Bryant Preferred 163A, Preferred 165A Installation Instructions Manual
163A / 165A
PREFERREDt SERIES AIR CONDITIONERS
WITH PURONRREFRIGERANT
1--1/2 TO 5 NOMINAL TONS (SIZE 018 TO 060)
Installation Instructions
TM
the environmentally sound refrigerant
Fig. 1 --- 163A / 165A
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 2......................
INSTALLATION RECOMMENDATIONS 2............
INSTALLATION 3--9.14............................
Step 1 -- Check Equipment & Jobsite 3................
Step 2 -- Install on Solid Pad 3......................
Step 3 -- Clearance Requirements 3...................
Step 4 -- Operating Ambient 3.......................
Step 5 -- Install TXV 3 -- 4.........................
Step 6 -- Make Piping Connections 5 -- 7..............
Step 7 -- Make Electrical Connections 7 -- 8............
Step 8 -- Compressor Crankcase Heater 8..............
Step 9 -- Install Electrical Accessories 8..............
Step 10-- Check OCT and OAT thermistor Attachment 8..
Step 11 -- Start--Up 9..............................
Step 12 -- Check Charge 9, 14.......................
GENERAL SEQUENCE OF OPERATION 10...........
CONTROL FUNCTIONS AND SEQUENCE OF
OPERATION 10 -- 11................................
TROUBLESHOOTING 11 -- 12........................
FINAL CHECKS 13.................................
CARE AND MAINTENANCE 13......................
SUBCOOLING TABLE 14............................
24 VOLT CONNECTION DIAGRAMS 15 -- 16...........
PURONR REFRIGERANT QUICK REF. GUIDE 17.....
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes
and National Electrical Code (NEC) for special requirements.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
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
163A / 165A
personal injury or death. WARNING sign ifies hazards wh ich
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.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect switch.
Lock out and tag switch with a suitable warning label.
!
WARNING
WARNING
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
1. Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.
2. Ensure that vapor and liquid tube diameters are
appropriate for unit capacity.
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
4. Leave some slack between structure and unit to absorb
vibration.
5. When passing refrigerant tubes through the wall, seal
opening with RTV or other pliable silicon--based caulk.
(See Fig. 2.)
!
!
6. Avoid direct tubing contact with water pipes, duct work,
floor joists, wall studs, floors, and walls.
7. Do not suspend refrigerant tubing from joists and studs
with a rigid wire or strap which comes in direct contact
with tubing.(See Fig. 2.)
8. Ensure that tubing insulation is pliable and completely
surrounds vapor tube.
9. When necessary, use hanger straps which are 1 in. wide
and conform to shape of tubing insulation. (See Fig. 2.)
10. Isolate hanger straps from insulation by using metal
sleeves bent to conform to shape of insulation.
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
LIQUID TUBE
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
PuronR refrigerant systems operate at higher pressures than
standard R-- 22 systems. Do not use R--22 service
equipment or components on Puron refrigerant equipment.
1” MIN.
SUSPENSION
Fig. 2 --- Connecting Tube Installation
Outdoor unit contains system refrigerant charge for operation
with ARI rated indoor unit when connected by 15 ft. of
field--su pplied or factory accessory tubing. For p ro p er unit
operation, check refrigerant charge using charging information
located on control box cover and/or in the Check Charge section
of this instruction.
IMPORTANT: Maximum liquid--line size is 3/8--in. OD for all
residential applications including long line.
IMPORTANT: Always install the factory--supplied liquid--line
filter drier. Obtain replacement filter driers from your distributor
or branch.
2
LIQUID TUBE
A94026
INSTALLATION
Specifications for this unit in residential new construction market
require the outdoor unit, indoor unit, refrigerant tubing sets,
metering device, and filter drier listed in presale literature. There
can be no deviation. Consult the Application Guideline and
Service Manual – Air Conditioners and Heat Pumps Using
Puronr Refrigerant to obtain required unit changes for specific
applications and for R--22 retrofit.
STEP 1 —Check Equipment and Job Site
UNPACK
UNIT
Move to final location. Remove carton taking care not to damage
unit.
INSPECT
EQUIPMENT
File claim with shipping company prior to installation if shipment
is damaged or incomplete. Locate unit rating plate on unit corner
panel. It contains information needed to properly install unit.
Check rating plate to be sure unit matches job specifications.
STEP 2 —Install on a Solid, Level Mounting Pad
If conditions or local codes require the unit be attached to pad, tie
down bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig.
3 to determine base pan size and knockout hole location.
For hurricane tie downs -- contact your local distributor for
details and PE (Professional Certification), if required by local
authorities.
On rooftop applications, mount on level platform or frame. Place
unit above a load-- bearing wall and isolate unit and tubing set
from structure. Arrange supporting members to adequately
support unit and minimize transmission of vibration to building.
Consult local codes governing rooftop applications.
Roof mounted units exposed to winds may require wind baffles.
Consult the Application Guideline and Service Manual -Residential Split System Air Conditioners and Heat Pumps Using
Puronr Refrigerant for wind baffle construction.
NOTE: Unit must be level to within ±2_ (±3/8 in./ft.) per
compressor manufacturer specifications.
STEP 3 —Clearance Requirements
When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 30 --in. clearance to
service end of unit and 48 in. above unit. For proper airflow, a
6--in. clearance on 1 side of unit and 12 in. on all remaining sides
must be maintained. Maintain a distance of 24 in. between units.
Position so water, snow, or ice from roof or eaves cannot fall
directly on unit.
3/8 - -- IN. DIA. TIED OWN
KNOCKOUTS IN BASEPAN
(2) PLACES
VIEW FROM TOP
UNIT BASE PAN
DIMENSIONS
29--1/2 X 33 10–1/16 5–5/8 23–3/4
36–1/2 X 40 9–5/8 6–13/16 28–3/4
TIEDOWN KNOCKOUT LOCATIONS
A B C
A05177
Fig. 3 --- Tiedown Knockout Locations
On rooftop applications, locate unit at least 6 in. above roof
surface.
STEP 4 —Operating Ambient
The minimum outdoor operating ambient in cooling mode is
55_F, and the maximum outdoor operating ambient in cooling
mode is 125_F.
STEP 5 —Install TXV
NOTE: Applies to rated non--TXV and R--22 TXV indoor units
only. If installing a rated and approved indoor coil without a
factory installed PuronR TXV, remove and replace the fixed
orifice or R--22 TXV expansion device with a hard shutoff Puron
TXV.
The thermostatic expansion valve is specifically designed to
operate with Puron refrigerant. Do not use an R-- 22 TXV. An
existing R--22 TXV must be replaced with a factory-- approved
TXV specifically designed for Puron refrigerant. Refer to
Product Data Sheet for the appropriate TXV kit number.
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Al indoor coil units must be installed with a hard shut
off PuronR TXV metering device.
163A / 165A
IMPORTANT: The TXV should be mounted as close to the
indoor coil as possible and in a vertical, upright position. Avoid
mounting the inlet tube vertically down. Valve is more
susceptible to malfunction due to debris if inlet tube is facing
down. A factory--approved filter drier must be installed in the
liquid line.
3
INSTALLINGTXVINPLACEOFPISTONINARA
INDOOR COIL
1. Pump system down to 2 psig and recover refrigerant.
2. Remove hex nut from piston body. Use backup wrench on
fan coils.
3. Remove and discard factory-- installed piston. Be sure
Teflon seal is in place.
4. Reinstall hex nut. Finger tighten nut plus 1/2 turn.
NOTE: If the piston is not removed from the body, TXV will
not function properly.
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Use a brazing shield and wrap TXV with wet cloth or
use heat sink material
163A / 165A
5. Install TXV on indoor coil liquid line. Sweat swivel
adapter to inlet of indoor coil and attach to TXV outlet.
Use backup wrench to avoid damage to tubing or valve.
Sweat inlet of TXV, marked “IN” to liquid line. Avoid
excessive heat which could damage valve.
6. Install vapor elbow with equalizer adapter to suction tube
of line set and suction connection to indoor coil. Adapter
has a 1/4--in. male connector for attaching equalizer tube.
7. Connect equalizer tube of TXV to 1/4-- in. equalizer fitting
on vapor line adapter.
8. Attach TXV bulb to horizontal section of suction line
using clamps provided. Insulate bulb with field-- supplied
insulation tape. See Fig. 4 for correct positioning of
sensing bulb.
9. Proceed with remainder of unit installation.
10 O’CLOCK
(PRE-- 2006)
!
2O’CLOCK
CAUTION
SENSING BULB
TED
REPLACING TXV ON A RATED R--22 INDOOR
(PRE-- 2006)
1. Pump system down to 2 psig and recover refrigerant.
2. Remove coil access panel and fitting panel from front of
cabinet.
3. Remove TXV support clamp using a 5/16--in. nut driver.
Save the clamp.
4. Remove R--22 TXV using a backup wrench on flare
connections to prevent damage to tubing.
5. Using wire cutters, cut equalizer tube off flush with vapor
tube inside cabinet.
6. Remove bulb from vapor tube inside cabinet.
7. Braze equalizer stub--tube closed. Use protective barrier as
necessary to prevent damage to drain pan.
IMPORTANT: Route the equalizer tube of Puron TXV through
suction line connection opening in fitting panel prior to replacing
fitting panel around tubing.
8. Install TXV with 3/8--in. copper tubing through small hole
in service panel. Use wrench and backup wrench, to avoid
damage to tubing or valve, to attach TXV to distributor.
9. Reinstall TXV support clamp (removed in item 3).
10. Attach TXV bulb to vapor tube inside cabinet, in same
location as original was when removed, using supplied
bulb clamps (nylon or copper). See Fig. 4 for correct
positioning of sensing bulb.
11. Route equalizer tube through suction connection opening
(large hole) in fitting panel and install fitting panel in
place.
12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid
excessive heat which could damage valve.
13. Install vapor elbow with equalizer adapter to vapor line of
line set and vapor connection to indoor coil. Adapter has
a 1/4--in. male connector for attaching equalizer tube.
14. Connect equalizer tube of TXV to 1/4-- in. equalizer fitting
on vapor line adapter. Use backup wrench to prevent
damage to equalizer fitting.
15. Proceed with remainder of unit installation.
COIL
SUCTION TUBE
7/8
IN. OD & SMALLER
Fig. 4 --- Position of Sensing Bulb
STRAP
8O’CLOCK 4O’CLOCK
LARGER THAN 7/8 IN. OD
A81032
4
STEP 6 —Make Piping Connections
!
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could result in personal
injury or death.
Relieve pressure and recover all refrigerant before
system repair or final unit disposal.
Use all service ports and open all flow--control
devices, including solenoid valves.
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not leave system open to atmosphere any longer than
minimum required for installation. POE oil in compressor is
extremely susceptible to moisture absorption. Always keep
ends of tubing sealed during installation.
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
If ANY refrigerant tubing is buried, provide a 6 in. vertical
rise at service valve. Refrigerant tubing lengths up to 36 in.
may be buried without further special consideration. Do
not bury lines longer than 36 in.
WARNING
CAUTION
CAUTION
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To prevent damage to unit or service valves observe the
following:
S Use a brazing shield.
S Wrap service valves with wet cloth or use a heat sink
material.
Outdoor units may be connected to indoor section using
accessory tubing pack age o r field-- supplied refrigerant grade
tubing of correct size and condition. Rated tubing diameters
shown in Table 1 recommended up to 80 ft. See Product Data
for acceptable alternates vapor diameters and associated capacity
losses. For tubing requirements beyond 80 ft., substantial
capacity and p erforman ce losses can occur. Follo win g the
recommend ation s in the Longline Guidelin e -- R esiden tial
Split--System Air Conditioners and Heat Pumps Using Puronr
Refrigerant will reduce these losses. Refer to Table 1 for field
tubing diameters. Refer to Table 2 for accessory requirements.
There are no buried--line applications greater than 36 in.
If refrigerant tubes or indoor coil are exposed to atmosphere, they
must be evacuated to 500 microns to eliminate contamination and
moisture in the system.
OUTDOOR UNIT CONNECTED TO FACTOR
APPROVED INDOOR UNIT
Outdoor unit contains correct system refrigerant charge for
operation with factory approved ARI rated indoor unit when
connected by 15 ft. of field--supplied or factory--accessory tubing,
and factory su p p lied filter d rier. Ch eck refrigerant charge for
maximum efficiency.
CAUTION
Y--
:
163A / 165A
Table 1—Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
LIQUID
UNIT SIZE
Connection
Diameter
018, 024
030, 036
042, 048
060
Notes:
1. Tube diameters are for total equivalent lengths up to 80 ft..
2. Do not apply capillary tube or fixed orifice indoor coils to these units.
* For Tubing Set lengths between 80 and 200 ft. horizontal or 20 ft. vertical differential (250 ft. Total Equivalent Length), refer to the Longline Guide l i n e --- A i r
Conditioners and Heat Pumps using Puron refrigerant.
3/8 3/8 5/8 5/8
3/8 3/8 3/4 3/4
3/8 3/8 7/8 7/8
3/8 3/8 7/8 1-- 1/8
Tube
Diameter
Connection
Diameter
VA P O R
(up to 80 ft. *)
Rated Tube
Diameter
5
Table 2—Accessory Usage
REQUIRED FOR LOW---AMBIENT
Accessory
Crankcase Heater Yes Yes
Evaporator Freeze Thermostat
Winter Start Control
Thermal Expansion Valve (TXV)
Hard Shutoff
Compressor Start Assist Capacitor and Relay Yes
Low---ambient Pressure Switch
Support Feet Recommended
Liquid Line Solenoid Valve No See Long--- Line Application Guideline
* For Tubing Set lengths between 80 and 200 ft. horizontal or 20 ft. vertical differential (250 ft. Total Equivalent Length), refer to the Longline
Guideline --- Air Conditioners and Heat Pumps using Puron refrigerant.
INSTALL LIQUID--LINE FILTER DRIER INDOOR
163A / 165A
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
Installation of filter drier in liquid line is required.
CAUTION
APPLICATIONS
(0°FTo55°F)
Yes
(For non---Evolution systems only)
Yes
(For non---Evolution systems only)
Yes
Yes
(For non --- Evolution system only)
REFRIGERANT TUBING CONNECTION
Conn ect vap o r tub e to fitting o n o u tdoor unit vapor service
valves (see Table 1.) Connect and braze the 3/8 ” cou p lin g
(provided with the filter drier) to the liquid service valve and
connect and b raze the liqu i d tu b ing to the other end of this
coupling. Use refrigerant grade tubing.
SWEAT
CONNECTION
!
REQUIRED FOR LONG LINE
APPLICATIONS* (Over 80 ft.)
No
No
Yes
Yes
No
No
CAUTION
OUTDOOR
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Filter drier must be wrapped in a heat---sinking material
such as a wet cloth while brazing.
Refer to Fig. 5 and install filter drier as follows:
1. Braze 5--in. liquid tube to the indoor coil.
2. Wrap filter drier with damp cloth.
3. Braze filter drier to above 5” liquid tube. Flow arrow
must point towards indoor coil.
4. Connect and braze liquid refrigerant tube to the filter drier.
Fig. 5 --- Liquid Line Filter Drier
A05178
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Service valves must be wrapped in a heat-- sinking
material such as a wet cloth.
Service valves are closed from factory and ready for brazing.
After wrapping service valve with a wet cloth, braze sweat
connections using industry accepted m ethods and materials.
Consult local code requirements. Refrigerant tubing and indoor
coil are now ready for leak testing. This check should include all
field and factory joints.
EVACUATE REFRIGERANT TUBING AND
COIL
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Never use the system compressor as a vacuum pump.
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. An alternate
triple ev acuatio n method may b e u sed if t he deep vacu um
procedure is not followed.
IMPORTANT: Always break a vacuum with dry nitrogen.
CAUTION
INDOOR
6
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