Bryant 576b User Manual

installation, start-up and service instructions

COMMERCIAL AIR-COOLED CONDENSING UNITS

IMPORTANT — READ BEFORE INSTALLING

1. Read and become familiar with these installation instructions before installing this unit (Fig. 1).

2. Be sure the installation conforms to all applicable local and national codes.

3. These instructions contai n importa nt inform ation for the proper maintenance and repair of this equipment. Retain these instructions for future u se.

CONTENTS

Page

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

I. Locate the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

II. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

III. Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . 2

IV. Unit Refrigerant Piping Connections . . . . . . . . . . . . 2

V. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 5

VI. Accessory Installation. . . . . . . . . . . . . . . . . . . . . . . . 8

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

I. Start-Up and Adjustments . . . . . . . . . . . . . . . . . . . . 9

CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

III. Condenser-Fan Adjustment . . . . . . . . . . . . . . . . . . 10

IV. Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

V. Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . 11

VI. Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VII. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 11

VIII. Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . 12

IX. High Flow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . .13,14

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

SAFETY CONSIDERATIONS

WARNING: Improper installation, adjustment,

alteration, service, maintenance, or use can cause explosion, fire, electric shock, or other occurrences which may injure you or damage your property. Consult a qualified installer or service agency for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when repairing th is pro duc t .

569C 576B

Cancels: II 569C-72-4 II 569C-72-5

8/15/00

Fig. 1 — Typical Unit (569C072 Shown)

Recognize safety information. This is the safety-alert symbol. ( ) When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words — DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. Danger id entifies the most serious h azards which will result in severe perso nal injury or death. Warning indicates a condition that could result in pers onal injury. Caution is used to identify unsafe practices whic h would res ult in minor personal injury or product and property damage.

WARNING: Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

1. The power supply (volts, hertz, and phase) must correspond to that specified on unit rating plate.

2. The electric al supply provi ded by the utili ty must be sufficient to handle load imposed by this unit.

3. Refer to the Locate the Unit section on page 2 and Fig. 2 and 3 for locations of electrical inlets, required clearances, and weight distributio n based on recommended support points before setting unit in place.

4. This installation must conform with local building codes. Refer to local plumbing or wastewater codes and other applicable local codes.

INSTALLATION

NOTE: When installing any accessory item, see the manufac-

turer’s installation instructions packaged with the accessory. A qualified agenc y must us e f ac tor y - au th or iz e d kits or accessories when modif ying this unit.

The 569C072,090, and 120 units use hermetic compressors. The 576B090,102, and 120 units use semi-hermetic compre ssors. Refer to Table 1.

NOTE: If vibration isolators are required for a particular installation, use corner weight information in Fig. 2 to make proper selection.

I. LOCATE THE UNIT

A. Clearance

Maintain cleara nce around and abo ve unit to provide mi nimum distance from combustible materials, proper airflow, and service access. Refer to Fig. 2.

Minimum clearance (local codes or jurisdiction may prevail): a. Bottom to combustible sur fac e s 0 inches. b. Condenser coil, for proper airflow, 36 in. one side, 12 in.

the other. The left or rear side receiving the greater clearance is optional.

c. Overhead, 60 in. to ensure proper condenser fan

operation.

d. Between units, control box side, 42 in. per NEC (National

Electrical Code).

e. Between unit and ungrounded surfaces, control box side,

36 in. per NEC.

f. Between unit and block or concrete walls and other

grounded surfaces, control box side, 42 in. per NEC.

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Slab-mounted units sho uld be a t least 4 in. abo ve the hig hest expected water level (flood and runoff). Do not use the unit if it has been under water.

II. RIG AND PLACE UNIT

Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright and do not drop. Spreader bars are not required if top crating is left on unit. Rollers may be used to move unit across a roof. Level by

using unit frame as a reference. See Table 1 and Fig. 3 for additional information. Operating weight is shown in Table 1.

These units are d esigned for o verhead rigg ing only. Rig with packaging assembly and wood bumper strips in place to prevent unit damage by rigging cab le. 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 roll unit into position, mount unit on longitudinal rails, using a minimum of 3 rollers. Apply force to rails, not unit. If 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 unit.

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

Lifting holes are provided in base rails as shown in Fig. 3. Refer to rigging instructions on unit.

IMPORTANT: If unit has forklift protection skids, be sure to remove forklift protection skids from under unit before setting unit in place.

After unit is in position, remove shipping materials and rigging skids.

III. COMPRESSOR MOUNTING

Semi-hermetic compressors are shipped from the factory held down by 4 bolts. After unit is installed, loosen each bolt until the snubber washer can be moved with finger pressure (576B units only). See Fig. 4.

IV. UNIT REFRIGERANT PIPING CONNECTIONS

Suction connections and liquid connection are sweat fittings. Refer to Table 2 for refrigerant piping sizes. Follow standard piping practices.

A. Size Refrigerant Lines

Consider length of piping required between condensing unit and evaporator, amount of liquid lift, and compressor oil return. See Table 3 for design details and line sizing. Refer to evaporator installation instructions for additional information.

—2—

Table 1 — Physical Data

UNIT 569C072 569C090 569C120 576B090 576B102 576B120

NOMINAL CAPACITY (tons)

OPERATING WEIGHT (lb)

Aluminum Coils (Std) Copper Coils (Optional)

RIGGING WEIGHT (lb)

Aluminum Coils (Std) Copper Coils (Optional)

REFRIGERANT*

Operating Charge†

Typical (lb)

Shipping Charge (lb)

COMPRESSOR

Qty...Type

Qty Cylinders (ea) Speed (rpm) Oil Charge (oz) (ea)

340 392 426 510 564 564 386 460 503 578 632 632

390 420 445 560 614 614 436 488 522 628 682 682

11.4 13.6 16.5 14.3 16.4 16.4

2.0 2.0 2.0 2.0 2.0 2.0

Reciprocating,

Hermetic

1...H26A72Q 1...ZR94KC 1...ZR125KC 1...06DA818 1...06DA824

2 NANA466

3500 3500 3500 1750 1750 1750

65 85 110 88 128 128

CONDENSER AIR FAN

Qty...Rpm Diameter (in.)

Motor Hp (NEMA) Watt s

Nominal Cfm Total

1...850 1...1100 1...1100 1...1100 1...1100 1...1100 26 26 26 26 26 26

444 976 960 930 930 930

3800 6500 7000 6500 6500 6500

CONDENSER COIL

Rows...Fins/in. Face Area (sq ft) Storage Capacity (lb)**

CONNECTIONS (sweat)

Suction (in.) Liquid (in.)

12.24 18.0 20.50 18.0 18.0 18.0

11.26 16.56 18.87 16.56 16.56 16.56

CONTROLS

Pressurestat Settings (psig) High Cutout

Cut-in

Low Cutout

Cut-in

LEGEND

NEMA —

*Unit is factory supplied with holding charge only.

†Typical operating charge with 25 ft of interconnecting piping.

National Electrical Manufacturers Association

10 71/

81/

R-22

Scroll, Hermetic Reciprocating, Semi-Hermetic

Propeller; Direct Drive

Enhanced Copper Tubes, Aluminum Lanced Fins

2...17

11/

320 ± 20

426 ± 7

11/

7 ± 3

22 ± 5

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

124 F.

NOTE:

Unit 576B120 has one step of unloading. Full load is 100% of capacity, and one step of unloading is 67% capacity. Unit 576B120 has the following unloader settings: load is 70 ± 1 psig and unload is 60 ± 2 psig.

1...06DH824 (See Note)

11/

—3—

DIMENSIONS (ft-in.)

UNIT A B C D E F

ELECTRICAL CONNECTIONS

With Aluminum Coils (Standard)

569C072

569C090

569C120

576B090

576B102

576B120

1-6

/21-23/

1-8 1-6

—1-21/41-45/162-95/

/22-913/

1-3 2-5/163-57/

1-9 1-8 2-0 1-3 2-

1-6 1-4

1-7 1-5 2-9

/42-913/

1-3 2-5/163-57/

/163-57/

With Copper Coils (Optional)

569C072

569C090

569C120

576B090

576B102

576B120

1-8 1-3 — 1-2

1-9

1-6 2-913/

1-10 1-7 2-0 1-3 2-

1-7

/21-41/22-913/

1-7

1-4 2-913/

1-7

1-4 2-913/

/41-45/162-95/

1-3 2-5/163-57/

/163-57/

1-3 2-5/163-57/

CONNECTION SIZES

SERVICE VALVE CONNECTIONS

UNIT SUCTION LIQUID

569C072

569C090

569C120

576B090

576B102

576B120

WEIGHT CHART (lb)

UNIT

569C072 569C090 569C120 576B090 576B102 576B120

UNIT

569C072 569C090 569C120 576B090 576B102 576B120

NOTE:

Al indicates weight with aluminum-fin coil (standard);

STD UNIT CORNER W CORNER X

Al Cu Al Cu Al Cu

340 386 86 106 53 65 392 460 91 120 84 100 426 503 96 126 99 126 510 578 114 143 89 106 564 632 133 161 97 114 564 632 133 161 97 114

CORNER Y CORNER Z

Al Cu Al Cu

77 82 124 133 105 113 113 127 117 127 113 127 133 142 173 187 141 150 193 207 141 150 193 207

Cu indicates weight with copper-fin coil (optional).

NOTES:

1. Dimensions in [ ] are in millimeters.

2. Center of Gravity. See chart for dimensions.

3. Direction of airflow.

4. Minimum clearance (local codes or jurisdiction may prevail): a. Bottom to combustible surfaces, 0 inches. b. Either left or rear side of condensing unit must have 36-in. clearance for proper airflow;

the remaining side(s) must have 12-in. clearance each. c. Overhead, 60 in., to assure proper condenser fan operation. d. Between units, control box side, 42 in. per NEC (National Electrical Code). e. Between unit and ungrounded surfaces, control box side, 36 in. per NEC.

f. Between unit and block or concrete walls and other grounded surfaces, control box side,

42 in. per NEC.

5. With the exception of the clearance for the condenser coil as stated in Note 4b, a removable fence or barricade requires no clearance.

6. Units may be installed on combustible floors made from wood or Class A, B, or C roof covering material.

7. Certified dimension drawings available on request.

″

Dia Field Power Supply Hole

2″ Dia Power Supply Knockout

″

Dia Power Supply Knockout

″

Dia Field Control Wiring Hole

″

Fig. 2 — Base Unit Dimensions

—4—

HOOK RIGGING SHACKLES THROUGH HOLES IN BA SE RAIL, ON ALL FOUR SIDES. HOLES IN BASE RAILS ARE CENTERED AROUND THE UNIT CEN TER OF GRAVITY. USE WOODEN TOP SKID, WHEN RIGGING, TO PREVENT RIGGING STRAPS FROM DAMAGING UNIT.

UNIT

569C072 569C090 569C120 576B090 576B102 576B120

CAUTION:

RIGGING WEIGHT* A B C

lb kg in. mm in. mm in. mm

390 177 45.0 1143 38.5 978 35.5 904 420 192 45.0 1143 38.5 978 43.5 1105 445 203 45.0 1143 38.5 978 43.5 1105 560 255 45.0 1143 38.5 978 43.5 1105 614 280 45.0 1143 38.5 978 43.5 1105 614 280 45.0 1143 38.5 978 43.5 1105

NOTICE TO RIGGERS

ALL PANELS MUST BE IN PLACE WHEN RIGGING.

*Weights are for aluminum coils.

Fig. 3 — Rigging Label

Fig. 4 — Typical Compressor Mounting (576B Units)

B. Filter Drier and Moisture Indicator

The filter drier is factory installed. Moisture indicator is a field-installed accessory and should be installed just after liquid line shu toff valve at th e evaporator coil. Do not use a receiver. A receiver is not supplied with the unit and should not be used.

NOTE: Unit is shipped with R-22 holding charge. System pressure must be relieved before removing caps. Recover refrigerant prior to brazing.

Pass nitrogen or other inert gas through piping while brazing to prevent formation of copper oxide.

Install field-supplied thermostatic expansion valve(s) in evaporator section. It is recommended that a field supplied liquid line solenoid be positioned in the main liquid line (near the evapor ator coil). It should be wired to close wh en compressor stops to m inimize refrigerant migration during the ‘‘OFF’’ cycle.

Table 2 — Refrigerant Piping Sizes

LINEAR LENGTH OF PIPING — FT (M)

UNIT

0-25

(0-7.6)

25-50

(7.6-15.2)

Line Size (in. OD)

50-75

(15.2-22.9)

75-100

(22.9-30.5)

LSLSLSLS

569C072

569C090

569C120

576B090

576B102

576B120

/211/

/811/

/211/

/811/

/211/

/813/

/211/

/811/

11/

13/

11/

13/

/211/

/813/

LEGEND

L—

Liquid Line

S—

Suction Line

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.

Table 3 — Liquid Line Data

MAX

UNIT

ALLOWABLE

LIQUID LIFT

Max Allowable Pressure Drop

Ft M psi kPa F C 569C072 569C090 569C120 576B090 576B102 576B120

NOTE:

86 26.2 7 48.3 2 1 60 18.3 7 48.3 2 1 70 21.3 7 48.3 2 1 60 18.3 7 48.3 2 1 65 19.8 7 48.3 2 1 65 19.8 7 48.3 2 1

Values shown are for units operating at 45 F (7.2 C) saturated

suction and 95 F (35 C) entering air.

LIQUID LINE

Max Allowable

Temp Loss

V. ELECTRICAL CONNECTIONS

WARNING: The unit cabinet must have an

uninterrupted, unbroken electrical ground to minimize the possibility of perso nal injury if an electrical fault should occur. This ground may co nsist of electrical wire connected to the unit ground lug in the control compartment or conduit approved for electrical ground when installed in accordance with the NEC and local electrical codes. Failure to adhere to this warning could result in personal injury.

CAUTION: Failure to follow these precautions

could result in damage to the unit being installed:

A. Field Power Supply (Fig. 5-7)

1. Make all electrical connections in accordance with NEC ANSI/NFPA (American National Standards Institute/ National Fire Protection Association) 70, latest edition, and local electrical codes governing such wiring. Refer to unit wiring diagram.

2. Use only copper or copper-clad conductor fa n con nections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE. Maximum wire size is no. 2 AWG (American Wire Gage).

3. Voltage to compressor terminals during operation must be within v ol tag e r ange indicated on unit nameplate (also see Table 4). On 3-phase units, voltages between phases must be balanced within 2% and

—5—

the current within 10%. Use the formula shown in Table 4, Note 2, to determine the percent voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable warranty.

4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

All units except 208/230-v units are factory wired for the voltage shown on the nameplate. If the 208/230-v unit is to be connecte d to a 208-v p ower sup ply, the tr ansfor mer must be rewired by moving the black wire from the 230 -v term ina l on the transforme r and connecting it to the 200-v terminal on the transformer.

Refer to unit label diagram for additional information. Pigtails are provi ded for field w ire conne ctions. Use factorysupplied splices or UL (Underwriters’ Laboratories) approved copper/aluminum connector.

When installing units, provide a disconnect per NEC. All field wiring must comply with NEC and local requirements.

Install field wiring as foll ows:

1. Install conduit through side panel openings.

2. Install power lines to terminal connections as shown in Fig. 5.

B. Control Voltage Connections

Install an accessory ther mostat ass embly accordi ng to installation instructions included with the accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance with thermostat installation instructions.

Route thermostat cable or equivalent single leads of colored wire from subbase terminals to low-voltage connections on unit (shown in Fig. 6) as described in Steps 1 through 4 below.

NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG

C— NEC —

LEGEND

Contactor National Electrical Code Field Wiring Factory Wiring

Splice Connection (Factory Supplied)

Fig. 5 — Power Wiring Connections

insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wi re larger than no. 18 AWG cannot be directly connected to the thermost at and will require a junction box and splice at the thermostat.

1. Connect thermosta t wires to screw terminals of low voltage connection boar d.

2. Pass the control wires through th e hole provided in the corner post. See Fig. 7.

3. Feed wire through raceway built into the corner post and into the 24-v thermostat connection board. The 24-v thermostat connection is located on the left side of the low voltage connection comp artment. The raceway provides the UL required clea rance between the high- and low-voltage wiring.

4. Total combined amperage draw of the field-in stalled liquid line solenoid valve and indoor fan contactor must not exceed 22 va. If the specified va must be exceeded, use a remo te relay to switch the load.

801

AHA — C— CB — CC — CLO — HPS — IFC —

→

Adjustable Heat Anticipator Contactor, Compressor Circuit Breaker Cooling Compensator Compressor Lockout High-Pressure Switch Indoor (Evaporator) Fan Contactor

Fig. 6 — Typical Control Wiring Connections (569C Shown)

LLSV — LPS — TB — TC — TDR — TH — TRAN —

LEGEND

Liquid Line Solenoid Valve Low-Pressure Switch Te r mi n al Bl oc k Thermostat-Cooling Time-Delay Relay Thermostat-Heating Transformer

—6—

Terminal (Marked) Spice

Factory Wiring Field Control Wiring To Indicate Common Potential Only, Not To Represent Wiring

Table 4 — Electrical Data

UNIT

569C072

569C090

569C120

576B090

576B102

576B120

CSA — FLA — HACR — LRA — MCA — MOCP — NEC — OFM — RLA — UL —

NOMINAL VOLTAGE

(V-Ph-Hz)

208/230-3-60 187 254 21.8 158 1.9 30.1 40

460-3-60 414 508 10.0 79 1.0 13.5 20 575-3-60 518 632 9.0 65 1.9 14.1 20

208/230-3-60 187 254 28.8 195 3.8 39.8 50

460-3-60 414 508 14.7 95 1.9 20.3 25 575-3-60 518 632 10.8 80 1.9 15.4 20

208/230-3-60 187 254 37.8 239 3.1 51.1 70

460-3-60 414 508 17.2 125 1.4 23.4 30 575-3-60 518 632 14.3 90 1.4 19.8 25

208/230-3-60 187 254 31.5 160 3.1 42.5 50

380-3-60 342 418 19.0 75 2.2 26.0 35 460-3-60 414 508 15.7 80 1.4 21.0 25 575-3-60 518 632 12.6 64 1.4 17.2 20

208/230-3-60 187 254 39.7 198 3.1 52.7 70

380-3-60 342 418 24.0 93 2.2 32.2 40 460-3-60 414 508 19.9 99 1.4 26.3 35 575-3-60 518 632 15.9 79 1.4 21.3 25

208/230-3-60 187 254 39.7 198 3.1 52.7 70

380-3-60 342 418 24.0 93 2.2 32.2 40 460-3-60 414 508 19.9 99 1.4 26.3 35 575-3-60 518 632 15.9 79 1.4 21.3 25

LEGEND

Canadian Standards Association Full Load Amps Heating, Air Conditioning and Refrigeration Locked Rotor Amps Minimum Circuit Amps Maximum Overcurrent Protection National Electrical Code Outdoor (Condenser) Fan Motor Rated Load Amps Underwriters’ Laboratories

VOLTAGE RANGE COMPRESSOR OFM POWER SUPPLY Min Max RLA LRA FLA MCA MOCP

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

452 + 464 + 455

1371

= 457

NOTES:

1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. The Canadian units may be fuse or circuit breaker.

Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

of voltage imbalance.

% of Voltage Imbalance =

100 x

max voltage deviation from average voltage

Use the following formula to determine the percent

average voltage

(AB) 457 – 452 = 5 v (BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

Maximum deviation is 7 v. Determine percent of voltage imbalance:

% Voltage Imbalance = 100 x

= 1.53%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT:

contact your local electric utility company immediately.

3. The 575-v units are CSA only.

4. The 380-v units are

If the supply voltage phase imbalance is more than 2%,

not

UL or CSA listed.

457

—7—

Fig. 7 — Field Control Wiring Raceway

(576B Unit Shown)

VI. ACCESSORY INSTALLATION

At this time any required accessories should be installed on the unit. Refer to Table 5 for available accessories. Control wiring information is provided in the unit wiring book.

Table 5 — Accessory List

PRE-START-UP

WARNING: Failure to observe the following warn-

ings could result in serious personal injury:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compres sor term inal cover until all electrical sources have been disconnected.

4. If refrigerant le ak is susp ected a roun d co mpre ssor terminals, recover refrigerant whenever possible and relieve all pressure from system before touching or disturbing anything inside terminal box.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear prote ctive goggles and proceed as follows :

a. Shut off electrical power to unit. b. Recover refrigerant. Relieve all pressure

from system.

c. Cut component-connecting tubing with tub-

ing cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs

when necessary . Oil can ignite when exposed to torch flame.

ACCESSORY

Gage Panel Winter-Start Relay Package Weatherprobe™ II Low Ambient Kit Hail Guard Package (072) Hail Guard Package (090,102,120) Thermostats Subbase

Proceed as follows to i nspect and pr epare the unit f or initial start-up:

1. Field electrical power source must agree with unit nameplate rating.

2. Check voltage imba la nc e as sho w n in Table 4, Note 2.

3. Check that all in ternal wiring connections are tight and that all barriers, covers, and panels are in place.

4. Ensure al l s er vice valves are ope n. On 57 6 B un i ts, be sure all compressor service valves are backseated.

5. Verify that compressor holddown bolts have been loosened and that flat/snubber washers can be rotated by applying finger pressure (snug, but not tight).

6. On 569C and 576B units, verify compressor crankcase heater is securely in place. Crankcase heater must operate for a least 24 hours before start-up.

7. Note that compressor oil level is visible in the sight glass (576B units only).

8. Check for leaks in refrigerant system by using soap bubbles and/or electronic leak detector.

9. Check that liquid line solenoid valve is located at evaporator coil as shown in Filter Drier and Moisture Indicator section, page 5.

10. Check that both outdoor and indoor units are properly mounted in a ccorda nc e with in st all ation in stru ctions and applicable codes.

—8—

START-UP

I. START-UP AND ADJUSTMENTS

CAUTION: Complete the required procedures

given in the Pre-Start-Up section and unit start-up checklist at the end of this publication before starting the unit. Do not jumper any safety devices when operating the unit.

Do not operate the com pressor when th e outdoor temperature is below 25 F (24 C) (unless accessory low ambient ki t i s in stalled).

A. Checking Cooling Control Operation

Start and check the unit f or prope r cool ing con trol o perati on as follows :

1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO. position.

2. Place SYSTEM switch in COOL position and FAN switch in AUTO. position. Set cool ing control below room temperature. Observe that compressor and condenser- and evaporator-fan motors start. Observe that cooling cycle shuts down when control setting is satisfied.

B. Unit Controls

All units have the following internal-protection controls: Compressor Overload This overload interrupts power to the compressor when

either the current or internal motor winding temperature become 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.

Time Guard® II Device

The unit is equipped with accessory Ti me Guard II recycle timer. The device will cause a 5-minute del ay between compressor starts.

Cycle-LOC™ Device

When high-pressure or low-pressure fault occurs, the Cycle LOC device will protect the system by not allowi ng the com pressor to start.

Low-Pressure Switch/(LPS) When the suction line pressure drops below 7 psig (48 kPa),

the LPS opens 24-v power to the c ompressor contactor and stops the compressor. When the pressure reaches 22 psig (152 kPa), the switch resets and the compressor is allowe d to restart.

High-Pressure Switch

When the refrigerant high-side pressure reaches 426 psig (2937 kP a), the HPS opens 24-v po wer to the compresso r contactor and stops the compressor. When the pressure drops to 320 psig (2206 kPa), the switch resets and the compressor is allowed to restart.

C. Sequence of Operation

At start-up, the thermostat calls for cooling. When all safety devices are satisfied, the compressor contactor (fan contactor) will en ergize caus ing the compressor and outdoo r (condenser) fan motor to operate. Terminal “G” at the

(HPS)

thermostat is also energized, allowing the field-supplied and -installed (24v) indoor (evaporator) fan contactor to function. A field-supplied and -installed liquid line valve (connected between Terminals G and C at the outdoor unit), will also open. This allows the system to f unction in cooling; the LPS will not open if compressor is not running. As cooling demand is satisfied, the thermostat c ontacts break, deenergizing the contactor causing the system to shut off. The liquid line solenoid (LLS) v alve closes, minimizing the pote ntia l for refrig erant migratio n at this time. Th e compressor do es not restart until the thermostat again calls for cooling. If a demand for cooling occurs within 5 minutes after the thermostat is satisfied, the system will not restart due to the feature of Time Guard II device. After the 5-minute time period, the system will res tart as normal upon thermostat demand.

The system is protected with a Cycle-LOC devi ce s o that the compressor will not start if a high-pressure or low-pressure fault occurs. To reset the Cycle-LOC device, set the thermostat to eliminate the cooling demand then return to the original set point . This should b e done only on ce, and if system shuts down due to the same fault, determine the problem before attempting to reset the Cycle-LOC device.

The crankcase heaters must be energize d for a minimum of 24 hours before starting a 569C and 576B unit.

D. Oil Charge

576B Units Allow unit to run for about 20 minutes. Stop unit and check

compressor oi l level . Ad d oil on ly if ne cess ary t o br ing oi l int o view in sight glass. Use only approved compressor oil.

Approved oils are:

Suniso 3GS WF32-150

If oil is added, run unit for an additional 10 minutes. Stop unit and check oil level. If level is still low, add oil only after determining that piping system is designed for proper oil return and that system is not leaking oil.

569C Units The 569C units do not have a sight glass and are factory

charged with the correct amount of oil. All Units

Do not reuse drained oil or use any oil that has b een expo sed to the atmosphere. Procedures for adding or removing oil are

given in the Standard Service Techniques Manual, Chapter 1, Refrigerants.

CARE AND MAINTENANCE

To ensure continuing high performance and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This cooling unit should be inspected at least once each year by a qualified service person.

NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

WARNING: The ability to properly perform maintenance on this equipment req uires certain expertise, mechanical sk ills, tools, and equipment . If you do not possess these, do not attempt to perform any maint enance on this equipment other than those procedures recommended in the User’s Manual. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT.

—9—

SERVICE

WARNING: When servicing unit, shut off all elec-

trical power to unit to avoid shock hazard or injury from rotating parts.

I. CLEANING

Inspect unit interior at the beginning of each cooling season and as operating conditions require.

A. Condenser Coil

Inspect coil monthly. Clean condenser coil annually, or as required by location and outdoor-air conditions.

Clean coil as follows:

1. Turn off unit power and tag disconnect.

2. Remove and save top panel screws on condensing unit.

3. Remove condenser coil corner post. See Fig. 8. To hold top panel open, place coil corner post between top panel and side panel. See Fig. 9.

4. Remove bracket holding coil sections together at return end of condenser coil. Carefull y separate the outer coil section 3 to 4 in. from the inner coil section. See Fig. 10.

5. Use a wate r hos e o r other suitable equipment t o flu s h down between the 2 coil se ctions to remove dirt and debris. Clean the outer surfaces with a stiff brush in the normal manner.

6. Reposition the outer coil section, attach the bracket removed in Step 4, and remove the coil corner post from between the top panel and side panel. Secure the sections together. Install the coil corner post and replace all screws (r emoved in Step 2).

II. LUBRICATION

A. Compressors

Each compressor is charged with the correct amount of oil at the factory. Refer to the Oil Charge section on page 9 for additional information.

B. Fan Motor Bearings

Fan moto r bearings are of the pe rmanently lubrica ted type. No further lubrication is required.

Fig. 9 — Propping Up Top Panel

Fig. 10 — Separating Coil Sections

III. CONDENSER-FAN ADJUSTMENT (Fig. 11)

1. Shut off unit power supply, and tag disconnect.

2. Remove condenser-fan assembly (grille, motor, motor cover, and fan).

3. Loosen fan hub setscrews.

4. Adjust fan height as shown in Fig. 11.

5. Tighten set screws.

6. Replace condenser-fan assembly.

Fig. 8 — Cleaning Condenser Coil

—10—

NOTE:

Fan height adjustments are as follows:

UNIT in. mm 569C072 All Units

(except 569C072)

4.50 114

6.42 163

Fig. 11 — Outdoor (Condenser) Fan Adjustment

IV. CAPACITY CONTROL (576B120 Only)

A suction pressure-actuated unloader controls 2 cylinders and provides capacity control . Unloaders are factory s et (see Table 1), but may be field adjusted:

A. Control Set Point

The control set po int (cyl inde r loa d poin t) is ad jus tabl e from 0 to 85 psig. To adjust, turn control set point adjustment nut (Fig. 12) clockwise to its bottom stop. In this position, set point is 85 psig. Then, turn a djustment counterclockwi se to desired control set point. Every full turn counterclockwise decreases set point by 7.5 psig.

B. Pressure Differential

The pressure differential (difference between cylinder load and unload points) is adjustable from 6 to 22 psig. To adjust, turn pressure differential adjustment screw (Fig. 12) counterclockwise to its back stop position. In this position, differential is 6 psig. Then, turn adjustment screw clockwise to desired pressure differential. Every full turn clockwise increases differential by 1.5 psig.

Fig. 12 — Compressor Capacity Control Unloader

V. COMPRESSOR REMOVAL

See Table 1 for compressor information. Follow safety codes and wear safety glasses and work gloves.

1. Shut off power to unit and install lockout. Remove unit access panel (front of unit).

2. Remove refrigerant from system using refrigerant removal methods described in GTAC II, Module 5, Charging, Recovery, Recycling, and Reclamation.

3. Disconnect compressor wiring at compressor terminal box.

4. Remove bolts from suction flange and discharge service valve (576B units).

CAUTION: Excessive movement of copper lines at compressor may cause higher le vels of vibration when unit is restored to service.

5. Remove crankcase heater from compressor base (576B units only).

6. Remove compressor ho lddown bolts.

7. Remove compressor from unit.

8. Clean system. Add new liquid line filter drier.

9. Install new compressor in unit.

10. Connect suction and discharge lines to compressor. Ensure that compressor holddown bolts are in place.

11. Install crankcase heater.

12. Connect wiring.

13. Evacuate and recharge unit, per Step VII.

14. Restore unit power.

VI. CRANKCASE HEATER

The crankcase heater prevents refrigerant migration and compressor oil diluti on during shutdown when compressor is not operating.

Close both compressor service valves if applicable when crankcase heater is deenergized for more than 6 hours.

VII. REFRIGERANT CHARGE

Unit panels must be in place when unit is operating during charging procedure. Unit is shipped with a holding charge only. Weigh in 7 lbs of R-22 to start unit. Refer to GTAC II, Module 5, Charging, Recovery, Recycling, and Reclamation for additional information.

See Troubleshooting Guide on page 13 for additional information.

A. Low Charge Cooling

Using Cooling Charging Charts, Fig. 13 and 14, vary refrigerant until the condit ions of the appropria te chart are met. Note the charging charts are different from type normally used. The charts are based on charging the units to the correct sub-cooling 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 the liquid line service valve, and insulate it so that outdoor ambient temperature does not affect the reading. Indoor-air cfm must be wi thin the norm al operating range of the unit.

Operate unit a minimum of 1 5 mi nute s. Ensure that temperature and pressure have stabilized. Plot liquid pressure and temperature on chart and add or reduce charge as required. Do not vent refrigerant to the atmosphere. Recover any excess charge. Operate the unit until the system stabilizes. Adjust charge to conform w ith charging chart, using liquid pressure and temperature to read chart.

B. Refrigerant Leaks

Proceed as follows to repair a refrigerant leak and to charge the unit:

1. Locate the leak and ensure that refrigerant system pressure has been relieved.

2. Repair leak following accepted practices.

NOTE: Install a new filter drier in the liquid line whenever the system has been opened for repair.

3. Add a small charge of R-22 refrigerant vapor to system and leak-test unit.

4. Evacuate refrigerant system up to 500 micons. If additional leaks are not found.

5. Charge unit with R-22 refrigerant.

NOTE: Do not vent refrigerant to the atmosphere. Recover any excess charge.

—11—

VIII. REFRIGERANT SERVICE PORTS

Each unit has 3 service ports: one on the suction line, one on the liquid line, and one on the com press or dis charge line. Be sure caps on the ports are tight.

IX. HIGH FLOW VALVES

Located on the compressor hot gas and suction tubes are High Flow Valves. Large black plastic caps distinguish these valves with O-rings located inside the caps. These valves can not be accessed for service in the field. Ensure the plastic caps are in place and tight or the possibility of refrigerant leakage could occur.

Fig. 13 — Cooling Charging Chart — 569C072

Fig. 14 — Cooling Charging Chart — 569C090, 120

and 576B090,102,120

—12—

SYMPTOM CAUSE REMEDY

Compressor does not run — Contactor open

Compressor does not run — Contactor closed

Compressor cycles on highpressure switch — Condenser fan on

Compressor cycles on highpressure switch — Condenser fan off

Compressor cycles on lowpressure switch — Evaporator fan running

Airflow restricted — Low suction pressure

Indoor (evaporator) fan stopped — Low suction pressure

Compressor runs but cooling insufficient — Suction pressure low

Compressor runs but cooling insufficient — Suction pressure high

NOTE:

See Fig. 15 and 16 for component arrangements.

TROUBLESHOOTING GUIDE

Power off. Restore power.

Fuses blown.

Transformer open/shorted.

Thermostat circuit open. Check thermostat setting.

Low-pressure switch open.

High-pressure switch open.

Connections loose. Tighten all connections. Compressor motor thermostat open. Check for excessive motor temperature. Compressor leads loose, broken. Check connections with power off. Single phasing. Replace blown fuse.

Compressor internal overload open.

High-pressure switch faulty. Replace switch. Airflow restricted. Dirty coil. Remove obstruction, clean condenser coil. Air recirculating. Clear airflow area.

Noncondensables in system.

Refrigerant overcharge. Recover as required.

Refrigerant system restrictions.

Fan slips on shaft. Tighten fan hub screws. Motor not running. Check power and capacitor

Motor bearings seized. Replace motor. Motor overload open. Check overload rating. Check for fan blade obstruction. Motor burned out, windings open. Replace motor. Filter drier plugged. Replace filter drier. Expansion valve power head

defective. Low refrigerant charge. Find leak, repair, evacuate system, and recharge. Expansion valve restricted/plugged. Remove and replace expansion valve. Evaporator coil iced up. Check refrigerant charge. Evaporator coil dirty. Clean coil fins. Indoor-air filter dirty. Clean or replace filters. Indoor-air dampers closed. Check damper operation and position. Electrical connections loose. Tighten all connections. Fan relay defective. Replace relay. Motor overload open. Check power supply. Motor defective. Replace motor. Fan belt broken or slipping. Replace or tighten belt. Refrigerant charge low. Add charge. Head pressure low. Check refrigerant charge. Indoor-air filters dirty. Clean or replace filters. Expansion valve power head

defective. Expansion valve restricted/plugged. Remove and replace expansion valve. Evaporator coil partially iced. Check low-pressure setting. Evaporator airflow restricted. Remove obstruction.

Heat load excessive. Check for open doors or windows.

Replace with correct fuses after finding cause and correcting.

Replace transformer if primary windings are receiving power and no output.

Check for refrigerant undercharge or system leak.

Check for refrigerant over charge or obstruction of outdoor airflow.

Allow compressor motor windings to cool down to reset overload. Determine cause for overload opening.

Recover, evacuate and recharge as required. Refer to Carrier GTAC-II, Module 5, Charging, Recovery, Recycling, and Reclamation.

Check or replace filter drier, expansion valve, etc.

/3 and 3/4 hp motor.

Replace power head.

—13—

C— CAP — CB — CH — CLO — COMP — COTP — EQUIP — GND — HPS —

Contactor, Compressor Capacitor Circuit Breaker Crankcase Heater Compressor Lockout Compressor Motor Compressor Temperature Protection Equipment Ground High-Pressure Switch

LEGEND FOR FIG. 15 AND 16

LPS — NEC — OFC — OFM — OL — QT — TB — TDR — TRAN —

Low-Pressure Switch National Electrical Code Outdoor (Condenser) Fan Contactor Outdoor (Condenser) Fan Motor Overload Relay Quadruple Terminal Terminal Block Time-Delay Relay Transformer

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Factory Wiring

Field Power Wiring

→→

Fig. 15 — Typical 569C Component Arrangement

Fig. 16 — Typical 576B Component Arrangement

→

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? _______ (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, WHERE APPLICABLE (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) _______

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

IS LIQUID LINE SOLENOID VALVE LOCATED AT THE EVAPORATOR COIL AS REQUIRED? (Y/N) _______

HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, CONDENSER, EVAPORATOR, TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS WITH A LEAK DETECTOR? (Y/N) _______

LOCATE, REPAIR, AND REPORT ANY LEAKS. ________________________________________________________________

ARE ALL 576B COMPRESSOR SERVICE VALVES FULLY OPENED (BACKSEATED)?

(Y/N) _______

HAVE LIQUID LINE SERVICE VALVE AND SUCTION LINE SERVICE VALVE BEEN OPENED? (Y/N) _______

IS THE OIL LEVEL IN COMPRESSOR CRANKCASE ON 576B UNIT IN VIEW 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 EVAPORATOR-FAN SPEED AND RECORD. _______

CHECK CONDENSER-FAN SPEED AND RECORD. _______

AFTER AT LEAST 15 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:

OIL PRESSURE (576B only) SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING CONDENSER-AIR TEMP LEAVING CONDENSER-AIR TEMP EVAP ENTERING-AIR DB (dry bulb) TEMP EVAP ENTERING-AIR WB (wet bulb) TEMP EVAP LEAVING-AIR DB TEMP EVAP LEAVING-AIR WB TEMP

COMPRESSOR AMPS (L1/L2/L3) _____ / _____ / _____

HAS REFRIGERANT CHARGE BEEN ADJUSTED PER UNIT CHARGING CHART? _______________

NOTES:

______________________________________________________________________________________________________

CUT ALONG DOTTED LINE

CL-2

CUT ALONG DOTTED LINE

CATALOG NO. 5356-903

Bryant 576b User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual