Bryant 566D, 576C, 566E, 569F, 569D Installation, Start-up And Service Instructions Manual

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Page 1

installation, start-up and

566D/E

service instructions

COMMERCIAL AIR-COOLED CONDENSING UNITS

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

I. Complete Pre-Installation Checks . . . . . . . . . . . . . . 1

II. Rig and Mount the Unit . . . . . . . . . . . . . . . . . . . . . . . 9

III. Complete Refrigerant Piping

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

IV. Install Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 11

V. Complete Electrical Connections. . . . . . . . . . . . . . 11

PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

I. System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

II. Leak Test and Dehydration . . . . . . . . . . . . . . . . . . . 15

III. Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . 15

IV. Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . 15

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20

I. 569D, 566E, 569F Units . . . . . . . . . . . . . . . . . . . . . . 15

II. 576C, 566D Units . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . 20, 21

I. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

II. Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-24

I. Capacity Control (576C, 566D Units) . . . . . . . . . . . 21

II. Head Pressure Control

(566D, 566E150-240 Units Only) . . . . . . . . . . . . . 21

III. Time Guard II Circuit (566D Only). . . . . . . . . . . . . . 21

IV. Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 22

V. Compressor Protection . . . . . . . . . . . . . . . . . . . . . . 22

VI. Low-Pressure Switches. . . . . . . . . . . . . . . . . . . . . . 22

VII. High-Pressure Switches . . . . . . . . . . . . . . . . . . . . . 22

VIII. Discharge Gas Thermostat . . . . . . . . . . . . . . . . . . . 22

IX. Outdoor Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

X. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

XI. Coil Cleaning and Maintenance . . . . . . . . . . . . . . . 22

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 26

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2

SAFETY CONSIDERATIONS

Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start-up, and service this equipment.

569D/F

576C

Sizes 072-240

6to20Tons

Cancels: II 569D-72-1 II 569D-72-2

9/15/04

Untrained personnel can perform basic maintenance functions such as cleaning coi ls. All other operat ions should be performed by trained service personnel.

When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.

Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby when brazing. Use care in handling, rigging, and setting bulky equipment.

WARNING: Before installing or servicing system, always turn off main power to system and install lockout tag on disconnect. There may be more than one disconnect switch. Electrical shock can cause personal injury.

INSTALLATION

I. COMPLETE PRE-INSTALLATION CHECKS

A. Uncrate Unit

Remove unit packaging except for the top skid assembly, which should be left in place until after the unit is rigged into its final location.

B. Inspect Shipment

File claim with shipping company if shipment is damaged or incomplete.

C. Consider System Requirements

• Con sult local b uil ding code s and Nation al Ele ctrica l Code (NEC) for special installation requirements.

• Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1-4 for unit dimensions and weight distribution data.

• Locate unit so that outdoor coil (condenser) airflow is unrestricted on all sides an d ab ove.

• Unit may be mounted on a level pad directly on the base channels or mounted o n a raised structural stee l frame. See Tables 1A to 1C for unit operating weights. See Fig. 1-4 for weight distribution based on recommended support points.

NOTE: If vibration isolators are required for a particular installation, use the data in Fig. 1-4 to make the proper selection.

Page 2

UNIT

569D072 300 (136) 62 (28) 103 (47) 62 (28) 72 (33) 352 (160) 95 (43) 92 (42) 92 (42) 72 (33) 569D090 383 (174) 86 (39) 123 (56) 85 (39) 89 (40) 484 (220) 122 (55) 137 (62) 122 (55) 104 (47) 569D120 430 (195) 84 (38) 166 (75) 66 (30) 114 (52) 531 (241) 121 (55) 176 (81) 103 (47) 128 (58) 576C090 550 (249) 49 (22) 262 (119) 75 (34) 165 (75) 651 (295) 88 (40) 273 (124) 114 (52) 177 (80) 576C102 575 (261) 55 (25) 265 (120) 88 (40) 167 (76) 676 (307) 94 (43) 276 (125) 127 (58) 179 (81) 576C120 575 (261) 55 (25) 265 (120) 88 (40) 167 (76) 676 (307) 94 (43) 276 (125) 127 (58) 179 (81)

Standard

Weight

ALUMINUM COIL lb (kg) COPPER COIL lb (kg)

Corner

UNIT

569D072 831.9 [32.75] 641.4 [25.25] 789.7 [31.09] 619.3 [24.38] 569D090 822.3 [32.38] 635.0 [25.00] 806.5 [31.75] 621.8 [24.48] 569D120 812.8 [32.00] 676.3 [26.63] 800.1 [31.50] 656.3 [25.84] 576C090 924.1 [36.38] 657.3 [25.88] 896.4 [35.29] 644.1 [25.36] 576C102 927.1 [36.50] 647.7 [25.50] 900.2 [35.44] 636.3 [25.05] 576C120 927.1 [36.50] 647.7 [25.50] 900.2 [35.44] 636.3 [25.05]

Fig. 1 — 569D072-120, 576C090-120 Unit Dimensions

Corner

ALUMINUM COIL COPPER COIL Center of Gravity

mm [in.]

XYXY

Corner

Standard

Weigh t

Center of Gravity

mm [in.]

Corner

—2—

Corner

Page 3

CORNER A

1162.7 [45.78]

OUTDOOR COIL

COMPRESSOR # 1

CORNER B

COMPRESSOR # 2

OUTDOOR COIL

ACCESS PANEL

O 34.5 [1.36] POWER ENTRY WITH 50.0/58.0/65. K.O.

OUTDOOR

COIL

FORK TRUCK SLOTS (3 SIDES ONLY)

111.7 [4.40]

O 22.2 [0.87] FIELD ENTRY SERVICE PORT

CORNER D

ELECTRICAL DISCONNECT LOCATION

CONTROL BOX ACCESS PANEL

CONVENIENCE OUTLET LOCATION

582.5

167.5 [6.59]

[22.93]

BOTTOM OF UNIT

116.7 [4.59]

644.6

[25.38]

LEFT SIDE VIEW

COMPRESSOR

ACCESS PANEL

SERVICE VALVE CONNECTIONS

UNIT SUCTION LIQUID

569F120

569F120 11/8(2)

UNIT

569F120 488 221 102 46 143 65 139 63 104 47

1-1/8

Std. Unit

Wt.

lb kg lb kg lb kg lb kg lb kg X Y lb kg lb kg lb kg lb kg lb kg X Y

3/8

/8(2)

ALUMINUM COIL COPPER COIL

CornerACornerBCornerCCornerDCenter of Gravity

TOP VIEW

CIRCUIT #2

LIQUID CONNECTION (3/8")

OUTDOOR

COIL

637.9

[25.11]

1509.3 [59.42]

FRONT VIEW

OUTDOOR

COIL

REAR VIEW

mm [in.]

873.8 [34.4]

591.8 589 267 129 59 166 75 164 74 130 59

[23.3]

CORNER C

CIRCUIT #2

SUCTION CONNECTION (1 1/8")

CIRCUIT #1

SUCTION CONNECTION (1 1/8")

CIRCUIT #1 LIQUID CONNECTION

Std. Unit

Wt.

CornerACornerBCornerCCornerDCenter of Gravity

(3/8")

OUTDOOR

COIL

ACCESS

RIGHT SIDE VIEW

845.8 [33.3]

PANEL

mm [in.]

872.8

[34.36]

579.1 [22.8]

Fig. 2 — 569F120 Unit Dimensions

—3—

Page 4

UNIT

Standard

566D

Weight

lb (kg) 150 779 (354) 70 (32) 177 (80) 68 (31) 100 (45) 261 (119) 103 (47) 919 (418) 99 (45) 224 (102) 96 (44) 114 (52) 268 (122) 118 (54) 180 789 (359) 70 (32) 180 (82) 69 (31) 101 (46) 265 (120) 104 (47) 929 (422) 99 (45) 228 (104) 96 (44) 115 (52) 273 (124) 118 (54) 240 900 (422) 84 (38) 234 (106) 82 (37) 108 (49) 310 (141) 111 (50) 1040 (473) 110 (50) 283 (129) 107 (49) 116 (53) 305 (139) 119 (54)

NOTES:

1. Service clearances are as follows: Side (compressor) — 3 Side (opposite compressor) — 3 ft (914 mm) Ends — 2 ft (610 mm) Top—5ft(1524mm)

ABCD E F A B C D E F

ALUMINUM COIL COPPER COIL

Operational Weight Points lb (kg) Standard

/2ft (1067 mm)

Weight

lb (kg)

2. Corner weights are approximate.

3. Actual support weights depend on level of unit and evenness of support posts.

4. Total weights represent approximate unit weights without shipping package.

5. Bottom or top skid is NOT included in the weights.

Fig. 3 — 566D150-240 Unit Dimensions

—4—

Operational Weight Points lb (kg)

Page 5

UNIT

Standard

566E

Weight

lb (kg) 150 676 (307) 84 (38) 168 (76) 72 (33) 78 (35) 183 (83) 91 (41) 822 (373) 118 (54) 219 (100) 103 (47) 90 (41) 190 (86) 102 (46) 180 740 (336) 86 (39) 186 (85) 71 (32) 82 (37) 216 (98) 99 (45) 886 (403) 119 (54) 238 (129) 102 (46) 95 (43) 221 (100) 111 (50) 240 764 (347) 87 (40) 192 (87) 72 (33) 85 (39) 226 (103) 102 (46) 904 (411) 120 (55) 243 (110) 102 (46) 96 (44) 230 (105) 113 (51)

NOTES:

1. Service clearances are as follows: Side (compressor) — 3 Side (opposite compressor) — 3 ft (914 mm) Ends — 2 ft (610 mm) Top—5ft(1524mm)

2. Corner weights are approximate.

ABCDE F A B CDE F

ALUMINUM COIL COPPER COIL

Operational Weight Points lb (kg) Standard

/2ft (1067 mm)

Weigh t

lb (kg)

3. Actual support weights depend on level of unit and evenness of support posts.

4. Total weights represent approximate unit weights without shipping package.

5. Bottom or top skid is NOT included in the weights.

Fig. 4 — 566E150-240 Unit Dimensions

—5—

Operational Weight Points lb (kg)

Page 6

Table 1A — Physical Data — 569D072-120, 576C090-120, 569F120 Units

UNIT SIZE 569D072 569D090 569D120 576C090 576C102 576C120 569F120

NOMINAL CAPACITY (tons) 67 OPERATING WEIGHT (lb)

Aluminum-Fin Coils (Standard) 300 383 430 550 575 575 488

10 71/

81/

10 10

Copper-Fin Coils (Optional) 352 484 531 651 676 676 589

REFRIGERANT TYPE* R-22

Operating Charge, Typical (lb)† 12 20 22 20 24 24 11/Circuit Shipping Charge (lb) 2.0

COMPRESSOR Scroll Reciprocating Scroll

Qty...Model 1...SR_68 1...SR_94 1...ZR125 1...06DA818 1...06DA824 1...06DH824 2...SR_60 Oil Charge (oz) 88 90 110 88 128 128 72 (ea) No. Cylinders N/A 4 6 6 N/A Speed (rpm) 3500 1750 3500

CONDENSER FANS

Qty...Rpm 2...850 2...1100 2...1100 2...1100 2...1100 2...1100 2...1100 Motor Hp Diameter 22 22 22 22 Nominal Airflow (Cfm Total) 5400 6500 6500 6500 Watts (Total) 340 570 570 570

CONDENSER COIL (Qty) 222

Face Area (sq ft total) 29.2 29.2 29.2 Rows...Fins/in. 1...17 2...17 2...17 2...17 2...17 Storage Capacity (lb)** 17.3 34.2 34.2 34.2 17.1 (ea)

CONTROLS

Pressurestat Settings (psig)

High Cutout 428 ± 10 428 ± 10 428 ± 10

Cut-in 320 ± 20 320 ± 20 320 ± 20

Low Cutout 27 ± 3 27 ± 3 27 ± 3

Cut-in 44 ± 5 44 ± 5 44 ± 5

DISCHARGE GAS THERMOSTAT (F)

Cutout — 270 ± 9 — — — — — Cut-in — 190 ± 13 — — — — —

PRESSURE RELIEF

Location Suction Line Temperature (F) 200

PIPING CONNECTIONS (in. ODM)

Qty...Suction 1...1 Qty...Liquid 1...3/

*Unit is factory-supplied with holding charge only.

†Typical operating charge with 25 ft of interconnecting piping.

**Storage capacity of condenser coil with coil 80% full of liquid R-22 at

95 F.

1...11/

1...3/

1...13/

1...1/

1...11/

1...3/

1...13/

1...1/

1...13/

1...1/

2...11/

2...3/

NOTE: Unit 576C120 has one step of unloading. Full load is at 100% of capacity, and one step of unloading is 67% capacity. Unit 576C120 has the following unloader settings: load is 70 ± 1 psig and unload is 60 ± 2psig.

—6—

Page 7

Table 1B — Physical Data — 566D150-240 Units

UNIT SIZE 566D150 566D180 566D240 NOMINAL CAPACITY (tons) 12 OPERATING WEIGHTS (lb)

Aluminum-Fin Coil (Standard) 779 789 900

15 20

Copper-Fin Coil (Optional) 919 929 1040

REFRIGERANT TYPE* R-22

Operating Charge, Typical (lb)† 23 23 28 Shipping Charge (lb) 3.1 3.1 3.1

COMPRESSOR Reciprocating, Semi-Hermetic

Qty...Model 1...06DD328 1...06DD537 1...06E4250 No. Cylinders 664 Speed (rpm) 1750 Oil Charge (pt) 10 10 15.5 Capacity Steps

Accessory 33**, 66, 100 33**, 66, 100 — Standard 66, 100 66, 100 50, 100

Unloader Setting (psig)

Load 70 ± 1 Unload 60 ± 2

Crankcase Heater Watts 125

CONDENSER FANS Axial Flow, Direct Drive

Qty...Rpm 2...1075 Diameter (in.) 26 Nominal Hp Nominal Airflow (cfm, total) 11,000

Watts (total) 1460

CONDENSER COIL Copper Tubes, Aluminum Fins

Rows...Fins/in. 3...15 3...15 3...15 Face Area (sq ft) 29.2 29.2 29.2 Storage Capacity (lb)†† 40.3 39.8 39.8

CONTROLS

Pressurestat (psig)

High Cutout 395 ± 10

Cut-in 295 ± 20

Low Cutout 27 ± 4

Cut-in 67 ± 7

FAN CYCLING CONTROLS

Operating Pressure (psig)

No. 2 Fan, Close 255 ± 10

Open 160 ± 10

PRESSURE RELIEF

Location Liquid Line Temperature (F) 200

PIPING CONNECTIONS (in. ODM)

Suction 1 Liquid Hot Gas Stub

13/

15/

*Unit is factory-supplied with holding charge only.

†Typical operating charge with 25 ft of interconnecting piping. Operating charge is approximate for maximum system capacity.

**Indicates capacity step (%) with electric unloader accessory.

††Storage capacity is measured at liquid saturated temperatures of 123 F for 566D150 and 130 F for 566D180 and 240.

—7—

Page 8

Table 1C — Physical Data — 566E150-240 Units

UNIT SIZE 566E150 566E180 566E240

NOMINAL CAPACITY (tons) 12 OPERATING WEIGHTS (lb)

Aluminum-Fin Coil (Standard) 676 740 764

15 20

Copper-Fin Coil (Optional) 822 886 904

REFRIGERANT TYPE* R-22

Operating Charge, Typical (lb)† 11.5/Circuit 11.5/Circuit 14/Circuit Shipping Charge (lb) 3.1

COMPRESSOR Scroll

Qty...Model 2...ZR72 2...ZR94 2...ZR125 Speed (rpm) 3500 3500 3500 Oil Charge (oz) 60 (ea) 85 (ea) 110 (ea) Crankcase Heater Watts 70

CONDENSER FANS

Qty...Rpm 2...1075 Diameter (in.) 26 Nominal Hp Nominal Airflow (cfm, total) 11,000 Watts (total) 1460

CONDENSER COIL

Rows...Fins/in. 3...15 Face Area (sq ft total) 29.2 Storage Capacity (lb)** 48

CONTROLS

Pressurestat (psig)

High Cutout 426 ± 7

Cut-in 320 ± 20

Low Cutout 27 ± 4

Cut-in 67 ± 7

FAN CYCLING CONTROLS

Operating Pressure (psig)

No. 2 Fan, Close 255 ± 10

Open 160 ± 10

PRESSURE RELIEF

Location Liquid Line Temperature (F) 200

PIPING CONNECTIONS (in. ODM)

Suction (2) 1 Liquid (2)1/ Hot Gas Stub

*Unit is factory-supplied with holding charge only.

†Typical operating charge with 25 ft of interconnecting piping. Operating charge is approximate for maxi-

mum system capacity.

**Storage capacity is measured at liquid saturated temperatures of 123 F for 566E150 and 130 F for

566E180 and 240.

—8—

Page 9

II. RIG AND MOUNT THE UNIT

CAUTION: Be sure unit panels are securely in

place prior to rigging.

A. Rigging

These units are designed for o verhead rigging. Refer to rigging label for preferred rigging method. Spreader bars are not required if top crating is left on unit. All panels must be in place when rigging. As further protection for coil faces, plywood sheets may be placed against sides of unit, behind cables. Run cables to a central suspension point so that angle from the horizontal is not less than 45 degrees. Raise and set unit down carefully.

If it is necessary to r o ll th e uni t int o po si ti on , mo unt the u nit on longitudinal rails, using a minimum of 3 rollers. Apply force to the rails, not the unit. If the unit is to be skidded into position, place it on a large pad and drag it by the pad. Do not apply any force to the unit.

Raise from above to lift unit from the rails or pad when unit is in final position.

After unit in position, remove all shipping materials and to p crating.

B. Compressor Mounting

As shipped, the compressor is held tightly in place by selflocking bolts. Before starting unit, loosen self-locking

bolts until the snubber washer can be moved sideways with finger pressure. Do not remove shipping bolts. See Fig. 5.

III. COMPLETE REFRIGERANT PIPING CONNECTIONS

IMPORTANT: DO NOT bury refrigerant piping underground. IMPORTANT: A refrigerant receiver is not provided wi th the

unit. Do not install a receiver.

A. Size Refrigerant Lines

Consider the length of piping required between outdoor unit and indoor unit (evaporator), the amount of liquid lift, and compressor oil return. See Tables 2A-4. Refer to indoor unit installation instructions for additional information.

IMPORTANT: Use the piping data in Tables 2A-4 as a general guide only. For 569D, 576C, 569F applications with liquid lift greater than 20 ft, u se

/8-in. liquid line. Maximu m

lift is 60 ft. Condensing units with multiple-step unloading may require

double suction risers to assure proper oil return at minimum load operating condition. See Tables 3A-4 and Fig. 6. Reduction of evaporator coil surface should be analyzed to provide sufficient refrigerant velocity to return oil to the compress or. Liquid line solenoid valves may be used in certain situations to accomplish this. Hot gas bypass, if used, should be introduced before the evaporator.

LEGEND

A — Suction Riser

B — Suction Riser

C — Suction Line to Condensing Unit

D — Short Vertical Riser into Condensing Unit:

566D150,180 — 1 566D240 — 1

Without

With

Tr ap

Tr a p

/8in. OD

Fig. 6 — Suction Line Piping

Note that refrigerant suction piping should be insulated.

Table2A—LiquidLineData—

566D150-240 Units

UNIT 566D

150 67 (20.4) 180 82 (25.0) 240 87 (26.5)

MAXIMUM

ALLOWABLE

LIQUID LIFT

ft (m)

Maximum Allowable

Pressure

Drop

psig (kPa)

7 (48.3) 2 (1.1)

LIQUID LINE

Maximum Allowable

Tem p.

Loss

F(C)

Filter Drier

and

Sight Glass

Flare Conn.*

in.

Table2B—LiquidLineData—

566E150-240 Units

UNIT 566E

150

240

*Inlet and outlet. NOTE: Data shown is for units operating at 45 F (7.2 C) saturated suc-

tion and 95 F (35 C) entering air.

MAXIMUM

ALLOWABLE

LIQUID LIFT

ft (m)

60 (18) 7 (48) 2 (1)180

LIQUID LINE

Maximum Allowable

Pressure

Drop

psig (kPa)

Maximum Allowable

Temp.

Loss F(C)

Fig. 5 — Compressor Mounting

—9—

Page 10

Table 3A — Refrigerant Piping Sizes —

569D, 576C, 569F Units

LINEAR LENGTH OF INTERCONNECTING PIPING —

UNIT

0-25

(0-7.5)

LSLSLSLS

072

0903/811/

569D

1201/213/

576C

/811/

/213/

569F 120 (2)3/8(2) 11/8(2)3/8(2) 11/8(2)3/8(2) 11/8(2)3/8(2) 11/

L—Liquid Line S—Suction Line

LEGEND

*Field-supplied suction accumulator required.

NOTES:

1. Pipe sizes are based on a 2 F (1 C) loss for liquid and suction lines.

2. Pipe sizes are based on the maximum linear length, shown for each column, plus a 50% allowance for fittings.

3. Charge units with R-22 in accordance with unit installation instructions.

FT (m)

26-50

(7.8-15)

Line Size (in. OD)

51-75

(15.3-23)

11/

11/ 13/

13/

76-100*

(23.3-30)

/811/

/213/

Table 3B — Refrigerant Piping Sizes —

566D Units

LENGTH OF INTERCONNECTING PIPING, FT (M)

UNIT

0-15

(0-4.5)

16-25

(4.8-7.5)

26-50

(7.8-15)

51-75

(15.3-23)

76-100*

(23.3-30)

Line Size (in. OD)

LSLSLSLSLS

566D

150

180

240

/211/

/213/

/815/

/213/

/813/

/815/

/813/

/815/

/815/8†5/815/8†

/815/

/821/

/821/8†

/821/

LEGEND

L—Liquid S—Suction

Close-coupled

*Field-supplied suction accumulator required. †Requires a double suction riser if 2 unloaders are used and the evaporator is

below the condensing unit. See Table 4 and Fig. 6 for more information.

NOTES:

1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F (0.8 C) loss for suction lines.

2. Pipe sizes are based on an equivalent length equal to the maximum length of interconnecting piping plus 50% for fittings. A more accurate estimate may result in smaller sizes.

3. For applications with refrigerant line lengths greater than 100 ft, contact Bryant representative.

Table 3C — Refrigerant Piping Sizes —

566E Units

LINEAR LENGTH OF INTERCONNECTING PIPING

UNIT

0-25

(0-7.5)

LSLSLSLS

566E

150

/211/

1801/213/

2401/213/

/211/

/213/

LEGEND

L—Liquid S—Suction

*Field-supplied suction accumulator required.

NOTES:

1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F (0.8 C) loss for suction lines.

2. Pipe sizes are based on an equivalent length equal to the maximum length of interconnecting piping plus 50% for fittings. A more accurate estimate may result in smaller sizes.

3. For applications with refrigerant line lengths greater than 100 ft, contact Bryant representative.

FT (M)

26-50

(7.8-15)

Line Size (in. OD)

51-75

(15.3-23)

/211/

/213/

/813/

76-100*

(23.3-30)

/213/

/813/

Table 4 — Refrigerant Piping Sizes, Double Suction

Risers — 566D150, 180 Units

LENGTH OF INTERCONNECTING PIPING, FT (M)

UNIT

50-75

(15-23)

76-100

(23.3-30)

Line Size (in. OD)

ABCABC

150 1

566D

180 ———1

NOTES:

1. See Fig. 5 for “A,” “B,” and “C” dimensions.

2. No double suction risers are needed for unit size 240.

13/

15/

11/

13/

15/

21/

B. Install Filter Drier(s) and Moisture Indicator(s)

Every unit should have a filter drier and liquid-moisture indicator (sight glass). Re fer to Table 5. In so me applica tions , depending on spa ce and co nven ienc e requ irem ents, it may be desirable to install 2 filter driers and sight glasses. One filter drier and sight glass may be inst alle d at A

locations in Fi g . 7, or, 2 filter driers and sight glasses may be installed at B locations.

Select the filter drier for maximum unit capacity and minimum pressure drop. Complete the refrigerant piping from indoor unit to outdoor unit before opening the liquid and suction lines at the outdoor unit.

C. Install Liquid Line Solenoid Valve — Solenoid Drop

It is recommended that a solenoid valve be placed in the main liquid line (se e F ig. 7) between con d ens ing u n it a nd fa n coil. Refer to Table 5. (A liquid line soleno id va lv e is requi r ed when the liquid line length exceeds 75 ft.) This valve prevents refrigerant migration (which cause s oil dilution) to the compressor during the off cycle at low outdoor ambient temperatures. The solen oid shoul d be wired in p arallel with the compressor contactor coil. This means of electrical control is referred to as solenoid drop control.

LEGEND

TXV — Thermostatic Expansion Valve

Fig. 7 — Location of Sight Glass(es)

and Filter Driers

—10—

Page 11

Table 5 — Refrigerant Specialities Part Numbers

UNIT

569D072

569D090

569D120 576C120

566D150

566D180

566D240

569F120 566E150

566E180

566E240

LIQUID LINE

SIZE (in.)

LIQUID LINE

SOLENOID VALVE (LLSV)

200RB5T3M AMG/24V AMI-1TT3 P502-8304S* S-7063S* 200RB5T3M AMG/24V AMI-1TT3 P502-8304S* S-7063S* 200RB5T4M AMG/24V AMI-1TT4 P502-8304S S-7063S* 200RB6T4M AMG/24V AMI-1TT4 P502-8307S* S-7063 200RB6T4M AMG/24V AMI-1TT4 P502-8307S* S-7063 200RB7T4M AMG/24V AMI-1TT4 P502-8757S* S-7063 200RA8T5M AMG/24V AMI-1TT5 P502-8757S* S-7063 200RB7T4M AMG/24V AMI-1TT4 P502-8757S* S-7721 240RA8T5M AMG/24V AMI-1TT5 P502-8757S* S-7721 200RA8T7M AMG/24V AMI-1TT7 P502-8757S S-7721 200RA9T5M AMG/24V AMI-1TT5 P502-8757S* S-7721

200RA9T7M AMG/24V AMI-1TT7 P502-8757S S-7721 200RB5T3M Qty 2 AMG/24VQty 2 AMI-1TT3 Qty 2 P502-8304S* Qty 2 S-7061 Qty 2 200RB5T4M Qty 2 AMG/24VQty 2 AMI-1TT4 Qty 2 P502-8304S Qty 2 S-7063S* Qty 2 200RB5T4M Qty 2 AMG/24VQty 2 AMI-1TT4 Qty 2 P502-8304S Qty 2 S-7063S Qty 2 200RB5T5M Qty 2 AMG/24VQty 2 AMI-1TT5 Qty 2 P502-8305S Qty 2 S-7063S Qty 2 200RB6T4M Qty 2 AMG/24VQty 2 AMI-1TT5 Qty 2 P502-8307S* S-7063S Qty 2 200RB6T5M Qty 2 AMG/24VQty 2 AMI-1TT5 Qty 2 P502-8307S* S-7063S Qty 2

*Bushings required.

D. Install Liquid Line Solenoid Valve (Optional) — Capacity Control

If 2-step cooling is desired, place a solenoid valve in the location shown in Fig. 7.

E. Make Piping Connections

Do not remove runaround loop from suction and liquid line stubs in the compressor compartment until piping connections are read y to be made. Pass nitroge n or other ine rt gas through piping while brazing to prevent formation of copper oxide.

WARNING: Recover holding charge prior to

removal of runaround piping loop.

1. Open service valves: a. Discharge service valve on compressor. b. Suction ser vic e valve on compressor.

c. Liquid line valve.

2. Remove

/4-in. flare cap from liquid valve Schrader

port.

3. Attach refrigerant recovery device and re cover hold-

ing charge.

4. Remove runaround loop.

5. Install a field-supplied liquid moisture indicator in

the piping immediately leaving outdoor unit.

6. If necessary, install field-supplied thermostatic

expansion val ve(s) (TXVs) in a ir handler.

If 2 TXVs are installed and two-step cooling is desired, install field-supplied capacity control liquid line solenoid valve ahead of the upper TXV (see Fig. 7).

F. Provide Safety Relief

A fusible plug is loca ted on the compressor crankcas e or in the liquid line (Fig. 8). Do not cap this plug. If local code requires additi onal safety devices, install them as directed.

LLSV COIL

SIGHT

GLASS

FILTER

DRIER

SUCTION LINE

ACCUMULATOR

IV. INSTALL ACCESSORIES

Field install accessories such as low-ambient control before proceeding with wiring. Refer to the instructions shipped with the accessory.

V. COMPLETE ELECTRICAL CONNECTIONS

A. Power Wiring

Unit is factory wired for volta ge shown on nameplate. Provide adequate fused disconnect switch within sight from unit and readily accessible from unit, but out of the reach of children. Lock switch open (off) to prevent power from being turned on while unit is being serviced. Disconnect switch, fuses, and field wiring must comply with national and local code requirements. See Tables 6A-6C.

Route power wires through opening in unit end panel to connection in unit control box as shown on unit label diagram and in Fig. 9. Unit must be grounded.

Affix crankcase heater warning sticker to unit disconnect switch.

B. Control Circuit Wiring

Control voltage is 24 v. See Fig. 10 a nd unit la bel dia gram for field-supplied wiring details. Route control wires through opening in unit end panel to connection in unit control box.

C. Control Transformer Wiring (569D, 576C, 569F Units Only)

On multivoltage u nits, check the transformer primary wiring connections. See Fig. 11 or refer to unit label diagram.

If unit will be operating at 208-3-60 power, remove black wire (BLK) from the transformer primary connection labelled “230” and move it to the connection labelled “208”. See Fig. 11.

—11—

Page 12

TERMINAL BOARD TB2 IN CONTROL BOX

TIME GUARD CIRCUIT

LLSV1

NOTES:

1. 566D240 has a fusible plug in the liquid line.

2. 569D120, 576C120 and 569F120 units have a fusible joint in the liquid line.

Fig. 8 — Location of Fusible Plug (566D)

IFC

HD1

HD2

ACCESSORY THERMOSTAT

JUMPER

NOTE 2

NOTE 1

LLSV2

LEGEND

C—Compressor Contactor HD — Heating Device IFC — Indoor-Fan Contactor LLSV1 — Liquid Line Solenoid Valve 1 — Refrigerant Migration

Control

LLSV2 — Liquid Line Solenoid Valve 2 — Capacity Control R—Relay

Factory Wiring Field Wiring

NOTES:

1. Combination LLSV plus IFC va should not exceed 30 va.

2. Do not exceed 5 va (24 vac) per coil.

3. If va values shown in Notes 1 and 2 must be exceeded, use accessory relay transformer package 38AE900001 (60 Hz).

Fig. 10 — Typical Remote Thermostat Wiring

(566D Unit Shown)

LEGEND

EQUIP GND — Equipment Ground NEC — National Electrical Code

Fac to ry Wiring Field Wiring

NOTE: Terminal block (TB1) is used for 566E150-240 and 566D150240 units. Pigtails are provided on 569D, 576C, 569F units.

Fig. 9 — Main Power Supply Wiring

(566D Unit Shown)

Fig. 11 — Control Transformer Wiring

(569D, 576C, 569F Unit Shown)

—12—

Page 13

Table 6A — Electrical Data — 569D072-120, 576C090-120, 569F120 Units

UNIT SIZE

072

569D

576C

569F 120

FLA — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection NEC — National Electrical Code RLA — Rated Load Amps

090

120

090

102

120

LEGEND *Units are suitable for use on electrical systems where voltage supplied

FACTORY

INSTALLED

OPTION

NONE OR DISCONNECT CONVENIENCE OUTLET 30.6 35

NONE OR DISCONNECT CONVENIENCE OUTLET 15.0 20

NONE OR DISCONNECT CONVENIENCE OUTLET 12.0 15

NONE OR DISCONNECT CONVENIENCE OUTLET 39.8 60

NONE OR DISCONNECT CONVENIENCE OUTLET 19.6 30

NONE OR DISCONNECT CONVENIENCE OUTLET 15.5 20

NONE OR DISCONNECT CONVENIENCE OUTLET 55.1 70

NONE OR DISCONNECT CONVENIENCE OUTLET 25.1 30

NONE OR DISCONNECT CONVENIENCE OUTLET 19.5 25

NONE OR DISCONNECT CONVENIENCE OUTLET 43.1 60

NONE OR DISCONNECT CONVENIENCE OUTLET 21.2 25

NONE OR DISCONNECT CONVENIENCE OUTLET 16.9 20

NONE OR DISCONNECT CONVENIENCE OUTLET 52.8 70

NONE OR DISCONNECT CONVENIENCE OUTLET 26.1 35

NONE OR DISCONNECT CONVENIENCE OUTLET 20.3 30

NONE OR DISCONNECT CONVENIENCE OUTLET 52.8 70

NONE OR DISCONNECT CONVENIENCE OUTLET 26.1 35

NONE OR DISCONNECT CONVENIENCE OUTLET 20.3 30

NONE OR DISCONNECT CONVENIENCE OUTLET 43.8 55

NONE OR DISCONNECT CONVENIENCE OUTLET 21.6 25

NONE OR DISCONNECT CONVENIENCE OUTLET 17.5 20

NOMINAL

VO LTAGE

V-Ph-Hz Min Max RLA LRA FLA (ea) LRA (ea) MCA MOCP

208/230-3-60 187 254 19.2 146 0.9 1.6

460-3-60 418 506 9.6 73 0.4 0.9

575-3-60 523 632 7.7 58.4 0.4 0.9

208/230-3-60 187 254 25.6 190 1.5 3.1

460-3-60 418 506 12.8 95 0.7 1.9

575-3-60 523 632 10.2 76 0.7 1.9

208/230-3-60 187 254 37.8 239 1.5 3.1

460-3-60 418 506 17.2 125 0.7 1.9

575-3-60 523 632 13.4 80 0.7 1.9

208/230-3-60 187 254 28.2 160 1.5 3.1

460-3-60 418 506 14.1 80 0.7 1.9

575-3-60 523 632 11.3 64 0.7 1.9

208/230-3-60 187 254 36 198 1.5 3.1

460-3-60 418 506 18 99 0.7 1.9

575-3-60 523 632 14 79 0.7 1.9

208/230-3-60 187 254 36 198 1.5 3.1

460-3-60 418 506 18 99 0.7 1.9

575-3-60 523 632 14 79 0.7 1.9

208/230-3-60 187 254 16 125 1.5 3.1

460-3-60 418 506 8 66.5 0.7 1.9

575-3-60 523 632 6.4 50 0.7 1.9

VO LTAGE

RANGE*

COMPRESSOR

to the unit terminals is not below or above the listed limits.

NOTES:

1. The MCA and MOCP values are calculated in accordance with the NEC, Article 440.

2. Motor RLA and LRA values are established in accordance with Underwriters’ Laboratories (UL), Standard 1995.

3. The 575-v units are UL, Canada-listed only.

4. Convenience outlet is available as either a factory-installed option or a field-installed accessory and is 115-v, 1 ph, 60 Hz.

FAN MO TOR S

(Qty 2)

POWER

SUPPLY

25.8 35

12.8 20

10.2 15

35.0 60

17.4 30

13.8 20

50.3 60

22.9 30

17.8 25

38.3 60

19.0 25

15.2 20

48.0 60

23.9 35

18.6 30

48.0 60

23.9 35

18.6 30

39.0 55

19.4 25

15.8 20

—13—

Page 14

Table 6B — Electrical Data — 566D150-240 Units

UNIT

150

566D

FLA — Full Load Amps HACR — Heating, Air Conditioning and

ICF — Maximum Instantaneous Current Flow

kW — Total Fan Motor Input (kilowatts) LRA — Locked Rotor Amps MCA — Minimum Circuit Amps per NEC,

MOCP — Maximum Overcurrent Protection (amps) RLA — Rated Load Amps (compressor)

180

240

Refrigeration

During Start-Up (LRA of compressor plus total FLA of fan motors)

Section 430-24

NOMINAL VOLTAGE

(3-Ph, 60 Hz)

208/230 187 253 49.3 191 4.3 3.7

460 414 528 22.1 80 2.3 1.9 31.7 50 84 575 518 660 17.9 69 1.8 1.8 25.6 40 73

208/230 187 253 63.6 266 4.3 3.7

460 414 528 29.3 120 2.3 1.9 40.7 60 124 575 518 660 23.8 96 1.8 1.8 33.0 50 100

208/230 187 254 67.9 345 4.3 3.7

460 414 508 34.7 173 2.3 1.9 48.1 80 177 575 518 632 28.8 120 1.8 1.8 40.1 60 124

LEGEND *Units are suitable for use on electrical systems where voltage sup-

VO LTAGE

RANGE*

Min Max 1 2

Table 6C — Electrical Data — 566E150-240 Units

UNIT

150

180

566E

240

FLA — Full Load Amps HACR — Heating, Air Conditioning and

ICF — Maximum Instantaneous Current Flow

kW — Total Fan Motor Input (kilowatts) LRA — Locked Rotor Amps MCA — Minimum Circuit Amps per NEC,

MOCP — Maximum Overcurrent Protection (amps) RLA — Rated Load Amps (compressor)

Refrigeration

During Start-Up (LRA of compressor plus total FLA of fan motors)

Section 430-24

FACTORY-

INSTALLED

OPTION

NONE OR DISCONNECT CONVENIENCE OUTLET

LEGEND *Units are suitable for use on electrical systems where voltage sup-

NOMINAL VO LTAGE

(3 Ph, 60 Hz)

208/230 187 253 20.7 156 20.7 156 4.3 3.7 1.41

460 414 528 10.0 75 10.0 75 2.3 1.9 1.41

575 518 660 8.2 54 8.2 54 1.8 1.8 1.41

208/230 187 253 32.1 195 32.1 195 4.3 3.7 1.41

460 414 528 16.4 95 16.4 95 2.3 1.9 1.41

575 518 660 12.0 80 12.0 80 1.8 1.8 1.41

208/230 187 253 37.8 239 37.8 239 4.3 3.7 1.41

460 414 528 19.2 125 19.2 125 2.3 1.9 1.41

575 518 660 13.8 80 13.8 80 1.8 1.8 1.41

COMPRESSOR FAN MOTORS (Qty 2) POWER SUPPLY

FLA (ea)

RLA LRA

†Fuse or HACR circuit breaker.

NOTES:

1. The MCA and MOCP values are calculated in accordance with the

2. Motor RLA and LRA values are established in accordance with

3. The 575-v units are UL, Canada-listed only.

VOLTAGE

RANGE*

Min Max RLA LRA RLA LRA 1 2 MCA MOCP† ICF

COMPRESSOR 1 COMPRESSOR 2

†Fuse or HACR circuit breaker.

NOTES:

1. The MCA and MOCP values are calculated in accordance with the

2. Motor RLA and LRA values are established in accordance with

3. The 575-v units are UL, Canada-listed only.

Fan No.

plied to the unit terminals is not below or above the listed limits.

National Electrical Code (NEC), Article 440.

Underwriters’ Laboratories (UL), Standard 1995.

plied to the unit terminals is not below or above the listed limits.

National Electrical Code (NEC), Article 440.

Underwriters’ Laboratories (UL), Standard 1995.

kW MCA MOCP† ICF

1.41

FAN MOTORS (Qty 2)

FLA (ea)

Fan No.

69.6 100 199

87.5 125 274

93.4 150 353

POWER

SUPPLY

55.6 70 186

63.5 80 194

27.7 35 90

31.3 40 94

23.1 30 67

25.9 30 70

81.2 100 236

89.2 100 244

42.1 50 117

45.7 60 120

31.6 40 97

34.5 40 99

94.1 125 286

102.0 150 294

48.4 60 149

52.0 70 153

35.7 45 98

38.5 50 101

—14—

Page 15

PRE-START-UP

IMPORTANT: Before beginning Pre-Start-Up or Start-Up,

review Start-Up Checklist at the back of this book. The Checklist assures proper start-up of a unit and pr ovides a record of unit condition, application requirements, system information, and operation at initial start-up.

CAUTION: Do not attempt to start the conde nsing unit, even momentarily, until the following steps have been completed. Compressor damage may result.

I. SYSTEM CHECK

1. Check all air handler(s) and other equipment auxiliary components. Consult the manufacturer’s instructions regarding any other equipment connected to the condensing unit. If unit has field-installed accessories, be sure all are properly installed a nd correctly wired. If used, airflow switch must be properly installed.

2. Backseat (open) compressor suction and discharge valves. Now close valves one turn to allow refrigerant pressure to reach test gages.

3. Open liquid lin e service valve.

4. Check tightness of all electrical connections.

5. For 576C, 566D units only, compressor oil level should be v isible in sight glass. Ref er to Ch eck Compressor Oil Level. Adjust the oil level as required. Refer to Start-Up, Preliminary Oil Charge section. No oil should be removed unless the crankcase heater has been energized for at least 24 hours.

6. Be sure unit is properly leak checked, dehydrated, and charged. See Preliminary Charge, this page.

7. Electrical power source must agree with nameplate rating.

8. Crankcase heater must be firmly locked into compres-

sor crankcase. Be sure crankcase is warm (heater must be on for 24 hours before starting compressor).

9. Be sure compressor floats freely on the mounting springs and that snubber washers can be moved with finger pressure. See Compressor Mounting, page 9, and Fig. 5 for loosening compressor bolts.

II. LEAK TEST AND DEHYDRATION

Leak test the entire refrigerant sys tem using soap bubbles and/or an electr onic leak detector. Evacuate and dehydrate entire refrigerant system.

III. TURN ON CRANKCASE HEATER

Turn on crankcase heater for 24 hours before starting the unit to be sure all the refrigerant is out of th e oil. To energize the

crankcase heater, proceed as follows:

1. Set the space thermostat set point above the space temperature so there is no demand for cooling.

2. Close the field disconnect.

3. Turn the fan circ uit breaker on. Le ave the compressor circuit breake rs off. The crankcase heater is now energized.

IV. PRELIMINARY CHARGE

Before starting the unit, charge liquid refrigerant into the high side of the system through the liquid service valve. The amount of refrigerant added must be at least 80% of the operating charge listed in the Physical Data table (Tables 1A-1C, pages 6-8). Allow high and low side pressures to equalize before starting compressor. If pressures do not

equalize readily, charge vapor on low side of system to assure charge in the ev aporat or. Refer to GTAC II, Modul e 5, Char ging, Recover, Recycling, and Reclamation for liquid charging procedures.

CAUTION: Prior to starting compressor, refrigerant equal to operating charge must be added to avoid possible compressor damage. See Tables 1A-1C.

START-UP

I. 569D, 566E, 569F UNITS

Compressor crankcase heater must be on for 24 ho ur s bef ore start-up. After the heater has been on for 24 hours, the unit can be started. If no time has elapsed since the preliminary charge step has been completed, it is unnecessary to wait the 24-hour period.

A. Preliminary Checks

1. Ensure that compressor service valves are backseated.

2. Verify that each compressor floats freely on its mounting springs.

3. Check that electric power supply agrees with unit nameplate data.

4. Verify that compressor cr ankcase heater is securel y in place.

5. Check that compres sor cr ankc ase heat er has b een on at least 24 hours.

6. Recheck for leaks using same procedure as previously outlined in Pre-Start-Up section, Leak Test and Dehydration.

7. If any leaks are detected, evacuate and dehydrate as previously outlined in Pre-Start-Up section, Leak Test and Dehydration.

8. All internal wiring connections must be tight, and all barriers and covers mu st be in place.

NOTE: The 569D , 566E, 56 9F units do no t ha ve a compr essor oil level sight glas s . Th ese uni ts ar e fact ory chan ged wit h the required amount of oil . If recharging is required, us e Zerol 150 for the 569F, 569D072, and 569D090. Use Replacement Components Division Oil (P/N P903-0101) for the 569D120 and 566E150-240.

B. Compressor Rotation

On 3-phase units with scroll compressors, it is important to be certain compressor is rotating i n the proper direc tion. To determine whether or not compressor is rotating in the proper direction:

1. Connect service gages to suct ion and discharge pressure fittings.

2. Energize the compressor.

3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up.

If the suction pressure does not drop and the discharge pressure does not rise to normal levels:

1. Note that the condenser fan is probably also rotating in the wrong direction.

2. Turn off power to the unit, tag disconnect.

3. Reverse any two of the unit power leads.

4. Reapply power to the compressor, verify correct pressures.

The suction and discharge pressure levels should now move to their normal start-up levels.

—15—

Page 16

C. Compressor Overload

This overload interrupts power to the compressor when either the current or internal motor winding temperature becomes excessive, and automatically resets when the internal temperature drops to a safe level. This overload may require up to 60 minutes (or longer) to reset. If the internal overload is sus pect ed of be ing op en, di sconn ect the elect ric al power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.

D. Advanced Scroll Temperature Protection (ASTP)

Advanced Scroll Temperature Protection (ASTP) is a form of internal dischar ge temperature protecti on that unloads the scroll compressor when the internal temperature reaches approximately 300 F. At this temperature, an internal bimetal disk valve opens and ca use s t he sc ro ll elements to sep arate, which stops compression. Suction and discharge pressures balance while the motor continues to run. The longer the compressor runs unloade d, the l onge r it m ust co ol be fore the bi-metal disk resets. See Fig. 12.

To manually reset ASTP, the compressor should be stopped and allowed to cool. If the compressor is not stopped, the motor will run un til the motor prote ctor trips, which occurs up to 90 minutes later. Advanced Scroll Temperature Protection will reset automatically before the motor protector resets, which may take up to 2 hours. A label located above the terminal box identifies Copeland Scroll compressor models (ZR94, 108 and 125) that contain t his technology. See Fig. 13.

120

110

100

es)

nut

(Mi

Recommended Cooli ng Time

0 102030405060708090

*Times are approximate. NOTE: Various factors, including high humidity, high ambient tempera-

ture, and the presence of a sound blanket will increase cool-down times.

Compressor Unloaded Run Time (Minutes)

Fig. 12 — Recommended Minimum Cool-Down Time After

Compressor is Stopped*

E. Compressor Lockout Device

The compressor lockout (CLO) device pre vents the compres sor from starting or running in a high pressure, loss-ofcharge or freeze-stat open situation. Reset the CLO device by setting the thermostat to eliminate cooling demand and return it to the original se t point. If the system shut s down again for the same fault, determine the possible cause before attempting to reset the CLO device.

F. S ta r t Un it

The field disconnect is closed, the fan circuit breaker is closed, and the sp ac e therm osta t is set above am bient so that there is no demand for cooling. Only the crankcase heater will be energized.

Next, reset space thermostat below ambient so that a call for cooling is ensured.

NOTE: Do not use circuit breaker to star t and stop the compressor except in an emergency.

CAUTION: Never charge liquid into the low-pressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating.

G. Adjust Refrigerant Charge

Unit must be charged in Cooling mode only. Refer to Cooling Charging Charts, Fig. 14-18 and to Table 7 for maximum charge level. Do not exceed maximum refrigerant charge. For applications with line lengths greater than 100 ft, contact Bryant representative. Vary refrigerant until the conditions of the chart are met. Note that charging charts are di fferent from type normally use d. Charts a re based on charging t he units to the correct subcoo ling for th e variou s operati ng conditions. Accurate pressure gage and temperature sensing device are required. Connect the pressure gage to the service port on the liquid line service valve. Mount the temperature sensing device on the liquid line, close to the liquid line service valve and insulate it so that outdoor ambient temperature does not affect the reading. Indoor airflow must be within the normal operating range of the unit. Operate unit a minimum of 15 min ut es. Ensure pressure a nd t e mpe rat ure readings have stabilized. Plot liquid pressure and temperature on chart and add or reduce charge to meet curve. Adjust charge to conform with charging chart, using the liquid pressure and temperature to read chart.

If the liquid line sight glass is cloudy, check refrigerant charge again. Ensure all fans are operating. Also ensure maximum allowable liquid lift has not been exceeded. If charged per chart and if the sight glass is sti ll cloudy, check for a plugged filter drier or a partially closed solenoid valve. Replace or repair, as needed.

Fig. 13 — Advanced Scroll Temperature Protection Label

—16—

Page 17

140

LIQUID TEMPERATURE AT LIQUID VALVE (C)

LIQUID TEMPERATURE AT LIQUID VALVE (F)

130

120

110

100

ADD CHARGE IF ABOVE CURVE

344

100

689

150 200 250 300 350 400

LIQUID PRESSURE AT LIQUID VALVE (PSIG)

1034

LIQUID PRESSURE AT LIQUID VALVE (Kilopascals)

REDUCE CHARGE IF BELOW CURVE

1379

1724

2069

2414

Fig. 14 — 569D072-120, 569F120, 576C090-120 Charging Chart

Fig. 15 — 566D150 Charging Chart

—17—

Page 18

Fig. 16 — 566D180 Charging Chart

Fig. 17 — 566D240 Charging Chart

—18—

Page 19

LIQUID TEMPERATURE AT LIQUID VALVE (C)

-12

LIQUID TEMPERATURE AT LIQUID VALVE (F)

160.00

150.00

140.00

130.00

120.00

110.00

100.00

90.00

80.00

70.00

60.00

50.00

40.00

30.00

20.00

10.00

0.00

BOTH OUTDOOR FANS MUST BE OPERATING

ADD CHARGE IF ABOVE CURVE

100

690

150

LIQUID PRESSURE AT LIQUID VALVE (psig)

1030

LIQUID PRESSURE AT LIQUID VALVE (kPa)

200

1379

566E150

250 300

1720

556E240

566E180

REDUCE CHARGE IF BELOW CURVE

350 400

2069

2410

2758

450 500

3100

3448

-1

-7

Fig. 18 — 566E150-240 Charging Chart

H. Final Checks

Ensure all safety contro ls are operating, control panel covers are on, and the s e rvice panels are in place.

Table 7 — Maximum Refrigerant Charge

UNIT R-22 (lb)

569D

576C

569F 120 (2) 17.1

566D

566E

NOTE: 569F120 has 2 charges, one per circuit.

072 090 120

090 102 120

150 180 240

17.3

34.2

40.3

39.8

48.0

II. 576C, 566D UNITS

Compressor crankcas e heater must be on for 24 hours before start-up. After th e heater h as been o n for 24 h ours, the uni t can be started. If no time has ela psed since the preliminary charge step has been completed, it is unnecessary to wait the 24-hour period.

A. Preliminary Checks

1. Ensure that compressor service valves are backseated.

2. Verify that each compressor floats freely on its mounting springs.

3. Check that electric power supply agrees with unit nameplate data.

4. Verify that compress or crankcase heater is securely in place.

5. Check that compres sor cr ankc ase heat er has b een on at least 24 hours.

6. Note that compressor oil level is visible in the sight glass.

7. Recheck for leaks using same procedure as previously outlined in Pre-Start-Up section, Leak Test and Dehydration.

8. If any leaks are detected, evacuate and dehydrate as previously outlined in Pre-Start-Up section, Leak Test and Dehydration.

9. All internal wiring connections must be tight, and all barriers and covers mu st be in place.

B. Preliminary Oil Charge

Compressor is f actory charged with oil (s ee Tables 1A-1C). When oil is ch eck ed at start- up , i t may be ne cessar y to a dd or remove oil to bring it to the proper level . One recommended oil level adjustment method follows:

Add Oil Close suction service valve and pump down crankcase to

2 psig. (Low-pressure switch must be jumpered.) Wait a few minutes and repeat until pressure remains steady at 2 psig. Remove oil fill plug above the oil level sight glass, add oil through plug hole, and replace plug. Run compressor for 20 minutes and check oil level. See Fig. 19.

NOTE: Use onl y Bryant approved compressor oi l. Approved sources are:

Petroleum Specialties Inc.. . . . . . . . . . . . . . . . . . . Cryol 150A

Texaco, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . Capella WF-32

Witco Chemical Co. . . . . . . . . . . . . . . . . . . . . . . . .Suniso 3GS

Do not use oil that has been drained out, or oil that has been exposed to atmosphere.

Remove Oil Pump down compressor to 2 psig. Loosen the 1/4-in. pipe plug

at the compressor base and all ow the o il to seep o ut pa st the threads of the plug.

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Page 20

NOTE: The crankcase will be slightly pressurized. Do not remove the plug, or the entire oil charge will be lost.

Small amounts of oil can be removed through the oil pump discharge connection while the compressor is running.

C. Start Unit

The field disconnect is closed, the fan circuit breaker is closed, and the s pace the rmos tat is se t abov e ambi ent so t hat there is no demand for cooling. Only the crankcase heater will be energized.

Next, close the compressor circuit breaker and then reset space thermostat below ambient so that a call for cooling is ensured.

NOTE: Do not use circu it breake r to st art and stop the compressor except in an emergency.

After starting, there is a delay of at least 3 seconds before compressor starts.

CAUTION: Never charge liq uid into the low-pressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating.

stops. The unloader is now at 0 psig set point. If electric actuated unloaders are installed, energize the solenoid to unload the compressor.

Return unloader to original setting after checks are complete.

F. Final Checks

Ensure all safety controls are operating, control panel covers are on, and the service panels are in place.

566D240

(06E COMPRESSOR)

566D150,180 AND

576C090-120

(06D COMPRESSOR)

Fig. 19 — Operating Oil Levels

D. Adjust Refrigerant Charge

Unit must be charged in Cooling mode only. Refer to Cooling Charging Charts, Fig. 14-18 and to Table 7 for maximum charge level. Vary refrigerant until the conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the units to the correct subcooling for the various operating conditions. Accurate pressure gage a nd temperature sensing dev ice are required. Connect the pressure gage to the service port on the liquid line service valve. Mount the temperature sensing device on the liquid line, close to the liquid line service valve and insulate it so that outdoor ambient temperature does not affect the reading. Indoor airflow mus t be wit hin th e normal operating range of the unit. Operate unit a minimum of 15 minutes. Ensure pressure and temperature readings have stabilized. Plot liquid pressure and temperature on chart and add or reduce charge to meet curve. Adjust charge to conform with charging chart, using the liquid pressure and temperature to read chart.

If the sight glass is cloudy, check refrigerant charge again. Ensure all fans are operating. Also ensure ma ximum allowable liquid lift has not been exceeded. If charged per chart and if the sight glass is still cloudy, check for a plugged filter drier or a partially closed solenoid valve. Replace or repair, as needed.

E. Check Compressor Oil Level

After adjusting the refrigerant charge, allow the compressor to run fully loaded for 20 minutes. Running oil level should be within view of the crankcase sight glass. Stop the compressor at the field power supply disconnect and check the crankcase oil level. Add oil only if necessary to bring the oil into view in the sight glass. If oil i s added, run t he compressor for an additional 10 minutes, then stop and check oil level. If the level remains low, check the piping system for proper design for oil return; also, check the system for leaks.

If the initial check shows too much oil (too high in the sight glass) remove oil to proper level. See Preliminary Oil Charge, this page, for proper procedure for adding and removing oil. See Fig. 19.

When the above checks are complete, repeat the procedure with the unit operating at minimum load conditions.

Unload the compressor by turning the control set point adjustment nut counterclockwise until the adjustment nut

OPERATING SEQUENCE

I. COOLING

A. 569D072-120, 576C090-120 Cooling

At start-up, the thermostat calls for cooling. With all safety devices satisfied, the compressor contac tor and fan contacto r energize, causing the compressor and outdoor-fan motor to operate. Contacts energize, allowing the field-supplied and field-installed indoor-fan contactor to function. A fieldsupplied and field-installed liquid line valve also opens, allowing the system to function in Cool ing mode. As cooling demand is satisfied, the thermostat c ontacts break, deenergizing the contactor and causing the system to shut off. The liquid line solenoid valve closes, minimizing the potential for refrigerant migratio n. The compressor does not rest art until the thermostat again calls for cooling. The system is protected with a safety circuit so that the system will not start if a fault exists (i.e., high-pressure or discharge gas temperature [569D090 and 120 only] fault). To reset the safety circuit, set the thermostat to eliminate the cooling demand, then return to original set point. This should be done only once, and if system shuts down due to the same fault, determine the problem before attempting to restart the system.

B. 566D150-240 Cooling

When the first sta ge of cooling thermostat closes, the ti mer starts. After approximately 3 seconds, the timer activates the compressor and fan motor no. 1 contactors. When the liquid pressure builds to approximately 257 psig, fan motor no. 2 is energized.

When there is demand for additional cooling capacity, the second stage of the cooling thermostat closes, energizing a field-supplied liquid line solenoid (LLS) valve, which opens. This increases the suction pressure, causing the compressor to operate at higher capacity (compressor loads).

When the fan switch is set at AUTO, the indoor-air fan cycles with the compressor. When the switch is set at CONT, the indoor-air fan runs continuously.

At shutdown, the Time Guard II timer prevents the compressor from restarting for approxi mately 5 minutes.

In addition, an LLS valve wired in parallel with the compressor contactor coil shuts off the liquid line to prevent

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refrigerant migration back to the compressor duri ng the off cycle.

C. 569F120 Cooling

When the thermost at calls for stag e one cooling at s tart-up, and all safety devices are satisfied, the compressor contactor no. 1 (C1) energizes causing compress or no. 1 and outdoorfan motor no. 1 to start (the indoor-fan contactor should be wired to start at the same time as the compressor ). The liquid line solenoid (LLS) valve will open when compressor no. 1 starts, allowing refrigerant to flow in the system.

When the thermostat calls for sta ge two cool ing, compresso r contactor no. 2 (C2) energizes causing compressor no. 2 and outdoor-fan motor no. 2 to start. As the cooling demand decreases, stage two on the thermostat opens, causing compressor no. 2 and outdoor-fan motor no. 2 to shut down. As the cooling continu es to decrease, stage one of the thermostat opens caus ing compressor no. 1 and outdoor-fan motor no. 1 to shut down. The LLS valve for each co mpressor will close when the associated compressor stops, minimizing the potential for refrigerant migration during the off cycle.

The indoor-fan motor will stop if the thermostat is set to AUTO and will continue to operate if the thermostat is set to CONT. Each compressor is protected with a CLO

device so that the compressor will not operate if there is a highpressure fault, low pressure fault, or a compressor is off due to internal line break overcurrent/over temperature protection. To reset the CLO device, set the thermostat higher to remove the cooling demand, then return to the original set point. This should be done only once. If the system shuts down with the same fault, the cause for the fault should be determined and corrected before the a CLO device is reset again.

D. 566E150-240 Cooling

At start-up, when the thermostat calls for first stage cooling and all safety devices are satisfied, the compressor contactor (C1) energizes causing compressor no. 1 and fan motor no. 1 to start. Fan motor no. 2 will start when the fan cycling pressure switch (FCPS) closes as discharge pressure builds. With the indoor-fan contactor wired to TB2-4 and TB2-9 contacts on the terminal block, the indoor-fan will also start wit h the compressor. The liquid line solenoid (LLS) valve will open when compressor no. 1 starts, allowing refrigerant to flow in the system.

When the thermostat calls for sta ge two cool ing, compresso r contactor no. 2 (C2) energizes causing compressor no. 2 to start. As the cooling demand decreases, stage two on the thermostat opens, causing compressor no. 2 to shut down. As the cooling continu es to decrease, stage one of the thermostat opens caus ing compressor no. 1 and outdoor-fan motor to shut down. The LLS valve fo r each compressor will close when the associated compressor stops, minimizing the potential for refrigerant migration during the off cycle.

The indoor-fan motor will stop if the thermostat is set to AUTO and wi ll co ntin ue to oper ate if the ther mostat is s et o n CONT. Each compressor is controlled by the thermostat so they will not start until there is a demand from the thermostat. Each compressor is protected with a CLO

device so that the compressor will not operate if there is a high-pressure fault, low-pressure fault, or compressor is off due to internal line break overc urrent/overtemp erature protectio n. To reset the a CLO device, set the thermostat higher to remove the cooling demand, then return to the original set point. This should be done only once. If the syste m sh uts do wn wi th the same fault, the cause for the fault should be determined and corrected before the a CLO device is reset again.

II. HEATING

The heating thermostat (TH) energizes a field-supplied relay which operates heating controls and energizes the indoor unit relay. When the fan switch is set at AUTO, the indoor unit fan cycles with the heating control. The indoor unit fan runs continuously when the fan switch is set at ON.

Causes of complete unit shutdown are: interruption of supplied power, open compressor internal protector (IP), open control circuit breaker, or an open high-pressure or low-pressure safety switch.

SERVICE

I. CAPACITY CONTROL (576C, 566D UNITS)

A suction pressure-actuated unloader controls 2 cylinders and provides capacity contr ol. Unlo aders are fa ctory set (see Tables 1A-1C), but can be field adjusted as described in the next paragraphs.

Control set point (cylinder load point) is adjustable from 0 to 85 psig (586 kPa). To adjust, turn control set point adjustment nut (Fig. 20) clockwise to its bottom stop. In this position, set point is 85 psig. Next, turn adjustment counterclockwise to desired control set point. Every full turn counterclockwise decreases set point by 7.5 psig.

Pressure differential (difference between cylinder load and unload points) is adjusta ble from 6 t o 22 psi g. To adjust, turn pressure differential adjustment screw (Fig. 20) counterclockwise to its back stop position. In this p osition, differential is 6 psig. Next, turn adjustment clockwise to desired pressure differential setting. Every full turn clockwise increases differential by 1.5 psig.

II. HEAD PRESSURE CONTROL (566D, 566E150-240 UNITS ONLY)

Fan cycling is a standard feature. The no. 2 fan cycles in response to changes in liquid pressure. The switch cycles the fan off at 160 ± 10 psig as pressure decreases, and cycles it back on at 255 ± 10 psig.

Fig. 20 — Compressor Capacity Control Unloader

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III. TIME GUARD II CIRCUIT (566D ONLY)

Circuit prevents short-cycling by providing a delay of approximately 5 minutes before restarting compressor afte r shutdown from safety device action.

On start-up, the Time Guard II timer causes a delay of approximately 3 seconds after thermostat closes.

On compressor shutdown, the timer recycles for approximately 5 minutes. During this time, the compressor canno t restart.

Refer to Fig. 21 and to label diagram on unit.

Fig. 21 — Timer Sequence Chart

IV. CRANKCASE HEATER

The heater prevents refrigerant migration and compressor oil dilution during shutdown whenever compressor is not operating. It is wired to cycle with the compressor; the heater is off when compressor is running, and on when compressor is off.

Both compressor service valves must be closed whenever the crankcase heater is deenergized for more than 6 hours. The crankcase heater is opera ble as long as the control circuit is energized.

V. COMPRESSOR PROTECTION

A. Circuit Breaker (566D Only)

Calibrated trip manual reset, ambient compensated, magnetic breaker protects against motor overload and locked rotor conditions.

B. Compressor Overtemperature Protection (IP)

A thermostat installed on compressor motor winding reacts to excessively high winding temperatures and shuts off the compressor.

C. Time Guard II Control (566D Only)

Control prevents com pres sor from sh ort cyclin g. See Ope rating Sequence.

D. Crankcase Heater

Heater minimizes absorption of liquid refrigerant by oil in crankcase during brief or extended shutdown periods. The control circuit is maintaine d if compresso r fan motor circuit breakers are turned off. The main disconnect must be on to energize crankcas e heater.

IMPORTANT: Never open any switch or disconnect that energizes the crankcas e he at er un l ess u ni t is bei n g servi ce d or is to be shut down for a prolonged period. After a prolonged shutdown on a service job, energize the crankcase heater for 24 hours before starting the compressor.

E. Advanced Scroll Temperature Protection (ASTP)

See Advanced Scroll Temperature Protection (ASTP) on page 16.

VI. LOW-PRESSURE SWITCHES

The 569D, 569F, 566E, 576C low-pressure switches are mounted on the suction line. The 566D low-pressure switches are mounted on the compressor. Switches are all fixed, non-adjustable type.

VII. HIGH-PRESSURE SWITCHES

The 569D, 576C and 569F high-pressure switches are mounted on the liquid line. The 566E150-240 high-pressure switches are mounted on the discharge line. The 566D high-pressure switches are mounte d on the compressor. The switches are all fixed, non-adjustable type.

A. To Check

Slowly close liquid shutoff valve and allow compressor to pump down. Do not allow compressor pumpdown below 2 psig. Compressor shou ld shut down when suction pressu re drops to cuto ut pr e ssu re in Tables 1A-1 C, and sh oul d res ta r t when pressure builds up to cut-in pressure shown.

VIII. DISCHARGE GAS THERMOSTAT (569D090 ONLY)

A sensor on the discha rge li ne will stop the comp ress or if an abnormally high discharge temperature is detected. If the unit shuts down on a high discharge temperature fault, restart the unit by cycling the thermostat or the power disconnect switch.

IX. OUTDOOR FANS

Each fan is suppor ted by a formed -wire mount bolted to the fan deck and covered with a wire guard. Fan motors have permanently lubr icate d beari ngs .

NOTE: On 566D units, the exposed end of the motor shaft is covered with a rubber boot. In case a fan motor must be repaired or rep laced, be su re the rubbe r boot is put ba ck on when the fa n is reinstall ed and be sur e the fan gu ard is in place before starting the unit. Figure 22 shows the proper position of the mounted fan.

X. LUBRICATION

Fan motors have sealed bea r ings. No provisions ar e made for lubrication.

Compressor has its own oil supply. Loss of oil due to a leak in the system should be th e only re ason for a dding o il afte r the system has been in operation .

XI. COIL CLEANING AND MAINTENANCE

This section discusses the cleaning and the maintenance of standard coils and E-Coated coils. Routine cleaning of coil surfaces is e ss ent i al t o mi nim ize c o ntamination build-up and remove harmful residue. Insp ect coils monthly and clea n as required.

A. Cleaning Standard Coils

Standard coils can be cleaned with a vacuum cleaner, washed out with low velocity water, blown out with low-pressure compressed air, or brushed (do not use wire brush). Fan motors are drip-proof but not waterproof. Do NOT use acid cleaners.

Clean outdoor coil annually or as required by location or outdoor air conditions. Inspect coil monthly, and clean as required. Fins are not continuous through coil sections; dirt and debris may pass through first section, become trapped between second and third rows of fins and restrict outdoor airflow. Use a flashlight to determine if dirt or debris has collected between coil sections. Clean coil as follo ws:

1. Turn off unit power.

2. Remove screws holding rear corner posts and top cover in place. Pivot top cover up 12 to 18 in. and support with a rigid support. See Fig. 23.

3. Remove clips securing tube sheets together at the return bend end of the coil. Carefully sprea d the ends of the coil rows apart by moving the outer sections. See Fig. 24.

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Page 23

Fig. 22 — Outdoor Fan — 566D Units

Fig. 23 — Pivot and Support Top Cover

Fig. 24 — Coil Cleaning (Typical)

4. Using a water hose, or other suitable equipment, flush down between the sections of coil to remove dirt and debris.

5. Clean the remaining surfaces in the normal manner.

6. Reposition outer coil sections.

7. Reinstall cl ips which secure tub e sheets.

8. Replace top cover and rear corner posts.

B. Cleaning and Maintaining E-Coated Coils

Routine cleaning of condenser coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residue will greatly increase the li fe of the coil and extend the life of the unit. The following m ainte nan ce and clea ning proc edures a re re commended as part of the routine maintenance a ctivities to extend the life of the coil.

Remove Surface Loaded Fibers Debris such as dirt and fibers on the surface of the coil

should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft brush may be used. The cleaning tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface debris must be completely removed prior to using a low velocity clean water rinse.

Periodic Clean Water Rinse A periodic clean water rinse is very beneficial for coils that

are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning is recommended.

Routine Cleaning of E-Coated Coil Surfaces Monthly cleaning with Environmentally Sound Coil Cleaner

is essential to extend the life of coils. It is recommended that all coils including standard aluminum, pre-coated, copper/ copper, or E-coated coils be cleaned with the Environmentally Sound Coil Cleaner as described below. Coil cleaning should be part of the regularly scheduled maintenance procedures of the unit to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.

Environmentally Sound Coil Cleaner is non-bacterial, biodegradable and will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

The following field-supplied equipment is required for coil cleaning:

•2

/2 gallon garden sprayer

• water rinse with low velocity spray nozzle Environmentally Sound Coil Cleaner Ap plication Inst ructions Perform the following procedure to clean the coil. NOTE: Wear proper eye protection such as safety glasses

during mixing and application.

1. Remove all surface debris and dirt from the coil with a vacuum cleaner.

2. Thoroughly wet finned surfaced with clean water and a low velocity garden hose, being careful not to bend fins.

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Page 24

3. Mix Environmentally Sound Coil Cleaner in a 21/2 gallon garden sprayer according to the instructions included with the Cleaner. The optimum solution temperature is 100 F.

CAUTION: DO NOT USE water in excess of 130 F. Enzymes in coil cleaner will be destroyed and coil cleaner will not be effective.

4. Thoroughly apply Environmentally Sound Coil Cleaner solution to all coil surfaces including finned area, tube sheets, and coil headers. Hold garden sprayer noz zle clos e to fin ned ar eas and appl y cl eaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage. Ensure cleaner thoroughly penetra tes deep into finned areas. Interior and exterior finned are as must be thoroughly cleaned.

5. Allow finned surfaces to remain wet with cleaning solution for 10 minutes. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved.

6. Thoroughly rinse all surfaces with low velocity clean water us in g do wn wa rd r in si ng m ot io n of wa te r sp r ay nozzle. Protect fins from damage from the spray nozzle.

CAUTION: Do not use bleach, harsh chemicals, or acid cleaners on outdoor or indoor coils of any kind. These types of cleaner s are difficult to rinse, and they promote rapid corrosion of the fin collar-copper tube connection. Only use the Environmentally Sound Coil Cleaner.

Never use high pressure air or liquids to clean coils. High pressures damage coils and increase the airside pressure drop. To promote unit integrity, follow cleaning and maintenance procedures in this document.

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Page 25

TROUBLESHOOTING

PROBLEM SOLUTION

COMPRESSOR DOES NOT RUN

Contactor Open

1. Power off. 1. Restore power.

2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse.

3. No control power. 3. Check control circuit breaker; reset if tripped or replace if defective.

4. Thermostat circuit open. 4. Check thermostat setting.

5. Time Guard II device not operating (566D only). 5. Check Time Guard II device.

6. Compressor circuit breaker tripped (566D only). 6. Check for excessive compressor current draw. Reset breaker;

7. Safety device lockout circuit active. 7. Reset lockout circuit at thermostat or circuit breaker.

8. Low-pressure switch open. 8. Check for refrigerant undercharge, obstruction of indoor airflow, or

9. High-pressure switch open. 9. Check for refrigerant overcharge, obstruction of outdoor airflow, air in

10. Compressor overtemperature switch open. 10. Check for open condition. Allow for reset. Replace if defective.

11. Loose electrical connections. 11. Tighten all connections.

12. Compressor stuck. 12. See compressor service literature. Contactor Closed

1. Compressor leads loose. 1. Check connections.

2. Motor windings open. 2. See compressor service literature.

3. Single phasing. 3. Check for blown fuse. Check for loose connection at compressor

COMPRESSOR STOPS ON HIGH-PRESSURE SWITCH

Outdoor Fan On

1. High-pressure switch faulty. 1. Replace switch.

2. Reversed fan rotation. 2. Confirm rotation, correct if necessary.

3. Airflow restricted. 3. Remove obstruction.

4. Air recirculating. 4. Clear airflow area.

5. Noncondensables in system. 5. Recover refrigerant and recharge as required.

6. Refrigerant overcharge. 6. Recover refrigerant as required.

7. Line voltage incorrect. 7. Consult power company.

8. Refrigerant system restrictions. 8. Check or replace filter drier, expansion valve, etc. Check that com-

Outdoor Fan Off

1. Fan slips on shaft. 1. Tighten fan hub setscrews.

2. Motor not running. 2. Check power and capacitor.

3. Motor bearings stuck. 3. Replace bearings.

4. Motor overload open. 4. Check overload rating. Check for fan blade obstruction.

5. Motor burned out. 5. Replace motor.

COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH

Indoor-Air Fan Running

1. Compressor suction service valve partially closed. 1. Open valve fully.

2. Liquid line solenoid valve(s) fails to open. 2. Check liquid line solenoid valve(s) for proper operation. Replace if

3. Filter drier plugged. 3. Replace filter drier.

4. Expansion valve power head defective. 4. Replace power head.

5. Low refrigerant charge. 5. Add charge. Check low-pressure switch setting.

replace if defective.

whether compressor suction shutoff valve is fully open. Make sure liquid line solenoid valve(s) is open.

system, or whether compressor discharge valve is fully open. Be sure outdoor fans are operating correctly.

terminal.

pressor discharge service valve is fully open.

necessary.

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Page 26

TROUBLESHOOTING (cont)

PROBLEM SOLUTION

COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH (cont)

Airflow Restricted

1. Coil iced up. 1. Check refrigerant charge.

2. Coil dirty. 2. Clean coil fins.

3. Air filters dirty. 3. Clean or replace filters.

4. Dampers closed. 4. Check damper operation and position. Indoor-Air Fan Stopped

1. Electrical connections loose. 1. Tighten all connections.

2. Fan relay defective. 2. Replace relay.

3. Motor overload open. 3. Power supply.

4. Motor defective. 4. Replace motor.

5. Fan belt broken or slipping. 5. Replace or tighten belt.

COMPRESSOR RUNNING BUT COOLING INSUFFICIENT

Suction Pressure Low

1. Refrigerant charge low. 1. Add refrigerant.

2. Head pressure low. 2. Check refrigerant charge. Check outdoor-air fan thermostat settings.

3. Air filters dirty. 3. Clean or replace filters.

4. Expansion valve power head defective. 4. Replace power head.

5. Indoor coil partially iced. 5. Check low-pressure setting.

6. Indoor airflow restricted. 6. Remove obstruction. Suction Pressure High

1. Unloaders not functioning. 1. Check unloader adjustments. Check unloader setting.

2. Compressor valve defective. 2. See compressor service literature.

3. Heat load excessive. 3. Check for open doors or windows in vicinity of fan coil.

UNIT OPERATES TOO LONG OR CONTINUOUSLY

1. Low refrigerant charge. 1. Add refrigerant.

2. Control contacts fused. 2. Replace control.

3. Air in system. 3. Purge and evacuate system.

4. Partially plugged expansion valve or filter drier. 4. Clean or replace.

SYSTEM IS NOISY

1. Piping vibration. 1. Support piping as required.

2. Compressor noisy. 2. Check valve plates for valve noise. Replace compressor if bearings

COMPRESSOR LOSES OIL

1. Leak in system. 1. Repair leak.

2. Crankcase heaters not energized during shutdown. 2. Check wiring and relays. Check heater and replace if defective.

3. Improper interconnecting piping design. 3. Check piping for oil return. Replace if necessary.

FROSTED SUCTION LINE

Expansion valve admitting excess refrigerant. Adjust expansion valve.

HOT LIQUID LINE

1. Shortage of refrigerant due to leak. 1. Repair leak and recharge.

2. Expansion valve opens too wide. 2. Adjust expansion valve.

FROSTED LIQUID LINE

1. Restricted filter drier. 1. Remove restriction or replace.

2. Liquid line solenoid valve partially closed. 2. Replace valve.

COMPRESSOR WILL NOT UNLOAD

1. Defective unloader. 1. Replace unloader.

2. Defective capacity control solenoid valve (if used). 2. Replace valve.

3. Miswired capacity control liquid line solenoid (if used). 3. Rewire correctly.

4. Weak, broken, or wrong valve body spring. 4. Replace spring.

COMPRESSOR WILL NOT LOAD

1. Miswired capacity control liquid line solenoid (if used). 1. Rewire correctly.

2. Defective capacity control solenoid valve (if used). 2. Replace valve.

3. Plugged strainer (high side). 3. Clean or replace strainer.

4. Stuck or damaged unloader piston or piston ring(s). 4. Clean or replace the necessary parts.

are worn.

Page 27

START-UP CHECKLIST

I. PRELIMINARY INFORMATION

OUTDOOR: MODEL NO. SERIAL NO.

INDOOR: AIR HANDLER MANUFACTURER

MODEL NO. SERIAL NO.

ADDITIONAL ACCESSORIES

II. PRE-START-UP

OUTDOOR UNIT

IS THERE ANY SHIPPING DAMAGE?

IF SO, WHERE:

WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N)

CHECKPOWER SUPPLY. DOES IT AGREE WITH UNIT? (Y/N)

HAS THE GROUND WIRE BEEN CONNECTED? (Y/N)

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (Y/N)

ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (Y/N)

HAVECOMPRESSOR HOLDDOWN BOLTS BEEN LOOSENED (Snubber washers are snug, but not tight)?

(Y/N)

CONTROLS

ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED?

(Y/N)

ARE ALL WIRING TERMINALS (including main power supply) TIGHT? (Y/N)

HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS? (Y/N)

(Y/N)

INDOOR UNIT

HAS WATER BEEN PLACEDINDRAINPAN TO CONFIRM PROPER DRAINAGE? (Y/N)

ARE PROPER AIR FILTERS IN PLACE? (Y/N)

HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT? (Y/N)

DO THE FAN BELTS HAVE PROPER TENSION? (Y/N)

HAS CORRECT FAN ROTATION BEEN CONFIRMED? (Y/N)

PIPING

ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED? (Y/N)

HAVELEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR AND INDOOR COILS,

TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS WITH A LEAK DETECTOR? (Y/N)

LOCATE, REPAIR, AND REPORT ANY LEAKS.

HAVEALLCOMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)? (Y/N)

HAVELIQUID LINE SERVICE VALVES BEEN OPENED? (Y/N)

IS THE OIL LEVEL IN EACH COMPRESSOR CRANKCASE VISIBLE IN THE COMPRESSOR SIGHT GLASSES

(576C/566D Units Only)? (Y/N)

CHECK VOLTAGE IMBALANCE

LINE-TO-LINE VOLTS: AB

(AB + AC + BC)/3 = AVERAGE VOLTAGE =

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =

V AC V BC V

VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) =

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPTTOSTARTSYSTEM!

CALL LOCAL POWER COMPANY FOR ASSISTANCE.

CL-1

Page 28

III. START-UP

CHECK INDOOR UNIT FAN SPEED AND RECORD.

CHECK OUTDOOR UNIT FAN SPEED AND RECORD.

AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:

OIL PRESSURE SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING OUTDOOR UNIT AIR TEMP LEAVING OUTDOOR UNIT AIR TEMP INDOOR UNIT ENTERING-AIR DB (dry bulb) TEMP INDOOR UNIT ENTERING-AIR WB (wet bulb) TEMP INDOOR UNIT LEAVING-AIR DB TEMP INDOOR UNIT LEAVING-AIR WBTEMP

COMPRESSOR AMPS (L1/L2/L3) / /

CHECK COMPRESSOR ROTATION (Scroll compressors only); IS COMPRESSOR ROTATING

IN PROPER DIRECTION? (Y/N)

CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES; ARE THE SIGHT GLASSES SHOWING

OIL LEVEL IN VIEW (576C/566D Units Only)? (Y/N)

CUT ALONG DOTTED LINE

NOTES:

CUT ALONG DOTTED LINE