cabinet) CORNER WEIGHTS (Large Cabinet)
Unit 30 36 —
Total Weight 320 328 — Total Weight 350 375 428
Corner Weight 1 63 64 — Corner Weight 1 75 81 92
Corner Weight 2 74 76 — Corner Weight 2 49 52 60
Corner Weight 3 56 58 — Corner Weight 3 95 102 116
Corner Weight 4 127 130 — Corner Weight 4 131 140 160
Fig. 4—Corner Weights (in Pounds)
holds in the composite pan.
unit as follows:
a. Open lever of tension buckle (ratchet type).
b. Feed strapping through tension buckle as shown in Fig.
8.
c. Pull strapping through tension buckle unit taut.
d. Snap lever down to lock strap in tension buckle. To
release strapping, squeeze safety latch, lift lever, and pull
webbing outward.
must be secure in the rigging holds.
hole in the lifting bracket (See Fig. 8).
4 rigging brackets. DO NOT attach the safety straps to the
lifting brackets (See Fig. 8).
gravity.
the 2 safety straps. Lower the equipment onto the roof curb.
x
C00071
Unit 48 60 —
Model 601A
Unit 424860
Model 602A
Select and size ductwork, supply-air registers, and return air grilles
according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply- and return-air openings on
the side of the unit.
When designing and installing ductwork, consider the following:
WARNING: For vertical supply and return units, tools
or parts could drop into ductwork and cause serious injury
or death. Install a 90 degree turn in the return ductwork
between the unit and the conditioned space. If a 90 degree
elbow cannot be installed, then a grille of sufficient
strength and density should be installed to prevent objects
from falling into the conditioned space. Units with
electric heaters require 90 degree elbow in supply duct.
1. All units should have field-supplied filters or accessory
filter rack installed in the return-air side of the unit.
Recommended sizes for filters are shown in Tables 1 and 2.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24-in.
from electric heater element.
—5—
HVAC unit
Scre w
(NO TE A)
*Gask eting
outer flange
Flashing field
supplied
Roofing material
field supplied
Cant str ip
field supplied
base
Gask eting
inner flange*
Wood nailer*
Roofcurb*
Insulation (field
supplied)
Duct wo rk
field supplied
HVAC unit
Scre w
(NOTE A)
*Gask eting
outer flange
Flashing field
supplied
Roofing material
field supplied
Cant str ip
field supplied
base
Gask eting
inner flange*
Duct wo rk
field supplied
Wood nailer*
Roofcurb*
Insulation (field
supplied)
Roof
*Provided with roofcurb
Roof Curb for Small Cabinet
Note A: When unit mounting scre w is used,
retainer bra cke t must also be used.
B Typ.
5
/16"
44
C Typ.
Supply opening
(B x C)
D
*Provided with roofcurb
Roof Curb for Large Cabinet
Note A: When unit mounting scre w is used,
retainer bra cket must also be used.
R/A
A
Gask et around
Roof
S/A
duct
Short
Insulated
Retur n opening
(B X C)
deck pan
Support
UNIT SIZE ODS CATALOG NUMBER
601A030-042 602A030-036
601A048, 060 602A042-060
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Dimensions in ( ) are in millimeters.
4. Roof curb is made of 16-gauge steel.
5. Table lists only the dimensions, per part number, that have changed.
6. Attach ductwork to curb (flanges of duct rest on curb).
7. Insulated panels: 1-in. thick fiberglass 1 lb density.
8. Dimensions are in inches.
9. When unit mounting screw is used (see Note A), a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or seismic
conditions. This bracket is available through Micrometl.
CPRFCURB006A00 8 (203) 11(279) 161/2 (419) 28-3/4 (730)
CPRFCURB007A00 14 (356) 11(279) 161/2 (419) 28-3/4 (730)
CPRFCURB008A00 8 (203) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022)
CPRFCURB009A00 14 (356) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022)
Support
Long
A
IN. (MM)
Insulated
deck pan
B
IN. (MM)
Gask et around
outer edge
C
IN. (MM)
C00076
D
IN. (MM)
Fig. 5—Roof Curb Dimensions
—6—
A
B
C
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B B-C A-C
1/4 1/4 1/4
C99065
Fig. 6—Unit Leveling Tolerances
3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Tables 3 and 4. Heater limit switches may trip at air
quantities below those recommended.
4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration-isolate duct openings in wall or roof according to good construction practices.
A. CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE UNITS
OPTIONAL
RETURN
AIR
OPENING
2"
EVAP. COIL COND. COIL
Fig. 7—Slab Mounting Detail
DETAIL A
OPTIONAL
SUPPLY
AIR
OPENING
C99096
WARNING: Before performing service or maintenance
operations on system, turn off main power to unit and
install lockout tag. Turn off accessory heater power
switch if applicable. Electrical shock could cause serious
injury or death.
1. Open all electrical disconnects and install lockout tag before
starting any service work.
2. Remove side duct covers to access bottom return and supply
knock outs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout.
3. Use a screwdriver and hammer to remove the panels in the
bottom of the composite unit base.
4. Ensure the side duct covers are in place to block off the
horizontal air openings.
NOTE: Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
VI. PROVIDE FOR CONDENSATE DISPOSAL
NOTE: Ensure that condensate-water disposal methods comply
with local codes, restrictions, and practices.
The units dispose of condensate through a 3/4 in. NPT female
fitting that exits on the compressor end of the unit. Condensate
water can be drained directly onto the roof in rooftop installations
(where permitted) or onto a gravel apron in ground level installations. Install a field-supplied condensate trap at end of condensate
connection to ensure proper drainage. Make sure that the outlet of
the trap is at least 1 in. lower than the drain-pan condensate
connection to prevent the pan from overflowing. Prime the trap
with water. When using a gravel apron, make sure it slopes away
from the unit.
If the installation requires draining the condensate water away
from the unit, install a field-supplied 2-in. trap at the condensate
connection to ensure proper drainage. Condensate trap is available
A05179
UNIT
Size lb kg in. mm. in. mm.
601A030 309 140.2 19.5 495.3 17.50 444.5
601A036 313 142.0 19.5 495.3 17.75 450.9
601A042 345 156.4 19.5 495.3 17.75 450.9
601A048 375 170.1 20.5 520.7 20.62 523.8
601A060 440 199.6 19.5 495.3 19.75 501.7
602A030 342 155.2 20.0 508 19.25 489
602A036 350 158.8 20.0 508 19.0 482.6
602A042 372 168.8 21.0 533.4 20.5 520.7
602A048 377 171.0 20.0 508 21.25 539.8
602A060 450 204.2 21.0 533.4 20.0 508.0
MAXIMUM WEIGHT
(INCLUDES SHIPPING SKID)
AB
Fig. 8—Suggested Rigging
as an accessory or is field-supplied. Make sure that the outlet of the
trap is at least 1 in. lower than the unit drain-pan condensate
connection to prevent the pan from overflowing. Connect a drain
trough using a minimum of field-supplied 3/4 -in. PVC or
field-supplied 3/4 -in. copper pipe at outlet end of the 2 -in. trap
(See Fig. 11). Do not undersize the tube. Pitch the drain trough
downward at a slope of at least 1 in. every 10 ft. of horizontal run.
Be sure to check the drain trough for leaks. Prime the trap at the
beginning of the cooling season start-up.
—7—
TABLE 1—PHYSICAL DATA
UNIT SIZE 601A030 601A036 601A042 601A048 601A060
NOMINAL CAPACITY (ton) 2-1/2 3 3-1/2 4 5
OPERATING WEIGHT (lb.) 287 291 323 353 418
COMPRESSOR QUANTITY 1
TYPE RECIPROCATING COMPRESSOR SCROLL COMPRESSOR
REFRIGERANT R-22
REFRIGERANT METERING DEVICE AccuRater®
Refrigerant (R-22) Quantity (lb.) 5.6 7.6 8.0 7.85 9.3
ORIFICE ID (in.) 0.068 0.078 0.078 0.088 0.093
ORIFICE OD (in.) 0.042 (2) 0.046 (2) 0.052 (2) 0.057 (2) 0.061 (2)
OUTDOOR COIL
Rows... Fins/in.
Face Area (sq. ft.)
OUTDOOR FAN
Nominal Airflow (CFM)
Diameter
Motor HP (RPM)
INDOOR COIL
Rows... Fins/in.
Face Area (sq. ft.)
INDOOR BLOWER
Nominal Airflow (CFM)
Size (in.)
Motor HP (RPM)
RETURN-AIR FILTERS (in.)
throwaway
1...17
12.0
2400
22
1/8 (825)
3...15
3.7
1000
10X10
1/4 (1075)
20X20X1 20X24X1 24X30X1 24X30X1 24X30X1
2...17
10.3
2800
22
1/4 (1100)
3...15
3.7
1200
11X10
1/2 (1075)
2...17
10.3
2400
22
1/8 (825)
4...15
3.7
1250
11X10
3/4 (1075)
2...17
11.6
3300
22
1/4 (1100)
3...15
4.7
1600
11X10
3/4 (1075)
1/4 (1100)
2...17
11.6
3300
22
4...15
4.7
2000
11X10
1 (1100)
TABLE 2—PHYSICAL DATA
UNIT SIZE 602A030 602A036 602A042 602A048 602A060
NOMINAL CAPACITY (ton) 2-1/2 3 3-1/2 4 5
OPERATING WEIGHT (lb.) 320 328 350 375 428
COMPRESSOR QUANTITY 1
TYPE SCROLL COMPRESSOR
REFRIGERANT R-22
REFRIGERANT METERING DEVICE AccuRater®
Refrigerant (R-22) Quantity (lb.) 6.4 7.0 10.8 10.1 12.3
ORIFICE ID (in.) 0.073 0.076 0.080 0.088 0.093
ORIFICE OD (in.) 0.043 (2) 0.040 (2) 0.052 (2) 0.057 (2) 0.063 (2)
OUTDOOR COIL
Rows... Fins/in.
Face Area (sq. ft.)
OUTDOOR FAN
Nominal Airflow (CFM)
Diameter
Motor HP (RPM)
INDOOR COIL
Rows... Fins/in.
Face Area (sq. ft.)
INDOOR BLOWER
Nominal Airflow (CFM)
Size (in.)
Motor HP (RPM)
RETURN-AIR FILTERS (in.)
throwaway
NOTE: Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg.
2...17
10.3
2350
22
1/8 (825)
3...15
3.7
1000
10X10
1/4 (1075)
20X20X1 20X24X1 24X30X1 24X30X1 24X30X1
2...17
10.3
2800
22
1/4 (1100)
4...15
3.7
1200
10X10
1/2 (1075)
2...17
13.7
2800
22
1/8 (825)
4...15
4.7
1400
11X10
1/2 (1075)
2...17
13.7
3300
22
1/4 (1100)
4...15
4.7
1450
11X10
1/2 (1075)
2...17
15.7
3300
22
1/4 (1100)
4...15
5.7
1750
11X10
1 (1040)
TABLE 3—MINIMUM AIRFLOW FOR RELIABLE ELECTRIC HEATER OPERATION (CFM)
SIZE 601A030 601A036 601A042 601A048 601A060
AIRFLOW (CFM) 1000* 1200 1400 1600 2000
* The 030 size models must be run on medium or high speed when used in conjunction with 15 kW electric heat accessory
—8—
TABLE 4—MINIMUM AIRFLOW FOR RELIABLE ELECTRIC HEATER OPERATION (CFM)
SIZE 602A030 602A036 602A042 602A048 602A060
AIRFLOW (CFM) 1000* 1200 1400 1600 2000
* The 030 size models must be run on medium or high speed when used in conjunction with 15 kw electric heat accessory
RETURN
AIR
TOP COVER
Fig. 9—Typical Installation
Horizontal Duct Covers
Fig. 10—602A with Duct Covers On
(Unit Shown with Optional Louvered Grille)
1” (25mm) MIN.
Fig. 11—Condensate Trap
TRAP
OUTLET
INDOOR
THERMOSTAT
2” (50mm) MIN.
FROM
POWER
SOURCE
DISCONNECT
PER NEC
C00139
C99030
C99013
VII. INSTALL ELECTRICAL CONNECTIONS
WARNING: The unit cabinet must have an uninter-
rupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should
occur. This ground may consist of an electrical wire
connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when
installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection
Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. Failure
to adhere to this warning could result in serious injury or
death.
CAUTION: Failure to follow these precautions could
result in damage to the unit being installed:
1. Make all electrical connections in accordance with
NEC ANSI/NFPA (latest edition) and local electrical
codes governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit.
DO NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within
operating voltage range indicated on unit rating plate.
On 3-phase units, ensure phases are balanced within 2
percent. Consult local power company for correction
of improper voltage and/or phase imbalance.
4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires
are in same conduit as high-voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit, etc.
A. HIGH-VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight
from the unit. Refer to the unit rating plate, NEC and local codes
for maximum fuse/circuit breaker size and minimum circuit amps
(ampacity) for wire sizing (See Tables 5 and 6 for electrical data).
The field-supplied disconnect may be mounted on the unit over the
high-voltage inlet hole (See Fig. 2 and 3).
If the unit has an electric heater, a second disconnect may be
required. Consult the Installation, Start-Up, and Service Instructions provided with the accessory for electrical service connections.
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
B. ROUTING POWER LEADS INTO UNIT
Use only copper wire between disconnect and unit. The highvoltage leads should be in a conduit until they enter the duct panel;
conduit termination at the duct panel must be watertight. Run the
high-voltage leads through the power entry knockout on the power
entry side panel. See Fig. 2 and 3 for location and size. When the
—9—
Fig. 12—Wiring Schematics (208/230-3-60)
—10—
C00134
Fig. 13—Wiring Schematics (460-3-60)
—11—
C00135
TABLE 5—ELECTRICAL DATA—601A
UNIT 601A
SIZE
030 208/230–3–60 187 253 9.9 78 0.9 2.0
036
042
048
060
V-PH-HZ
208/230–3–60 187 253 9.9 78 1.5 4.1
460–3–60 414 506 5.5 40 0.8 1.9
208/230–3–60 187 253 12.4 90 0.9 3.8
460–3–60 414 506 6.7 45 0.8 1.8
208/230–3–60 187 253 14.1 105 1.5 3.5
460–3–60 414 506 7.1 53 0.8 1.8
208/230–3–60 187 253 19.4 125 1.5 6.2
460–3–60 414 506 8.0 63 0.8 3.2
VOLTAGE
RANGE
MIN MAX RLA LRA
COMPRESSOR
OFM
FLA
IFM
FLA
ELECTRIC HEAT SINGLE POINT POWER SUPPLY
Nominal
kW*
-/-
3.8/5.0
7.5/10.0
11.3/15.0
-/-
3.8/5.0
7.5/10.0
11.3/15.0
-/5
10
15
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/19.9
-/5
10
15
20.0
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/20.0
-/5
10
15
20
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/19.9
-/5
10
15
20
FLA MCA
-/-
10.4/12 .0
20.8/24.1
31.3/36.1
-/-
10.4/12.0
31.3/36.1
36.1/41.7
-/-
6.0
12.0
18.0
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-/-
6.0
12.0
18.0
24.1
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-
6.0
12.0
18.0
24.1
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-
6.0
12.0
18.0
24.1
15.3/15.3
28.3/30.3
41.3/45.3
54.4/60.4
18.0/18.0
31.0/33.0
44.0/48.0
57.1/63.1
9.6
17.1
24.6
32.1
20.2/20.2
33.2/35.2
46.3/50.3
59.3/65.3
72.2/80.2
11.0
18.5
26.0
33.5
41.0
22.6/22.6
35.7/37.7
48.7/52.7
61.7/67.7
74.6/82.6
11.5
19.0
26.5
34.0
41.5
32.0/32.0
45.0/47.0
58.0/62.1
71.1/77.1
83.9/91.9
14.0
21.5
29.0
36.6
44.1
FUSE OR
CKT BKR
20/20
30/35
45/50
60/25/25
35/35
45/50
60/-
15
20
25
35
25/25
40/40
50/60
60/-
15
20
30
35
45
30/30
40/40
50/60
-
15
20
30
35
45
40/40
50/50
-
-
20
25
30
40
45
MOCP
-
-
-
-/70
-
-
-
-/70
-
-
-
-
-
-
-
-/70
80/90
-
-
-
-
-
-
-
70/70
80/90
-
-
-
-
-
-
60/70
80/80
90/100
-
-
-
-
-
—12—
TABLE 6—ELECTRICAL DATA—602A
UNIT 602A
SIZE
030 208/230–3–60 187 253 10.4 63 0.9 2.1
036
042
048
060
V-PH-HZ
208/230–3–60 187 253 11.2 75 1.6 3.6
460–3–60 414 506 5.4 37.5 0.9 1.9
208/230–3–60 187 253 12.4 88 0.9 4.1
460–3–60 414 506 5.8 44 0.9 2.0
208/230–3–60 187 253 13.0 93 1.6 4.1
460–3–60 414 506 6.4 46.5 0.9 2.0
208/230–3–60 187 253 17.3 123 1.4 6.2
460–3–60 414 506 9.0 62 0.9 3.2
VOLTAGE
RANGE
MIN MAX RLA LRA Nominal kW* FLA MCA
COMPRESSOR
OFM
FLA
IFM
FLA
ELECTRIC HEAT SINGLE POINT POWER SUPPLY
FUSE OR
-/-
3.8/5.0
7.5/10.0
11.3/15.0
-/-
3.8/5.0
7.5/10.0
11.3/15.0
-/5
10
15
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/20.0
-/5
10
15
20
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/20.0
-/5
10
15
20
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15.0/19.9
-/5
10
15
20
-/-
10.4/12.0
20.8/24.1
31.3/36.1
-/-
10.4/12.0
36.1/41.7
31.3/36.1
-/6
12
18
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-/6
12
18
24.1
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-/6
12
18
24.1
-/-
10.4/12.0
20.8/24.1
31.3/36.1
41.6/48.0
-/6
12
18
24.1
16.0/16.0
29.0/31.0
42.1/46.1
55.1/61.1
19.2/19.2
32.2/34.2
45.2/49.3
58.3/64.3
9.6
17.1
24.6
32.1
20.5/20.5
33.5/35.5
46.6/50.6
59.6/65.6
72.5/80.5
10.2
17.7
25.2
32.7
40.2
21.9/21.9
34.9/36.9
47.9/51.9
60.9/67.0
73.8/81.8
10.8
18.3
25.8
33.3
40.8
29.2/29.2
42.3/44.3
55.2/59.4
68.3/74.3
81.2/89.2
15.4
22.9
30.4
37.9
45.4
CKT BKR
20/20
35/35
45/50
25/25
35/35
50/50
-
15
20
25
35
25/25
40/40
50/60
-
15
20
30
35
45
30/30
40/40
50/60
-
15
20
30
35
45
35/35
50/50
60/60
-
20
25
35
40
50
MOCP
-
-
-
60/70
-
-
-
60/70
-
-
-
-
-
-
60/70
80/90
-
-
-
-
-
-
-
70/70
80/90
-
-
-
-
-
-
-
70/80
90/90
-
-
-
-
-
LEGEND
FLA — Full Load Amps
LRA — Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
RLA — Rated Load Amps
CKT BKR
—
Circuit Breaker
®
NOTES:
1. In compliance with NEC (National Electrical Code) requirements
for multimotor and combination load equipment (refer to NEC
Articles 430 and 440), the overcurrent protective device for the
unit shall be Power Supply fuse. Canadian units may be
fuse or circuit breaker.
2. Minimum wire size is based on 60 C copper wire. If other than
60 C wire is used, or if length exceeds wire length in table,
determine size from NEC.
3. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater than 2%.
the percentage of voltage imbalance.
Use the following formula to determine
% Voltage imbalance
= 100 x
max voltage deviation from average voltage
average voltage
Fig. 14—Electrical Data Legend
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
452 + 464 + 455
3
1371
=
3
= 457
Determine maximum deviation from average voltage.
(AB) 457
(BC) 464
(AC) 457
452=5v
457=7v
455=2v
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.
—13—
leads are inside the unit, run leads up the high-voltage raceway to
the line wiring splice box (See Fig. 12–17). On all 3-phase units,
connect the leads to the black, yellow, and blue wires (See Fig.
16).
C. CONNECTING GROUND LEAD TO GROUND LUG
Connect the ground lead to the chassis using the ground lug in the
wiring splice box (See Fig. 16).
D. ROUTING CONTROL POWER WIRES (24-V)
Form a drip-loop with the thermostat leads before routing them
into the unit. Route the thermostat leads through grommeted,
low-voltage hole provided in unit into unit control power splice
box (See Fig. 2 and 3). Connect thermostat leads to unit control
power leads as shown in Fig. 15.
The unit transformer supplies 24-v power for complete system
including accessory electrical heater. An automatic-reset circuit
breaker (See Fig. 17) is provided in the 24-v circuit; see the caution
label on the transformer or Fig. 18. Transformer is factory wired
for 230-v operation. If supply voltage is 208-v, rewire transformer
primary as described in Special Procedures for 208-v Operation
section.
E. SPECIAL PROCEDURES FOR 208-V OPERATION
1. Disconnect the yellow primary lead from the transformer.
See unit wiring label (See Fig. 12).
GROUND
LEAD
SINGLE-PHASE
L1
CONNECTIONS
TO DISCONNECT
PER NEC
3-PHASE
CONNECTIONS
L2
L3
NOTE: Use copper wire only.
LEGEND
NEC – National Electrical Code
Field Wiring
Splice Connections
Fig. 16—Line Power Connections
GROUND LUG
(IN SLPICE BOX)
BLK
YEL
BLU
C99057
2. Connect the yellow primary lead to the transformer terminal
labeled 200-v.
Indoor blower-motor speeds may need to be changed for 208-v
operation. Refer to indoor airflow and airflow adjustments section.
C
O
R
G
Y
E
W2
THERMOSTAT
AND SUBBASE
UNIT CONTROL POWER
BRN
ORN
RED
GRN
YEL
WHT
SPLICE BOX
C99056
Fig. 15—Control Connections
24 V Circuit Breaker
24 Volt Compartment
Fig. 17—Control Wiring Plate
TRANSFORMER CONTAINS A MANUAL
RESET OVERCURRENT PROTECTOR
IT WILL NOT AUTOMATICALLY RESET
DISCONNECT POWER AND INSTALL
LOCKOUT TAG PRIOR TO SERVICING
THIS COMPARTMENT MUST BE CLOSED
EXCEPT WHEN SERVICING
C99070
—14—
C99058
Fig. 18—Transformer Label
PRE-START-UP
WARNING: Failure to observe the following warnings
could result in serious personal injury or death:
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric
power to unit unless compressor terminal cover is in
place and secured.
3. Do not remove compressor terminal cover until all
electrical sources are disconnected and tagged.
4. Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box if
refrigerant leak is suspected around compressor terminals.
5. Never attempt to repair soldered connection while
refrigerant system is under pressure.
6. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective goggles and
proceed as follows:
a. Shut off electrical power to unit and install lockout
tag.
b. Relieve and reclaim all refrigerant from system
using both high- and low-pressure ports.
c. Cut component connecting tubing with tubing cutter
and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove access panel.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or
shipped with, unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and
on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections
using electronic leak detector, or liquid-soap solution. If
a refrigerant leak is detected, see following Check for
Refrigerant Leaks section.
c. Inspect all field and factory-wiring connections. Be sure
that connections are completed and tight.
d. Ensure wires do not touch refrigerant tubing or sharp
sheet metal edges.
e. Inspect coil fins. If damaged during shipping and han-
dling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
a. Make sure that outdoor-fan blade is correctly positioned
in fan orifice (See Fig. 19).
b. Make sure that condensate drain pan and trap are filled
with water to ensure proper drainage.
c. Make sure that all tools and miscellaneous loose parts
have been removed.
5. Compressors are internally spring mounted. Do not loosen
or remove compressor holddown bolts.
MOTOR
1/8" MAX BETWEEN
MOTOR AND FAN HUB
6. Each unit system has 2 Schrader-type ports, one low-side
Fig. 19—Fan Blade Clearance
MOTOR SHAFT
FAN GRILLE
1/2˝
C99009
Schrader fitting located on the suction line, and one
high-side Schrader fitting located on the compressor discharge line. Be sure that caps on the ports are tight.
7. High flow valves are located on the compressor hot gas and
suction tubes. These valves can not be accessed for service
in the field. Ensure the plastic caps are in place and tight or
the possibility or refrigerant leakage could occur.
START-UP
Using the Start-Up Checklist supplied at the end of this book,
proceed as follows:
I. CHECK FOR REFRIGERANT LEAKS
Locate and repair refrigerant leaks and charge the unit as follows:
1. Use both high- and low-pressure ports to relieve system
pressure and reclaim remaining refrigerant.
2. Repair leak following accepted practices.
NOTE: Install a bi-flow filter drier whenever the system has been
opened for repair.
3. Check system for leaks using an approved method.
4. Reclaim refrigerant and evacuate refrigerant system to 500
microns if no additional leaks are found.
5. Charge unit with R-22 refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating
plate for required charge. Be sure to add extra refrigerant to
compensate for internal volume of filter drier.
II. START-UP ADJUSTMENTS
Complete the required procedures given in the Pre-Start-Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the unit in Cooling mode
when the outdoor temperature is below 40° F (unless accessory
low-ambient kit is installed). Do not rapid-cycle the compressor.
Allow 5 minute between “on” cycles to prevent compressor
damage.
A. CHECKING COOLING AND HEATING
CONTROL OPERATION
Start and check the unit for proper control operation as follows:
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is
placed in ON position and shuts down within 60 sec. when
FAN switch is placed in AUTO position.
2. Place SYSTEM switch in COOL position and FAN switch
in AUTO position. Set control below room temperature.
Observe that cooling cycle shuts down when control setting
is satisfied.
3. Place system switch in HEAT position. Set control above
room temperature. Observe that compressor, outdoor fan,
and indoor blower motors start. Observe that heating cycle
shuts down when control setting is satisfied.
4. When using an automatic changeover room thermostat,
place both SYSTEM and FAN switches in AUTO positions.
Observe that unit operates in Cooling mode when temperature control is set to “call for Cooling” (below room
temperature), and unit operates in Heating mode when
temperature control is set to “call for Heating” (above room
temperature).
—15—
HPS
ACCUMULATOR
COMPRESSOR
LEGEND
HPS – High Pressure Switch
LCS – Loss of Charge Switch
Accurater
®
Arrow indicates direction of flow
OUTDOOR COIL
Metering
Position
Bypass
Position
LCS
Metering Device
Fig. 20—Typical Heat Pump Operation, Heating Mode
INDOOR COIL
C00095
OUTDOOR COIL
HPS
ACCUMULATOR
COMPRESSOR
LEGEND
HPS – High Pressure Switch
LCS – Loss of Charge Switch
®
Accurater
Metering Device
Arrow indicates direction of flow
Fig. 21—Typical Heat Pump Operation, Cooling Mode
IMPORTANT: Three-phase, scroll compressors are direction
oriented. Unit must be checked to ensure proper compressor
3-phase power lead orientation. If not corrected within 5 minute,
the internal protector will shut off the compressor. The 3-phase
power leads to the unit must be reversed to correct rotation. When
turning backwards, scroll compressors emit elevated noise levels,
and the difference between compressor suction and discharge
pressures may be dramatically lower than normal.
B. CHECKING AND ADJUSTING REFRIGERANT
CHARGE
The refrigerant system is fully charged with R-22 refrigerant and
is tested and factory sealed. Allow system to operate a minimum
of 15 minutes before checking or adjusting charge.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-22 charge.
The charging label and the tables shown refer to system temperatures and pressures in cooling mode only. A refrigerant charging
label is attached to the outside of the service access door. If charge
INDOOR COIL
C00096
Bypass
Position
Metering
Position
LCS
level is suspect in Heating mode, reclaim all refrigerant and charge
to nameplate amount. (This information may be obtained from the
physical data table also.)
IMPORTANT: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be
very minimal. If a substantial adjustment is indicated, an abnormal
condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.
C. REFRIGERANT CHARGE
The amount of refrigerant charge is listed on the unit nameplate
and/or the physical data table. Refer to the Refrigeration Service
Techniques Manual, Refrigerants Section.
D. NO CHARGE
Check for leak. Use standard evacuating techniques. After evacuating system to 500 microns, weigh in the specified amount of
refrigerant (refer to system data plate).
—16—
70
Based on Indoor Entering Air of 70 F and Rated CFM
60
50
Balance Point Worksheet
40
30
Building Heat Loss, 1000BTUH
20
Unit Integrated Heating Capacity (x1000BTUH)
10
0
-100 1017203040475060
Outdoor Air Temp (Deg F)
Fig. 22—602A Balance Point Worksheet
E. LOW CHARGE COOLING
Use Cooling Charging Charts (Fig. 24-33). 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 correct superheat for the various operating conditions.
Accurate pressure gauge and temperature sensing devices are
required. Connect the pressure gauge to the service port on the
suction line. Mount the temperature sensing device on the suction
line and insulate it so that the outdoor ambient does not affect the
reading. Indoor air CFM must be within the normal operating
range of the unit.
F. TO USE COOLING CHARGING CHARTS
Take the outdoor ambient temperature and read the suction
pressure gauge. Refer to the chart to determine what the suction
temperature should be.
NOTE: If the problem causing the inaccurate readings is a
refrigerant leak, refer to Check for Refrigerant Leaks section.
G. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS
CAUTION: For heating and cooling operation, the rec-
ommended airflow is 350 to 450 cfm for each 12,000
Btuh of rated cooling capacity. For units with optional
electric heat, the airflow must not be reduced below the
levels stated in Tables 3 and 4. Failure to maintain these
airflows could result in damage to the unit.
Tables 7 and 8 shows both heating and cooling airflows at various
external static pressures. Refer to these tables to determine the
airflow for the system being installed.
NOTE: Be sure that all supply-and return-air grilles are open, free
from obstructions, and adjusted properly.
030
036
042
048
060
C00093rev2
Airflow can be changed by changing the lead connection of the
blower motor.
Unit 601A and 602A three-speed motors (except 602A030) are
factory wired for low speed operation. Unit 602A030 is factory
wired for medium speed.
For 208/230-v Motors:— The motor leads are color-coded as
follows:
3-SPEED
Black = high speed
Blue = medium speed
Red = low speed
To change the speed of the indoor fan motor (IFM), remove the fan
motor speed leg lead from the Time Delay Relay (TDR). This wire
is attached to TDR-3 for 3-phase units. To change the speed,
remove and replace with lead for desired blower motor speed.
Insulate the removed lead to avoid contact with chassis parts.
For 460-v GE Motors—The motor leads are color coded as
follows:
3-SPEED
Black = high
Violet = jumper
Orange = medium
Red = low
To change the speed of the indoor fan motor (IFM), remove fan
motor speed lead from the Time Delay Relay (TDR) and replace
with the lead for the desired blower motor speed. The motor speed
lead is attached to terminal TDR-3. For low and medium speeds,
black must be connected to the jumper wire. Insulate removed lead
end to avoid contact with chassis parts. To select high speed on
460-v GE motors, separate the black female quick connect (QC)
from the jumper lead male quick connect (QC) and connect the
black lead to the BR. Insulate the jumper to avoid contact with any
chassis parts.
—17—
70
Based on Indoor Entering Air of 70 F and Rated CFM
60
50
40
30
Building Heat Loss, 1000BTUH
20
Unit Integrated Heating Capacity (x1000BTUH)
10
Balance Point Worksheet
030
036
042
048
060
0
-100 1017203040475060
Outdoor Air Temp (Deg F)
Fig. 23—601A Balance Point Worksheet
MAINTENANCE
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This heat pump unit should
be inspected at least once each year by a qualified service person.
To troubleshoot unit, refer to Table 11.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
WARNING: The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess
these, do not attempt to perform any maintenance on this
equipment, other than those procedures recommended in
the User’s Manual. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY OR
DEATH AND POSSIBLE DAMAGE TO THIS EQUIPMENT.
WARNING: Failure to follow these warnings could
result in serious injury or death:
1. Turn off electrical power to the unit and install lockout
tag before performing any maintenance or service on
this unit.
2. Use extreme caution when removing panels and parts.
As with any mechanical equipment, personal injury
can result from sharp edges.
3. Never place anything combustible either on, or in
contact with, the unit.
C00094rev2
CAUTION: Errors made when reconnecting wires may
cause improper and dangerous operation. Label all wires
prior to disconnecting when servicing.
The minimum maintenance requirements for this equipment are as
follows:
1. Inspect air filter(s) each month. Clean or replace when
necessary.
2. Inspect indoor coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness each
cooling season. Clean when necessary.
4. Check electrical connections for tightness and controls for
proper operation each cooling season. Service when necessary.
5. Ensure wires are not contacting refrigerant tubing or sharp
sheet metal edges.
I. AIR FILTER
IMPORTANT: Never operate the unit without a suitable air filter
in the return-air duct system. Always replace the filter with the
same dimensional size and type as originally installed (See Tables
1 and 2 for recommended filter sizes.)
Inspect air filter(s) at least once each month and replace
(throwaway-type) or clean (cleanable-type) at least twice during
each cooling season or whenever the filter becomes clogged with
dust and lint.
II. INDOOR BLOWER AND MOTOR
NOTE: All motors are prelubricated. Do not attempt to lubricate
these motors.
—18—
TABLE 7—WET COIL AIR DELIVERY
UNIT 601A 030-060 (DEDUCT 10 PERCENT FOR 208-V)*
UNIT
30
36
42
48
60
* Air delivery values are based on operating voltage of 230-v or 460-v, wet coil, without filter or electric heater. Deduct filter and electric heater pressure drops to obtain static
pressure available for ducting.
NOTES:
1. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator coil frosting may occur at airflows below
this point.
2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended.
3. Deduct 10 percent for 208-v.
MOTOR
SPEED
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Watts295292289--------
Cfm928882802--------
Watts388383377372366361-----
Cfm 1203 1120 1062 1004 930 838 -----
Watts----469458449442---
Cfm----1141 1027 924 828 - - -
Watts 592 581 567 552 538 525 512 499 - - -
Cfm 1499 1421 1351 1281 1207 1125 1034 936 - - -
Watts - - - 660 636 617 603 592 581 566 -
Cfm - - - 1475 1371 1274 1186 1105 1024 928 -
Watts-----776761744725706689
Cfm-----1452 1356 1254 1145 1030 910
Watts 606 596 586 575 563 550 537 - - - -
Cfm 1464 1399 1341 1282 1218 1146 1066 - - - -
Watts 680 665 649 635 622 611 600 590 - - -
Cfm 1608 1535 1461 1387 1316 1247 1180 1111 - - -
Watts 768 755 742 730 718 707 696 684 671 - -
Cfm 1656 1576 1508 1447 1390 1331 1268 1198 1119 - -
Watts 741 724 709 690 664 631 594 562 552 543 -
Cfm 1994 1937 1869 1797 1722 1645 1566 1480 1384 1269 -
Watts - - - 773 744 715 687 662 640 625 -
Cfm - - - 1957 1867 1787 1719 1653 1575 1463 -
Watts-----799782773756704-
Cfm-----1914 1842 1774 1686 1538 -
Watts 742 723 698 666 629 591 559 540 - - -
Cfm 2197 2141 2103 2057 1988 1894 1783 1674 - - -
Watts 838 822 803 780 752 721 689 661 639 632 -
Cfm 2485 2406 2269 2127 2012 1937 1894 1855 1770 1571 -
Watts - 934 913 891 866 837 806 776 750 735 -
Cfm - 2483 2391 2283 2170 2061 1960 1868 1780 1687 -
EXTERNAL STATIC PRESSURE (IN. WG)
For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.
WARNING: Disconnect and tag electrical power to the
unit before cleaning and lubricating the blower motor and
wheel. Failure to adhere to this warning could cause
serious injury or death.
III. OUTDOOR COIL, INDOOR COIL, AND
CONDENSATE DRAIN PAN
Inspect the condenser coil, evaporator coil, and condensate drain
pan at least once each heating and cooling season or sooner if
conditions require.
The coils are easily cleaned when dry; therefore, inspect and clean
the coils either before or after each cooling season. Remove all
obstructions, including weeds and shrubs, that interfere with the
airflow through the condenser coil.
Straighten bent fins with a fin comb. If coated with dirt or lint,
clean the coils with a vacuum cleaner, using the soft brush
attachment. Be careful not to bend the fins. If coated with oil or
grease, clean the coils with a mild detergent-and-water solution.
Rinse coils with clear water, using a garden hose. Be careful not to
splash water on motors, insulation, wiring, or air filter(s). For best
results, spray condenser coil fins from inside to outside the unit.
On units with an outer and inner condenser coil, be sure to clean
between the coils. Be sure to flush all dirt and debris from the unit
base.
Inspect the drain pan and condensate drain line when inspecting
the coils. Clean the drain pan and condensate drain by removing all
foreign matter from the pan. Flush the pan and drain trough with
clear water. Do not splash water on the insulation, motor, wiring,
or air filter(s). If the drain trough is restricted, clear it with a
“plumbers snake” or similar probe device. Ensure that the auxiliary
drain port above the drain trough is also clear.
IV. OUTDOOR FAN
CAUTION: Keep the condenser fan free from all ob-
structions to ensure proper cooling operation. Never place
articles on top of the unit. Damage to unit may result.
1. Inspect the fan blades for cracks or bends.
2. If fan needs to be removed, remove screws holding outdoor
air intake grille and remove grille.
3. Loosen the setscrew and slide the fan off the motor shaft.
4. When replacing fan blade, position blade so that the hub is
1/8 in. (See Fig. 19) away from the motor end (1/8 in. of
motor shaft will be visible) .
—19—
TABLE 8—WET COIL AIR DELIVERY
UNIT 602A 030-060 (DEDUCT 10 PERCENT FOR 208-V)*
UNIT
30
36
42
48
60
* Air delivery values are based on operating voltage of 230-v or 460-v, wet coil, without filter or electric heater. Deduct filter and electric heater pressure drops to obtain static
pressure available for ducting.
NOTES:
1. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator coil frosting may occur at airflows below
this point.
2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended.
3. Deduct 10 percent for 208-v.
MOTOR
SPEED
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Watts276276272--------
Cfm963929781--------
Watts375377371362354350-----
Cfm 1202 1170 1079 976 884 807 -----
Watts----469449435428---
Cfm----1174 988 828 718 - - -
Watts462451431411394381-----
Cfm 1374 1290 1205 1116 1020 916 -----
Watts523506490471449426-----
Cfm 1500 1408 1301 1190 1082 977 -----
Watts-645628610595584575----
Cfm - 1474 1369 1267 1169 1069 962 ----
Watts 620 600 586 574 562 548 530 510 487 462 439
Cfm 1662 1621 1581 1540 1496 1447 1392 1331 1263 1186 1103
Watts----686661634606577547517
Cfm----1722 1662 1594 1515 1427 1330 1227
Watts-------757730704682
Cfm-------16691577 1486 1402
Watts 620 600 586 574 562 548 530 - 487 - -
Cfm 1662 1621 1581 1540 1496 1447 1392 1331 1263 - -
Watts 763 747 729 709 686 661 634 606 577 547 517
Cfm 1917 1868 1822 1774 1722 1662 1594 1515 1427 1330 1227
Watts - - - 852 832 809 784 757 730 704 682
Cfm - - - 1982 1914 1839 1757 1669 1577 1486 1402
Watts597592578526460452445----
Cfm 2265 2190 2101 2033 1974 1869 1614 ----
Watts 754 730 707 687 671 658 646 630 603 558 486
Cfm 2383 2282 2202 2134 2070 2005 1935 1858 1771 1667 1576
Watts 901 876 856 836 813 785 755 723 696 681 687
Cfm 2480 2383 2301 2233 2175 2122 2066 1998 1910 1788 1619
EXTERNAL STATIC PRESSURE (IN. WG)
5. Ensure that setscrew engages the flat area on the motor shaft
when tightening.
6. Replace grille.
V. ELECTRICAL CONTROLS AND WIRING
Inspect and check the electrical controls and wiring annually. Be
WARNING: System under pressure. Relieve pressure
and recover all refrigerant before system repair or final
unit disposal to avoid serious injury or death. Use all
service ports and open all flow-control devices, including
solenoid valves.
sure to turn off the electrical power to the unit and install lockout
tag.
Remove access panel to locate all the electrical controls and
wiring. Check all electrical connections for tightness. Tighten all
screw connections. If any smoky or burned connections are
noticed, disassemble the connection, clean all the parts, restrip the
wire end and reassemble the connection properly and securely.
After inspecting the electrical controls and wiring, replace all the
panels. Start the unit, and observe at least one complete cooling
cycle to ensure proper operation. If discrepancies are observed in
operating cycle, or if a suspected malfunction has occurred, check
each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts.
NOTE: Refer to the Sequence of Operation section as an aid in
determining proper control operation.
VI. REFRIGERANT CIRCUIT
Inspect all refrigerant tubing connections and the unit base for oil
accumulation annually. Detecting oil generally indicates a refrigerant leak.
If oil is detected or if low performance is suspected, leak-test all
refrigerant tubing using an electronic leak detector, or liquid-soap
solution. If a refrigerant leak is detected, refer to Check for
Refrigerant Leaks section.
If no refrigerant leaks are found and low performance is suspected,
refer to Checking and Adjusting Refrigerant Charge section.
VII. INDOOR AIRFLOW
The indoor airflow does not require checking unless improper
performance is suspected. If a problem exists, be sure that all
supply- and return-air grilles are open and free from obstructions,
and that the air filter is clean. When necessary, refer to Indoor
Airflow and Airflow Adjustments section to check the system
airflow.
VIII. METERING DEVICE
Refrigerant metering devices are fixed orifices and are located in
the inlet header to the indoor and outdoor coils.
—20—
689
100
620
90
551
80
483
70
414
60
SUCTION LINE PRESSURE (PSIG)
345
50
SUCTION LINE PRESSURE (KILOPASCALS)
276
40
(030) 60HZ CHARGING CHART
OUTDOOR TEMP
° F ° C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
689
100
620
90
551
80
483
70
414
60
SUCTION LINE PRESSURE (PSIG)
345
50
SUCTION LINE PRESSURE (KILOPASCALS)
276
40
(036) 60HZ CHARGING CHART
OUTDOOR TEMP
° F ° C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
207
30
20.0 30.0 40.0 50.0 60.0 70.0 80.0
SUCTION LINE TEMPERATURE (°F)
-7 -1 4 10 16 21 27
SUCTION LINE TEMPERATURE (°C)
Fig. 24—Cooling Charging Chart, 601A030 Units
(042) 60HZ CHARGING CHART
689
100
620
90
551
80
483
70
414
60
SUCTION LINE PRESSURE (PSIG)
345
50
SUCTION LINE PRESSURE (KILOPASCALS)
276
40
50JS500089
C00028
OUTDOOR TEMP
° F ° C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
207
30
20.0 30.0 40.0 50.0 60.0 70.0 80.0
SUCTION LINE TEMPERATURE (°F)
-7 -1 4 10 16 21 27
SUCTION LINE TEMPERATURE (°C)
Fig. 25—Cooling Charging Chart, 601A036 Units
(048) 60HZ CHARGING CHART
689
100
620
90
551
80
483
70
414
60
SUCTION LINE PRESSURE (PSIG)
345
50
SUCTION LINE PRESSURE (KILOPASCALS)
276
40
50JS500090
C00029
OUTDOOR TEMP
° F ° C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
207
30
20.0 30.0 40.0 50.0 60.0 70.0 80.0
SUCTION LINE TEMPERATURE (°F)
-7 -1 4 10 16 21 27
SUCTION LINE TEMPERATURE (°C)
Fig. 26—Cooling Charging Chart, 601A042 Units
50JS500091
C00030
—21—
207
30
20.0 30.0 40.0 50.0 60.0 70.0 80.0
SUCTION LINE TEMPERATURE (°F)
-7 -1 4 10 16 21 27
SUCTION LINE TEMPERATURE (°C)
Fig. 27—Cooling Charging Chart, 601A048 Units
50JS500092
C00031
(060) 60HZ CHARGING CHART
689
100
620
90
551
80
483
70
414
60
SUCTION LINE PRESSURE (PSIG)
345
50
SUCTION LINE PRESSURE (KILOPASCALS)
276
40
207
30
20.0 30.0 40.0 50.0 60.0 70.0 80.0
SUCTION LINE TEMPERATURE (°F)
-7 -1 4 10 16 21 27
SUCTION LINE TEMPERATURE (°C)
Fig. 28—Cooling Charging Chart, 601A060 Units
OUTDOOR TEMP
° F ° C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
50JS500093
C00032
IX. LIQUID LINE STRAINERS
The liquid line strainers (to protect metering devices) are made of
wire mesh and are located in the liquid lines on the inlet side of the
metering devices.
X. HIGH FLOW VALVES
High flow valves are located on the compressor hot gas and
suction tubes. Large black plastic caps distinguish these valves
with O-rings located inside the caps. These valves can not be
accessed for service in the field. Ensure the plastic caps are in
place and tight or the possibility of refrigerant leakage could occur.
XI. TIME-DELAY RELAY
The Time-Delay Relay (TDR) is a solid-state control, recycle
delay timer which keeps indoor blower operating for 60 sec. after
thermostat is satisfied. This delay enables blower to remove
residual cooling in coil after compression shutdown, thereby
improving efficiency of system. The sequence of operation is that
on closure of wall thermostat and at end of a fixed on delay of 1
sec., fan relay is energized. When thermostat is satisfied, an off
delay is initiated. When fixed delay of 60± 5 sec. is completed, fan
relay is de-energized and fan motor stops. If wall thermostat closes
during this delay, TDR is reset and fan relay remains energized.
TDR is a 24-v device that operates within a range of 15-v to 30-v
and draws about 0.5 amps. If the blower runs continuously instead
of cycling off when the fan switch is set on AUTO, the TDR is
probably defective and must be replaced.
XII. LOSS OF CHARGE SWITCH
The loss of charge switch is located on the outdoor liquid line. This
switch contains a Schrader core depressor. This switch opens at 7
psig and closes at 22 psig. No adjustment is necessary.
NOTE: Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device for
troubleshooting unless you are reasonably certain that a problem
exists. If switch must be removed, remove and recover all system
charge so that pressure gauges read 0 psi. Never open system
without breaking vacuum with dry nitrogen.
XIII. CHECK DEFROST THERMOSTAT
There is a liquid header with a brass distributor and feeder tube
going into outdoor coil. At the end of 1 of the feeder tubes, there
is a 3/8-in. OD stub tube approximately 3 in. long (See Fig. 36).
The defrost thermostat should be located on this stub tube. Note
that there is only 1 stub tube used with liquid header, and on most
units it is the bottom circuit.
XIV. DEFROST THERMOSTAT
Defrost thermostat signals heat pump that conditions are right for
defrost or that conditions have changed to terminate defrost. It is
a thermally actuated switch clamped to outdoor coil to sense its
temperature. Normal temperature range is closed at 30° +/- 3°F
and open at 80° +/- 5°F.
NOTE: The defrost thermostat must be located on the liquid side
of the outdoor coil on the bottom circuit and as close to the coil as
possible.
TROUBLESHOOTING
Refer to the Cooling and Heating Troubleshooting Chart (Table
11) for troubleshooting information.
START-UP CHECKLIST
Use the Start-Up Checklist to ensure proper start-up procedures are
followed.
—22—
(030) 60 Hz CHARGING CHART
689 100.0
620
90.0
551
80.0
483
70.0
414
60.0
345
50.0
SUCTION LINE PRESSURE (PSIG)
276
40.0
SUCTION LINE PRESSURE (KILOPASCALS)
207
30.0
20.0
-7 272116104-1
SUCTION LINE TEMPERATURE (DEG. F)
SUCTION LINE TEMPERATURE (DEG. C)
Fig. 29—Cooling Charging Chart, 602A 030 Units
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
80.070.060.050.040.030.0
OUTDOOR
TEMP
F C
45 7
50JX500220
C99032
(036) 60 Hz CHARGING CHART
689 100.0
620
90.0
551
80.0
483
70.0
414
60.0
345
50.0
SUCTION LINE PRESSURE (PSIG)
276
40.0
SUCTION LINE PRESSURE (KILOPASCALS)
207
30.0
20.0
-7 272116104-1
SUCTION LINE TEMPERATURE (DEG. F)
SUCTION LINE TEMPERATURE (DEG. C)
Fig. 30—Cooling Charging Chart, 602A 036 Units
(048) 60 Hz CHARGING CHART
689 100.0
620
90.0
551
80.0
483
70.0
414
60.0
345
50.0
SUCTION LINE PRESSURE (PSIG)
276
40.0
SUCTION LINE PRESSURE (KILOPASCALS)
207
30.0
20.0
-7 272116104-1
SUCTION LINE TEMPERATURE (DEG. F)
SUCTION LINE TEMPERATURE (DEG. C)
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
80.070.060.050.040.030.0
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
80.070.060.050.040.030.0
OUTDOOR
TEMP
F C
45 7
50JX500221
OUTDOOR
TEMP
F C
45 7
50JX500223
C99033
(042) 60 Hz CHARGING CHART
689 100.0
620
90.0
551
80.0
483
70.0
414
60.0
345
50.0
SUCTION LINE PRESSURE (PSIG)
276
40.0
SUCTION LINE PRESSURE (KILOPASCALS)
207
30.0
20.0
-7 272116104-1
SUCTION LINE TEMPERATURE (DEG. F)
SUCTION LINE TEMPERATURE (DEG. C)
80.070.060.050.040.030.0
Fig. 31—Cooling Charging Chart, 602A 042 Units
(060) 60 Hz CHARGING CHART
689 100.0
620
90.0
551
80.0
483
70.0
414
60.0
345
50.0
SUCTION LINE PRESSURE (PSIG)
276
40.0
SUCTION LINE PRESSURE (KILOPASCALS)
207
30.0
20.0
-7 272116104-1
SUCTION LINE TEMPERATURE (DEG. F)
SUCTION LINE TEMPERATURE (DEG. C)
80.070.060.050.040.030.0
OUTDOOR
TEMP
F C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
50JX500222
C99034
OUTDOOR
TEMP
F C
125 52
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
50JX500224
Fig. 32—Cooling Charging Chart, 602A 048 Units
C99035
C99036
Fig. 33—Cooling Charging Chart, 602A 060 Units
—23—
TABLE 9—FILTER PRESSURE DROP (IN. WG)
FILTER SIZE
20X20X10.050.070.080.100.120.130.140.15———————————
20X24X1————0.090.100.110.130.140.150.16————————
24X30X1————— — —0.070.080.090.100.110.120.130.140.150.160.170.18
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300
CFM
TABLE 10—ELECTRIC HEAT PRESSURE DROP TABLE
SMALL CABINET
STATIC
5kW 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07
10 kW 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 0.09 0.10 0.11
15 kW 0.00 0.00 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18
20 kW 0.00 0.00 0.02 0.04 0.06 0.08 0.09 0.11 0.13 0.15 0.17 0.19
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
CFM
LARGE CABINET
STATIC
5kW 0.00 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12
10 kW 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13
15 kW 0.00 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15
20 kW 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16
1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
CFM
Fig. 34—Refrigerant Circuit
C99097
FEEDER TUBE
Fig. 35—Defrost Thermostat
STUB TUBE
DEFROST
THERMOSTAT
C99092
—24—
TABLE 11—COOLING AND HEATING TROUBLESHOOTING CHART
SYMPTOM CAUSE REMEDY
Compressor and outdoor
fan will not start
Compressor will not start
but condenser fan runs
Three-phase scroll compressor (size 030-
060 units) makes excessive noise, and
there may be a low pressure differential
(other than normally satisfying thermostat)
(Continued next page)
Compressor cycles
Compressor operates continuously
Excessive head pressure
Head pressure too low
Excessive suction pressure
Power Failure Call power company
Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker
Defective thermostat, contractor, transformer,
control relay or defrost board
Insufficient line voltage Determine cause and correct
Incorrect or faulty wiring Check wiring diagram and rewire correctly
Thermostat setting too high
Units have a 5-minute time delay
Faulty wiring or loose connections in compressor
circuit
Compressor motor burned out, seized, or
internal overload open
Defective run capacitor, overload, or PTC
(positive temperature coefficient) thermistor
Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor
One leg of 3-phase power dead
Scroll compressor is rotating in the wrong
direction
Refrigerant overcharge or undercharge
Defective compressor Replace and determine cause
Insufficient line voltage Determine cause and correct
Blocked outdoor coil Determine cause and correct
Defective run/start capacitor, overload or start
relay
Defective thermostat Replace thermostat
Faulty outdoor-fan motor or capacitor Replace
Damaged reversing valve Determine cause and correct
Restriction in refrigerant system Locate restriction and remove
Dirty air filter Replace filter
Unit undersized for load Decrease load or increase unit size
Thermostat set too low Reset thermostat
Low refrigerant charge Locate leak, repair, and recharge
Leaking valves in compressor Replace compressor
Frosted coil with incorrect defrost operation
Air in system
Outdoor coil dirty or restricted Clean coil or remove restriction
Dirty air filter Replace filter
Dirty indoor or outdoor coil Clean coil
Refrigerant overcharged Recover excess refrigerant
Air in system
(Heat) Indoor air restricted or recirculating Determine cause and correct
Indoor or outdoor air restricted or air short-cycling Determine cause and correct
Low refrigerant charge Check for leaks, repair and recharge
Compressor valves leaking Replace compressor
Restriction in liquid tube Remove restriction
(Heat) Outdoor coil frosted
(Cool) High Heat load Check for source and eliminate
Compressor valves leaking Replace compressor
Reversing valve hung up or leaking internally Replace valve
Refrigerant overcharged Recover excess refrigerant
Replace component
Lower thermostat setting below room
temperature
DO NOT bypass this compressor time
delay-wait for 5 minute until time-delay relay is
de-energized
Check wiring and repair or replace
Determine cause.
Replace compressor
Determine cause and replace
Determine cause and replace
Replace fuse or reset circuit breaker
Determine cause
Correct the direction of rotation by reversing the
3-phase power leads to the unit
Recover refrigerant, evacuate system, and
recharge to capacities shown on nameplate
Determine cause and replace
Check defrost time settings
Reset as necessary
Check defrost temperature switch
Replace as necessary
Recover refrigerant, evacuate system,
and recharge
Recover refrigerant, evacuate system,
and recharge
Move timer on control board to 30 minute between
defrost cycles
—25—
TABLE 11—COOLING AND HEATING TROUBLESHOOTING CHART (CONT’D)
SYMPTOM CAUSE REMEDY
Suction pressure too low
Compressor runs but outdoor fan does not
IFM* does not run
IFM* runs when it should be off
IFM* operation is intermittent
* IFM–Indoor Fan Motor
I. PRELIMINARY INFORMATION
Model No .............................................................................................................................................................
Serial No ..............................................................................................................................................................
Date .....................................................................................................................................................................
Technician ...........................................................................................................................................................
Job Location ...........................................................................................................................................................
II. PRE-START-UP
____ Verify that all packing materials have been removed from unit
____ Remove all shipping holddown bolts and brackets per installation instructions
____ Verify that condensate connection is installed per installation instructions
____ Check all electrical connections and terminals for tightness
____ Check that indoor (evaporator) air filter is clean and in place
____ Verify that unit installation is level
____ Check fan wheel propeller for location in housing and setscrew tightness
III. START-UP
Supply Voltage: L1-L2 __________ L2-L3 __________ L3-L1 __________
Compressor Amps: L1 __________ L2 __________ L3 __________
Indoor Fan Amps: __________
TEMPERATURE
Outdoor-Air Temperature: __________ DB
Return-Air Temperature: __________ DB __________ WB
Heat Pump Supply Air: __________
Electric Heater Supply Air: __________
PRESSURES
Refrigerant Suction __________ psig
Refrigerant Discharge __________ psig
(Cool) Dirty air filter Replace filter
(Heat) Outdoor coil frosted
Low refrigerant charge Check for leaks, repair and recharge
Metering device or low side restricted Remove source of restriction
(Cool) Insufficient coil airflow
(Cool) Temperature too low in conditioned area Reset thermostat
(Cool) Outdoor ambient below 40° F Install low-ambient kit
Field-installed filter-drier restricted Replace
NC (normally closed) contacts on defrost board
open
Blower wheel not secured to shaft Properly tighten blower wheel to shaft
Insufficient voltage at motor Determine cause and correct
Power connectors not properly sealed Connectors should snap easily; do not force
Motor programmed with a delay profile Allow a few minute for motor to shut off
With thermostat in off state, the voltage on G,
Y1,Y, Y2, W with respect to common, should be
1/2 of actual low voltage supply
Water dripping into motor Verify proper drip loops in connector wires
Connectors not firmly sealed
Move timer on control board to 30 minute
between defrost cycles
Increase air quantity
Check filter–replace if necessary
Check condition of relay on board
Replace if necessary
If measured voltage is more than 1/2, the
thermostat is incompatible with motor
If voltage is less than 1/2, the motor has failed
Gently pull wires individually to be sure they are
crimped into the housing
START-UP CHECKLIST
(REMOVE AND STORE IN JOB FILE)
____ Verify Refrigerant charge using charging tables
____ Verify that 3-phase scroll compressor is rotating in correct direction
© 2006 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
—26—
Printed in U.S.A. Catalog No. II 601A-30-1
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