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—
Duplex 575C120, 541A180 with 524A-H240 or 524A-H300
In order to properly connect two heat pump condensing
units to a single 524A-H packaged air handler, it is
necessary to add field-supplied Fan Coil Relay Board(s),
P/N 33ZCRLYBRD. Relay board(s) no. 1 and no. 2 should be
installed in the control box of condensing unit.
IMPORTANT: The common (COM) terminals from the fan
coil relay board(s) mu st be connected to the ‘C’ terminal in
condensing unit ‘A’.
Route thermostat cable or equivalent single leads of
no. 18 AWG (American Wire Gage) colored wire from subbase terminals through conduit in unit to low-voltage connections as shown on unit wiring diagram and Fig. 12
and 13.
NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire
(35 C minimum). For 51 to 75 ft, use no. 16 AWG insulated
wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated
wire (35 C minimum). All wire larger than no. 18 AWG cannot
be directly connected to the thermostat and will require a junction box and a splice at the thermostat.
Table 7 — Electrical Data
Fig. 8 — Wiring Diagram — 575C090,120 —
Control Transformer
UNIT
575B 072 NONE
090
575C
120
541A 180 NONE
LEGEND
FLA — Full Load Amps
LRA — Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
NEC — National Electrical Code
RLA — Rated Load Amps
*Units are suitable for use on electrical systems where voltage supplied
to the unit terminals is not below or above the listed limits.
FAC TORY -
INSTALLED
OPTION
NONE OR DISCONNECT
CONVENIENCE OUTLET 43.8 60
NONE OR DISCONNECT
CONVENIENCE OUTLET 21.9 30
NONE OR DISCONNECT
CONVENIENCE OUTLET 50.0 70
NONE OR DISCONNECT
CONVENIENCE OUTLET 25.0 30
NONE OR DISCONNECT
CONVENIENCE OUTLET 20.0 25
NOMINAL VOLTAGE
(V-Ph-Hz)
208/230-3-60 187 253 18.9 146 5.1 28.7 45
460-3-60 414 506 9.5 73 2.6 14.5 20
575-3-60 517 633 7.6 58 1.2 10.7 15
208/230-3-60 187 254 29.0 190 1.5
460-3-60 418 506 15.0 95 0.7
208/230-3-60 187 254 34.0 225 1.5
460-3-60 418 506 17.0 114 0.7
575-3-60 523 632 14.0 80 0.7
208/230-3-60 187 253 63.6 266 4.3 87.5 125
460-3-60 414 528 29.3 120 2.3 40.7 60
575-3-60 518 660 23.8 96 1.8 33.0 50
VOLTAGE RANGE* COMPRESSOR FAN MOTORS POWER SUPPLY
Min Max RLA LRA FLA MCA MOCP
39.0 60
19.8 30
45.0 60
23.0 30
18.0 25
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.
—10—
FAN
R-RV
DEFROST
CONTROL
C
R
BL
O
Y-R V
RV
CC
PS2
PS1
DF
LEGEND
DF — Defrost Relay
LP/HP — Low or High-Pressure Switch (Optional)
RV
BK
COIL
BK
BL
BL
Y
LP/HP
LP/HP
Y
BK
SEN
BK
Y
WR
PS — Pressure Switch
RV — Reversing Valve
SEN — Outdoor Coil Temperature Sensor
TSTAT — Thermostat
Line Voltage Factory
Low Voltage Factory
Low Voltage Field
COLOR CODE
BK Black
BL Blue
O Orange
R Red
W White
Y Ye l l o w
W
Y
O
DEFROST HEAT
COMPRESSOR
HEAT/COOL
COMMON
24 VAC
FROM
TS TAT
NOTES:
1. All electrical work must be done in conformance with the National
Electrical Code (NFPA No. 70) and in conformance with local
codes and authorities having jurisdiction.
2. For use with copper conductors only.
CAUTION: Not suitable for use on systems exceeding
150 volts to ground.
Fig. 9 — Wiring Diagram — 575B072; 208/230-3-60 Units
TO ELECTRIC
HEATER
ACCESSORY,
IF EQUIPPED
THERMOSTAT
R
Y
O
E
W2
G
C
CONNECTION
BOARD (TB)
1
2
3
4
IFC
LLSV
5
6
7
8
NOTES:
1. For thermostat and subbase part no. see
2. Use copper conductors only.
Fig. 10 — Wiring Diagram — 575C090,120; 230-3-60 Units
LEGEND
IFC — Indoor Fan Contactor
LLSV — Liquid Line Solenoid Valve
TB — Terminal Block
Field Wiring
price pages.
—11—
LEGEND
EQUIP — Equipment
GND — Ground
HC — Heater Contactor
IFC — Indoor Fan Contactor
IFM — Indoor Fan Motor
NEC — National Electrical Code
TB — Terminal Block
Fig. 11 — Wiring Diagram — 541A180 Unit With Standard Thermostat and Electric Heat
—12—
DISCONNECT
3-Ph ONLY
524A-H240
TERMINAL BLOCK
TB1
R
Y1
Y2
W1
W2
G
C
X
FIELD
POWER
SUPPLY
EQUIP GND
FIELD POWER
WIRING
C1
WHT
TB1
L1
L2
L3
524A-H
HEAT ACCESSORY
IFC
C2
WHT
HC1
HC1
CIRCUIT BREAKER
(5 HP AND LARGER)
W1
W2
C
R
Y1
Y2
W1
W2
G
C
O
TS TAT
HTR1
IFC
21
11
22
12
23
13
BLK
BLK
BLK
1
2
3
UNIT WIRING
IFM
HEAT PUMP “A”
TB2
R
Y1
Y2
W1
W2
G
CR
C
X
CR
G
G2/(W)
G3/(Y)
COM
RELAY BOARD
(33ZCRLYBRD)
(VALVE)
HI(COOL)
MED(HEAT)
LO
FAN
LEGEND
CR — Control Relay (Field-Supplied)
EQUIP — Equipment
GND — Ground
HC — Heating Contactor
HTR — Electric Heater
IFC — Indoor-Fan Contactor
IFM — Indoor-Fan Motor
TB — Terminal Block
TSTAT — Thermostat
Factory Wiring
Field Control Wiring
NOTE: Use copper conductors only.
Fig. 12 — Wiring Diagram — Duplex 575C120 With 524A-H240 and Electric Heat
HEAT PUMP “B”
TB2
R
Y1
Y2
W1
W2
G
C
X
—13—
DISCONNECT
3-Ph ONLY
524A-H300
TERMINAL BLOCK
TB1
R
Y1
Y2
W1
W2
G
C
X
FIELD
POWER
SUPPLY
EQUIP GND
FIELD POWER
WIRING
C1
WHT
TB1
L1
L2
L3
HEAT ACCESSORY
IFC
C2
WHT
CIRCUIT BREAKER
(5 HP AND LARGER)
524A-H
W1
W2
C
R
Y1
Y2
W1
W2
G
C
X
TS TAT*
HC1
HC1
HTR1
IFC
21
11
22
12
23
13
BLK
BLK
BLK
G
G2/(W)
G3/(Y)
COM
1
2
3
UNIT WIRING
RELAY BOARD
(33ZCRLYBRD)
(VALVE)
HI(COOL)
MED(HEAT)
LO
IFM
FAN
HEAT PUMP A
541A180
TB2
R
B
W1
A2
Y1
Y2
Q
C
P
X
1
2
CR
G
G2/(W)
G3/(Y)
COM
RELAY BOARD
(33ZCRLYBRD)
(VALVE)
HI(COOL)
MED(HEAT)
LO
FAN
LEGEND
HEAT PUMP B
575C120
CR — Control Relay (Field-Supplied)
EQUIP — Equipment
GND — Ground
HC — Heating Contactor
HTR — Electric Heater
IFC — Indoor-Fan Contactor
IFM — Indoor-Fan Motor
TB — Terminal Block
TSTAT — Thermostat
Factory Wiring
Field Control Wiring
*Do not configure TSTAT for heat pump.
NOTE: Use copper conductors only.
TB2
Y1
Y2
W1
W2
R
CR
G
C
X
Fig. 13 — Wiring Diagram — Duplex 575C120 and 541A180 With 524A-H300 and Electric Heat
CR
LEGEND
AFS — Airflow Switch (Sail Switch)
CR — Control Relay
DB — Defrost Board
Factory Wiring
Field Control Wiring
NOTES:
1. Locate YEL wire between on DB and terminal 5 of CR3
and cut.
Y
2. Splice airflow switch (AFS) (field supplied) contact wires (field
provided) to two ends of cut YEL wire as depicted.
Fig. 14 — Typical Field Wiring for Airflow Switch —
541A180/524A-H
—14—
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 the system and provides
a record of unit condition, application requirements, system
information, and operation at initial start-up.
CAUTION: Do not attempt to start the heat pump
system, even momentarily, until the following steps
have been completed. Compressor damage may result.
I. PRELIMINARY CHECKS
1. Check all air handler and other equipment auxiliary
components. Consult manufacturer’s instructions regarding any other equipment attached to unit. If unit
has field-installed accessories, be sure all are properly
installed and correctly wired. If used, airflow switch
must be properly installed. See Fig. 14 for typical field
wiring.
2. As shipped, compressor is held down by 4 bolts. After
unit is installed, loosen each bolt and locknut until
flat washer or snubber can be moved with finger pressure. Be sure compressor floats freely on the moun ting springs (541A units only). See Fig. 15A and 15B
for compressor mountin g.
3. Check tightness of all electrical connections.
4. Electrical power source must agree with nameplate
rating.
5. Turn on crankcase heater for 24 hours before starting
the unit to be sure a ll refrigeran t is out of the oil . To
energize crankcase heater, perform the following steps:
a. Set the space thermostat system switch to OFF, or
adjust the tem perature so t here is no dem and for
cooling.
b. Close the field disconnect.
c. Leave the compressor circuit breaker off. The
crankcase heater is now energized.
6. Leak test the field refrigerant piping, connections
and joints, and indoor coil. To perform leak test, complete the following steps:
a. Pressurize refrigerant piping; do not exceed
150 psi.
b. Using soap bubbles and/or an electronic leak
detector, test refrigerant piping, connections and
joints, and the indoor coil. See Fig. 16.
c. Check for leaks.
Evacuate and dehydrate entire refrigerant system.
7. 541A180 only — compressor oil le vel s hould be visibl e
in sight glass. Adjust the oil level as required. No oil
should be removed unless the crankcase heater has
been energized for at least 24 hours. See Start-Up
section, Preliminary Oil Charge.
NOTE: The 575B, 575C units do not have a compressor oil level sight glass. These units are factory
charged with the required amount of oil. If required,
use the followin g oil for repl acement: For 575B units
use Zerol 150, part number P903-2001. For 575C
units use RCD, part number P903-0101.
8. Backseat (open) compressor suction and discharge
valves. Now close valves one turn to allow refrig erant
pressure to reach test gages.
SELF-LOCKING
BOLT
SNUBBER WASHER
NEOPRENE
SNUBBER
COMPRESSOR FOOT
Fig. 15A — Compressor Mounting — 575B072 and
575C090,120 Units
Fig. 15B — Compressor Mounting — 541A180 Units
150 PSI MAX
DRY
OUTDOOR
UNIT
NITROGEN
SUCTION LINE
LIQUID LINE
LIQUID LINE
SOLENOID VALVE
TXV
SOAP
→ Fig. 16 — Recommended Process for
Checking for Leaks
II. PRELIMINARY CHARGE
CAUTION: The 575C090 and 575C120 units contain a
9 lb charge of refrigerant. Add remainder of preliminary
charge and allow pressure to equalize before starting
compressor. Failure to do so WILL cause the compressor to
overheat in a few minutes, possibly causing permanent
compressor damage. The amount of refrigerant added
must be at least 80% of the operating charge listed in
the Physical Data table (Table 1).
INDOOR
COIL
—15—
Before starting the unit, charge liquid refrigerant into the
high side of the system through the liquid service valve.
Allow high and low side pre ssu res t o equali ze be for e star ting
compressor. If pressures do not equalize readily, charge
vapor on low side of system to assure charge in the evaporator. Refer to GTAC II, Module 5, Charging, Recovery, Recycling, and Reclamation for liquid charging procedures.
III. LIQUID LINE SOLENOID
To minimize refrigerant migration to the compresso r during
the heat pump OFF cycle, the 575B,C unit must have a
bi-flow liquid line solenoid valve (field supplied). The valve
opens when the compressor is energized, and closes when
the compressor is deenergized. This reduces compressor
flooded starts, thus significantly increasing compressor life.
IV. ACCUMULATOR
The unit accumulator controls the rate of l iquid refrigerant
to the compressor during heat pump operation.
The 541A accumulator features a unique method for
returning oil to the comp ress or. The oil return mechanism is
external to the accumulator. The mixture of oil and refrigerant is metered to the compressor by a brass orifice which is
removable and cleanable. The oil return mechanism also
contains a solen oid va lve th at op ens wh en the c ompres sor is
ON and closes when the compressor is OFF. This keeps the
liquid refrigerant stored in the accumulator from dra ining to
the compressor during the heat pump OFF cycle, which
further protects the compressor against flooded starts.
becomes excessive, and automatically resets when the
internal temperature drops to a safe level. This overload
usually resets within 60 minutes (or longer). If the internal
overload is sus pected of bei ng open , disco nnec t the elect ric al
power to the unit and check the circuit through the overload
with an ohmmeter o r continuity tester.
III. ADVANCED SCROLL TEMPERATURE PROTECTION
(ASTP)
Advanced Scroll Temperature Protectio n (ASTP) is a form of
internal dischar ge temperature protection that unloads the
scroll compressor when the internal temperature reaches
approximately 300 F. At this temperature, an internal bimetal disk valve opens and causes the scroll elements to separate, which stops compression. Suction and discharge pressures balance while the motor continues to run. The longer
the compressor runs unloaded, the longe r it must cool before
the bi-metal disk re sets. See Fig. 17.
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 protector trips, which occu rs
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 contai n this t ec hno lo gy. See
Fig. 18.
START-UP
CAUTION: Compres sor crankcase heat er must be
on for 24 hours before start-u p. After the heater has
been on for 24 hours, the unit can be started.
CAUTION: Prior to starting compressor, a preliminary
charge of refrigerant must be added to avoid possible
compressor damage.
I. COMPRESSOR ROTATION (575B,C Units)
On 3-phase units with scroll compressors, it is important to
be certain compressor is rotating i n the proper di rection. To
determine whether or not compressor is rotating in the
proper direction:
1. Connec t service gages to suctio n 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.
II. COMPRESSOR OVERLOAD
This overload interrupts power to the compressor when
either the current or internal motor winding temperature
120
110
100
90
80
es)
70
nut
60
50
(Mi
40
30
20
Recommended Cooling Ti me
10
0
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. 17 — Recommended Minimum Cool-Down Time After
Compressor is Stopped*
Fig. 18 — Advanced Scroll Temperature Protection Label
—16—
IV. COMPRESSOR LOCKOUT DEVICE
The compressor lockout (CLO) device pre vents the compressor from starting or running in a high pressure, loss-ofcharge or freezestat op en s it uati on. Reset t he CLO d evic e b y
setting the thermostat to eliminate cooling demand and
return it to the original set point. If the system shuts down
again for the same fault, determine the possible cause before
attempting to reset the CLO device.
V. PRELIMINARY OIL CHARGE (541A)
The compressor is factory charged with oil (see Table 1).
When oil is chec ke d at sta rt-up , i t may be ne cessar y to a dd or
remove oil to bring it to the proper level. Add oil only if
necessary to bring oil into view in sight glass. Use only
Bryant-approved compressor oil. One recommended oil
level adjustment method is as follows:
A. Add Oil
Close suction service valve and pump down crankcase to
2 psig. Wait a few minutes and repeat until pressu re remains
steady at 2 psig. Remove oil fill plug above the sight gla ss,
add oil through plug hole, and replace plug. Run compressor
for 20 minutes and check oil level.
NOTE: Use only Bryant-approved compre ssor oil. 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.
B. Remove Oil
Pump down compressor to 2 psig. Loosen the
1
/4-in. pipe plug
at the compressor base and all ow t he oil to seep o ut past the
threads of the plug. Retighten plug when level is correct.
NOTE: The crankcase is 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.
VI. 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 start and stop the compressor except in an emergency.
After starting, there is a delay of at least 3 seconds before
compressor starts.
VII. ADJUST REFRIGERANT CHARGE
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.
CAUTION: Charge unit on cooling cycle only. If
unit is charged on heating cycle, overcharging may
occur.
Refer to Charging Charts Fig. 19A-19C and Table 8. Do not
exceed maximum refri gerant charge. 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 un its to the corr ect subc ooling for the
various operating conditions. Accurate pressure gage and
temperature sensing device are required.
Connect the pressure ga ge to the service port on the liquid
line service valve. Mount the temperature sensing device
on the liquid line, close to the l iquid line servi ce valve and
insulate it so that outdoor ambient temperature does not
affect the reading. Indoor airflow mus t be withi n the norm al
operating range of the unit. Operate unit a minimum of
15 minutes. Ens ur e press ur e and tem per atu re re adin gs h a v e
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 maximum allo wable 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.
VIII. CHECK HEATING CYCLE OPERATION
Place thermostat selector switch at HEAT and reset the
space set point above ambient temperature so that a call for
heating is ensured. Compressor will start wi thin 5 minutes.
Observe system operation.
IX. CHECK COMPRESSOR OIL LEVEL (541A)
After adjusting the refrigerant charge, allow the system to
run fully loaded for 20 minutes. Running oil level should be
within view in the cran kcas e si ght g las s. Stop comp resso r a t
the field power supply disconnect and check the crankcase
oil level. Add oil o n l y if ne ce ssa r y to br ing the oil into view in
the sight glass. If oil is added, run the system for an additional 10 minu tes, 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
section for proper procedure for adding and removing oil.
When the above checks are complete, repeat the procedure
with the unit operating at minimum load conditions. Unload
the compressor by disconnecti ng the field-control circuit lea d
at TB2 .
Y2
Reconnect the field-control circuit lead when checks are
complete.
X. FINAL CHECKS
Ensure all safety controls are operating, control panel covers
are on, and the service panels are in place.
Table 8 — Maximum Refrigerant Charge
UNIT
575B 072 27.0
575C
541A 180 62.0
090 34.2
120 34.2
R-22
(lb)
—17—
0
60
54
49
43
38
32
27
21
LIQUID TEMPERATURE AT LIQUID VALVE (C)
16
10
Fig. 19A — 575B072 Charging Chart
140
130
ADD CHARGE IF ABOVE CURVE
120
110
100
90
80
LIQUID TEMPERATURE AT LIQUID VALVE (F)
70
60
50
344
100
50
150 200 250 300 350 40
LIQUID PRESSURE AT LIQUID VALVE (PSIG)
1034
689
LIQUID PRESSURE AT LIQUID VALVE (Kilopascals)
REDUCE CHARGE IF BELOW CURVE
1379
1724
Fig. 19B — 575C090,120 Charging Chart
Fig. 19C — 541A180 Charging Chart
2069
2414
SEQUENCE OF OPERATION
I. 575B072 UNITS
When power is supplied to unit, the transfor mer (TRAN) a nd
crankcase heater (CCH) are energized.
A. Cooling
On a call for cooling, the thermostat completes the following
circuits: R-G, R-Y , and R-O . If the compressor recycle delay of
3 minutes is complete, the compressor and outdoor fan start.
The reversing valv e is energized for cool ing and the indoorfan motor starts.
When the thermostat is satisfied, the circuits are opened,
and the compressor, outdoor-fan motor, and indoor-fan motor
stop. The reversing valve is deenergized.
B. Heating
On a call for heating, the thermostat completes the following
circuits: R-G and R-Y. If the compressor recycle delay of
3 minutes is complete, the compressor and outdoor fan start.
The indoor-fan motor will also start.
If room temperature continues to fall, the thermostat
completes circuit R-W. If the optional electric heat package is
used, the heat relay is energized, and the electric heaters are
energized.
When the thermostat is satisfied, the circuits are opened,
and the compressor, outdoor-fan motor, heaters, and indoorfan motor stop.
C. Defrost
Defrost board (DB) is a time and temperature control, which
includes a field-selectable time period between checks for
frost (30, 50, a nd 90 minutes). Electron ic timer and defrost
cycle start only when contactor is energized and defrost thermostat (DFT) is cl osed (below 28 F).
Defrost mode is identical to Cooling mode, except outdoor-fan
motor (OFM) stops and a bank of supplemental electric heat
turns on to warm air supplying the conditioned space.
Defrost mode is terminated when the DFT reaches 65 F.
D. Air Circulation
When the fan switch is at FAN ON, the indoor-air fans operate continuously to provide ventilation. The thermostat
operates the other components as described above.
E. Emergency Heat Cycle
If the compressor is inoperative due to a tripped safety
device, the second stage of the thermostat automatically
energizes the ind oor-air fan and t he el ectri c resis tance heaters (if equipped).
II. 575C090,120 UNITS
When power is supplied to unit, the transformer (TRAN) is
energized. The crankcase heater is also energized.
A. Cooling
With the thermostat subbase in the cooling position, and
when the space temperature comes within 2° F of the cooling
set point, the thermostat makes circu it R-O. This energizes
the reversing valve solenoid (RVS) and places the unit in
standby condition for cooling.
As the space temperature continues to rise, the second stage
of the thermostat m ak es, closing ci rcuit R-Y. When compressor time delay (5 ± 2 minutes) is completed, a circuit is made
to contactor (C), starting the compressor (COMP) and
outdoor-fan motor (OFM). Circuit R-G is made at the same
time, energizing the ind oor-fan contactor (IFC) and starting
the indoor-fan motor (IFM) after one-second delay.
—18—
When the thermost at is satisfied, contacts open, deenergizing C. The COMP, IFM, and OFM stop.
B. Heating
On a call for heat, thermostat make s circuits R-Y and R-G.
When compressor time delay (5 ± 2 minutes) is completed, a
circuit is made to C, starting COMP and OFM. Circuit R-G
also energizes IFC and starts IFM after a 1-second delay.
III. 541A180 UNITS
A. Heating
Place thermostat selector at HEAT and set temperature
selector above room ambient.
B. Cooling
Place thermostat selector at COOL and set temperature
selector below room ambient.
When thermosta t calls for unit ope ration (eithe r heating or
cooling), the indoor-fan motor starts immediately. The
outdoor-fan motors and compressor start within 3 seconds to
5 minutes depending on when unit was last shut off by thermostat, because u nit contains a compressor ti me delay circuit. When fir st-stage cooling is re quired, thermost at (TC1)
closes, causing the heat pump to start with an unloaded compressor. When TC2 closes, demanding addition a l c ooli ng, the
compressor loads to full load operation.
During heating, compressor is always fully loaded. When
TH1 demands first-stage heating, the heat pump starts
within 3 seconds to 5 minutes depending on when unit was
last shut off by thermostat, because unit c onta ins a compr e ssor time delay circuit. (The defrost board has speed terminals to shorten this cycle.) When TH2 of the thermostat
closes, auxiliary heat supply (electric strip heat) is ener gize d
in 1 or 2 stages dependin g on number of stages availab le and
whether outdoor ther mostats are closed.
Defrost is achieved by reversal fro m heating to cooling cycle
and deenergization of outdoor-fan motors, allowing hot
refrigerant gas to defrost outdoor coil. Defrost is achieved
with a timer set to initiate defrost every 30, 50, or
90 minutes (factory set at 30 minutes).
Defrost is initiated when refrigerant temperature leaving
the outdoor coil is me asured below 2 7 F, (typical ly when the
outdoor ambi en t tem perature is be lo w 4 5 F a s sen s ed b y t he
defrost thermostat [DFT]).
Defrost is terminated when: The refrigerant temperature
rises to 80 F at the DFT location on the liq uid line; or the
refrigerant pressure rises to 280 psig at the HPS2 l ocation
on the liquid line; or the defrost timer completes the
10-minute cycle.
IV. DUPLEX UNITS
A. Duplex 575C120 Units with 524A-H240 (See Fig. 12)
Cooling
When the thermostat is set for cooling, and the space tem-
perature comes within 2° F of the coolin g set point, the the rmostat completes the circuit from R to O a nd the reversing
valves in both un its are energiz ed. If the space temperature
continues to rise, the circuit from R to Y1 is completed. If the
time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of
Heat Pump A. A t t h e sa me t i me th e c ir cuit is c o mpl ete d fro m
R to G, starting the indoor-fan mot or. If the space temp erature continues to rise, the circuit is completed from R to
Y2 and the Cooling mode is initiated in Heat Pump B in a
similar ma nner.
When the thermostat is satisfied, the contacts open, deene rgizing first the Heat Pump B and then Heat Pump A.
Heating
When the thermostat calls for heating, the circuit from R to
Y1 is completed. If the time delays and safeties are satisfied,
the compressor contactor closes, starting the compressor and
outdoor-fan motors of Heat Pump A and Heat Pump B. At
the same time the circuit is completed from R to G, starting
the indoor-fan motor. If the second stage of heating is
required, the circuit from R to W2 will be compl eted and the
electric resistance heaters will be energized.
When the thermostat is satisfied, the contacts open, deene rgizing Heat Pump A an d Heat Pump B.
B. Duplex 575C120 and 541A180 Units With 524A-H300
(See Fig. 13)
Cooling
When the thermostat c alls for cooling, the circui t from R to
Y1 is completed. If the time delays and safeties are satisfied,
the compressor contactor closes, starting the compressor and
outdoor-fan motors of Heat Pump A (541A180). At the same
time the circuit is completed from R to G, starting the indoorfan motor. If the space temperature continues to rise, the
circuit is completed from R to Y2 and the Cooling mode is
initiated in Heat Pump B (575C120).
When the thermostat is satisfied, the contacts open, deene rgizing first the Heat Pump B and then Heat Pump A.
Heating
When the thermostat calls for heating, the circuit from R to
W1 is completed. If the time delays and safeties are satisfied,
the compressor contactor closes, starting the compressor and
outdoor-fan motors of Heat Pump A and Heat Pump B. At
the same time the circuit is completed from R to G, starting
the indoor-fan motor. If the second stage of heating is
required, the circuit from R to W2 will be compl eted and the
electric resistance heaters will be energized.
When the thermostat is satisfied, the contacts open, deene rgizing Heat Pump A an d Heat Pump B.
C. Safeties
The high-pressure switch, loss-of-charge switch, oil pressure
safety switch, and compressor overtemperature safety are
located in a CLO circuit that prev ents heat pump operation
if these safety devices are activated. A light at the thermostat energizes when CLO c irc ui t i s af fe cte d. Th e lo ckout s ys tem can be reset by adjusting the thermostat to open the
contacts (down for Heating mode, up for Cooling mode),
deenergizing the CLO circuitry. Compressor overcurrent protection is achieved with a circuit breaker which requires
manual resetting at the outdoor unit control box.
The unit is equipped with an oil pressure safety switch that
protects the compr essor if oil pressure does not devel op on
start-up or is lost during operation. The oil pressure switch
is of the manual reset type and therefore must be reset at
the outdoor unit. DO NOT RESET MORE THAN ONCE.
If oil pressure switch trips, determine cau se and correct. DO
NOT JUMPER OIL PRESSURE SAFETY SWITCH.
To reset the oil pressu re switch:
1. Disconnect power to the unit.
2. Press the RESET button on the oil pressure switch.
3. Reconnect power to the unit.
—19—
Unit is equipped with a no-dump reversing valve circuit.
When unit is in Cooling mode, reversing valve remains in
cooling positi on unti l a cal l for he ating is reque sted by thermostat. When unit is in Heating mode, reversing valve
remains in heating position until there is a call for cooling.
The crankcase heater is in a lockout circuit. If crankcase
heater is defective, compressor is locked off. Heat pump
remains off until cor rective action i s taken. The locko ut circuit cannot be reactivated by adjusting the thermostat. To
reset the crankcase heater lockout, disconnect and then
reconnect power to unit.
D. Check Operation
Ensure operation of all safety controls. Replace all service
panels. Be sure that control panel cover is closed tightly.
V. RESTART
Manual reset of the 24-v control circu it is necessary if unit
shutdown is caused by automatic reset devices (including IP
[internal compressor overcurrent protection], HPS [highpressure switch], and LCS [loss-of-charge switch]) or if
shutdown is caused by manual reset devices (including
OPS [oil pressure switch] and compressor circuit breaker
protection). To restart the unit when IP, HPS, or LCS has
tripped (after device has reset automatically), open an d then
close the thermostat contacts. Opening and then closing
thermostat contacts interrupts and restores 24-v power to
the compressor lockout (CLO), which resets the circuit.
It is necessary to manually reset the compressor circuit
breaker and OPS at the unit if either of these safeties should
shut down the unit.
IMPORTANT: If OPS trips, it must be reset first before mak-
ing and breaking the thermostat contacts to reset CLO. If
this procedure is not followed, the CLO cannot reset.
VI. CAUSES OF COMPLETE UNIT SHUTDOWN:
• interruption of supplied power
• open compressor overtemperature prote c tion (IP)
• compressor electrical overload prote c tion (CB)
• open high-pressure or loss-of-charge safety switches
• open oil pressure switch
• open crankcase heater lockout (C LO2)
• open control circuit fuse (FU1 or FU2)
• open discharge gas thermostat (575C only)
SERVICE
I. COMPRESSOR REMOVAL
See Table 1 for compressor informatio n. Follow safety codes
and wear safety glasses and work gloves.
1. Shut off power to unit. Remove unit access panel.
2. Recover refrigerant from system using refrigerant
recovery methods, and in accor dance with local and
national standards.
3. Disconnect compressor wiring at compressor terminal box.
4. Disc onnect refrigerant lines from compressor.
5. Remove screws from compressor mounting plate.
CAUTION: Exce ssive movement of copper lines at
compressor may cause higher l evels of vibration when
unit is restored to service.
6. Remove or disconnect crankcase heater from compressor base.
7. Remove compressor from unit.
8. On 541A180 un it remove co mpressor ho lddown bolts
and lift compressor off mounting plate.
9. Clean system. Add new liquid line filter drier.
10. Install new compressor on compressor mounting
plate and position in unit. Connect suction and discharge lines to compressor. Secure mounting plate
with compressor to unit. Ensure that compressor
holddown bolts are in place. Connect wiring. Install
crankcase heater.
11. Evacuate and recharge unit.
12. Restore unit power.
II. 575C090,120 COOLING MODE OPERATION (See Fig. 20)
1. High pressure, high temperature refrigerant vapor
from the compressor flows through the reversing
valve and is directed to the vapor headers of both
outdoor coils.
2. At the o utdoor coil vapor header, the high pressure,
high temperature refrigerant vapor flows up to check
valve “A” that blocks the flow. All the refrigerant is
then directed to flow into the coil circuits.
3. Subcooled refrigerant liquid leaves the coil circuits
through the side outlet on the liquid headers. The
liquid refrigerant from each coi l flows through check
valves “B” which are op en, enters the l iquid line an d
goes to the indoor c oil.
4. The liquid refrigerant is expanded and evaporated in
the indoor coil result ing in low pressure vapor. This
low pressure vapor returns to the outdoor unit
through the system vapor line, reversing valve, and
accumulator, reentering the compressor at the suction connection.
III. 575C090,120 HEATING MODE OPERATION (See Fig. 21)
1. High pressure, high temperature refrigerant vapor
from the compressor flows through the reversing
valve and is directed through the system vapor line to
the indoor coil. Refrigerant is condensed and subcooled in the indoor co il and returns to the outdoor
unit through the system liquid line.
2. Check valve “B” blocks the flow of liquid and the
liquid refrigerant must flow through the filter driers,
through check valve “C”, and into the liquid header
assembly.
3. The liquid refrigerant is expanded as it passes
through the fixed orifice metering devices into
outdoor coil circui ts. The refrigera nt evaporat es as it
passes through the coil circuits resulting in low
pressure vapor.
4. The low pressure vapor leaves the coil circuits and
enters the vapor headers, check valves “A” are open,
and return s to th e com pre ss or th ro ug h th e vap or li ne ,
reversing valve, and accumulator, reentering the
compressor at the suction connection.
—20—
IV. 541A180 COOLING MODE OPERATION (See Fig. 22)
1. High pressure, high temperature refrigerant vapor
from the compressor flows through the reversing
valve and is directed to the outdoor coil vapor header.
2. At the outdoor coil vapor header, the high pressure,
high temperature refrigerant vapor flows up to check
valve “A” that blocks the flow. All the refrigerant is
then directed to flow into the coil circuits.
3. Subcooled refrigerant liquid leaves the coil circuits
entering the portion of the vapor header which is
above check valve “A”. Check valve “C” is closed,
therefore, the liquid refrigerant passes through check
valve “B,” which is open, and enters the liquid line
and goes to the indoor coil.
4. The liquid refrigerant is expanded and evaporated in
the indoor coil resulting in low pressure vapor. This
low pressure vapor returns to the outdoor unit
through the system vapor line, reversing valve, and
accumulator, reentering the compressor at the suction connection.
V. 541A180 HEATING MODE OPERATION (See Fig. 23)
1. High pressure, high temperature refrigerant vapor
from the compressor flows through the reversing
valve and is directed through the system vapor line
to the indoor coil. Refrigerant is condensed and
subcooled in the indoor coil and returns to the
outdoor unit through the system liquid line.
2. Check valve “B” blocks the flow of liquid and the
refrigerant is then directed to flow through check
valve “C” (which is open), through the filter drier, and
into the liquid header assembly.
3. The liquid refrigerant is expanded as it passes
through the capillary tubes into outdoor coil circuits.
The refrigerant eva porates as it passes throug h the
coil circuits resulting in low pressure vapor.
4. The low pressure vapor leaves the coil circuits and
enters the vapor header, check valve “A” is open, and
returns to the compressor through the vapor line,
reversing valve, and accumulator, reentering the
compressor at the suction connection.
VI. CRANKCASE HEATER
The crankcase heater prevents refrigerant migration and
compressor oil diluti on during shutdown when compressor is
not operating.
Close both compress o r se rvice val ves when cr ankc as e h eate r
is deenergized for more than 6 hours.
VII. OUTDOOR UNIT FANS
Each fan is suppor ted by a formed -wire mount bolted to the
fan deck and covered wit h a wi re guard. O n the 54 1A18 0, the
exposed end of the mo tor shaft is covered wi th a rubber boot.
In case a fan motor must be repaired or replaced, be sure the
rubber boot i s put back on when the fan is reinst alled and be
sure the fan guard is in place before starting the unit.
VIII. LUBRICATION
Fan motors have permanently sealed bearings. No further
lubrication is required.
COMPRESSOR
REVERSING VALVE
ACCUMULATOR
CK VALVE B
CK VALVE A
CK VALVE C
FILTER
DRIER
FIXED ORIFICE
METERING DEVICE
FILTER
DRIER
LIQUID LINE
Fig. 20 — 575C090,120 Cooling Mode (Size 090 Shown)
VAPOR LINE
BALL
VALV E
BALL
VALV E
FROM
INDOOR
UNIT
TO
INDOOR
UNIT
—21—
COMPRESSOR
REVERSING VALVE
ACCUMULATOR
CK VALVE B
CK VALVE A
CK VALVE C
FILTER
DRIER
FIXED ORIFICE
METERING DEVICE
FILTER
DRIER
LIQUID LINE
Fig. 21 — 575C090,120 Heating Mode (Size 090 Shown)
VAPOR LINE
BALL
VALV E
BALL
VALV E
TO
INDOOR
UNIT
FROM
INDOOR
UNIT
CK VALVE B
CK VALVE A
FILTER
DRIER
COMPR
GAS AND OIL
MUFFLER
ACCUMULATOR
HOT GAS
REVERSING
VALV E
REFRIGERANT MIXTURE
FROM INDOOR
COIL
LIQUID
LLSV
TO INDOOR
COIL
ANGLE
VALV E
WITH SCHRADER
PORT
COIL RETURN
BEND END
CK VALVE C
Fig. 22 — 541A180 Cooling Mode
—22—
CK VALVE B
COMPR
GAS AND OIL
MUFFLER
ACCUMULATOR
REVERSING
VALV E
REFRIGERANT MIXTURE
TO INDOOR
COIL
LIQUID
LLSV
FROM INDOOR
COIL
ANGLE
VALV E
WITH SCHRADER
PORT
CK VALVE A
FILTER
DRIER
CK VALVE C
COIL RETURN
BEND END
Fig. 23 — 541A180 Heating Mode
IX. 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 essenti al to mi ni mize c o ntam ina tion b uil d-up and
remove harmful residue. Ins pect coils monthly and cl ean as
required.
A. Cleaning Standard Coils
Standard coils can be cleaned with a vacuum cleaner,
washed out with low velocity water, blown out with compressed air, or brushed (do not use wire brush). Fan motors
are dripproof but not waterproof. Do not use acid cleaners.
Clean 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 and become trapped, restricting
airflow. Use a flashlight to determine if dirt or debris has collected between coil section s.
Clean coils as follows:
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 board or other adequate rigid support.
See Fig. 24.
3. Remove clips securing tube sheets together at the
return bend end of the coil. Carefully sp read the ends
of the coil rows apart by moving the outer sections.
See Fig. 25.
4. Using a water hose or other suitabl e equipment, flu sh
down between the sections of coil to remove dirt and
debris.
HOT GAS
5. Clean the remaining surfaces in the norma l manner.
6. Reposition outer coil sections. Reinstall clips which
secure tube sheets, and replace top cover and rear
corner posts.
7. Restore unit power.
B. Cleaning and Maintaining E-Coated Coils
Routine cleaning of coil surfaces is essential to maintain
proper operation of the unit. Elimination of contamination
and removal of harmf ul res idue wil l greatl y increa se the l ife
of the coil and extend the life of the unit. The following
maintenance and cleaning procedures are recommended as
part of the routine maintenance activities 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 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.
—23—
Fig. 24 — Pivot and Support Top Cover
Fig. 25 — Coil Cleaning (Typical)
The following field supplied equipment is required for coil
cleaning:
1
•2
/2 gallon garde n sp rayer
• water rinse with low velocity spray nozzle
Environmentally Sound Coil
Cleaner Application Instructions
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. Th oro ughl y we t fin ned s u rfac es with cl ea n water and
a low velocity garden hose, being careful not to bend
fins.
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 nozz le clos e to f inned 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 pen etrates deep
into finned ar eas. Interior and exterior f inned areas
must be thorough ly 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.
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 Envir onmentally Sound Coil Cleaner as described below. Coil cleaning should be part of th e regularly scheduled maintenance
procedures of the un it 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.
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 fi n coll ar — coppe r 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 do cument.
X. REPLACEMENT PARTS
A complete list of replacement parts is available from your
Bryant dealer.
—24—
LEGEND
CCH — Crankcase Heater
N.C. — Normally Closed
TROUBLESHOOTING CHART — HEATING CYCLE
—25—
LEGEND
CCH — Crankcase Heater
TXV — Thermostatic Expansion Valve
TROUBLESHOOTING CHART — COOLING CYCLE
Copyright 2004 Bryant Heating & Cooling Systems Printed in U.S.A. CATALOG NO. 5357-506
START-UP CHECKLIST
I. PRELIMINARY INFORMATION
OUTDOOR UNIT: MODEL NO. _______________________________ SERIAL NO.: ____________________________ ______
INDOOR UNIT: MODEL NO. _________________________________ SERIAL NO.: __________________________________
ADDITIONAL ACCESSORIES __________________________________________________________________________________
II. PRE-START-UP
OUTDOOR UNIT
IS THERE ANY SHIPPING DAMAGE? (Y/N)____________
IF SO, WHERE:________ ________________________________________________________________________________________
_______________________________________________________________________________________________________________
WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) _____________
CHECK POWER 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) ___________
HAVE COMPRESSOR HOLDDOWN BOLTS BEEN LOOSENED (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) ______________
INDOOR UNIT
HAS WATER BEEN PLACED IN DRAIN PAN 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
HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR UNIT, INDOOR UNIT,
TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE
PLUGS WITH A LEAK DETECTOR? (Y/N)_______ _________
LOCATE, REPAIR, AND REPORT ANY LEAKS. ___________________________________________________________ ______
HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)? (Y/N)___________
HAS LIQUID LINE SERVICE VALVE BEEN OPENED? (Y/N)___________
IS THE OIL LEVEL IN COMPRESSOR CRANKCASE VISIBLE IN THE COMPRESSOR SIGHT GLASS?
(Y/N) _______________
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS: AB_ __________ V AC___________ V BC ___________V
(AB + AC + BC)/3 = AVERAGE VOLTAGE =________________V
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =_______________V
VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) = _______________ %
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM!
CALL LOCAL POWER COMPANY FOR ASSISTANCE.
CL-1
III. START-UP
CHECK INDOOR FAN SPEED AND RECORD._______________
CHECK OUTDOOR FAN SPEED AND RECORD.________________
AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
COOLING HEATING
OIL PRESSURE ______________ ____ __________________
SUCTION PRESSURE _______ ___________ _____ _____________
SUCTION LINE TEMP ______________ ____ __________________
DISCHARGE PRESSURE __________________ __________________
DISCHARGE LINE TEMP __________________ __________________
ENTERING OUTDOOR AIR __________________ __________________
LEAVING OUTDOOR AIR TEMP __________________ ____________ ______
INDOOR ENTERING-AIR DB (d ry bulb) TEMP __________________ __________________
INDOOR ENTERING-AIR WB (wet bulb) TEMP __________________ __________________
INDOOR LEAVING-AIR DB TEMP __________________ __________________
INDOOR LEAVING-AIR WB TEMP ______________ ____ __________________
COMPRESSOR AMPS (L1/L2/L3) _______ / _______ / _______ _______ / ____ ___ / _______
CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES; ARE THE SIGHT GLASSES SHOWING
OIL LEVEL IN VIEW? (Y/N)
NOTES:
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
CUT ALONG DOTTED LINE
Copyright 2004 Bryant Heating & Cooling Systems Printed in U.S.A. 10-05A CL-2 CATALOG NO. 5357-506
CUT ALONG DOTTED LINE
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