installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
STANDARD-EFFICIENCY HEAT PUMP UNITS
Cancels: II 548D-90-1 II 548D-90-2
548D
Sizes 090-120
71/2 to 10 Tons
10/15/00
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
I. Step 1— Provide Unit Support . . . . . . . . . . . . . . . . . 1
II. Step 2 — Field Fabricate Ductwork . . . . . . . . . . . . . 3
III. Step 3 — Install Condensate Drain Line
and External Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IV. Step 4 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . 3
V. Step 5 — Make Electrical Connections . . . . . . . . . . 7
VI. Step 6 — Adjust Factory-Installed Options . . . . . . 11
VII. Step 7 — Adjust Indoor-Fan Speed . . . . . . . . . . . . 19
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-30
I. Unit Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
II. Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
III. Outdoor-Air Inlet Screen . . . . . . . . . . . . . . . . . . . . . 28
IV. Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . 28
V. Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VI. Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . 28
VII. High Flow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VIII. Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . 28
IX. Adjust Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
X. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
XI. Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
XII. Safety Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
XIII. Ventilation (Continuous Fan) . . . . . . . . . . . . . . . . . 29
XIV. Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . 29
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-33
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
III. Outdoor Fan Adjustment. . . . . . . . . . . . . . . . . . . . . 32
IV. Economizer Adjustment . . . . . . . . . . . . . . . . . . . . . 32
V. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 32
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .34-38
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install, rep air, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All
other operations s hou l d b e pe rform ed by train ed se rvic e p ersonnel. 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 o perations. Have fire extinguisher available for all brazing operations.
WARNING: Before performing service or maintenance operations on unit, turn off main power switch
to unit and tag disconnect with lockout tag. Electrical
shock could cause personal injury.
INSTALLATION
Unit is shipped in the vertical configuration. To convert to
horizontal configuration, remove side duct opening covers.
Using the same scre ws, install covers on vertical du ct openings with the insulation-side down. Seals around duct openings must be tight.
I. STEP 1 — PROVIDE UNIT SUPPORT
A. Roof Curb
Assemble and install access ory roof curb in accorda nce with
instructions shipped with curb. See Fig. 1. Install in su lation,
cant strips, roofing felt, and counte r flashing as sho wn. Duct-
work must be attached to curb. If electric or cont rol power is
to be routed through the basepan, attach the accessory thruthe-bottom service conn ections to the basepa n in acco rdance
with the accessory installation instructions. Connections
must be installed before unit is set on roof curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for watertightness. Install gasket supplied with the
roof curb as shown in Fig. 1. Improperly applied gask et can
also result in air leaks and poor unit performance.
Curb should be level. Unit leveling tolerances are shown in
Fig. 2. This is necessary for unit drain to function properly.
Refer to Accessory Roof Curb Installation Instructions for
additional information as required.
B. Slab Mount (Horizontal Units Only)
Provide a level concrete slab that exte nds a m ini mum o f 6 i n.
beyond unit cabinet. Install a 6 in. gravel apron in front of
condenser coil air inlet to prevent grass and foliage from
obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if
required.
CAUTION: Ensure voltage listed on unit data
plate agrees with electrical supply provided for the
unit.
ROOF CURB
ACCESSORY
CRRFCURB003A00
CRRFCURB004A00
“A”
1′-2″ [356]
2′-0″ [610]
UNIT SIZE
548D
090-150
“B” “C”
7
″
2′-8
[827]
1′-10
/
16
“D” ALT
DRAIN
HOLE
15
/
16
[583]
NOTES:
1. Roof curb accessor y is shipped
unassembled.
2. Insulated panels, 1 in. thick polyurethane foam, 1
3. Dimensions in [ ] are in millimeters.
4. Roof curb: 16 gage steel.
5. Attach ductwork to curb (flanges of duct
rest on curb).
3
″
″
1
/
4
[44.5]
3
/4 lb density.
“E”
GAS
3
″
/
4
[19] NPT
1
″
/
2
[12.7] NPT
3
″
/
4
[19] NPT
“F”
POWER
3
″
[19] NPT
/
4
1
″
[31.7] NPT CRBTMPWR002A00
1
/
4
3
″
[19] NPT
/
4
1
″
1
[31.7] NPT CRBTMPWR004A00
/
4
“G”
CONTROL
1
″
[12.7]
/
2
NPT
1
″
[12.7]
/
2
NPT
CONNECTOR
PACKAGE
ACCESSORY
CRBTMPWR001A00
CRBTMPWR003A00
6. Service clearance 4 ft on each side.
7. Direction of airflow.
8. Connector packages CRBTMPWR001A00 and
002A00 are for thru-the-curb connections.
Packages CRBTMP003A00 and 004A00 are
for thru-the-bottom connections.
PLACE UNIT AS CLOSE TO
THIS END OF CURB AS POSSIBLE
Fig. 1 — Roof Curb Details
—2—
MAXIMUM ALLOWABLE
DRAIN PLUG
DIFFERENCE (in.)
A-B B-C A-C
0.5 1.0 1.0
Fig. 2 — Unit Leveling Tolerances
II. STEP 2 — FIELD FABRICATE DUCTWORK
On vertical discharge un its, secure a ll duct s to roo f curb an d
building structure. Do not connect ductwork to unit. For hori-
zontal applications, fiel d-suppl ied fl anges sh ou ld be a ttach ed
to horizontal discharge openin gs and all ductwork attached
to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and
mastic in accordance with applicable codes.
Ducts passing through a n unc ondit i one d spa ce must be insulated and covered with a vapor barrier.
If a plenum return is used on a vertical unit, the return
should be ducted through the r oof deck to comply with applicable fire codes.
A minimum clearance to combustibles is not required around
ductwork on vertical discharge units. On horizontal discharge
units with electric heat, a minimum clearance of 1 in. is
required for the first 12 in. of ductwork. Cabinet return-air
static should no t exceed –0.35 in. wg with Du rablade econ omizer, –0.30 in. wg with EconoMi$er, or –0.45 in. wg without
economizer.
Lifting holes are provided in base rails as shown in Fig. 5
and 6. Refer to rigging instructions on unit.
Positioning
Maintain clearance around and above unit to provide proper
airflow and service access. See Fig. 6.
Position unit on roof curb so that the following clearances are
maintained:
1
/4-in. clearance bet ween roof c urb and bas e rails
on each side and in duct end of unit; 35/16-in. clearanc e between
roof curb and condenser end (see Fig. 1, section C-C).
Do not install unit in an indoor location. Do not locate unit
air inlet near exhaust vents or other sources of contaminated air.
Although unit is weatherproof, guard against water from
higher level runoff and overhangs.
After unit is in position, remove polyethylene shipping wrapper and rigging skid.
CAUTION: Ensure voltage listed on unit data
plate agrees with electrical supply provided for the
unit.
III. STEP 3 — INSTALL CONDENSATE DRAIN LINE AND
EXTERNAL TRAP
Condensate drain connections are located on the botto m and
end of the unit. Unit discharge connections do not determine
the use of drain connections; either drain connection can be
used in ver tical or horizontal applications.
When using the standard end drain connection, make sure
the plug (Red) in the alternate bottom connection is tight
before installing the unit.
To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug (Red) from the bottom connection to the end connection. See Fig. 3. The piping
for the condensate drain and external trap can be compl eted
after the unit is in place.
All units must have an external trap for condensate drainage. Install a trap at least 4-in. deep and protect against
freeze-up. See Fig. 4. If drain line is installed downstream
from the external trap, pitch the line away from the unit at
1 in. per 10 ft of run. Do not use a pipe size smaller than the
unit connection (
3
/4 in.).
IV. STEP 4 — RIG AND PLACE UNIT
Inspect unit for transportation damage. File any claim with
transportation agency. Keep unit upright and do not drop.
Spreader bars are not required if top crating is left on unit.
Rollers may be used to move unit across a roof. Level by
using unit f rame as a reference. See Table 1 and Fig. 5 for
additional information. Operating weight is shown in
Table 1 and Fig. 5.
NOTE:
Drain plug is shown in factory-installed position.
Fig. 3 — Condensate Drain Connection
NOTE:
Trap should be deep enough to offset maximum unit static dif-
ference. A 4-in. trap is recommended.
Fig. 4 — External Trap Condensate Drain
—3—
NOTES:
1. Dimension in ( ) is in millimeters.
2. Hook rigging shackles through holes in base rail, as shown in detail
‘‘A.’’ Holes in base rails are centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging straps
from damaging unit.
3. Unit weights do not include economizer. See Table 1 for economizer weights.
UNIT
548D
090
102
120
MAX
WEIGHT
lb kg in. mm in. mm in. mm
940 426 77.42 1966.5 41.5 1054 42.12 1070
965 438 77.42 1966.5 41.5 1054 42.12 1070
1015 460 77.42 1966.5 41.5 1054 42.12 1070
‘‘A’’ ‘‘B’’ ‘‘C’’
DIMENSIONS
CAUTION:
lifting.
All panels must be in place when rigging and
Fig. 5 — Rigging Details
—4—
BOTTOM POWER CHART, THESE HOLES REQ’D
) OR
″
4
/
3
,
″
2
/
1
CRBTMPWR001A00 (
FOR USE WITH ACCESSORY PACKAGES —
)
″
4
/
1
, 1
″
2
/
1
CRBTMPWR002A00 (
[28.4]
[44.4]
[22.2]
″
″
″
8
(Max.)
USE
SIZE
924
8
/
3
1253 3-0
16
/
5
4
8
/
/
/
1
3
7
for power, depending on wire
″
4
/
24 V
1
Pow er* 1
Pow er* 1
or 1
″
4
/
3
″
″
″″
″
″″
″
2
4
FPT
/
/
″
″″
″
1
3
4
/
1
1
size.
*Select either
SIZES
REQ’D HOLE
WIRE
CONDUIT
THREADED
856
856
16
16
/
/
11
11
1050 2-9
1050 2-9
16
16
/
/
5
5
“H” “J” “K”
(D)
WEIGHT
CORNER
(C)
WEIGHT
CORNER
(B)
WEIGHT
CORNER
(A)
WEIGHT
CORNER
WEIGHT
ECONOMI$ER
WEIGHT
DURABLADE
ECONOMI ZER
632 3-5
632 3-5
885 4-1
8
8
8
/
/
/
7
7
7
Fig. 6 — Base Unit Dimensions
Dia. [35] Field Power Supply Hole
Dia. [64] Power Supply Knockout
Dia. [44] Charging Port Hole
″
″
″
Dia. [22] Field Control Wiring Hole
CONNECTION SIZESA1
8
/
3
— 14 NPT Condensate Drain
2
4
″
″
/
1
2
B
Dia. [51] Power Supply Knockout
/
8
4
3
″
/
/
7
3
2
1
F
E
C
D
″
-0
′
[495] for 090 and 102, 2
″
2
/
1
-7
′
WEIGHT
STD UNIT
UNIT
548D
940 426 44 20 62 28 207 94 178 81 254 115 301 136 2- 0
965 438 44 20 62 28 212 96 183 83 261 119 309 140 2- 0
Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Ft-in. mm Ft-in. mm Ft-in. mm
1015 460 44 20 62 28 223 101 193 88 274 124 325 147 2-10
on horizontal discharge units with electric heat 1 in. clearance to
ductwork for 1 ft.
other. The side getting the greater clearance is optional.
cal Code).
per NEC.
surfaces, control box side, 42 in. per NEC.
e. Between unit and ungrounded surfaces, control box side, 36 in.
f. Between unit and block or concrete walls and other grounded
g. Horizontal supply and return end, 0 inches.
6. With the exception of the clearance for the condenser coil as stated
[610] for 120 up from the bottom of the base rail.
in Notes 5a, b, and c, a removable fence or barricade requires no
clearance.
Class A, B, or C roof covering material.
7. Units may be installed on combustible floors made from wood or
8. The ver tical cente r of gravity is 1
090
102
120
a. Bottom to combustible surfaces (when not using curb) 0 inches,
b. Condenser coil, for proper airflow, 36 in. one side, 12 in. the
c. Overhead, 60 in. to assure proper condenser fan operation.
1. Dimensions in [ ] are in millimeters.
2. Center of gravity.
3. Direction of airflow.
4. Ductwork to be attached to accessory roof curb only.
NOTES:
5. Minimum clearance (local codes or jurisdiction may prevail):
d. Between units, control box side, 42 in. per NEC (National Electri-
—5—
Table 1 — Physical Data
UNIT SIZE 548D 090 102 120
NOMINAL CAPACITY (tons)
OPERATING WEIGHT (lb)
Unit
Al/Al*
Economizer
Durablade
EconoMi$er
Roof Curb†
COMPRESSOR
Quantity
Oil (oz)
REFRIGERANT TYPE
Operating Charge (lb-oz)
Circuit 1
Circuit 2
OUTDOOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Quantity...Diameter (in.)
Motor Hp...Rpm
Watts Input (Total)
INDOOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
INDOOR FAN
Quantity...Size (in.) Std
Type Drive Std
Nominal Cfm
Maximum Continuous Bhp Std
Motor Frame Size Std
Nominal Rpm High/Low Std
Fan Rpm Range Std
Motor Bearing Type
Maximum Allowable Rpm
Motor Pulley Pitch Diameter Min/Max (in.) Std
Nominal Motor Shaft Diameter (in.) Std
Fan Pulley Pitch Diameter (in.) Std
Belt, Quantity...Type...Length (in.) Std
Pulley Center Line Distance (in.) Std
Speed Change per Full Turn of
Movable Pulley Flange (rp m) Std
Movable Pulley Maximum Full Turns
From Closed Position Std
Factory Setting Std
Factory Speed Setting (rpm) Std
Fan Shaft Diameter at Pulley (in.)
HIGH-PRESSURE SWITCH (psig)**
Standard Compressor Internal Relief (Differential)
Cutout
Reset (Auto.)
LOSS-OF-CHARGE SWITCH (psig)**
Cutout
Reset (Auto.)
FREEZE-PROTECTION THERMOSTAT (F)**
Opens
Closes
OUTDOOR-AIR INLET SCREENS
Quantity...Size (in.)
RETURN-AIR FILTERS
Quantity...Size (in.)
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
Alt
LEGEND
Al —
Aluminum
Bhp —
Brake Horsepower
*Indoor coil fin mater ial/outdoor coil fin material.
†Weight of 14-in. roof curb.
**Requires an accessory or optional controls upgrade kit.
Enhanced Copper Tubes, Aluminum Double-Wavy Fins, Acutrol Fixed Orifice Metering Feed Device
1
7
/
2
81/
2
940 965 1015
44 44 44
62 62 62
143 143 143
222
45 ea 62 ea 54 ea
Hermetic Scroll
R-22
5-14 8- 6 7-14
5-13 8-13 8- 3
Enhanced Copper Tubes, Aluminum Lanced Fins, Acutrol™ Feed Device
1...17 2...17 2...17
20.50 18.00 18.30
6500 6500 6500
2...22 2...22 2...22
1
/4...1100
600 600 600
3...15 3...15 3...15
8.0 8.0 11.1
1...15 x 15 1...15 x 15 1...15 x 15
1...15 x 15 — 1...15 x 15
Belt Belt Belt
Belt — Belt
3000 3600 4000
2.40 2.40 2.40
——2.90
56 56 56
——56
———
———
590-840 685-935 685- 935
685-935 — 835-1085
Ball Ball Ball
2100 2100 2100
2.4/3.4 2.8/3.8 2.8/3.8
2.8/3.8 — 3.4/4.4
5
/
8
—
7.0 7.0 7.0
7.0 — 7.0
1...A...48 1...A...48 1...A...48
1...A...48 — 1...A...48
16.75-19.25 16.75-19.25 15.85-17.50
15.75-19.25 — 15.85-17.50
50 50 50
50 — 50
555
5—5
555
5—5
590 685 685
685 — 835
111
4...16 x 20 x 2 4...16 x 20 x 2 4...20 x 20 x 2
NOTE:
The 548D units have a loss-of-charge switch located in the liquid line avail-
able as an option or an accessory. (Standard on 120 units.)
Propeller Type
1
/4...1100
Centrifugal Type
5
/
8
—
450 ± 50
428
320
7 ± 3
22 ± 5
30 ± 5
45 ± 5
Cleanable
1...20 x 25 x 1
1...16 x 25 x 1
Throwaway
1
/4...1100
10
5
/
8
7
/
8
—6—
V. STEP 5 — MAKE ELECTRICAL CONNECTIONS
WARNING: 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 c o nsi st of electrical wire
connected to unit ground lug in control compartment,
or conduit approved for electrical ground when
installed in accordance with NEC (National Electrical
Code) ANSI (American Natio nal S tandards In stitute) /
NFPA (National Fire Protection Association) 70 latest
year and local electrical codes. Failure to follow this
warning could result in the installer being liable for
personal injury of others.
A. Field Power Supply
All units except 208/230-v units are factory-wired for the
voltage shown on the unit nameplate. If the 208/230-v unit is
to be connected to a 208-v power supply, the transformer
must be rewired by disconnecting the black wire from the
230-v terminal on the transformer and co nnecting it to the
200-v terminal from the transformer.
Refer to unit label diagram for additional information. Pigtails are provided for field wire connections. Use factorysupplied splices or UL (Underwriters’ Laboratories)
approved copper/aluminum connector.
When installing units, provide a disconnect per the NEC.
All field wiring must comply with the NEC and local re-
quirements. In Canada, electrical connections must be made
in accordance with CSA (Canadian Standards Association)
C22.1 Canadian Electrical Code Part One.
Install field wiring as follows:
1. Install conduit thr ough side panel openin gs . For units
without electric heat, install conduit between disconnect and control box.
2. Install power lines to terminal connections as shown
in Fig. 7.
3. For units with electric heat, refer to Accessory Installation Instructions.
4. If thru-the-bottom control connections are used, refer
to the accessory install ation ins tructions for information on control wiring. Refer to Fig. 6 for drilling holes
in basepan.
During operation, vo ltage to compressor termina ls must be
within range indicated on unit nameplate (see Tables 2A and
2B). On 3-phase units, voltages between phases must be balanced within 2%, and the current within 10%. Use the formula shown in Tables 2A and 2B, Note 2 on page 10 to
determine the percentage of voltage imbalance. Operation on
improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable
warranty.
208/230-3-60
460-3-60
LEGEND
C—
COMP —
IFC —
NEC —
TB —
Contactor
Compressor
Indoor Fan Contactor
National Electrical Code
Terminal Block
Field Wiring
Factory Wiring
Splice Connection
(Factory-Supplied)
Fig. 7 — Power Wiring Connections
—7—
575-3-60
Table 2A — Electrical Data (Units Without Electrical Convenience Outlet)
VOLTAGE
UNIT
548D
NOMINAL
V-PH -H z
TYPE
RANGE
IFM
Min Max RLA LRA
208/230-3-60 STD 187 254 13.4 91.0 1.4 5.8
090
1
(7
/2 Tons)
460-3-60 STD 414 508 6.7 42.0 0.7 2.6
575-3-60 STD 518 632 5.4 39.0 0.7 2.6
208/230-3-60 STD 187 254 16.0 137.0 1.4 5.8
102
1
/2 Tons)
(8
460-3-60 STD 414 508 8.3 69.0 0.7 2.6
575-3-60 STD 518 632 6.4 58.0 0.7 2.6
STD 187 254 17.2 124.0 1.4 5.8
208/230-3-60
ALT 187 254 17.2 124.0 1.4 7.5
120
STD 414 508 8.6 59.6 0.7 2.6
(10 Tons)
460-3-60
ALT 414 508 8.6 59.6 0.7 3.4
STD 518 632 6.9 49.4 0.7 2.6
575-3-60
ALT 518 632 6.9 49.4 0.7 3.4
NOTE:
Legend and Notes for Electrical Data are on page 10.
COMPRESSOR
(each)
OFM
FLA
ELECTRIC HEAT* POWER SUPPLY
IFM
FLA
Nominal
kW**
FLA MCA MOCP FLA LRA
DISCONNECT
— — 38.8/ 38.8 40/ 40†† 41/ 41 229/229
7.8/10.4 21.7/ 25.0 65.9/ 70.0 70/ 80 66/ 69 251/254
12.0/16.0 33.3/ 38.5 80.4/ 86.9 90/ 90 79/ 85 262/268ll
18.6/24.0 50.0/ 57.7 103.3/113.4 110/125 100/109 281/289ll
24.0/32.0 66.6/ 77.0 122.0/135.0 125/150 117/129 296/306ll
31.8/42.4 88.3/102.0 149.1/166.3 150/175 142/158 317/331ll
— — 19.1 20†† 20 108
13.9 16.7 40.0 45†† 39 124
16.5 19.8 43.8 45†† 43 128
27.8 33.4 60.8 70 58 141
33.0 39.7 68.7 70 66 147
41.7 50.2 81.8 90 78 158
— — 15.4 20†† 16 97
17.0 17.1 36.7 40†† 36 114
34.0 34.1 68.0 60†† 55 131
— — 44.6/ 44.6 45/ 45†† 47/ 47 321/321
7.8/10.4 21.7/ 25.0 71.7/ 75.9 80/ 80 72/ 75 343/346
12.0/16.0 33.3/ 38.5 86.2/ 92.7 90/100 85/ 91 354/360II
18.6/24.0 50.0/ 57.7 109.1/119.2 110/125 106/115 373/381II
24.0/32.0 66.6/ 77.0 127.9/140.9 150/150 123/135 388/398II
31.8/42.4 88.3/102.0 155.0/172.0 175/175 148/164 409/423II
— — 22.7 25†† 24 162
13.9 16.7 43.6 45†† 43 178
16.5 19.8 47.4 50†† 46 182
27.8 33.4 64.4 70 62 195
33.0 39.7 72.3 80 69 201
41.7 50.2 85.4 90 81 212II
— — 17.3 20†† 18 135
17.0 17.1 39.0 40†† 38 152
34.0 34.1 60.2 60†† 58 169
— — 47.3/ 47.3 50/ 50†† 49/ 49 295/295
7.8/10.4 21.7/ 25.0 74.4/ 78.6 80/ 80 74/ 78 317/320
12.0/16.0 33.3/ 38.5 88.9/ 95.4 90/100 88/ 94 328/334ll
24.0/32.0 66.6/ 77.0 130.6/143.6 150/150 126/138 362/372ll
31.8/42.4 88.3/102.0 157.7/174.8 175/175 151/167 383/397ll
37.6/50.0 104.4/120.3 177.8/167.6 200/175 170/188 399/415ll
— — 49.0/ 49.0 50/ 50†† 51/ 51 314/314
7.8/10.4 21.7/ 25.0 76.1/ 80.8 80/ 90 76/ 80 336/389ll
12.0/16.0 33.3/ 38.5 90.6/ 97.1 100/100 90/ 96 347/353ll
24.0/32.0 66.6/ 77.0 132.3/145.3 150/150 128/140 381/391ll
31.8/42.4 88.3/102.0 159.4/176.5 175/200 153/169 402/416ll
37.6/50.0 104.4/120.3 179.5/169.3 200/175 171/190 418/434ll
— — 23.4 25†† 24 143
16.5 19.8 48.1 50†† 47 163
27.8 33.4 65.1 70 63 176
33.0 39.7 73.0 80 70 183
41.7 50.2 86.1 90 82 193ll
50.0 60.1 83.5 90 93 203ll
— — 24.2 25†† 25 182
16.5 19.8 48.9 50†† 48 202
27.8 33.4 65.9 70 64 216
33.0 39.7 73.8 80 71 222
41.7 50.2 86.9 90 83 233ll
50.0 60.1 84.3 90 94 243ll
— — 18.7 20†† 20 118
17.0 17.1 40.1 50†† 39 135
34.0 34.1 61.4 70 59 152
51.0 51.2 69.9 70 78 159
— — 19.4 20†† 20 149
17.0 17.1 40.7 50†† 40 166
34.0 34.1 62.0 70 60 183
51.0 51.2 70.6 80 79 201
SIZE†
—8—
Table 2B — Electrical Data (Units With Electrical Convenience Outlet)
VOLTAGE
UNIT
548D
NOMINAL
V- PH -H z
RANGE
IFM
TYPE
Min Max RLA LRA
208/230-3-60 STD 187 254 13.4 91.0 1.4 5.8
090
1
(7
/2 Tons)
460-3-60 STD 414 508 6.7 42.0 0.7 2.6
575-3-60
STD 518 632 5.4 39.0 0.7 2.6
208/230-3-60 STD 187 254 14.4 103.0 1.4 5.8
102
1
/2 Tons)
(8
460-3-60 STD 414 508 7.2 52.5 0.7 2.6
575-3-60 STD 518 632 6.0 44.0 0.7 2.6
STD 187 254 17.2 124.0 1.4 5.8
208/230-3-60
ALT 187 254 17.2 124.0 1.4 7.5
120
STD 414 508 8.6 59.6 0.7 2.6
(10 Tons)
460-3-60
ALT 414 508 8.6 59.6 0.7 3.4
STD 518 632 6.9 49.4 0.7 2.6
575-3-60
ALT 518 632 6.9 49.4 0.7 3.4
NOTE:
Legend and Notes for Electrical Data are on page 10.
COMPRESSOR
(each)
OFM
FLA
ELECTRIC HEAT* POWER SUPPLY
IFM
FLA
Nominal
kW**
FLA MCA MOCP FLA LRA
DISCONNECT
— — 43.6/ 43.6 45/ 45†† 46/ 46 234/234
7.8/10.4 21.7/ 25.0 70.7/ 74.8 80/ 80 71/ 75 256/259
12.0/16.0 33.3/ 38.5 85.2/ 91.7 90/100 85/ 91 267/272ll
18.6/24.0 51.6/ 59.7 108.1/118.2 110/125 106/115 285/294ll
24.0/32.0 66.6/ 77.0 126.8/139.8 150/150 123/135 300/311ll
31.8/42.4 88.3/102.0 153.9/171.1 175/175 148/164 322/336ll
— — 21.3 25†† 23 110
13.9 16.7 42.1 45†† 42 127
16.5 19.8 46.0 50†† 45 130
27.8 33.4 63.0 70 61 143
33.0 39.7 70.9 80 68 150
41.7 50.2 84.0 90 80 160ll
— — 17.1 20†† 18 99
17.0 17.1 38.5 40†† 38 116
34.0 34.1 59.7 60†† 57 133
— — 49.4/ 49.4 50/ 50†† 52/ 52 326/326
7.8/10.4 21.7/ 25.0 76.5/ 80.7 80/ 90 77/ 81 348/351ll
12.0/16.0 33.3/ 38.5 91.0/ 97.5 100/100 91/ 96 359/364ll
18.6/24.0 51.6/ 59.7 113.9/124.0 125/125 112/121 377/386ll
24.0/32.0 66.6/ 77.0 132.7/145.7 150/150 129/141 392/403ll
31.8/42.4 88.3/102.0 159.8/176.9 175/200 154/170 414/428ll
— — 24.9 25†† 26 164
13.9 16.7 45.7 50†† 45 181
16.5 19.8 49.6 50†† 49 184
27.8 33.4 66.6 70 65 197
33.0 39.7 74.5 80 72 204
41.7 50.2 187.6 90 84 214ll
— — 19.3 20†† 20 137
17.0 17.1 40.7 45†† 40 154
34.0 34.1 62.0 70 60 171
— — 52.1/ 52.1 60/ 60†† 55/ 55 300/300
7.8/10.4 21.7/ 25.0 79.2/ 83.4 80/ 90 80/ 84 322/325ll
12.0/16.0 33.3/ 38.5 93.7/100.2 100/110 93/ 99 333/338ll
24.0/32.0 66.6/ 77.0 135.4/148.4 150/150 132/144 366/377ll
31.8/42.4 88.3/102.0 162.5/179.6 175/200 157/172 388/402ll
37.6/50.0 104.4/120.3 182.6/172.4 200/200 175/193 404/420ll
— — 53.8/ 53.8 60/ 60†† 57/ 57 319/319
7.8/10.4 21.7/ 25.0 80.9/ 85.1 90/ 90 82/ 86 341/344ll
12.0/16.0 33.3/ 38.5 95.4/101.9 100/110 93/101 352/357ll
24.0/32.0 66.6/ 77.0 137.1/150.1 150/175 134/145 385/396ll
31.8/42.4 88.3/102.0 164.2/181.3 175/200 158/174 407/421ll
37.6/50.0 104.4/120.3 184.3/174.1 200/200 177/195 423/439ll
— — 25.5 30†† 27 145
16.5 19.8 50.3 60†† 50 165
27.8 33.4 67.3 80 65 178
33.0 39.7 75.2 80 73 185
41.7 50.2 88.3 90 85 195ll
50.0 60.1 85.6 90 96 205ll
— — 26.3 30†† 28 185
16.5 19.8 51.1 60†† 51 204
27.8 33.4 68.1 70 66 218
33.0 39.7 76.0 80 73 224
41.7 50.2 89.1 90 85 235ll
50.0 60.1 86.4 90 97 245ll
— — 20.5 20†† 22 120
17.0 17.1 41.8 45†† 41 137
34.0 34.1 63.1 70 61 154
51.0 51.2 71.7 80 80 171ll
— — 21.1 20†† 22 151
17.0 17.1 42.5 45†† 42 168
34.0 34.1 63.7 70 62 185
51.0 51.2 72.3 80 81 202ll
SIZE†
—9—
LEGEND AND NOTES FOR TABLES 2A AND 2B
LEGEND
FLA —
HACR —
IFM —
LRA —
MCA —
MOCP —
NEC —
OFM —
RLA —
*Heaters are field installed only.
†Used to determine minimum disconnect per NEC.
**Heater capacity (kW) is based on heater voltage of 208 v, 240 v, or 480 v and
575 v. If power distribution voltage to unit varies from rated heater voltage,
heater kW will vary accordingly.
††Fuse or HACR circuit breaker.
Optional disconnect switch is unavailable. (Applies to units with an FLA greater
||
or equal to 80.)
NOTES:
1. In compliance with NEC requirements for multimotor and combination load
equipment (refer to NEC Articles 430 and 440), the overcurrent protective
device for the unit shall be fuse or HACR breaker.
Unbalanced 3-Phase Supply Voltage
2.
Never operate a motor where a phase imbalance in supply voltage is greater
than 2%.
imbalance.
Full Load Amps
Heating, Air Conditioning and Refrigeration
Indoor-Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor-Fan Motor
Rated Load Amps
Use the following formula to determine the percentage of voltage
% Voltage Imbalance
= 100 x
Example: Supply voltage is 460-3-60.
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance = 100 x
This amount of phase imbalance is satisfactory as it is below the maximum
allowable 2%.
IMPORTANT:
tact your local electric utility company immediately.
max voltage deviation from average voltage
AB = 452 v
BC = 464 v
AC = 455 v
= 457
If the supply voltage phase imbalance is more than 2%, con-
average voltage
Average Voltage =
7
457
= 1.53%
452 + 464 + 455
1371
=
3
3
—10—
COMPRESSOR
NO. 2
DISCONNECT
BOARD
DISCONNECT
SWITCH
(OPTIONAL)
RACEWAY
HOLE IN
END
PANEL
COMPRESSOR NO. 1
B. Field Control Wiring
Install an approved ac cessory thermostat assembly according to installation instructions included with the accessory.
Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance
with thermostat installation instructions.
Route thermostat cable or equivalent single leads of colored
wire from subb ase term inals to low-voltage conne ctions on
unit (shown in Fig. 8) as described in Steps 1 through 4
below.
NOTE: If using Bryant electronic thermostat, set thermostat
configuration f or “non-hea t pump opera tion.” The use of the
O terminal is not required to energize the reversing valve in
this family of products.
NOTE: For wire runs up to 50 ft, use no. 18 AWG (American
Wire Gage) insulated wire (35 C minimum). For 51 to 75 ft,
use no. 16 AWG insulated wire (35 C minimum). For over
75 ft, use no. 14 AWG insulated wire (35 C minimum). All
wire larger than no. 18 AWG cannot be dire ctly c onn ected to
the thermostat and will require a junction box and splice at
the thermostat.
1. If unit is mounted on roof cu rb and accessory thruthe-curb service plate connection is used, route wire
through connection plate.
2. Pass control wires through the hole provided on unit
(see connection D in Connection Sizes table in Fig. 6).
3. Feed wire through the raceway built into the corner
post to the 24-v barrier located on the l eft side of the
control box. See Fig. 9. The raceway provides the UL
required clearance between the high- and low-voltage
wiring.
4. Connect thermostat wires to s crew terminals of lo wvoltage connector (see Fig. 8).
NOTE: I f thru-the-bottom po wer connections are u sed refer
to the accessory installation instructions for information on
power wiring. Refer to Fig. 6 for drilling holes in basepan.
C. Defrost Board
The defrost board timer cycle is set to 30 minutes. To change
the cycle time, remove the wire from defrost board connected
to the 30-minute quick-connect. See Fig. 10. Connect the
wire to the 50 or 90 minute quick-connects on the defrost
board, depending on the desired defrost time.
D. Heat Anticipator Settings
For units with electric heat, set heat anticipator settings as
shown in Table 3.
VI. STEP 6 — ADJUST FACTORY-INSTALLED OPTIONS
A. Disconnect Switch
The optional disconnect switch is non-fused. The switch has
the capability of being locked in place for safety purposes.
(See Fig. 9.)
B. Optional Durablade Economizer
The optional economizer hood assembly is packaged and
shipped in the filter section. Damper blades and control
boards are installed at the factory and the economizer is
shipped in the vertical discharge position.
NOTE: Horizontal discharge block-off plate is shipped with
the air hood package. If u nit is to be used for vertical discharge application, discard this plate.
Assembly
1. Determine if ventilation air is required in building. If
so, determine the minimum amount to be supplied by
each unit and record quantity of ventilation air
needed for use in Step 8.
2. Remove filter access panel by raising panel and
swinging panel outward. Panel is now disengaged
from track and can be removed. No tools are required
to remove filter access panel. Remove outdoor-air
opening panel. Save panels and screws. See Fig. 11.
Remove optional outdoor-air damper hood package
from filter section.
3. Assemble outdoor-air hood top and side plates as
shown in Fig. 12. Install seal strips on hoop top and
sides. Put aside screen retainer and retainer screw
for later assembly. Do not attach hood to u nit at this
time.
LEGEND
AHA —
CC —
Adjustable Heat Anticipator
Cooling Compensator
Field Wiring
Factory Wiring
Fig. 8 — Low-Voltage Connections
Fig. 9 — Typical Field Control Wiring Raceway
—11—
Table 3 — Heat Anticipator Settings
208/230 460 575
UNIT
548D
*Heater capacity (kW) is based on heater voltage of 208 v, 240 v,
480 v and 575 v. If power distribution voltage to unit varies from
rated heater voltage, heater kW will vary accordingly.
Heater
kW*
10.4, 16.0 0.3 NA NA
24.8, 32.0 0.6 0.3 0.3
42.4, 50.0 0.9 0.6 0.3 41.7, 50.0 0.6 0.3 0.3 51.0 0.6 0.3 0.3
1-Stage
Configuration
2-Stage
Stage 1 Stage 2 Stage 1 Stage 2 Stage 1 Stage 2
Heater
kW*
13.9, 16.5
27.8, 33.0
Fig. 10 — Defrost Board
UNIT VOLTAGE
Configuration
1-Stage
0.3 NA NA 17.0, 34.0 0.3 NA NA
2-Stage
Heater
kW*
1-Stage
Configuration
2-Stage
Adjust minimum position setting by loosening the
screws on the position setting bracket. See Fig. 18.
Slide bracket until the top screw is in the position
determined by Fig. 17. Tighten screws.
9. Remove tape and shipping screw from outdoor-air
thermostat (OAT). Fas-ten OAT to inside of hood
using screws and speed clips provided. See Fig. 19.
Make sure OAT terminals are positioned up.
10. Repl ace outdoor-air opening p anel using scr ews from
Step 2. Replac e filter access panel. Ensure t he filter
access panel slides along the tracks and is securely
engaged.
11. Fasten hood top and side plate assembly to outdoorair opening panel with screws provided.
12. Place knob supplied with economizer on OAT. See
Fig. 19. Set for 3° F below indoor room thermostat
setting. If accessory enthalpy control (EC) i s used in
place of OAT, see instructions shipped with EC for
installation and adjustment . See F ig. 19.
13. Connect OAT per Fig. 20.
14. Slide outdoor-air inlet screen into screen track on
hood side plate. While holding screen in place, fasten
screen retainer to hood usi ng screws provided.
NOTE: Refer to Fig. 21 for economizer barometric relief
damper characteristics.
4. On size 120 units, install vertical discharge block-off
plate over duct openings. See Fig. 13.
5. Economizer is factory-installed in unit and secured
with screws. See Fig. 14.
NOTE: Be sure rear economizer flange is engaged under tabs
in vertical return-air ope ni ng.
6. To convert to horizontal discharge application:
a. Rotate the economizer 90 d egrees unti l the econ-
omizer motor faces the outdoor section (see
Fig. 15).
b. Remove shipping screw and tape from baromet-
ric damper and rotate the barometric relief
damper hinge 90 degrees. Barometric relief
damper should open vertically to operate
properly.
c. Install horizontal discharge block-off plate over
the opening on the acce ss panel. (Block-off plate
MUST be installed before installing hood assembly.) See Fig . 16.
7. Remove existing 12-pin blue and yellow wire jumper
plug and store. Insert 12-pin economizer plug into
economizer harness. See Fig. 14.
8. If ventilation air is not req uired , proce ed to Step 9. If
ventilation air is required, determine the minimum
position setting for required airflow. See Fig. 17.
Fig. 11 — Panel Locations
—12—
Loading...