Bryant 637G Installation And Start-up Instructions Manual

installation and
start-up instructions

14 SEER ENERGY STAR
SPLIT-SYSTEM HEAT PUMP
WITH PURON®

NOTE: Read the entire instruction manual before starting the
installation.

This symbol → indicates a change since the last issue.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions thor­oughly and follow all warnings or cautions included in literature
and attached to the unit. Consult local building codes and National
Electrical Code (NEC) for special requirements.

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 identifies the most serious hazards which willresultinsevere
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.

WARNING: Before installing, modifying, or servicing
system, main electrical disconnect switch must be in the
OFF position. There may be more than 1 disconnect
switch. Lock out and tag switch with a suitable warning
label. Electrical shock can cause personal injury or death.

CAUTION: Puron® (R-410A) systems operate at higher
pressures than standard R-22 systems. Be certain that
service equipment is rated for Puron®. Some R-22
service equipment may not be acceptable. Check with
your distributor.

INSTALLATION RECOMMENDATIONS

NOTE: In some cases noise in the living area has been traced to

gas pulsations from improper installation of equipment.

1. Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.

2. Ensure that vapor and liquid tube diameters are appropriate
to capacity of unit.

637G

Cancels: New II 637G-18-1

11-02

A98524

.

3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.

4. Leave some slack between structure and unit to absorb
vibration.

5. When passing refrigerant tubes through the wall, seal
opening with RTV or other pliablesilicon-basedcaulk. (See
Fig. 2.)

6. Avoid direct tubing contact with water pipes, duct work,
floor joists, wall studs, floors, and walls.

7. Do not suspend refrigerant tubing from joists and studs with
a rigid wire or strap which comes in direct contact with
tubing. (See Fig. 2.)

8. Ensure that tubing insulation is pliable and completely
surrounds vapor tube.

9. When necessary, use hanger straps which are 1 in. wide and
conform to shape of tubing insulation. (See Fig. 2.)

10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.

When outdoor unit is connected to factory-approved indoor unit,
outdoor unit contains system refrigerant charge for operation with
indoor unit of same size when connected by 15 ft of field-supplied
or factory accessory tubing. Add (or subtract) 0.6 oz/ft of 3/8
liquid line for lengths greater (or less) than 15 ft. For proper unit
operation, check refrigerant charge using charging information
located on control box cover and/or in the Check Charge section of
this instruction.

IMPORTANT: Maximum liquid-line size is 3/8-in. O.D. for all
residential applications including long line.

IMPORTANT: Always install the factory-supplied Puron® heat
pump (bi-flow) liquid-line filter drier. If replacing the filter drier,
refer to Product Data Sheet for appropriate part number. Obtain
replacement filter driers from your distributor or branch.

Fig. 1—Model 637G

—1—

Avoid contact between tubing and structureNOTE:

OUTDOOR WALL INDOOR WALL

CAULK

INSULATION

THROUGH THE WALL

HANGER STRAP

(AROUND VAPOR

TUBE ONLY)

1″ MIN.

SUSPENSION

LIQUID TUBE

VAPOR TUBE

JOIST

INSULATION

VAPOR TUBE

LIQUID TUBE

A94028

Fig. 2—Connecting Tubing Installation

INSTALLATION

IMPORTANT: Specifications for this unit in residential new

construction market require using the outdoor unit, indoor unit,
refrigerant tubing sets, metering device, and filter drier listed in
presale literature. There can be no deviation. Consult the Appli­cation Guideline and Service Manual for Residential Split-System
Air Conditioners and Heat Pumps using Puron® Refrigerant to
obtain required unit changes for specific applications and for R-22
retrofit.

I. CHECK EQUIPMENT AND JOB SITE
A. Unpack Unit

Move to final location. Remove carton taking care not to damage
unit.

B. Inspect Equipment

File claim with shipping company prior to installation if shipment
is damaged or incomplete. Locate unit rating plate on unit corner
panel. It contains information needed to properly install unit.
Check rating plate to be sure unit matches job specifications.

II. INSTALL ON A SOLID, LEVEL MOUNTING PAD

If conditions or local codes require the unit be attached to pad, tie
down bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig. 3
to determine base pan size and knockout hole location.

On rooftop applications, mount on level platform or frame. Place
unit above a load-bearing wall and isolate unit and tubing set from
structure. Arrange supporting members to adequately support unit
and minimize transmission of vibration to building. Consult local
codes governing rooftop applications.

C

3

⁄8″D. (9.53) TIEDOWN

A

B

KNOCKOUTS (2) PLACES

A94199

DIMENSIONS (IN.)

UNIT
SIZE

018–060 30 X 30 6-1/2 23-1/2 20

MINIMUM

MOUNTING PAD

DIMENSIONS

TIEDOWN KNOCKOUT

LOCATIONS

ABC

Fig. 3—Mounting Unit to Pad

Roof mounted units exposed to winds above 5 mph may require
wind baffles. Consult the Application Guideline and Service
Manual for Residential Split-System Air Conditioners and Heat
Pumps using Puron® Refrigerant for wind baffle construction.

NOTE: Unit must be level to within ± 2° (± 3/8 in./ft) per
compressor manufacturer specifications.

III. CLEARANCE REQUIREMENTS

When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 30-in. clearance to
service end of unit and 48 in. above unit. For proper airflow, a 6-in.
clearance on 1 side of unit and 12 in. on all remaining sides must
be maintained. Maintain a distance of 24 in. between units.
Position so water, snow, or ice from roof or eaves cannot fall
directly on unit.

On rooftop applications, locate unit at least 6 in. above roof
surface.

IV. OPERATING AMBIENT

The minimum outdoor operating ambient in cooling mode without
additional accessories is 55°F, and the maximum outdoor operat­ing ambient in cooling mode is 125°F. The maximum outdoor
operating ambient in heating mode is 66°F.

V. ELEVATE UNIT

CAUTION: Accumulation of water and ice in base pan

may cause equipment damage.

CAUTION: Do not allow POE lubricant to come into
contact with roofing material. POE may deteriorate cer­tain types of synthetic roofing.

Elevate unit per local climate and code requirements to provide
clearance above estimated snowfall level and ensure adequate
drainage of unit.

—2—

COIL

SENSING
BULB

EQUALIZER
TUBE

SENSING BULB

STRAP

THERMOSTATIC
EXPANSION
VALVE

A91277

Fig. 4—Typical TXV Installation

VI. CHECK INDOOR EXPANSION DEVICE

CAUTION: For proper unit operation and reliability,

units must be installed with hard shutoff TXV specifically
designed to operate with Puron®. Do not use R-22 TXV.
Do not install with evaporator coils having capillary tube
metering devices or pistons.

For TXV kit part number and charging instructions, refer to TXV
label in outdoor unit.

A. Furnace Coils

If indoor unit (furnace coil) comes factory equipped with a bi-flow
hard shutoff TXV specifically designed for Puron®, no TXV
change is required. If TXV installation is required, remove existing
Check-Flo-Rater® from indoor coil. Refer to Fig. 4 and 5 and
install TXV kit (specifically designed for Puron®) as follows:

1. Install suction tube adapter.

2. Install liquid flare-to-sweat adapter.

3. Connect external equalizer tube to fitting on suction tube
adapter.

4. Position sensing bulb on horizontal portion of suction tube
adapter. Secure using supplied hardware.

5. Insulate bulb after installation. (See Fig. 5.)

6. Leak check all connections.

B. Fan Coils

If indoor unit (fan coil) comes factory equipped with a bi-flow
hard shutoff TXV specifically designed for Puron®, no TXV
change is required.

If fan coil is not designed for Puron®, a Puron® TXV installation
is required. Refer to TXV kit Installation Instructions for details.

VII. CHECK DEFROST THERMOSTAT

Check defrost thermostat to ensure it is properly located and
securely attached. There is a liquid header with a brass distributor
and feeder tube going into outdoor coil. At the end of 1 of the
feeder tubes, there is a 3/8-in. OD stub tube approximately 3 in.
long. (See Fig. 6.) The defrost thermostat should be located on stub
tube. Note that there is only 1 stub tube used with liquid header,
and on most units it is the bottom circuit.

VIII. IN LONG-LINE APPLICATIONS, INSTALL LIQUID­LINE SOLENOID VALVE (LSV)

For refrigerant piping arrangements with equivalent lengths
greater than 50 ft or when elevation difference between indoor and
outdoor unit is greater than ± 20 ft, follow all requirements of the
Long-Line Guideline section in the Application Guideline and
Service Manual for Residential Split-System Air Conditioners and
Heat Pumps Using Puron® Refrigerant.

8 O'CLOCK

4 O'CLOCK

A00399

Fig. 5—Positioning of Sensing Bulb

If required by Long-Line Application Guideline, install LSV kit
part No. KHALS0401LLS specifically designed for Puron® Heat
Pump. LSV should be installed within 2 ft of the outdoor unit with
arrow pointing toward outdoor unit, as close as possible to filter
drier. Follow the Installation Instructions included with accessory
kit.

IX. MAKING PIPING CONNECTIONS

WARNING: Relieve pressure and recover all refrigerant

before system repair or final unit disposal to avoid
personal injury or death. Use all service ports and open all
flow-control devices, including solenoid valves.

CAUTION: Do not leave system open to atmosphere
any longer than minimum required for installation. POE
oil in compressor is extremely susceptible to moisture
absorption. Always keep ends of tubing sealed during
installation.

CAUTION: If ANY refrigerant tubing is buried, provide
a 6 in. vertical rise at service valve. Refrigerant tubing
lengths up to 36 in. may be buried.

CAUTION: To prevent damage to unit or service valves
observe the following:

• Use a brazing shield

• Wrap service valves with wet cloth or use a heat sink
material.

Outdoor units may be connected to indoor section using accessory
tubing package or field-supplied refrigerant grade tubing of correct
size and condition. For tubing requirements beyond 50 ft, substan­tial capacity and performance losses can occur. Follow the
recommendations in the Application Guideline and Service
Manual for Residential Split-System Air Conditioners and Heat
Pumps using Puron® Refrigerant to minimize losses. Refer to
Table 1 for field tubing diameters. Refer to Table 2 for accessory
requirements.

Refrigerant tubes and indoor coil must be evacuated to 500
microns to minimize contamination and moisture in the system.

—3—

FEEDER TUBE

STUB TUBE

DEFROST
THERMOSTAT

PISTON

PISTON BODY

SWEAT/FLARE
ADAPTER

TEFLON
SEAL

A97517

Fig. 6—Defrost Thermostat Location

A. Outdoor Unit Connected To Factory-Approved In­door Unit

These outdoor units are carefully evaluated and listed with specific
indoor coils for proper system performance.

IMPORTANT: Do not apply indoor coils which are not factory
approved to these units.

B. Install Adapter Tube

1. Remove plastic retainer holding outdoor piston in liquid
service valve.

2. Check outdoor piston size with matching number listed on
unit rating plate.

3. Locate plastic bag taped to unit containing adapter tube.

4. Remove teflon washer from bag and install on open end of
liquid service valve. (See Fig. 7.)

5. Remove adapter tube from bag and connect threaded nut to
liquid service valve. Tighten nut finger tight and then with
wrench an additional 1/12 turn (15 ft-lb). DO NOT OVER­TIGHTEN.

C. Refrigerant Tubing And Filter Drier

CAUTION: Installation of filter drier in liquid line is

required to avoid performance loss due to plugged
circuits or plugged expansion devices, and to avoid
compressor failure.

Connect vapor tubing to fittings on outdoor unit vapor service
valve. Connect liquid tubing to filter drier. (See Table 1 and Fig.

8.) Use refrigerant grade tubing. Connect other end of filter drier
to adapter tube on liquid service valve.

D. Sweat Connection

CAUTION: To avoid valve damage while brazing, ser-

vice valves must be wrapped in a heat-sink material such
as a wet cloth.

Wrap service valves and filter drier with a wet cloth or heat­sinking material. Braze connections using either silver bearing or
non-silver bearing brazing material. Do not use soft solder
(materials which melt below 800° F.) Consult local code require­ments.

E. Leak Checking

Leak test all joints in indoor, outdoor, and refrigerant tubing.

LIQUID SERVICE VALVE

A99441

Fig. 7—Liquid Service Valve with Sweat Adapter Tube

F. Evacuate Refrigerant Tubing And Indoor Coil

CAUTION: To avoid compressor damage, never use the

system compressor as a vacuum pump.

Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used if the procedure outlined
below is followed.

IMPORTANT: Never open system under vacuum to atmosphere
without first breaking it open with nitrogen.

DEEP VACUUM METHOD

The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum
method is the most positive way of assuring a system is free of air
and liquid water. (See Fig. 9.)

TRIPLE EVACUATION METHOD

The triple evacuation method should only be used when vacuum
pump is only capable of pumping down to 28 in. of mercury
vacuum and system does not contain any liquid water. Refer to
Fig. 10 and proceed as follows:

1. Pump system down to 28 in. of mercury and allow pump to
continue operating for an additional 15 minutes.

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and
open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1 hr.
During this time, dry nitrogen will be able to diffuse
throughout the system absorbing moisture.

5. Repeat this procedure as indicated in Fig. 10. System will
then contain minimal amounts of contaminants and water
vapor.

G. Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both indoor

and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, making sure wire ties on feeder tubes are
secure and tight.

—4—