Bryant 664B User Manual

664B 13 SEER SINGLE--PACKAGED HEAT PUMP SYSTEM WITH R--22 REFRIGERANT SINGLE AND THREE PHASE 2--5 NOMINAL TONS (SIZES 024--060)

Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 2.........................

INTRODUCTION 2...................................

RECEIVING AND INSTALLATION 2-- 7..................

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

Identify Unit 2....................................

Inspect Shipment 2.................................

Provide Unit Support 2...............................

Slab Mount 2.....................................

Ground Mount 2..................................

Provide Clearances 2.................................

Place Unit 2........................................

Select and Install Ductwork 2...........................

Configuring Units for Downflow (Vertical) Discharge 3....

Connect Condensate Drain 3...........................

Install Electrical Connections 6.........................

High--Voltage Connections 6.........................

Routing Power Leads Into Unit 6......................

Connecting Ground Lead to Unit Ground 6..............

Routing Control Power Wires 6......................

Accessory Electric Heat Wiring 6......................

PRE--START--UP 7....................................

START--UP 8--17......................................

Check for Refrigerant Leaks 8..........................

Start--Up Cooling and Make Adjustments 8................

Checking Cooling and Heating Control Operation 8.......

Refrigerant Charge 8.................................

No Charge 8......................................

Low Charge Cooling 8..............................

Heating Mode Charge 8.............................

Indoor Airflow and Airflow Adjustments 9................

Unit Controls 9.....................................

High--Pressure Relief Valve 9.........................

L o s s -- o f -- C h a r g e S w i t c h 9...........................

Compressor Overload 10............................

Compressor Rotation 10...............................

Sequence of Operation 10.............................

Fan Operation 10..................................

Cooling Operation 10, 17............................

Heating Operation 17...............................

Continuous Fan 17.................................

Defrost 17.......................................

Electric Resistance Heating 17........................

MAINTENANCE 17-- 2 0................................

Air Filter 18........................................

Unit Top Removal 18.................................

Indoor Blower and Motor 18...........................

Outdoor Coil, Indoor Coil, and Condensate Drain Pan 19.....

Outdoor Fan 19.....................................

Electrical Controls and Wiring 19.......................

Refrigerant Circuit 20.................................

Indoor Airflow 20...................................

Metering Devices 20.................................

Liquid Line Strainers 20...............................

High Flow Valves 20.................................

TROUBLESHOOTING 20..............................

START--UP CHECKLIST 20............................

A05194

Fig. 1 -- Unit 664B

SAFETY CONSIDERATIONS

Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. Installation must be in compliance with local and national building codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.

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 these signal words: DANGER, WARNING, and CAUTION. These words are used with the safety --alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury

664B

or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may 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

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing system, always turn off main power to system and tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate clothing.

CAUTION

INTRODUCTION

The 664B packaged heat pump is fully self--contained and designed for outdoor installation (See Fig. 1). Standard units are shipped in a horizontal--discharge configuration for installation on a ground--level slab or directly on the ground if local codes permit. Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications with a field supplied plenum.

RECEIVING AND INSTALLATION

Step 1 — Check Equipment

IDENTIFY UNIT

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

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. 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 equipment distribution office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

Step 2 — Provide Unit Support

For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate, if required.

SLAB MOUNT Place the unit on a solid, level concrete pad that is a minimum of 4

in. (102 mm) thick with 2 in. (51 mm) above grade. The slab should extend approximately 2 in. (51 mm) beyond the casing on all 4 sides of the unit. Do not secure the unit to the slab except when required by local codes.

A 6--in. (152 mm) wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs. The unit should be level within 1/4 in. (6 mm). This is necessary for the

unit drain to function properly.

GROUND MOUNT The unit may be installed either on a slab or placed directly on the

ground if local codes permit. Place the unit on level ground prepared with gravel for condensate discharge.

Step 3 — Provide Clearances

The required minimum service clearances are shown in Fig. 5. Adequate ventilation and outdoor air must be provided.

The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille. 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. (1219 mm) above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in. (1219 mm).

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 should be at least 4 in. (102 mm) above the highest expected water and runoff levels. Do not use unit if it has been under water.

Step 4 — Place Unit

Unit can be moved with the rigging holds provided in the unit base. Refer to Table 1 for operating weights. Use extreme caution to prevent damage when moving the unit. Unit must remain in an upright position during all moving operations. The unit must be level with in 1/4 in. (6 mm) for proper condensate drainage; the ground--level pad 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.

Step 5 — Select and Install Ductwork

The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non--residence type air conditioning and ventilating systems, NFPA 90A or residence type, NFPA 90B 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 Conditioning Engineers) recommendations.

Use the duct flanges provided on the supply-- and return--air openings on the side of the unit. See Fig. 5 for connection sizes and locations. The 14 --in. (356 mm) round duct collars are shipped inside the unit attached to the base pan in the indoor blower compartment. They are field--installed and must be removed from the indoor blower compartment prior to start--up, even if they are not used for installation.

When designing and installing ductwork, consider the following:

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit components.

When connecting ductwork to units, do not drill deeper than 3/4 in. (19 mm) in shaded area shown in Fig. 2 or coil may be damaged.

CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DISCHARGE

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before performing service or maintenance operations on the system, turn off main power to unit and install lockout tag.

19.17 in. (487 mm)

3.92 in.

(100 mm)

A08003

Fig. 2 -- Area Not to be Drilled More Than 3/4 --in. (19 mm)

Deep

1. All units should have field--supplied filters or accessory 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 weather tight 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) must extend 24--in. (610 mm) 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.

4. Seal, insulate, and weatherproof all external ductwork. Seal, 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.

Fig. 6 shows a typical duct system with 664B unit installed.

Units are dedicated side supply products. They are not convertible to vertical air supply. A field--supplied plenum must be used to convert to vertical air discharge.

Step 6 — Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Unit removes condensate through a 1--3/64 in. (27 mm) ID hole (using 3/4--in. (19 mm) OD piping or tubing) which is located at the end of the unit. See Fig. 5 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 ground level 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. (25 mm) lower than the drain pan condensate connection to prevent the pan from overflowing (See Fig. 3 and 4). When using a gravel apron, make sure it slopes away from the unit.

If the installation requires draining the condensate water away from the unit, install a 2--in. (51 mm) trap using a 3/4--in. (19 mm) OD tubing or pipe. (See Fig. 3 and 4.) Make sure that the outlet of the trap is at least 1 in. (25 mm) 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. (19 mm) PVC, 3/4 --in. (19 mm) 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. (25 mm) for every 10 ft (3 m) of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season start--up. Allowable glues for condensate trap connection are: Standard ABS, CPVC, or PVC cement..

1” (25 mm) MIN

1" (25 mm) MIN

TRAP OUTLET

Fig. 3 -- Condensate Trap

TRAP OUTLET

Fig. 4 -- PVC Condensate Trap

2” (51 mm) MIN.

2" (51 mm) MIN

A08001

664B

Fig. 5 -- Unit Base Dimensions, 664B024 --060

A08414

RETURN AIR

INDOOR THERMOSTAT

TOP COVER

Power Wirin g

Control Wiring

Condenser Airflow

Evaporator Airflow

POWER AND LOW-VOLTAGE ENTRY

COMPOSITE RUST-PROOF BASEPAN

CONDENSATE DRAIN CONNECTION

FROM POWER SOURCE

DISCONNECT PER NEC (UNIT AND ELECTRIC HEATER)

A08207

Fig. 6 -- Typical Installation

Table 1 – Physical Data

UNIT SIZE 024 030 036 042 048 060

NOMINAL CAPACITY (ton) 2 2--1/2 3 3--1/2 4 5

OPERATING WEIGHT (lb)

(kg)

COMPRESSOR Scroll Ultra Tech Scroll

REFRIGERANT (R-- 22)

Quantity (lb)

(kg)

REFRIGERANT METERING DEVICE AccuRater

Orifice ID (in.) 0.067 0.067 0.082 0.086 – –

Orifice OD (in.) 0.049 0.057 0.059 0.063 0.070 0.073

CONDENSER COIL Copper Tubes, Aluminum Plate Fins

Rows…Fins/in. 2…21 2…21 2…21 2…21 2…21 2…21

Face Area (sq. ft.) 11. 1 12.7 15.8 15.8 13.3 15.8

CONDENSER FAN Propeller

Nominal Cfm 2600 2600 3200 3200 3200 3300

Diameter (in.)

(mm)

Motor HP (RPM) 1/8 (825) 1/8 (825) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/2 (1100)

EVAPORATOR COIL Copper Tubes, Aluminum Plate Fins

Rows…Fins/in. 3…17 3…17 4…17 4…17 4…17 4…17

Face Area (sq. ft.) 4.3 4.9 4.9 6.1 4.9 6.1

Evaporator blower Direct Drive

Nominal Airflow (Cfm) 800 1000 1200 1400 1600 1875

Size (in.)

(mm)

Motor HP (RPM) 1/2 (1050) 1/2 (1050) 3/4 (1050) 3/4 (1050) 1 (1050) 1 (1050)

CONNECTING DUCT SIZES Round

Supply Air (in.)

(mm)

Return Air (in.)

(mm)

Return--Air Filters* Throwaway (in.)

(mm)

*Required filter sizes shown are based on the ARI (Air conditioning & Refrigeration Institute) rated airflow at a velocity of 300 ft/min (91 m) for throwaway type or 450 ft/min (137 m) for high capacity type. Recommended filter s are 1 - --in. (25 mm) thick.

293 133

7.5

3.4

508

10x8

254 x 203

324 147

10.3

4.7

508

24 x 24

610 x 610

377 171

10.3

4.7

508

11x 9

279 x 229

389 176

11. 9

5.4

508

384 174

11. 4

5.2

508

433 196

13.3

6.0

TXV

508

11x 10

279 x 254

356

24 x 30

610 x 762

30 x 30

762 x 762

664B

Table 2 – Minimum Airflow for Safe Electric Heater Operation

Unit Size

024 500 650 750 -- -- 030 600 800 1050 -- -- 036 600 800 1050 1150 1200 042 600 800 1050 1150 1200 048 600 800 1050 1150 1200 060 600 800 1050 1150 1200

5kW 7.5kW 10kW 15kW 20kW

Minimum Airflow (CFM)

Step 7 — Install Electrical Connections

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may

664B

consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA 70 American National Standards Institute/ National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

CAUTION

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 unit; conduit termination at the unit must be watertight. Run the high--voltage leads through the hole on the control box side of the unit (See Fig. 7). When the leads are inside the unit, run leads to the control box (See Fig. 8). For single--phase units, connect leads to the black and yellow wires (See Fig. 9).

CONNECTING GROUND LEAD TO UNIT GROUND Connect the ground lead to the chassis using the unit ground in the

control box (See Fig. 8 and 9).

ROUTING CONTROL POWER WIRES (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 into unit control box (See Fig. 7). Connect thermostat leads and unit power leads as shown in Fig. 9, 10 and

11. Route thermostat wires through grommet providing a drip--loop at

the panel. Connect low--voltage leads to the thermostat as shown in Fig. 10 & 11.

The unit transformer supplies 24--v power for complete system including accessory electrical heater. Transformer is factory wired for 230-- v operation.

ACCESSORY ELECTRIC HEAT WIRING Refer to accessory electric heat installation instructions for

information on installing accessory electric heat. Accessory electric heat wiring is shown in Fig. 17 and 18.

HIGH-VOLTAGEPOWER

WIRINGENTRYHOLE

LOW-VOLTAGEWIRING

ENTRYHOLE (grommethole)

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit being installed.

1. Make all electrical connections in accordance with NEC ANSI/NFPA 70 (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. On 3--phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

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

HIGH--VOLTAGE CONNECTIONS The unit must have a separate electrical service with a

field--supplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing.

The field--supplied disconnect 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. 6 and 7 for acceptable location.

Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.

A08407

Fig. 7 -- Unit Electrical Connection

3-PHASE

Thermostat

Unit Control

RED

GRN

YEL

ORN

BRN

WHT

VIO

Thermostat

Unit Control

RED

GRN

YEL

PNK

ORN

WHT

VIO

BRN

CONNECTIONS TO DISCONNECT PER NEC

and subbase

Fig. 8 -- Control Box Wiring

UNIT GROUND

LEAD

SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC

GROUND

Fig. 9 -- Line Power Connections

HEATER LOW VOLTAGE PLUG

A05388

BLK

YEL

BLU

C00012

and subbase

Power

Fig. 11 -- Control Connections (Sizes 048--060)

PRE--START--UP

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death and/or property damage.

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

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

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

4. Do not use torch to remove any component. System contains oil and refrigerant under pressure.

5. To remove a component, wear protective goggles and proceed as follows:

a. Shut off electrical power to unit and install

lockout tag.

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 flame.

A05208

664B

Power

Fig. 10 -- Control Connections (Sizes 024-- 042)

A05207

Proceed as follows to inspect and prepare the unit for initial start-- up:

1. Remove all access panels.

2. Read and follow instructions on all DANGER, 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.

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, or liquid-- soap solution. If a refrigerant leak is detected, see Check for Refrigerant Leaks section.

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