Bryant 575C User Manual
installation, start-up and
service instructions
AIR-COOLED SPLIT SYSTEM
HEAT PUMP
Cancels: II 575B-72-3 II 575B-72-4
575B/575C/541A
Sizes 072-180
6 to 15 Tons
9/15/04
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
I. Complete Pre-Installation Checks . . . . . . . . . . . . . . 1
II. Rig and Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1
III. Complete Refrigerant Piping
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IV. Complete Electrical Connections. . . . . . . . . . . . . . . 9
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15,16
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-18
SEQUENCE OF OPERATION. . . . . . . . . . . . . . . . . . . . . .18-20
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-24
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .25,26
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical
components, and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics
should install, start-up, and service this equipment.
Untrained personnel can perform basic maintenance functions such as cleaning coils. All other 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 powe r to syst em a nd ins tall lockout tag on disconnect. There may be more than one disconnect switch. Electrical shock can cause personal
injury.
GENERAL
The split system heat pump units described in this book are
designed for use with the 524A-H indoor packaged air
handler sections only.
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
• Consult local bui ldin g codes and Nati onal Electr ical C ode
(NEC) for special installation requiremen ts.
• Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1-3 for unit
dimensions. Figure 4 shows typical componen t locations
for 541A180 units.
• Locate unit so that outdoor coi l airflow is unrestricte d on
all sides and above.
• Unit may be mounted on a level pad directly on the base
channels or mounted on raised pads at support points.
See Table 1 for unit operating weights.
II. RIG AND MOUNT UNIT
CAUTION: Be sure unit panels are securely in
place prior to rigging. Be careful rigging, handling, and
installing unit. Improper unit location can cause system malfunction and material damage. Inspect base
rails for any shipping damage and make sure they are
fastened securely to unit before rigging.
A. Rigging
These units are designed for over head rigging. Refer to rigging label for preferred ri gging 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 no t les s tha n 45 degr ee s. Raise and set
unit down carefully.
If it is necessary to roll the unit into position, mount the unit
on field-supplied rails placed lengthwise under the unit,
using a minimum of 3 rollers. Apply force to the rails, not the
unit. If the unit is to be skidded into position, place it on a
large pad and drag it by the pad. Do not apply any force to
the unit.
Raise from above to lift unit from the rails or pad when unit
is in final position.
After unit in position, remove all shipping materials and top
crating.
B. Locate Unit
For service access and unrestricted airflow, provide clearance
on each end and side of unit. Position un it so that there is
unrestricted airflow above unit.
NOTE: Be fore mounting unit, remov e holddown br acke ts and
release skid.
If conditions or local codes requ ire unit to be fastene d t o pad,
use the mounting ho les in the b ase rai ls.
C. Mount Unit
The unit may be mounted on a solid, level concrete pad, on
accessory mounting legs, or on field-supplied raised supports
at each mounting position. (Note that mounting hardware is
field supplied.)
Bolt unit securely to pad or supports after unit is in position
and is level. Be sure to mount unit level to ensure proper oil
return to compressors. Mou nting ho les on unit can be used to
secure unit to vibration isolators, if required.
19 3/8
10
24 1/2
4 7/8
D
CONTROL BOX
Line & Low
Voltage Wiring
Entrances
1-1/2
2-1/8
9-3/4
1-1/8
5-3/4
2-1/2
4-1/4
33
1-1/2
REAR
38-1/2
1-1/2
A
C
FRONT
7/8
4 PLACES
27
24
33
B
35
BOTTOM
35
33
1-1/2
TOP FRONT
NOTES:
1. All dimensions are in inches.
2. Recommended clearance for proper airflow (local codes or jurisdictions may prevail):
Top — 60 in.
Sides — 24 in. on 3 sides, one side may be 6 in. (Control box side should have 24-in. clearance for service
access.)
3. Corner Weights (lb): A = 86
B = 84
C = 92
D = 90
Fig. 1 — 575B072 Unit Dimensions
—2—
38-1/2
1-1/2
Fig. 2 — 575C090,120 Unit Dimensions
—3—
WEIGHT DISTRIBUTION
UNIT
541A
180
WEIGHT — lb (kg)
Tot al
Operating
Weight
803
(364)
Support Point
12 34
158
243
244
(72)
(110)
(111)
158
(72)
Fig. 3 — 541A180 Unit Dimensions
—4—
NOTE: Recommended service clearances are as
follows (local codes or jurisdictions may prevail):
Side (compressor) — 3
Side (opposite compressor) — 3 ft (914 mm)
Ends — 2 ft (616 mm)
Top — 5 ft (1524 mm)
1
/2 ft (1067 mm)
12 3 45 6 78 9101112
13
14
15
28
27
26
19202122232425
LEGEND
1— Defrost Board/Time Guard II Control 11 — Power Terminal Block 20 — High-Pressure Switch
2— Fuse 12 — Control Terminal Block 21 — Compressor
3— Fan No. 1 13 — Compressor Lockout (CLO2 for
4— Compressor Lockout (CLO) Device 23 — Filter Drier
Crankcase Heater)
22 — Capacity Control Solenoid
5— Outdoor-Fan Relay 14 — Control Relay (CR3) 24 — Muffler
6— Outdoor-Fan Contactor 15 — Liquid Line Solenoid 25 — Oil Solenoid
7— Compressor Contactor 16 — Control Relay (CR2) 26 — Reversing Valve
8— Fan Motor Capacitors 17 — No Dump Relay (NDR) 27 — Accumulator
9— Circuit Breaker 18 — Oil Pressure Switch 28 — Coil
10 — Fan No. 2 19 — Fusible Plug (hidden)
Fig. 4 — Component Locations — 541A180 Shown
16
17
18
—5—
Table 1 — Physical Data — 575B072, 575C090,120 and 541A180 Units
UNIT 575B072 575C090 575C120 541A180
NOMINAL CAPACITY (tons) 6 7.5 10 15
OPERATING WEIGHTS (lb)
Aluminum-Fin Coils (standard) 345 464 506 803
Copper-Fin Coils (optional) N/A 565 607 945
REFRIGERANT* R-22
Operating Charge, Typical (lb)† 20 20 22 37
Shipping Charge (lb) 19 9 3
COMPRESSOR Scroll Semi-hermetic reciprocating
Qty...Model 1...SR_75 1...ZR_94 1...ZR125 1...06DF537††
Oil Charge (oz) 88 90 110 128
No. Cylinders N/A 6
Speed (rpm) 3500 1750
OUTDOOR FANS
Qty...Rpm 1…1100 2…1100 2…1075
Diameter (in.) 26 22 26
Nominal Hp
Nominal Airflow (cfm total) 6300 6500 11,000
Watts (total) 750 570 1460
OUTDOOR COILS (Qty) 12 1
Face Area (sq ft total) 24 29.2 29.2
Rows...Fins/in. 2…18 2…17 3…15
Storage Capacity (lb)** 17.3 34.2 40.1
CONTROLS
Pressurestat Settings (psig)
High Pressure
Open 420 428 ± 10 395 ± 20
Close 300 320 ± 20 295 ± 20
Low Pressure
Open 5 7 ± 3 7 ± 3
Close 20 22 ± 5 22 ± 5
PIPING CONNECTIONS (in. ODM)
Vapor 1
Liquid
*Unit is factory supplied with holding charge only.
†Typical operating charge with 25 ft of interconnecting pipe.
**Storage capacity of condenser coil with 80% full of liquid at 95 F.
††Equipped with an electric solenoid unloader, capacity steps are 100% and 67%.
3
/
4
1
/
8
5
/
8
11/
8
1
/
2
1
/
4
13/
8
1
/
2
15/
1
/
2
8
5
/
8
—6—
III. COMPLETE REFRIGERANT PIPING CONNECTIONS
Refrigerant lines mu st b e ca reful ly desig ne d a nd c onstr ucted
to ensure equipment reliabili ty and efficiency. Line length,
pressure drop, compressor oil return, and vertical separation
are several of the design criteria that must be evaluated. See
Table 2.
IMPORTANT: Do not bury refrigerant piping underground.
IMPORTANT: Piping must be properly sized and installed for
the system to operate efficiently.
A. Check Vertical Separation
If there is any vertical separation between the indoo r and o utdoor units, check to ensure that the separation is within
allowable limits. Relocate equipment if necessary. See Table 3.
B. Refrigerant Line Sizing
Consider the length of the piping required betwe en the outdoor and indoor units. The maximum allowable line length is
100 ft. See Table 3. Refrigerant suction piping should be
insulated.
IMPORTANT: A refrigerant receiver is not provided with the
unit. Do not install a receiver.
IMPORTANT: For 575C090,120 applications with liquid lift
greater than 20 ft, use
5
/8-in. liquid line. Maximum lift is
60 ft.
Table 2 — Refrigerant Piping Sizes
LENGTH OF PIPING ft
OUTDOOR
UNIT
575B072
575C090
575C120
541A180
*If there is a vertical separation between indoor and outdoor units, see
Table 3 — Maximum Vertical Separation.
LEGEND
L — Liquid Line V — Vapor Line
NOTES:
1. Pipe sizes are based on a 2 F loss for liquid and vapor lines.
2. Pipe sizes are based on the maximum linear length, shown for each
column, plus a 50% allowance for fittings.
3. Charge units with R-22 refrigerant in accordance with unit installation
instructions.
4. Maximum line length must not exceed 100 ft.
5. Do not bury refrigerant piping.
0-25 26-60 61-100
Line Size (in. OD)
LVLVLV
1
/211/
3
/811/
1
/213/
5
/815/
8
8
8
8
5
/811/
1
/211/
1
/213/
3
/415/
8
8
8
8
5
/811/
1
/211/
1
/213/
3
/415/
8
8
8
8
MAXIMUM
LIQUID
LINE
(in. OD)*
5
/
8
5
/
8
5
/
8
3
/
4
Table 3 — Maximum Vertical Separation*
unit to outdoor unit before opening the liquid and vapor lines at
the outdoor unit. For specific filter driers see Table 4.
D. Liquid Line Piping Procedure
Pipe the system liquid line as follows:
WARNING: Unit is pressurized with a holding
charge of refrigerant. Recover R-22 holding charge
before removing runaround liquid piping loop. Failure
to recover holding charge before removing piping loop
could result in equipment damage and personal injury.
1. Open service valves in sequence:
a. Discharge service valve on compressor.
b. Suction service valve on compress or.
c. Liquid line valve.
2. Remove
1
/4-in. flare cap from liquid valve Schrader
port.
3. Attach refri gerant recovery device and recover hold-
ing charge.
4. Remove runaround loop (581A180 only).
5. Connect system liquid line from liquid connection of
outdoor unit (575B,C, 541A) to indoor unit (524A-H)
liquid line connections. Select proper field-supplied
bi-flow filter driers and install in the liquid line. See
Fig. 5. Install a field-supplied liquid moisture indicator between the filter drier(s) and the liquid connections on the indoor un it. Braze or silver alloy so lder
all connections. Pass nitrogen or other inert gas
through piping while making connections to prevent
formation of copper oxide. (Copper oxides are
extremely active under high temperature and pressure. Failure to prevent collection of copper oxides
may result in system component failures.)
E. Liquid Line Solenoid Valve
Addition of a li qui d so le noi d v alv e (LL SV ) is required (except
for 541A180 units that already ha ve LLSV factory-i nstalle d).
The LLSV must be a bi-f low type suited for use in heat pump
systems. Refer to Table 4. Wire the solenoid valve in parallel
with the compressor contactor coil.
The LLSV must be installed at the outdoor unit with the
flow arrow pointed toward the outdoor unit (in-flow direction
for the Heating mode).
OUTDOOR
UNIT
575B 072 090 50
575C
541A 180 180 80
*Vertical distance between indoor and outdoor units.
090 090 60
120 120 60
INDOOR UNIT
524A-H
DISTANCE FT
Outdoor Unit
Above 524A-H
C. Install Filter Drier(s) and Moisture Indicator(s)
Every unit should have a filter drier and liquid-moisture
indicator (sight glass). In some applications, depending on
space and convenience requirements, it may be desirable to
install 2 filter driers and sight glasses. One filter drier and
sight glass may be installed at A
locations in Fig. 5. If
desired, 2 filter driers and sight glasses may be installed at
B
locations in Fig. 5.
Select the filter drier for maximum unit capacity and minimum
pressure drop. Complete the refrigerant piping from indoor
LEGEND
TXV — Thermostatic Expansion Valve
Fig. 5 — Location of Sight Glass(es)
and Filter Driers
—7—
Table 4 — Refrigerant Specialties Part Numbers
UNIT
575B072
575C090
575C120
541A180
*A filter drier is shipped loose with the 575B072 units.
†Bushings required.
**Factory Installed.
LIQUID LINE
SIZE
1
/2″ 200RB GS-1928 5T4 AMG-24/50-60 AMI1TT4 *
5
/8″ 200RB GS-1929 5T5 AMG-24/50-60 AMI1TT5 *
3
/8″ 200RB GS-1928 5T4† AMG-24/50-60 AMI1TT3 P504-8083S
1
/2″ 200RB GS-1928 5T4 AMG-24/50-60 AMI1TT4 P504-8084S
1
/2″ 200RB GS-1928 5T4 AMG-24/50-60 AMI1TT4 P504-8164S
5
/8″ ** ** AMI1TT5 P504-8085S Qty 2
3
/4″ ** ** AMI1TT5 P504-8085S Qty 2
LIQUID LINE
SOLENOID VALVE (LLSV)
F. Provide Safety Relief
A fusible plug is loca ted on the compressor crankcas e or in
the liquid line. See Fig. 6. Do not cap this plug. If local code
requires additi onal safety devices, insta ll them as directed.
Head Pressure Control (541A180 only)
Fan cycling for head pressure control is a standa rd offering
but is functional on the cooling cycle only. Number 2 fan
cycles as a function of liquid pressure. Fan cycling pressure
switch cycles the fan off at 160 ± 10 psig as pressure
decreases and cycles bac k on at 255 ± 10 psig. Switch is automatically bypassed in h ea ting c yc le. Table 5 s ho ws min im um
outdoor air temperature for full cooling capacity.
G. Vapor Line Piping Procedure
Connect system vapor li ne to the vapor line s tub on the outdoor unit and the vapor stubs on the indoor unit. At the
indoor unit, construct vapor piping branches as shown in
Fig. 7 for good mixi ng of the refri gerant leaving the ind oor
coil during cooling. This will ensure proper TXV (thermostatic expansion valve) bulb sensing.
Where vapor line is expose d to outd oor ai r, line must be insulated. See Table 6 for insulation requirements.
Table 5 — Minimum Outdoor Air
Operating Temperature
LLSV COIL SIGHT GLASS FILTER DRIER
Fig. 6 — Location of Fusible Plug —
541A180 Unit
UNIT
COMPRESSOR
CAPACITY
575B 072
%
575C
090 35 –20
120 35 –20
541A 180
*Applies to Cooling mode of operation only.
†Wind baffles (field-supplied and field-installed) are recommended for
100
100
67
MINIMUM OUTDOOR TEMP — F*
Standard
Unit
Head Pressure
Control†
00
23
36
–20
–20
all units with low ambient head pressure control. Refer to Low Ambient
Control Installation Instructions (shipped with accessory) for details.
Table 6 — Insulation for Vapor Line Exposed
to Outdoor Conditions
LENGTH OF EXPOSED
VAPOR LINE*
ft in.
10
25
35
50
*Recommended vapor line insulation for piping exposed to outdoor
conditions to prevent loss of heating during heating cycle. When vapor
line goes through interior spaces, insulation should be selected to prevent condensation on cooling cycle. Heating capacity should be
reduced 1000 Btuh if over 35 ft of vapor line with
exposed to outdoor conditions.
†Closed cell foam insulation with a thermal conductivity of: 0.28 Btu
2
• in./ft
• h • °F.
INSULATION THICKNESS†
3
/
8
1
/
2
3
/
4
3
/
4
3
/4 in. insulation is
LEGEND
TXV — Thermostatic Expansion Valve
Fig. 7 — Vapor Line Branch Piping Details
—8—
IV. COMPLETE ELECTRICAL CONNECTIONS
7
A. Power Supply
Electrical characteristics of available power supply must
agree with nameplate rating. Supply voltage must be within
tolerances shown in Table 7. Phase imbalance must not
exceed 2%. Operat ion of unit on improper supply voltage or
with excessive phase imbalance constitutes abuse and is not
covered by Bryant warranty.
Per local code requirements, provide an adequate fused
disconnect switch within sight of unit and out of reach of
children. Provision the switch for locking open (off) to
prevent power from being turned on while unit is being
serviced. The disconnect switch, fuses, and field wiri ng mus t
comply with local requirements. Refer to Table 7 for unit
electrical data.
B. Power Wiring
All power wiring must comply with applicable local requirements. Run power wires from disconnect switch through unit
power opening and connect to terminal block inside the unit
control box. Unit must be grounded.
C. Unbalanced 3-Phase Supply Voltage
Never operat e a motor where a phase imbala nce in supply
voltage is greater than 2%. Use the following formula to
determine the percentage of voltage im balance:
% Voltage Imbalance:
= 100 x
max voltage deviation from average voltage
average voltage
Example: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
452 + 464 + 455
1371
=
3
3
= 457
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance= 100 x
457
= 1.53%
This amount of phase imbalance is satisfactory as it is below
the maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is
more than 2%, contact your local electric utility company
immediately.
WARNING: Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the
possibility of personal injury if an electrical fault
should occur. This ground may consist of electrical wire
connected to unit ground lug in control compartment,
or conduit approved for electrical ground when
installed in accordance with NEC (National Electrical
Code), ANSI/NFPA (American National Standards
Institute/National Fire Protection Association), and
local electrical codes. Failure to follow this warning
could result in the installer being liable for personal
injury of others.
IMPORTANT: Operation of unit on improper power supply
voltage or with excessive phase imbalance constitutes abuse
and is not covered by Bryant warranty.
D. General Wiring Notes (See Fig. 8-13)
1. A crankcase heater is wired in the c ontr ol ci rcuit so it
is always operable as l ong as po wer su pply discon nect
is on, even if any saf ety device is open or unit stop/
start switch is off.
2. The power-circuit field supply disconnect should
never be open except when unit is being service d or is
to be down for a prolonged period. When operation is
resumed, crankcase heater should be energized for
24 hours before start-up. If system is to be shu t down
for a prolonged period, it is recommended that the
suction and discharge valves be closed to prevent
an excessive accumulation of refrige rant in the compressor oil.
3. Terminals for field power supply are suitable for copper, copper-clad aluminum, or aluminum conductors.
4. Bryant recommends an indoor airflow switch (field
supplied) be installed and interlocked with the
outdoor unit. This prevents the outdoor unit from
operating if ind oor airflow fails (broken fan belt, etc.).
Operation of the compressor in vacu um can damage
bearing surfaces. Install indoor airflow switch in a
convenient locati on at the indo or supply air d uct and
wire per Fig. 14.
5. If the system is equipped with an accessory electri c
heater, refer to the 524A-H inst allation instructions
and tables.
E. Control Circuit Wiring
Control voltage is 24 v. See unit label diagram for field
supplied wiring details. Route control wires through opening
in unit to connection in unit control box.
Control Tran sf o r me r W iring
On 208/230V units, check the transformer primary wiring
connections. See Fig. 8 or refer to unit label diagram.
For 575B,C Unit — If unit will be operating at 208-3-60
power, remove black wire (BLK) from the transformer primary connection labeled “230” and move it to the connection
labeled “208”. See Fig. 8.
For 541A Unit — Transformers no. 1 and 2 are wired for a
230-v unit. If a 208/230-v unit is to be run with a 208-v
power supply, the transformers must be rewired as follows:
1. Remov e ca p from red (208 v) wire.
2. Remove cap from orange (230 v) spliced wire.
3. Replace orange wire with red wire.
4. Recap both wires.
IMPORTANT: BE CERTAIN UNUSED WIRES ARE
CAPPED. Failure to do so may result in damage to the
transformer.
—9—
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