Bryant 657A User Manual

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Installation, Start-Up and Operating Instructions

657A SINGLE PACKAGED HEAT PUMP UNITS

Cancels: II 657A.24.4 II 657A.24.5

7–03

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

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

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

Introduction ....................................................................................2

RECEIVING AND INSTALLATION..........................................2

Check Equipment......................................................................2

IDENTIFY UNIT................................................................2

INSPECT SHIPMENT........................................................2

Provide Unit Support................................................................3

ROOF CURB & SLAB MOUNT.......................................3

Provide Clearances....................................................................4

Select and Install Ductwork .....................................................5

Rig and Place Unit....................................................................6

INSTALLATION ................................................................8

Connect Condensate Drain.......................................................9

Install Duct Connections ..........................................................9

CONFIGURING UNITS FOR DOWNFLOW (VERTI-

CAL) DISCHARGE-STANDARD UNITS (024–042)....11

CONFIGURING UNITS FOR DOWNFLOW (VERTI-

CAL) DISCHARGE-ECM UNITS (048–060).................13

Install Electrical Connection ..................................................14

HIGH-VOLTAGE & CONTROL-VOLTAGE CONNEC-

TIONS................................................................................14

SPECIAL PROCEDURES FOR 208-V OPERATION ...15

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

START-UP...................................................................................17

CHECK FOR REFRIGERANT LEAKS..........................17

START UP AND MAKE ADJUSTMENTS....................18

CHECKING COOLING CONTROL OPERATION .......18

CHECKING HEATING CONTROL OPERATION........18

CHECKING AND ADJUSTING REFRIGERANT

CHARGE...........................................................................18

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS..............................................................................21

For 208/230v-PSC Blower Motor.....................................21

For 208/230v-ECM Blower Motor...................................21

COOLING SEQUENCE OF OPERATION.....................22

HEATING SEQUENCE OF OPERATION.....................23

MAINTENANCE.........................................................................23

AIR FILTER......................................................................24

UNIT TOP REMOVAL....................................................24

INDOOR BLOWER AND MOTOR................................24

OUTDOOR COIL, INDOOR COIL, AND CONDENSATE

DRAIN PAN......................................................................27

OUTDOOR FAN...............................................................28

ELECTRICAL CONTROLS AND WIRING ..................28

REFRIGERANT CIRCUIT...............................................29

INDOOR AIRFLOW ........................................................29

METERING DEVICE — ACUTROL DEVICE .............29

LIQUID LINE STRAINER ..............................................29

Troubleshooting............................................................................31

Start-UpChecklist........................................................................32

NOTE TO INSTALLER — Before the installation, READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY. Also, make sure the User’s Manual and Replacement Guide are left with the unit after installation.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations. 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 modifying this product.

C95002

Fig. 1—Unit 657A with Optional Base Rails

WARNING: Before performing service or maintenance

operations on system, turn off power to unit. Turn off accessory heater power switch, if applicable. Electrical shock can cause personal injury.

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

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in

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C95003

UNIT ELECTRICAL CHARACTERISTICS

657A024 208/230-1-60 257 117 57/26 69/31 75/34 56/25 20.4/519 21.1/540 11.2/286 657A030 208/230-1-60 288 131 56/25 87/40 74/34 71/32 20.3/518 21.5/547 11.2/286

UNIT WEIGHT

lb. kg A B C D X Y Z

CORNER WT

LB/KG

CENTER OF GRAVITY

IN/MM

Fig. 2— 657A024-030 Unit Dimensions (without base rails)

severe personal injury or death. WARNING signifies a hazard 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.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

INTRODUCTION

The 657A units (see Fig. 1) are fully self-contained, and designed for outdoor installation. See Figs. 2–5 for unit dimensions. All

units are shipped in a horizontal-discharge configuration for installation on a ground-level slab. All units can be converted to down-flow discharge configurations for rooftop applications. (See Fig. 6 for roof curb dimensions.)

RECEIVING AND INSTALLATION

I. CHECK EQUIPMENT A. IDENTIFY UNIT

The unit model number and serial number are stamped on the unit identification plate. Check this information against shipping papers.

B. INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal.

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C95004

UNIT ELECTRICAL CHARACTERISTICS

657A024 208/230-1-60 277 126 62/28 74/34 80/36 61/28 20.2/515 21.3/541 13.8/351 657A030 208/230-1-60 308 140 61/28 92/42 79/36 76/35 20.2/514 21.5/547 13.8/351

UNIT WEIGHT

lb. kg A B C D X Y Z

CORNER WT

LB/KG

CENTER OF GRAVITY

IN/MM

Fig. 3— 657A024-030 Unit Dimensions (with base rails)

Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest distributor if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

II. PROVIDE UNIT SUPPORT A. ROOF CURB & SLAB MOUNT

ROOF CURB - Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 6). Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in (See Fig. 8). This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.

SLAB MOUNT - Place the unit on a solid, level concrete pad that is a minimum of 4 in. thick with 2 in. above grade (See Fig. 10). The slab should extend approximately 2 in. beyond the casing on all 4 sides of the unit. Install a 6-in. gravel apron in front of

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UNIT ELECTRICAL CHARACTERISTICS

657A036 208/230-1-60 316 144 46/21 103/47 81/37 86/39 21.2/539 20.4/520 13.6/347 657A042 208/230-1-60 316 144 46/21 103/47 81/37 86/39 21.2/539 20.4/520 13.6/547 657A048 208/230-1-60 359 163 89/40 81/37 113/51 76/35 19.7/500 20.5/522 15.0/381 657A060 208/230-1-60, 373 170 92/42 85/39 116/53 80/36 19.6/499 20.6/523 15.0/381

UNIT WEIGHT

lb. kg A B C D X Y Z

CORNER WT

LB/KG

CENTER OF GRAVITY

IN/MM

Fig. 4— 657A036-060 Unit Dimensions (without base rails)

outdoor coil-air inlet to prevent obstruction of airflow by grass or shrubs. Do not secure the unit to the slab except when required by local codes.

III. PROVIDE CLEARANCES

The required minimum service clearances are shown in Fig. 2-5. Adequate ventilation and outdoor air must be provided. The outdoor fan pushes air through the outdoor coil and discharges it through the louvers on the top cover, the decorative grille, and the compressor access panel. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a

corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in.

IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoor-air inlet or the fan discharge may be detrimental to compressor life.

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab-mounted units

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C95005

C95006

UNIT ELECTRICAL CHARACTERISTICS

657A036 208/230-1-60 336 153 51/23 108/49 86/39 91/41 21.0/535 20.5/521 16.4/418 657A042 208/230-1-60 336 153 51/23 108/49 86/39 91/41 21.0/535 20.5/521 16.4/418 657A048 208/230-1-60 379 172 94/43 86/39 118/54 81/37 19.6/498.3 20.6/524 17.3/440 657A060 208/230-1-60, 393 179 97/44 90/41 121/55 85/39 19.5/497.3 20.6/524 17.3/440

UNIT WEIGHT

lb. kg A B C D X Y Z

CORNER WT

LB/KG

CENTER OF GRAVITY

IN/MM

Fig. 5— 657A036-060 Unit Dimensions (with base rails)

should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water.

IV. SELECT AND INSTALL DUCTWORK

The design and installation of the duct system must be in accordance with the standards of the NFPA (National Fire Protection Association) for installation of nonresidence-type air conditioning and ventilating systems, NFPA90A or residence type, NFPA90B; and/or local codes and residence-type, NFPA90B; and/or local codes and ordinances. Select and size ductwork, supply-air registers and return-air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Condition-

ing Engineers) recommendations. The unit has duct flanges on the supply- and return-air openings on the side of the unit. See Fig. 2-5 for connection sizes and locations. When designing and installing ductwork, consider the following:

CAUTION: When connecting ductwork to units, do not drill deeper than 1/2–in. in shaded area shown or coil may be damaged.

1. All units should have field-supplied filters or accessory

—5—

ODS CATALOG NUMBER

Flat

Curb

CPRFCURB001A00 8 (203) CPRFCURB002A00 11 (279) CPRFCURB003A00 14 (356)

Fig. 6— Roof Curb Dimensions

filter rack installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 1.

2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weathertight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) should extend 24-in. from electric heater element.

3. Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended.

C95007

IN. (MM)

NOTE: A 90-degree elbow must be provided in the supply

ductwork to comply with UL (Underwriters’ Laboratories) codes for use with electric heat.

4. Insulate and weatherproof all external ductwork. Insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.

5. Secure all ducts to building structure. Flash, weatherproof, and vibration-isolate duct openings in wall or roof according to good construction practices.

V. RIG AND PLACE UNIT

Use spreader bars or crate top when rigging the unit. The units must be rigged for lifting as shown in Fig. 7. Use extreme caution

—6—

CHART A CHART B

UNIT

SIZE

024 296 134 16.1 410 32.2 817 309 140 16.0 406 28.9 733 030 327 148 16.2 411 32.2 817 340 154 16.0 407 28.9 733 036 355 161 15.4 390 38.2 969 368 167 15.2 385 34.9 885 042 355 161 15.4 390 38.2 969 368 167 15.2 385 34.9 885 048 398 180 16.9 428 38.2 969 411 186 16.8 426 34.1 867 060 412 187 16.9 429 38.2 969 425 193 16.8 427 34.1 867

Max

Weight

LB KG IN MM IN MM LB KG IN MM IN MM

Max

Weight

Fig.7—657A RiggingInstructions

C95006

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B B-C A-C

1/4 1/4 1/4

Fig. 8—Unit Leveling Tolerances

to prevent damage when moving the unit. Unit must remain in an upright position during all rigging and moving operations. The unit must be level for proper condensate drainage; the ground-level pad or accessory roof curb must be level before setting the unit in place. When a field-fabricated support is used, be sure that the support is level and that it properly supports the unit.

UNITS WITHOUT BASE RAILS-Accessory rigging brackets are recommended to be used for rigging. Install brackets as follows:

C99065

—7—

RETURN AIR

INDOOR THERMOSTAT

TOP COVER

Fig. 9—Typical Unit Installation

REAR SIDE OF UNIT

PAD

UNIT OUTLINE

933 mm (36 3/4”)

1110 mm

(43 11/16”)

984 mm (38 3/4”)

1161 mm

(45 11/16”)

FROM POWER SOURCE

DISCONNECT PER NEC

SIDE OF UNIT WITH DUCT CONNECTIONS

C95013

SIDE OF UNIT WITH ACCESS PANELS FOR CONTROL BOX AND INDOOR BLOWER HOUSING

NOTES:

1. Extend

2. Provide a3-ft service clearance

gravel apron around pad.

6-in.

Fig.10—Typical Slab Layout

WARNING: Secure screws and paint protectors solidly

against unit base to hold lifting brackets in position. Never use lifting brackets when the temperature is below

-10 F (-23 C). Never exceed 200 lbs per bracket of lifting force. Never use lifting brackets for lifting other models of air conditioning units. Lifting point should be directly over the unit center of gravity. Failure to follow this warning could result in personal injury or death.

1. Position brackets as close to the corners of unit as possible. Be sure brackets are well outside of center of gravity (See Fig. 2-5, and 7).

2. Position paint protectors and foam strips between screws and painted surface of unit. Tighten screws until they make contact with the paint protectors.

3. Secure device or hook of sufficient strength to hole in bracket as shown in detail ’’C’’ of Fig. 7.

4. If wood top is available, use it for a spreader bar to prevent straps from damaging unit. If wood top is not available, use spreader bars of sufficient length.

at front and rear sides of unit.

C95039

UNITS WITH OPTIONAL BASE RAILS - Keep unit upright and do not drop. Use spreader bars or top crate when rigging unit. Rollers may be used to move unit across roof. Level unit for proper condensate disposal. See Fig. 7 for additional information. Lifting holes are provided in base rails as shown in Fig. 7, See Detail “A” or “B-B”. Refer to rigging instructions on unit.

A. INSTALLATION

1. Position the lifting bracket assembly around the base of the unit. Leave the top shipping skid on the unit to act as a spreader bar. Be sure the strap does not twist.

2. Place each of the four (4) metal lifting brackets into the rigging holds in the composite pan.

3. Tighten the ratchet strap unit tight. Lifting brackets should be secure in the rigging holds.

4. Attach the clevis or hook of sufficient strength to hole in the lifting bracket (See Fig. 7).

5. Attach safety straps directly to the field supplied rigging straps or clevis clip. Do not attach the safety straps to the lifting brackets.

6. Use the top of the unit as a spreader bar to prevent the rigging straps from damaging the unit. If the wood top is not available, use a spreader bar of sufficient length to not damage the unit.

—8—

959 mm

(37 3/4 in.)

1 2 3

305 mm (12 in.) TO 610 mm (24 in.) (4) REQ.

1010 mm (39 3/4 in.) (2) REQ.

909 mm (35 3/4 in.) (2) REQ. 38 mm (1 1/4 in.)

1060 mm

(41 3/4 in.)

NOTES:

1. Material consistsof angle iron — 31.8 mm (1-1/4 in.) to 38 mm

2. We ldframetogether.

3. Pa int with z inc-rich paint (rust-proof).

406 mm (16 in.) (8) REQ.

(1-1/2 in.) commerical standard.

C95013

Fig. 11—Optional Heat Pump Mounting Frame

ACCESS PANEL (REMOVE SCREWS)

Fig. 12—Indoor Coil Access Panel

WARNING: Lifting point should be directly over the

center of gravity for the unit. Failure to follow this warning could result in personal injury or death.

VI. CONNECT CONDENSATE DRAIN NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions. Unit disposes of condensate through a 3/4-in. NPT fitting which

exits through the compressor access panel. See Fig. 2–5 (Front View) for location of condensate connection. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1-in. lower than the drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes

C95014

away from the unit. If the installation requires draining the condensate water away from the unit, install a 2-in. trap using a 3/4-in. NPT connection (See Fig. 18). Make sure that the outlet of the trap is at least 1-in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. Connect a drain tube using a minimum of 3/4-in. PVC, 3/4-in. CPVC, or 3/4-in. copper pipe (all field supplied). Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season start-up.

VII. INSTALL DUCT CONNECTIONS

The unit has duct flanges on the supply- and return-air openings on the side and bottom of the unit. For downshot applications the ductwork can be connected to the roof curb. See Fig. 2-5 for connection sizes and locations. IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weathertight and airtight seal. When electric heat is

—9—

Fig. 13—Removing Insulation and Vertical Duct Cover

INDOOR BLOWER ACCESS PANEL

(REMOVE SCREWS)

Fig. 14—Indoor Blower Access Panel

C95015

C950016

BLOWER SHELF

FILLER BRACKET

RACEWA Y

PLUG ASSEMBLIES

HORIZONTAL DUCT OPENING

Fig. 15—Converting Blower Assembly to Vertical Airflow

—10—

C950010

FILLER BRACKET

REMOVE

Fig. 16—Blower Shelf and Housing

DEFROST BOARD CONTACTOR RELAY

C95017

Fig. 17—Control Box Detail View

1” (25mm) MIN.

Fig. 18–Condensate Trap

installed, use fire proof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If

flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24-in. from the unit discharge connection flange into the ductwork.

ACCESSORY DUCT FLANGE KIT INSTALLATION-

1. Mark hole locations (See instructions included in Flange Kit).

CAUTION: Do not drill deeper than 1/2–in. into area between round duct openings. Damage to refrigerant coil could result.

2. At marked locations, drill holes using a no. 26 (.147-in.) twist drill (See Fig. 19).

C95017

TRAP OUTLET

2” (50mm) MIN.

C99013

3. Partially secure duct flanges using two of the no. 10, 1/2-in. screws provided.

4. See the following caution. Using remaining holes in duct flanges as templates, drill the remaining holes with the no. 26 (.147-in.) drill.

5. Fully secure the duct flanges using the remaining screws provided.

NOTE: The finished kit installation accommodates a 14 3/4-in. x 14 3/4-in. duct.

A. CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DISCHARGE-STANDARD UNITS (024–042)

Units 024–042 (Units with PSC Indoor Blower Motors) are shipped in a horizontal configuration. To convert a horizontal unit for downflow (vertical) discharge, perform the following steps:

—11—

TABLE 1—PHYSICAL DATA—UNIT 657A

UNIT SIZE 024 030 036 042 048 060

NOMINAL CAPACITY (ton) 2 2-1/2 3 3-1/2 4 5 OPERATING WEIGHT (lb.)

Without Base Rails WIth Optional Rails

COMPRESSOR Scroll

REFRIGERANT (R-22)

Quantity (lb.)

REFRIGERANT METERING DEVICE Acutrol™ System

OUTDOOR COIL

Rows...Fins/in.

Face Area (sq. ft.)

OUTDOOR FAN

Nominal Cfm

Diameter (in.)

Motor Hp (Rpm)

INDOOR COIL

Rows...Fins/in.

Face Area (sq. ft.)

INDOOR BLOWER

Motor Type

Speeds

Nominal Airflow (Cfm)

Size (in.)

Motor Hp (RPM)

RETURN-AIR FILTERS (in.)

Throwaway

ECM-Electronic Computated Motor.

309 296

5.4 5.6 8.6 6.8 7.9 8.1

2...17

7.0

2200

1/4 (1100)

3...15

3.6

PSC

800

10x9

1/4 (1075)

24x24x1 24x24x1 24x30x1 24x30x1 24x30x1 24x30x1

340 327

2...17

7.0

2200

1/4 (1100)

3...15

3.6

PSC

3 1000 10x9

1/4 (1075)

368 355

2...17

8.7

2200

1/4 (1100)

4...15

4.5

PSC

3 1300 10x9

1/2 (1100)

368 355

2...17

8.7

2400

1/4 (1100)

4...15

4.5

PSC

3 1400 10x9

1/2 (1100)

411 398

2...17

8.7

2400

1/3 (1100)

4...15

4.5

ECM

Variable

1550

10x10

1.0 (Variable)

425 412

2...17

8.7

2400

1/3 (1050)

4...15

4.5

ECM

Variable

1800

10x10

1.0 (Variable)

19-1/2"

[495]

NOTES:

Do not drill more than 1/2-in into shaded area.

Dimensions in [ ] are in mm.

Fig. 19—Area Not To Be Drilled

WARNING: Before performing service or maintenance

operations on the system, turn off main power to unit and install lockout tag or electrical shock could result.

1. Open all electrical disconnects and install lockout tag before starting any service work.

2. Remove indoor coil access panel (See Fig. 12).

3. Locate lances in unit base insulation that are placed over the perimeter of the vertical duct opening cover (See Fig. 13).

4. Using a straight edge and sharp knife, cut and remove the insulation around the perimeter of the cover. Remove the screws securing the cover to the unit base and slide out the cover. Discard the cover.

[127]

C95012

5. Remove indoor blower access panel (See Fig. 14).

6. Disconnect indoor-fan motor leads from indoor fan relay and unit contactor (See Fig. 15). Carefully disengage wire tie containing indoor-fan motor leads from the unit control box (See Fig. 15 & 17).

7. Remove screws securing indoor blower housing to blower shelf and carefully slide out blower housing. There is a filler bracket attached to the blower shelf; remove this filler bracket and retain for later use (See Fig. 16).

8. Locate lances in unit base insulation that are placed over the perimeter of the vertical discharge opening cover (See Fig.

13).

9. Using a straight edge and sharp knife, cut the insulation around the perimeter of the cover. Remove the screws

—12—

14 11/16” (372)

13 3/4” (348)

3 3/4” (94)

9 11/16” (245)

21 9/16” (547)

11/32” DIA (8 Places/Holes)

11/16” (17) TYP

0 10 5/8” (270)

22-GAGE SHEET METAL COVER (SEE ABOVE)

SEAL ALL FOUR CORNERS WITH SILICONE SEALER

Fig. 20—Field-Fabricated Duct Cover

9/32” (7) TYP

19” (482)

4 ADHESIVE-BACKED SPONGE RUBBER SEAL STRIPS-1/8” (3.2) THICK

1//2-IN. THICK, 1-lb. DENSITY FIBERGLASS INSULATION WITH ALUMINUM FOIL BACKING; SECURE WITH ADHESIVE

31 3/16” (792)

1 3/4” (43) 0

C95019

TABLE 2—MINIMUM AIRFLOW FOR SAFE ELECTRIC HEATER

OPERATION (CFM)

SIZE

024 030 036 042 048 060 700 875 1225 1225 1400 1750

securing the cover to the unit base and slide out the cover. Discard the cover. Install filler bracket removed in Step 7.

10. If unit ductwork is to be attached to vertical opening flanges on the unit base (jackstand applications only), do so at this time.

11. It is recommended that the unit base insulation around the perimeter of the vertical opening be secured to the unit base with aluminum tape to prevent the insulation from tearing or bunching up when the blower housing is installed in the vertical discharge position.

12. Orient blower housing for vertical airflow (blower motor adjacent to horizontal duct opening) and slide into vertical opening making sure the flanges on the blower side plates engage the tabs in the unit base (See Fig. 15). Resistance will be felt as the blower housing contacts the unit base insulation; this can be overcome by applying a slight force to the base of the blower. Continue sliding blower in until

hole in side plate flange aligns with the hole in the unit base. Secure using screw removed in Step 7. Reconnect indoorfan motor leads and insert wire tie back into unit control box.

13. Cover the horizontal duct openings. Duct covers can be ordered as an accessory or field fabricated (See Fig. 20).

14. Reinstall the indoor coil and indoor blower access panels.

15. After completing unit installation, perform all safety checks and power up unit.

B. CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DISCHARGE-ECM UNITS (048–060)

Units 048–060 (Units with ECM Indoor Blower Motors) are shipped in a horizontal configuration. To convert a horizontal unit for downflow (vertical) discharge, perform the following steps:

—13—

WARNING: Before performing service or maintenance operations on the system, turn off main power to unit and install lockout tag or electrical shock could result.

1. Open all electrical disconnects and install lockout tag before starting any service work.

2. Remove indoor coil access panel (See Fig. 12).

3. Locate lances in unit base insulation that are placed over the perimeter of the vertical duct opening cover (See Fig. 13).

5. Remove indoor blower access panel (See Fig. 14).

6. Disconnect the plug assemblies from the indoor-fan motor (See Fig. 15 & 17).

8. Locate lances in unit base insulation that are placed over the perimeter of the vertical discharge opening cover (See Fig.

13).

9. Using a straight edge and sharp knife, cut the insulation around the perimeter of the cover. Remove the screws securing the cover to the unit base and slide out the cover. Discard the cover. Install filler bracket removed in Step 6.

10. If unit ductwork is to be attached to vertical opening flanges on the unit base (jackstand applications only), do so at this time.

12. Remove screws securing the high-voltage raceway to duct panel. Temporarily place raceway on top of unit until blower housing is installed.

13. Orient blower housing for vertical airflow (blower motor adjacent to horizontal duct opening) and slide into vertical opening making sure the flanges on the blower side plates engage the tabs in the unit base (See Fig. 15). Resistance will be felt as the blower housing contacts the unit base insulation; this can be overcome by applying a slight force to the base of the blower. Continue sliding blower in until hole in side plate flange aligns with the hole in the unit base. Secure using screw removed in Step 6.

14. Reinstall the high-voltage raceway removed in Step 12.

15. Cover the horizontal duct openings. Duct covers can be ordered as an accessory or field fabricated (See Fig. 20).

16. Reinstall the indoor coil and indoor blower access panels.

17. After completing unit installation, perform all safety checks and power up unit.

VIII. INSTALL ELECTRICAL CONNECTION

WARNING: The unit cabinet must have an uninter-

rupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code) ANSI/NFPA (latest edition) and local electrical codes. In Canada, follow Canadian Electrical Code CSA (Canadian Standards Association) C22.1 and local electrical codes. Failure to adhere to this warning could result in personal injury or death.

CAUTION: Failure to follow these precautions could result in damage to the unit being installed:

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate.

4. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. On 3-phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

A. HIGH-VOLTAGE & CONTROL-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a fieldsupplied, waterproof, disconnect switch mounted at, or within sight from, the unit. Refer to the unit rating plate for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. See Table 3 for electrical data. The field-supplied disconnect switch box may be mounted on the unit over the high-voltage inlet hole when the standard power and low-voltage entry points are used. See Fig. 21 for acceptable location. See unit wiring label and Fig. 23, 24 & 26-27 for reference when making high voltage connections. Proceed as follows to complete the high-voltage connections to the unit.

If the unit has an electric heater, a second disconnect may be required. Consult the Installation Instructions provided with the accessory heater for electrical service connections.

1. ROUTING POWER LEADS INTO UNIT-Use only copper wire between disconnect and unit. The high-voltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight. Run the high-voltage leads through the knockout on the duct panel (see Fig. 21 for location and size). When the leads are inside the unit, run leads up the high-voltage raceway to the line wiring splice box (Fig. 22). For single-phase units, connect leads to the black and yellow wires (see Fig. 24 & 26-27).

2. CONNECTING GROUND LEAD TO WIRE-BINDING SCREW - Refer to Fig. 22. Connect the ground lead to the chassis using the wire-binding screw in the wiring splice box.

—14—

HIGH VOLTAGE POWER ENTRY (KNOCKOUT)

2 DIA. 1 1/8 DIA. 1 3/8 DIA. 2 DIA.

7/8 DIA. CONTROL POWER ENTRY*

*Knockout on rectangular-duct panel units; entry hole on round-duct

panel units.

NOTE: For rectangular duct knockout sizes, see Fig. 2-9.

Fig. 21–Typical Duct Panel Knockouts

3. ROUTING CONTROL POWER WIRES - STD NONECM UNITS (24 v) -Form a drip-loop with the thermostat

leads before routing them into the unit. Route the thermostat leads through grommeted hole provided in unit (see Fig. 21) into unit control power splice box. Connect thermostat leads to unit control power leads as shown in Fig. 23.

4. ROUTING CONTROL POWER WIRES - ECM UNITS (24 v) - Remove knockout in the duct panel (see Fig. 21). Remove the rubber grommet from the installer’s packet (included with unit) and install it in the knockout opening. Route thermostat wires through grommet providing a drip loop at the panel. Connect low-voltage leads to the thermostat as shown in Fig. 23. The Easy Select interface board is located in the return-air section and is attached to the duct panel. The Easy Select interface board is factory wired to the motor and factory default selections are preset.

5. The unit transformer supplies 24-v power for complete system including accessory electrical heater. Transformer is factory wired for 230-v operation. If supply voltage is 208 v, rewire transformer primary as described in the Special Procedures for 208-v Operation section.

NOTE: Do not use any type of power-stealing thermostat. Unit control problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insulated (35 C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft. from the unit (as measured along the control voltage wires), use no. 16 AWG color-coded, insulated (35 C minimum) wires.

B. SPECIAL PROCEDURES FOR 208-V OPERATION

WARNING: Make sure that the power supply to the unit

is switched OFF and lockout tag installed before making any wiring changes. Electrical shock can cause serious injury or death.

C95036

6. Wrap the wire nut with electrical tape so that the metal terminal cannot be seen.

NOTE: Indoor blower motor speeds may need to be changed for 208-v operation. Refer to Indoor Airflow and Airflow Adjustment Section.

PRE-START-UP

WARNING: Failure to observe the following warnings

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 compressor terminal cover until all electrical sources are disconnected.

4. Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

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 protective goggles and proceed as follows: a. Shut off electrical power to unit. b. Relieve and reclaim all refrigerant from system using

both high- and low-pressure ports.

c. Cut component connecting tubing with tubing cutter

and remove component from unit.

d. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to torch flame.

1. Disconnect the orange transformer-primary lead from the contactor. See unit wiring label

2. Remove the wire nut from the terminal on the end of the red transformer-primary lead.

3. Save the wire nut.

4. Connect the red lead to the contactor terminal from which the orange lead was disconnected.

5. Using the wire nut removed from the red lead, insulate the loose terminal on the orange lead.

Proceed as follows to inspect and prepare the unit for initial startup:

1. Remove access panel.

2. Read and follow instructions on all WARNING, CAUTION, and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections: a. Inspect for shipping and handling damages such as

broken lines, loose parts, disconnected wires, etc.

—15—

UNIT POWER LEAD

UNIT LINE WIRE SPLICE BOX

Fig. 22—Wiring Splice Boxes

WIRE-BINDING SCREW

CONTROL POWER SPLICE BOX

C95022

→

VOLTAGE

RANGE

UNIT 657A SIZE

(–SERIES,

USED)

024–311 208/230-1 187 253 11.2 56.0 1.4 2.0

024–321 208/230-1 187 253 12.1 54.0 1.4 2.0

030 208/230-1 187 253 15.0 73.0 1.4 2.6

036 208/230-1 187 253 16.0 88.0 1.2 2.6

042 208/230-1 187 253 20.0 104.0 1.4 3.1

048–301 208/230-1 187 253 26.4 129.0 2.1 7.2

048–311 208/230-1 187 253 20.8 109.0 2.1 7.2

060 208/230-1 187 253 32.1 169.0 2.1 7.2

(See legend following Electrical Data chart)

V-PH

(60 HZ)

Min Max RLA LRA FLA FLA kW FLA

COMPRESSOR OFM IFM

TABLE 3—ELECTRICAL DATA—657A

ELECTRIC

HEAT

3.75/5.00

5.60/7.50

7.50/10.0

3.75/5.00

5.60/7.50

7.50/10.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

15.0/20.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

15.0/20.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

15.0/20.0

3.75/5.00

5.60/7.50

7.50/10.0

11.30/15.0

15.0/20.0

18.1/20.8

27.1/31.3

36.1/41.7

18.1/20.8

27.1/31.3

36.1/41.7

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

72.2/83.3

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

72.2/83.3

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

72.2/83.3

18.1/20.8

27.1/31.3

36.1/41.7

54.1/62.0

72.2/83.3

SINGLE-POINT

POWER SUPPLY

Single-

Point

Wiring

MCA

40.3/43.4

51.0/56.5

62.5/69.5

41.4/44.5

52.2/57.7

63.7/70.7

45.3/48.8

56.6/61.8

67.9/74.8

90.4/100.3

48.3/51.7

56.6/61.8

67.9/74.8

90.4/100.3

52.1/55.5

63.3/68.6

74.6/81.6

97.1/107.0

119.8/133.7

65.2/68.3

75.9/81.4

87.4/94.4

110.2/120.4

131.8/145.9

58.2/61.3

68.9/74.4

80.4/87.4

103.2/113.4

124.8/138.9

72.0/75.5

83.3/88.5

94.6/101.5

117.1/126.9

139.6/153.5

Single-

Point

Max

Fuse

or Ckt Bkr

45/45 60/60

—

45/45 60/60

—

50/50

60/–

—

60/60

60/–

—

60/60

—

60/-

—

Single-

Point

MOCP

— —

70/80

— —

70/80

—

–/70

70/80

100/100

—

–/70

80/80

100/110

— 70/80 80/90

100/110 125/150

70/70 80/90

90/100 125/125 150/150

-/70 70/80 90/90

110/125 125/150

90/100 100/100 100/110 125/150 150/175

Heater

Only DualPoint

Wiring

MCA

22.5/26.0

33.7/39.1

45.1/50.8

22.5/26.0

33.7/39.1

45.1/50.8

22.5/26.0

33.7/39.1

45.1/50.1

67.9/78.1

22.5/26.0

33.7/39.1

45.1/50.1

67.9/78.1

22.5/26.0

33.7/39.1

45.1/50.8

67.9/78.1

90.1/104.2

22.5/26.0

33.7/39.1

45.1/50.8

67.9/78.1

90.1/104.2

22.5/26.0

33.7/39.1

45.1/50.8

67.9/78.1

90.1/104.2

22.5/26.0

33.7/39.1

45.1/50.8

67.9/78.1

90.1/104.2

DUAL-POINT

POWER SUPPLY

(INCLUDING UNIT ONLY)

Heater

Only

Dual-

Heater

Point

Max

Fuse

or Ckt Bkr

25/30 35/40 50/60 25/30 35/40 50/60 25/30 35/40 50/60

—

25/30 35/40 50/60

—

25/30 35/40 50/60

—

25/30 35/40 50/60

—

25/30 35/40 50/60

—

25/30 35/40 50/60

—

100/110

Unit

Only

Dual-

Point

MOCP

MCA

— ——17.4 25/25 —

— ——18.5 25/25 —

— —

22.8 30/30 —

—

70/80

— —

23.8 35/35 —

—

70/80

— — —

29.5 45/45 —

70/80

— — —

42.3 50/50 —

70/80

— — —

35.3 45/45 —

70/80

— — —

48.7 — 80/80

70/80

Unit Only

Dual-

Point

Max

Fuse

or Ckt Bkr

Unit

Only DualPoint

MOCP

b. Inspect for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant tubing connections

using electronic leak detector, halide torch, or liquidsoap solution. If a refrigerant leak is detected, see Check for Refrigerant Leaks section.

—16—

LEGEND

FLA — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection RLA — Rated Load Amps CKT BKR

NOTES:

1. In compliance with NEC (National Electrical Code) requirements

2. Minimum wire size is based on 60 C copper wire. If other than

3. Unbalanced 3-Phase Supply Voltage

—

Circuit Breaker

for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. Canadian units may be fuse or circuit breaker.

60 C wire is used, or if length exceeds wire length in table, determine size from NEC.

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

the percentage of voltage imbalance. % Voltage imbalance

= 100 x

max voltage deviation from average voltage

Use the following formula to determine

average voltage

EXAMPLE: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 (BC) 464 (AC) 457

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

% Voltage Imbalance = 100 x

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.

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

Average Voltage =

452=5v

457=7v 455=2v

= 1.53%

457

= = 457

452 + 464 + 455

1371

C99024

THERMOSTAT

AND SUBBASE

Fig. 23—Control-Voltage Connections

c. Inspect all field- and factory-wiring connections. Be sure

that connections are completed and tight.

d. Ensure electrical wiring does not contact refrigerant

tubes or sharp metal edges.

e. Inspect coil fins. If damaged during shipping and han-

dling, carefully straighten fins with a fin comb.

4. Verify the following conditions a. Make sure that outdoor-fan blade is correctly positioned

in fan orifice. Leading edge of outdoor-fan blade should be 2 in. back from inlet grille or 1/2–in. maximum from

the fan deck. b. Make sure that air filter(s) is in place. c. Make sure that condensate drain trap is filled with water

to ensure proper drainage. d. Make sure that all tools and miscellaneous loose parts

have been removed.

5. Compressors are internally spring mounted. Do not loosen or remove compressor hold-down bolts.

BRN

ORN

RED

GRN

YEL

WHT

UNIT CONTROL POWER

SPLICE BOX

C99056

6. Each unit (system) has 2 Schrader-type ports, one low-side fitting located on the suction line, and one high-side fitting located on the compressor discharge line. Be sure that caps covering these Schrader fittings are tight.

START-UP

A. CHECK FOR REFRIGERANT LEAKS

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

1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high- and low-pressure ports.

2. Repair leak following accepted practices. NOTE: Install a filter drier 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. Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are not found.

5. Charge unit with R-22 refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating plate for required charge. Be sure to add extra refrigerant to compensate for internal volume of filter drier.

—17—

GROUND

LEAD

GROUND LUG

(IN SLPICE BOX)

SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC

3-PHASE CONNECTIONS

LEGEND NEC – National Electrical Code

Field Wiring Splice Connections

Fig. 24—High-Voltage Connections

1/2 IN. MAX FR OM FAN DECK

MOTOR SHAFT

MOTOR

C95027

Fig. 25—Fan Blade Clearance

B. START UP AND MAKE ADJUSTMENTS

CAUTION: Complete the required procedures given in

the Pre-Start- Up section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the compressor when the outdoor temperature is below 40°F (unless accessory low-ambient kit is installed). Do not rapid-cycle the compressor. Allow 5 minutes between “on” cycles to prevent compressor damage.

C. CHECKING COOLING CONTROL OPERATION

Start and check the unit for proper cooling control operation 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 cooling control below room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that compressor and outdoor fan shut down when control setting is satisfied and that indoor blower shuts down after fan time delay expires.

L2 L3

BLK

YEL

BLU

NOTE: Use copper wire only.

3. When using an auto-changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that unit operates in heating mode when temperature control is set to “call for heating” (above room temperature) and operates in cooling mode when temperature control is set to “call for cooling” (below room temperature).

D. CHECKING HEATING CONTROL OPERATION

Start and check the unit for proper cooling control operation 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 HEAT position and FAN switch in AUTO position. Set cooling control above room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that compressor and outdoor fan shut down when control setting is satisfied and that indoor blower shuts down after fan time delay expires.

4. If system is equipped with supplemental or emergency heat (resistance heaters), observe that when thermostat is placed in EMERGENCY HEAT mode and temperature control is set above room temperature that heaters and indoor blower come on. Observe that heaters shut off when control setting is satisfied and that the indoor blower shuts off after fan time delay expires.

E. CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with R-22 refrigerant, tested, and factory-sealed. NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R-22 charge. A superheat charging chart is attached to the outside of the compressor access panel. The chart includes the required suction line temperature at given suction line pressures and outdoor ambient temperatures (See Table 13A-H and Fig. 30). An accurate superheat, thermocouple- or thermistor-type thermometer, a sling psychrometer, and a gauge manifold are required when using the superheat charging method for evaluating the unit charge. Do not use mercury or small dial-type thermometers

because they are not adequate for this type of measurement.

C99057

—18—

Fig. 26—Wiring Diagram–024 to 042 (208/230-60-1)

—19—

C95037

Fig. 27—Wiring Diagram–048 to 060 (208/230-60-1 with ECM Indoor)

—20—

C95038

TRANSFORMER CONTAINS A MANUAL RESET OVERCURRENT PROTECTOR

IT WILL NOT AUTOMATICALLY RESET DISCONNECT POWER AND INSTALL

LOCKOUT TAG PRIOR TO SERVICING THIS COMPARTMENT MUST BE CLOSED

EXCEPT WHEN SERVICING

Fig. 28—Transformer Label

NOTE: Allow system to operate in the cooling mode for a

minimum of 10 minutes before checking or adjusting refrigerant charge.

CAUTION: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils. Failure to adjust charge properly or correct the abnormal conditions will cause damage to the unit.

C95025

WARNING: Disconnect electrical power to the unit and install lockout tag before changing blower speed. Electrical shock can cause serious injury or death.

Airflow can be changed by changing the lead connections of the blower motor.

Unit 657A three-speed motors (024–042) are factory wired for low speed operation.

G. For 208/230v-PSC Blower Motor

For color coding on the 208/230V motor leads, see Table 4.

Proceed as follows:

1. Remove caps from low- and high-pressure service fittings.

2. Using hoses with valve core depressors, attach low- and high-pressure gauge hoses to low- and high-pressure service fittings, respectively.

3. Start unit in Cooling mode and let unit run until system pressures stabilize.

4. Measure and record the following: a. Outdoor ambient-air temperature (°F db).

b. Indoor coil inlet-air temperature (°F wb). c. Suction-tube temperature (°F) at low-side service fitting. d. Suction (low-side) pressure (psig).

5. Using “Superheat Charging Charts” compare outdoor-air temperature (°F db) with the Indoor coil air inlet temperature (°F wb) to determine desired system operating superheat temperature. See Table 13A–H and Fig. 30.

6. Using ’’Required Suction-Tube Temperature (F)’’ table, compare desired superheat temperature with suction (lowside) operating pressure (psig) to determine proper suctiontube temperature. See Fig. 30.

7. Compare actual suction-tube temperature with proper suction-tube temperature. Using a tolerance of ±3° F, add refrigerant if actual temperature is more than 3° F higher than proper suction-tube temperature, or remove refrigerant if actual temperature is more than 3° F lower than required suction-tube temperature.

NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section.

F. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS NOTE: For cooling operation, the recommended airflow is 350 to

450 cfm for each 12,000 Btuh of rated cooling capacity. Table 8 shows cooling airflows at various external static pressures.

Table 9 shows Fan Only and Cooling modes for ECM units (048-060). Refer to these tables to determine the airflow for the system being installed.

NOTE: Be sure that all supply- and return-air grilles are open, free from obstructions, and adjusted properly.

TABLE 4—COLOR CODING FOR 208/230–V MOTOR

LEADS

3-SPEED

black = high speed

blue = medium speed

red = low speed

To change the speed of the indoor fan motor (IFM), remove the fan motor speed leg lead from the indoor fan relay (IFR) and replace with lead for desired blower motor speed. Insulate the removed

lead to avoid contact with chassis parts.

H. For 208/230v-ECM Blower Motor

To configure the 657A 048-60 unit, move the 5 Easy Select board wires to the terminals which control the airflow. Refer to the Easy Select interface board (Fig. 29) located next to the terminal. Perform the following steps for basic system configuration.

1. AUX HEAT RANGE (VIO) NOTE: If no heater is installed, this step can be omitted. The airflow for electric heat is selected with the AUX HEAT RANGE terminals. Refer to Table 2 and the installation instructions for electric heaters for minimum airflow required for safe heater operation. Refer to table below for the available airflows. Each select pin is configured for a certain airflow. The airflow will be supplied in the Heating mode on air conditioners when electric heat is the primary heating source. The preset factory default selection is the highest airflow.

2. AC/HP SIZE (BLU) - The preset factory default selection for AC/HP SIZE (air conditioner/heat pump) is set to 400 cfm/ton. The selection pins are configured for 350 cfm/ton and 400 cfm/ton.

3. TYPE (ORN) - The TYPE is a preset factory default selection. The preset factory default setting is AC for the 657A units. Default setting should not be altered.

4. AC/HP CFM ADJUST (BLK) - The preset factory default selection is MED. Selections HI and LO will adjust the airflow supplied for all operational modes (see table below). The selection options allow installer to adjust airflow to meet such individual needs as noise and static compensation, etc.

—21—

TABLE 5—TERMINAL CONFIGURATION

TERMINAL 1234

Available

Airflow (CFM)

1365 1470 1680 1840

AUX HEAT

RANGE

VIO

BLU

BRN

BLK

GR Y

AC/HP SIZE

AC HPC HP

AC/HP CFM ADJUST

LO MED HI

AC/HP TIME DELAY

1 2 3 4

RED

2 3 4

TYPE

JW1 JW2

1 P2

JW3

JW 4

/W1

Y/Y2

JW 5

D3 D1 D2

/Y2

IFO

SEC-1

SEC-2

R2 R3

P1 1

5 AMP FUSE

Fig. 29—Easy Select Interface Board for Units 048-060 with ECM Blower Motor

TABLE 6—CFM ADJUST (PERCENT OF CFM)

MODE FAN ONLY COOLING HEATING

LO-Adjust

–15 –10 –10

C95024

HI-Adjust

15 10 10

5. AC/HP TIME DELAY (GRY) - Four motor operation delay options are provided to customize system operation. See listing below:

Unit Controls— All compressors have the following internalprotection controls.

1. High-Pressure Relief Valve - This valve opens when the pressure differential between the low and high side becomes excessive.

2. Compressor Overload - This overload interrupts power to the compressor when either the current or internal 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; therefore, if the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.

I. COOLING SEQUENCE OF OPERATION

PSC BLOWER MOTOR UNITS (024–042)

NOTE: With the FAN switch in the ON position, 24-v is supplied to the IFR through the G terminal on the thermostat. This voltage energizes the coil of the contactor, closing the normally-open set of contacts which provide continuous power to the indoor (evapora-

tor) fan motor (IFM). Moving the FAN switch back to the AUTO. position, providing there is not a call for cooling, deenergizes the IFR, opens the IFR contacts, and deenergizes the IFM. The FAN switch in AUTO. position cycles upon a call for cooling.

On a call for cooling, 24 v is supplied to the compressor contactor (C) and IFR simultaneously through the Y and G terminals of the thermostat, respectively. On units with a compressor time delay relay, there is a built-in, 5-minute (± 45 seconds) delay between compressor starts. Energizing the contactor closes the normallyopen set of contacts supplying power to both the compressor and outdoor (condenser) fan motor (OFM). Energizing the IFR closes the normally-open set of contacts providing power to the IFM. On the loss of the call for cooling, 24 v is removed from both the Y and G terminals of the thermostat (providing the FAN switch is in the AUTO. position), deenergizing both the contactor and IFR and opening both the contacts supplying power to compressor/OFM and IFM.

ECM BLOWER MOTOR UNITS (048–060)

Indoor Fan - With the fan switch in the ON position, 24-v is supplied to the ECM motor through the ’’G’’ terminal on the thermostat. This voltage provides continuous power to the indoor (evaporator) fan motor (IFM). If the fan switch is moved back to the AUTO position and there is not a call for heating or cooling, 24-v is removed from the ’’G’’ terminal and the indoor fan

—22—

OPTION DESCRIPTION

30-Sec On/60-Sec Off Delay

Profile (Terminal 1)

No Delay Option

(Terminal 2)

30-Sec Off Delay

(Terminal 3)

45-Sec Off Delay

(Terminal 4)

TABLE 7—ECM BOARD PIN SELECTION

Used when it is desirable to allow system coils time to heat

up or cool down prior to airflow

Used for servicing or when other components are used to

perform the delay function

Preset factory setting for 657A units

Enhances system efficiency

remains energized for the delay timing. When the fan switch is in AUTO, the fan cycles with either the call for heating or cooling.

Cooling- On a call for cooling, 24 v is supplied to the compressor contactor (C) and IFM simultaneously through the ’’Y’’ and ’’G’’ terminals of the thermostat. Energizing the contactor closes the normally open set of contacts supplying power to both the compressor and outdoor (condenser) fan motor (OFM). On the loss of the call for cooling, 24 v is removed from the ’’Y’’ and ’’G’’ terminals of the thermostat, deenergizing the compressor and OFM. The indoor fan remains energized for the delay timing.

NOTE: Once the compressor has started and then stopped, it cannot be restarted again until 5 minutes have elapsed.

J. HEATING SEQUENCE OF OPERATION

PSC BLOWER MOTOR UNITS (024–042)

Heat Pump Heating - On a call for heat, thermostat makes 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 IFR and starts IFM after 1-sec. delay.

Should room temperature continue to fall, circuit R-W is made through second-stage thermostat bulb. If optional electric heat package is used, a relay is energized, bringing on first bank of supplemental electric heat. When thermostat is satisfied, contacts open, deenergizing contactor and relay; motors and heaters deenergize. The IFM may be controlled by a time-delay relay that will extend IFM operation for a matter of sec.

Defrost Mode - Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for defrost (30, 50 or 90 minutes). Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat (DFT) is closed.

Defrost mode is identical to Cooling mode, except outdoor-fan motor stops and a bank of optional electric heat turns on to warm air supplying the conditioned space.

Auxiliary Heating - If accessory electric heaters are installed, on a call for heat, circuit R-W is made through the thermostat contacts. Circuit R-G is made which energizes the IFR. If the heaters are staged, then the thermostat closes a second set of contacts W2 when second stage is required. When thermostat is satisfied, contacts open, deenergizing the heater relay and the IFR.

ECM BLOWER MOTOR UNITS (048–060)

Should room temperature continue to fall, circuit R-W is made through second-stage thermostat bulb. If optional electric heat package is used, a relay is energized, bringing on first bank of supplemental electric heat. At this time, the airflow (CFM) will be either the AUX HEAT RANGE (VIO) setting or the AC/HP SIZE (BLU) setting, whichever is greater. This may be a noticeable change in airflow. When thermostat is satisfied, contacts open, deenergizing contactor and relay; motors and heaters deenergize. The IFM has a time delay relay that keeps the fan on for 30-sec.

Defrost mode is identical to Cooling mode, except outdoor-fan motor stops and a bank of optional electric heat turns on to warm air supplying the conditioned space.

Auxiliary Heating - If accessory electric heaters are installed, on a call for heat, circuits R-W and R-G are made through the thermostat contacts, energizing the heater relay and IFM. If the heaters are staged, then the thermostat closes the second set of contacts, W2, when the second stage is required. When the thermostat is satisfied, contacts open, deenergizing the heater relay and the IFM.

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. To troubleshoot cooling of units, refer to tables at the back of the book. 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 requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance 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.

WARNING: Failure to follow these warnings could result in serious personal injury:

1. Turn off electrical power to the unit and install lockout tag before performing any maintenance or service on the unit.

2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.

3. Never place anything combustible either on, or in contact with, the unit.

CAUTION: Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnection when servicing.

The minimum maintenance requirements for this equipment are as follows:

—23—

TABLE 8—DRY COIL AIR DELIVERY (DEDUCT 10 PERCENT FOR 208V)*

HORIZONTAL AND DOWNFLOW DISCHARGE

UNIT 657A024-042

230 AND 460 VOLT

Unit

024 & 030

036

042

* Air delivery values are based on operating voltage of 230-v dry coil, without filter or electric heater. Deduct wet coil, filter and electric heater pressure drops to obtain static pressure available for ducting.

NOTES:

1. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Indoor coil frosting may occur at airflows below this point.

2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended.

Motor

Speed

Low

Med

High

Low

Med

High

Low

Med

High

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Watts 280 275 265 255 250 245 240 ————

Cfm820810755700660600560————

Watts 365 360 350 345 340 330 320 310 300 — —

Cfm 1025 1010 975 940 900 850 800 720 630 — —

Watts — — 490 480 470 460 445 430 410 390 380

Cfm — — 1300 1255 1200 1150 1080 1005 915 790 620

Watts 520 495 474 458 445 425 —————

Cfm 1375 1335 1290 1240 1200 1140 —————

Watts 575 560 535 510 480 460 440 425 — — —

Cfm 1520 1490 1450 1400 1380 1300 1200 1080 — — —

Watts ————650614575540510480—

Cfm————1560 1500 1380 1280 1170 1060 —

Watts 490 480 470 460 450 430 410 390 — — —

Cfm 1400 1380 1340 1300 1250 1200 1140 1070 — — —

Watts 590 580 560 545 525 505 480 450 420 — —

Cfm 1600 1560 1540 1470 1430 1360 1300 1220 1120 — —

Watts —————700670640600560500

Cfm—————1780 1670 1600 1480 1340 1100

External Static Pressure (in. wg)

TABLE 9—048 & 060 ECM AIRFLOW (CFM)

UNIT 657A

048 1400 1600 060 1750 2000

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, drain pan, and condensate drain at least each cooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness and check lubrication each heating and cooling season. Clean when necessary.

4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary.

5. Ensure electric wires are not in contact with refrigerant tubing or sharp metal edges.

A. AIR FILTER

CAUTION: Never operate the unit without a suitable air

filter in the return-air duct system. Always replace the filter with the same size as originally installed. See Table 1 for recommended filter sizes.

Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least twice during each heating and cooling season or whenever the filter(s) becomes clogged with dust and lint.

B. UNIT TOP REMOVAL NOTE: When performing maintenance or service procedures that

require removal of the unit top, be sure to perform all of the routine maintenance procedures that require top removal, including coil inspection and cleaning, and condensate drain pan inspection and cleaning.

FAN ONLY

(CFM)

COOLING

(CFM)

Only qualified service personnel should perform maintenance and service procedures that require unit top removal. Refer to the following top removal procedures:

1. Remove 7 screws on unit top cover surface. (Save all screws.)

2. Remove 4 screws on unit top cover flange. (Save all screws.)

3. Lift top from unit carefully. Set top on edge and make sure that top is supported by unit side that is opposite duct (or plenum) side.

4. Carefully replace and secure unit top to unit, using screws removed in Steps 1 and 2, when maintenance and/or service procedures are completed.

C. INDOOR BLOWER AND MOTOR NOTE: Motors without oilers are prelubricated. Do not attempt to

lubricate these motors. For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and motor annually.

Lubricate the motor every 5 years if the motor is used intermittently (thermostat FAN switch in AUTO. position), or every 2 years if the motor is used continuously (thermostat FAN switch in ON position).

—24—

UNIT SIZE

024

030

036

042

048

060

TABLE 10—WET COIL PRESSURE DROP

AIRFLOW

(CFM)

600 0.039 700 0.058 800 0.075 900 0.088

900 0.088 1000 0.095 1200 0.123 1000 0.068 1200 0.088 1400 0.108 1600 0.123 1000 0.048 1200 0.069 1400 0.088 1600 0.102 1400 0.068 1550 0.073 1600 0.075 1800 0.088 1700 0.082 1900 0.095 2100 0.108 2300 0.123

PRESSURE DROP

(IN. WG)

TABLE 11—ACCESSORY ELECTRIC HEATER PRESSURE DROP (IN. WG)

HEATER

600 800 1000 1200 1400 1600 1800 2000 2200

5–20 0.030 0.033 0.037 0.042 0.047 0.052 0.060 0.067 0.075

CFM

TABLE 12—FILTER PRESSURE DROP (IN. WG)

UNIT SIZE

024–036 24 x 24 x 1 — — 0.06 0.06 0.07 0.07 0.08 0.09 0.10 —————————— 042–060 24 x 30 x 1 — — — — — — — — 0.08 0.09 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.17 0.18

FILTER

SIZE

(IN.)

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

TABLE 13A—SUPERHEAT CHARGING TABLE, UNIT 024–311

TEMP (F)

AIR ENT

COND

65 70 — — 19.5 24.4 29.3 29.9 30.4 29.5 28.6 28.2 27.8 75 — — 15.0 21.4 27.8 28.6 29.4 28.5 27.7 27.2 26.7 80 — — 7.5 14.4 21.4 24.5 27.6 27.1 26.5 26.1 25.6 85 — — — 7.5 15.0 20.4 25.8 25.6 25.4 24.9 24.5 90 — — — — 7.5 14.0 20.4 22.3 24.2 23.8 23.4

95 — — — — — 7.5 15.0 19.0 23.1 22.7 22.3 100 ——————7.513.5 19.5 20.3 21.1 105 ———————8.016.0 18.0 20.0 110 ————————12.4 15.7 18.9 115 ————————8.913.3 17.8

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76 — — 24.0 27.4 30.8 31.1 31.5 30.5 29.5 29.2 28.9

EVAP AIR – CFM

800

EVAP AIR – Ewb (F)

WARNING: Disconnect and tag electrical power to the unit before cleaning the blower motor and wheel. Failure to adhere to this warning could cause personal injury or death.

To clean the blower motor and wheel:

1. Remove and disassemble blower assembly as follows: a. Remove unit access panel.

b. For PSC Blower Motors Disconnect motor lead from

indoor fan relay (IFR). Disconnect yellow lead from terminal L2 of the contactor.

—25—

TABLE 13B—SUPERHEAT CHARGING TABLE, UNIT 024–321

TEMP (F)

AIR ENT

COND

65 70 33.3 32.3 33.2 33.9 36.9 36.0 35.2 34.4 33.4 32.5 31.8 75 24.6 25.6 24.1 25.0 33.3 34.8 33.8 32.6 31.8 31.0 30.2 80 16.4 17.6 21.4 16.8 23.2 31.8 32.2 31.3 30.4 29.5 28.6 85 — — 9.4 8.6 14.7 21.6 29.4 29.8 28.9 27.8 27.0 90 —————11.6 18.9 26.4 27.3 26.4 25.5

95 —————3.710.8 18.0 24.1 25.0 24.1 100 ———————8.016.3 22.1 22.6 105 ————————7.214.8 20.1 110 —————————5.213.8 115 ——————————5.1

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

38.0 37.3 37.4 37.5 38.3 37.7 36.8 35.9 35.0 34.3 33.5

EVAP AIR – CFM

750

EVAP AIR – Ewb (F)

TABLE 13C—SUPERHEAT CHARGING TABLE, UNIT 030

TEMP (F)

AIR ENT

COND

70 — — — 10.5 17.5 24.5 24.8 25.1 25.4 25.1 24.8

75 — — — 8.4 15.5 22.5 22.8 23.1 23.4 23.8 24.2

80 — — — 6.8 12.9 18.9 20.3 21.5 22.9 23.0 23.0

85 — — — 5.1 10.2 15.4 17.7 20.1 22.3 22.1 21.8

90 — — — — 7.9 11.9 15.2 18.5 21.8 21.5 21.2

95 — — — — 5.6 8.4 12.7 17.0 21.2 20.8 20.6 100 — — — — — — 9.2 14.1 191 19.5 19.9 105 — — — — — — 5.7 11.4 17.1 18.2 19.3 110 — — — — — — 5.0 10.0 15.1 16.9 18.6 115 ———————8.713.0 15.5 18.0

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

5.5 5.5 5.5 12.5 19.6 26.6 26.9 27.2 27.5 26.5 25.4

EVAP AIR – CFM

1000

EVAP AIR – Ewb (F)

TABLE 13D—SUPERHEAT CHARGING TABLE, UNIT 036

TEMP (F)

AIR ENT

COND

70 23.8 23.8 25.5 27.2 29.5 32.3 32.0 30.9 29.7 28.6 27.6

75 19.0 19.1 20.6 22.2 25.7 30.4 30.6 29.7 28.7 27.5 26.3

80 15.0 15.0 15.8 16.5 21.1 26.5 27.7 27.8 27.8 26.6 25.3

85 10.9 10.9 10.9 10.9 16.6 22.6 24.8 25.9 26.9 25.6 24.3

90 7.7 7.7 7.0 8.3 12.6 19.1 21.5 23.4 25.3 24.4 23.6

95 ————8.614.5 16.5 20.9 23.6 23.3 22.9 100 —————11.3 14.3 17.4 20.4 21.1 21.8 105 —————7.110.5 13.9 17.2 19.0 20.8 110 ——————7.111.7 16.4 18.2 19.9 115 ———————9.615.5 17.3 19.1

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

28.6 28.6 30.4 32.1 33.3 34.3 33.4 32.0 30.7 29.8 28.9

c. On all units remove blower assembly from unit. Remove

screws securing blower and slide assembly out. Be careful not to tear insulation in blower compartment.

EVAP AIR – CFM

1150

EVAP AIR – Ewb (F)

d. Allow time for oil to be absorbed by each bearing, then

wipe excess oil from motor housing.

e. Replace dust caps or plugs in oil ports.

d. Ensure proper reassembly by marking blower wheel and

motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft,

remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing.

2. Lubricate motor as follows: a. Thoroughly clean all accumulations of dirt or grease

from motor housing.

b. Remove dust caps or plugs from oil ports located at each

end of motor.

c. Use a good grade of SAE 20 non-detergent motor oil and

put one teaspoon (1.16 oz. or 16 to 25 drops) in each oil port.

3. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel orientation.

b. Remove screws holding cut-off plate, and remove plate

from housing.

c. Lift wheel from housing. When handling and/or cleaning

blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.

d. Remove caked-on dirt from wheel and housing with a

brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.

e. Reassemble wheel and cut-off plate into housing.

—26—

TABLE 13E—SUPERHEAT CHARGING TABLE, UNIT 042

TEMP (F)

AIR ENT

COND

65 70 11.4 11.4 11.5 15.1 18.7 22.3 23.6 25.1 26.4 26.1 25.8 75 9.4 9.4 9.4 13.0 16.5 20.1 21.6 23.0 24.4 24.5 24.6 80 8.9 8.9 8.9 12.4 16.0 19.4 21.0 22.4 23.8 24.0 24.0 85 8.2 8.2 8.2 11.8 15.3 18.7 20.2 21.8 23.3 23.4 23.4 90 7.7 7.7 7.7 10.8 13.7 16.7 18.7 20.7 22.7 22.7 22.9

95 7.2 7.2 7.2 9.7 12.2 14.6 17.2 19.7 22.2 22.3 22.3 100 6.6 6.6 6.6 9.6 12.6 15.5 17.6 19.7 21.6 21.7 21.7 105 6.1 6.1 6.1 9.6 13.1 16.5 18.0 19.5 21.1 21.1 21.2 110 — — — 7.0 9.9 13.0 15.0 17.1 19.1 19.8 20.6 115 ————6.99.411.9 14.5 17.0 18.5 20.0

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

13.5 13.5 13.5 17.1 20.7 24.3 25.7 27.1 28.5 27.8 27.0

EVAP AIR – CFM

1400

EVAP AIR – Ewb (F)

TABLE 13F—SUPERHEAT CHARGING TABLE, UNIT 048–301

TEMP (F)

AIR ENT

COND

70 24.0 23.8 23.6 25.0 26.4 27.8 28.4 29.0 29.7 29.6 29.5

75 19.7 19.7 19.7 21.4 23.2 25.0 25.9 26.8 27.6 27.9 28.2

80 15.8 15.8 15.8 17.6 19.4 21.2 22.7 24.1 25.6 26.2 26.9

85 12.0 12.0 12.0 13.8 15.6 17.5 19.5 21.5 23.5 24.5 25.6

90 7.5 7.5 7.5 9.4 11.3 13.2 16.3 19.3 22.4 23.3 24.2

95 — — — 5.0 7.0 9.0 13.1 17.1 21.2 22.0 22.8 100 ——————9.414.3 19.1 20.3 21.4 105 ——————5.711.4 17.1 18.6 20.1 110 ———————9.013.5 15.8 18.0 115 ———————6.710.0 13.0 16.0

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

26.3 27.0 27.6 28.6 29.6 30.5 30.9 31.3 31.7 31.2 30.7

EVAP AIR – CFM

1600

EVAP AIR – Ewb (F)

TABLE 13G—SUPERHEAT CHARGING TABLE, UNIT 048–311

TEMP (F)

AIR ENT

COND

70 35.3 35.8 36.8 37.6 37.7 37.8 38.4 38.2 38.4 38.0 37.6

75 31.7 31.4 32.6 34.0 34.5 35.1 35.3 35.5 35.6 35.8 35.5

80 28.1 28.0 28.8 29.8 30.9 31.6 32.8 32.9 32.7 33.0 33.4

85 24.7 24.0 24.6 26.1 27.5 28.3 29.9 30.3 30.5 30.2 30.7

90 21.2 20.8 19.3 21.0 23.4 25.0 26.6 27.4 27.9 28.1 28.0

95 16.5 16.1 16.3 16.5 18.8 21.2 22.7 23.9 25.4 25.7 25.9 100 12.4 7.5 5.6 11.5 14.9 16.8 19.1 21.4 22.0 23.3 23.5 105 ————9.712.7 15.2 18.3 19.5 20.2 21.1 110 —————7.711.2 13.7 16.7 17.8 18.5 115 ———————7.3. 10.2 11.8 14.3

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

39.4 39.4 40.4 40.6 40.6 40.8 41.0 40.8 40.7 40.2 39.9

f. Reassemble motor into housing. Be sure setscrews are

tightened on motor shaft flats and not on round part of shaft.

g. Reinstall unit access panel.

4. Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles.

D. OUTDOOR COIL, INDOOR COIL, AND CONDENSATE DRAIN PAN

Inspect the outdoor coil, indoor coil, and condensate drain pan at least once each year. See Unit Top Removal section. The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the

EVAP AIR – CFM

1550

EVAP AIR – Ewb (F)

grease, clean the coils with a mild detergent-and-water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best results, spray outdoor coil fins from inside to outside the unit. On units with an outer and inner (2 row) outdoor coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain tube with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain tube is restricted, clear it with a “plumbers snake” or similar probe device. Ensure that the auxiliary drain port above the drain tube is also clear

airflow through the outdoor coil. Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or

—27—

TABLE 13H—SUPERHEAT CHARGING TABLE, UNIT 060

TEMP (F)

AIR ENT

COND

65 70 16.5 16.5 16.5 18.8 21.1 23.5 25.2 27.0 28.8 28.2 27.6 75 12.0 12.0 12.0 14.8 17.6 20.4 22.7 24.9 27.2 26.9 26.6 80 10.5 10.5 10.5 12.7 14.9 17.1 19.8 22.5 25.2 25.4 25.5 85 9.0 9.0 9.0 10.6 12.3 13.9 17.0 20.0 23.1 23.8 24.5 90 4.5 4.5 4.5 6.5 8.5 10.5 14.3 18.1 21.9 22.7 23.5

95 ————4.87.211.7 16.2 20.7 21.6 22.5 100 —————3.68.613.6 18.6 20.0 21.4 105 ——————5.511.1 16.6 18.5 20.4 110 ———————10.0 15.5 17.5 19.4 115 ———————9.214.7 16.5 18.5

Ewb-Entering Wet Bulb SPH-Superheat at Compressor (F) – -Do not attempt to charge system under these conditions as refrigerant slugging may occur.

SPH

56 58 60 62 64 66 68 70 72 74 76

21.0 21.0 21.0 22.8 24.7 26.5 27.8 29.1 30.4 29.5 28.6

EVAP AIR – CFM

1800

EVAP AIR – Ewb (F)

Required Suction Tube Temperature

SUPERHEAT

TEMP (F)

0 35 37 39 41 43 45 47 49 51 2 37 39 41 43 45 47 49 51 53 4 39 41 43 45 47 49 51 53 55 6 41 43 45 47 49 51 53 55 57

8 43 45 47 49 51 53 55 57 59 10 45 47 49 51 53 55 57 59 61 12 47 49 51 53 55 57 59 61 63 14 49 51 53 55 57 59 61 63 65 16 51 53 55 57 59 61 63 65 67 18 53 55 57 59 61 63 65 67 69 20 55 57 59 61 63 65 67 69 71 22 57 59 61 63 65 67 69 71 73 24 59 61 63 65 67 69 71 73 75 26 61 63 65 67 69 71 73 75 77 28 63 65 67 69 71 73 75 77 79 30 65 67 69 71 73 75 77 79 81 32 67 69 71 73 75 77 79 81 83 34 69 71 73 75 77 79 81 83 85 36 71 73 75 77 79 81 83 85 87 38 73 75 77 79 81 83 85 87 89 40 75 77 79 81 83 85 87 89 91

NOTE: Measure suction tube temperature with accurate superheat ther-

mometer or thermistor-type thermometer

61.5 64.2 67.1 70 73 76 79.2 82.4 85.7

SUCTION PRESSURE AT SERVICE PORT (Psig)

Fig. 30—Required Suction Tube Temperature (F) *

C95030

E. OUTDOOR FAN

CAUTION: Keep the outdoor fan free from all obstruc-

tions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Remove 2 screws at bottom of outdoor air intake grille and remove plastic grille.

2. Inspect the fan blades for cracks or bends.

3. If fan needs to be removed, loosen the setscrew and slide the fan off the motor shaft.

4. When replacing fan blade, position blade so that the leading edge is 2-in. back from outdoor inlet grille or 1/2-in. maximum fro fan deck (See Fig. 25).

5. Ensure that setscrew engages the flat area on the motor shaft when tightening

6. Replace grille.

F. ELECTRICAL CONTROLS AND WIRING

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit and install lockout tag.

Remove the control/blower and compressor compartment access panels to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely. After inspecting the electrical controls and wiring, replace the access panel. Start the unit, and observe at least one complete heating cycle and one complete cooling cycle to ensure proper operation. If discrepancies are observed in either or both operating cycles, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts. NOTE: Refer to the heating and/or cooling sequence of operation in this publication as an aid in determining proper control operation

—28—

OUTDOOR COIL

INDOOR COIL

ACCUMULATOR

COMPRESSOR

Check Valves

Closed

Open

Closed

Open

LCS Loss of Charge Switch

1. Hot gas from compressor flows through the 4-way valve and is directed to the heating liquid line check valve. It is then condensedandsubcooledthroughconverging circuits. Refrigerant leaves the outdoor coil by way of the strainer and the check valve in the cooling liquid line.

2. The refrigerant then feeds the indoor coil through the Acutrol metering device on each circuit.

LEGEND

Acutrol Metering Device Check Valve (Arrow indicates direction of flow)

Fig. 31—Typical Heat Pump Operation-Cooling Mode

G. REFRIGERANT CIRCUIT

Inspect all refrigerant tubing connections and the unit base for oil accumulations annually. Detecting oil generally indicates a refrigerant leak.

WARNING: System under pressure. 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.

COOLING CYCLE

3. Each circuit evaporates the refrigerant and the circuits are com-

4. The refrigerant then flows through the 4-way valve, accumulator,

LCS

STRAINER

bined in the indoor coil header with some of the circuits flowing through the check valve.

and back to the compressor.

C95044

I. METERING DEVICE — ACUTROL DEVICE

This unit uses metering devices that are of the fixed orifice type (located in the header to the indoor and outdoor coils).

J. LIQUID LINE STRAINER

The liquid line strainer (to protect metering device) is made of wire mesh and located in the liquid line on the inlet side of the metering device.

TROUBLESHOOTING

If oil is detected or if low cooling performance is suspected, leak-test all refrigerant tubing using an electronic leak-detector, halide torch, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low cooling performance is suspected, refer to Checking and Adjusting Refrigerant Charge section.

H. INDOOR AIRFLOW

The heating and/or cooling air-flow does not require checking unless improper performance is suspected. If a problem exists, be

sure that all supply- and return-air grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer

to Indoor Airflow and Airflow Adjustments section to check the system airflow.

UsetheTroubleshooting–Cooling&Heatingguide(seeTable14) if problems occur with these units.

START-UP CHECKLIST

Use the Start-Up checklist to ensure proper start-up procedures are followed.

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OUTDOOR COIL

INDOOR COIL

ACCUMULATOR

COMPRESSOR

Check Valves

Open

Closed

Open

Closed

LCS Loss of Charge Switch

LEGEND

Acutrol Metering Device Check Valve (Arrow indicates direction of flow)

HEATING CYCLE

1. Hot gas from compressor flows through the 4-way valve and is directed to the cooling liquid line check valve. It is then condensed and directed through subcooling circuits and out to the strainer and the check valve in the heating liquid line.

2. The refrigerant then feeds the outdoor coil through the Acutrol metering device on each circuit.

Fig. 32—Typical Heat Pump Operation-Heating Mode

LCS

STRAINER

3. Each circuit evaporates the refrigerant and the circuits are combinedintheoutdoorheaderwithsomeofthecircuits flowing through the check valve.

4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor.

C95045

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SYMPTOM CAUSE REMEDY

Compressor and outdoor fan will not start

Compressor will not start but condenser fan runs

Compressor cycles (other than normally satisfying thermostat)

Compressor operates continuously

Excessive head pressure

TABLE 14—TROUBLESHOOTING CHART

Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat, contactor, transformer, control relay, defrost board, or high pressure or lossof-charge/low pressure switch Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostat setting too high Faulty wiring or loose connections in compressor

circuit Compressor motor burned out, seized, or internal overload open Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor Low input voltage (20 percent low) Determine cause and correct

Refrigerant overcharge or undercharge Defective compressor Replace and determine cause

Insufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run/start capacitor, overload or start relay Defective thermostat Replace thermostat Faulty outdoor-fan motor or capacitor Replace Damaged reversing valve Determine cause and correct Restriction in refrigerant system Locate restriction and remove Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak, repair, and recharge

Frosted coil with incorrect defrost operation

Air in system Outdoor coil dirty or restricted Clean coil or remove restriction

Dirty air filter Replace filter Dirty indoor or outdoor coil Clean coil Refrigerant overcharged Recover excess refrigerant

Air in system (Heat) Indoor air restricted or recirculating Determine cause and correct

Indoor or outdoor air restricted or air short-cycling Determine cause and correct

Replace component

Lower thermostat setting below room temperature

Check wiring and repair or replace Determine cause.

Replace compressor Determine cause and replace

Recover refrigerant, evacuate system, and recharge to capacities shown on nameplate

Determine cause and replace

Check defrost time settings Reset as necessary Check defrost temperature switch Replace as necessary Recover refrigerant, evacuate system, and recharge

Recover refrigerant, evacuate system, and recharge

SYMPTOM CAUSE REMEDY

Head pressure too low

Excessive suction pressure

Suction pressure too low

Compressor runs but

outdoor fan does not IFM does not run

IFM operation is intermittent

IFM (048–060) runs when

it should be off

IFM–Indoor Fan Motor

TABLE 14—TROUBLESHOOTING CHART (CONT’D)

Low refrigerant charge Check for leaks, repair and recharge Restriction in liquid tube Remove restriction

(Heat) Outdoor coil frosted (Cool) High Heat load Check for source and eliminate

Reversing valve hung up or leaking internally Replace valve Refrigerant overcharged Recover excess refrigerant (Cool) Dirty air filter Replace filter

(Heat) Outdoor coil frosted Low refrigerant charge Check for leaks, repair and recharge

Metering device or low side restricted Remove source of restriction (Cool) Insufficient coil airflow (Cool) Temperature too low in conditioned area Reset thermostat

(Cool) Outdoor ambient below 40°F Install low-ambient kit Filter-drier restricted Replace NC (normally closed) contacts on defrost board open Blower wheel not secured to shaft Properly tighten blower wheel to shaft Insufficient voltage at motor Determine cause and correct Power connectors not properly sealed Connectors should snap easily; do not force Water dripping into motor Verify proper drip loops in connector wires

Connectors not firmly sealed Motor programmed with a delay profile Allow a few minutes for motor to shut off

With thermostat in “off” mode, the voltage on G, Y1, Y2, W with respect to common, should be 1/2 of actual low voltage supply

Move timer on control board to 30 minutes between defrost cycles

Increase air quantity Check filter–replace if necessary

Check condition of relay on board Replace if necessary

Gently pull wires individually to be sure they are crimped into the housing

If measured voltage is more that 1/2, the thermostat

is incompatible with motor. If voltage is less than

1/2, the motor has failed

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I. PRELIMINARY INFORMATION

Model No .............................................................................................................................................................

Serial No ..............................................................................................................................................................

Date .....................................................................................................................................................................

Technician ...........................................................................................................................................................

Job/ Location...............................................................................................................................................

II. PRE-START-UP

____ Verify that all packing materials have been removed from unit ____ Verify that condensate connection is installed per installation instructions ____ Check all electrical connections and terminals for tightness ____ Check that indoor (evaporator) air filter is clean and in place ____ Verify that unit installation is level ____ Check fan wheel propeller for location in housing and setscrew tightness

III. START-UP

SupplyVoltage:C-S__________S-R__________R-C__________ Compressor Amps: C __________ S __________ R __________ Indoor (Evaporator) Fan Amps: __________

TEMPERATURE

Outdoor (Condenser) Air Temperature: __________ DB Return-Air Temperature: __________ DB __________ WB Cooling Supply Air: __________ DB __________ WB

PRESSURES

Refrigerant Suction __________ psig Suction Line Temp*__________ Refrigerant Discharge __________ psig Discharge Temp† __________ ____ Verify Refrigerant charge using charging tables

START-UP CHECKLIST

(REMOVE AND STORE IN JOB FILE)

* Measured at suction inlet to compressor † Measured at liquid line leaving outdoor coil

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Printed in U.S.A. ii657a245 Catalog No. 5365-702

Bryant 657A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual