Bryant 598B Air Conditioner User Manual
Contents
1. A01050 Fig 1 Model 598B 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 When outdoor unit is connected to factory approved indoor unit outdoor unit contains system refrigerant charge for operation with indoor unit of the same size when connected by 15 ft of field supplied or factory accessory tubing For proper unit opera tion check refrigerant charge using charging information located on control box2. 208 230 1 60 2 POWERSUPPLY EQUIP GND NOTE 11 PHEII2131415 HPAC C SV RVS C FORCED DEFROST pgosr TME MIN 1 58 NE _ COMM STA Y11Q wt xt ae YEL men EN WM QI VIE uu pet MERE ce ida ni BLK 1 OL BRN CO 111 220 ROI BEN RED OCH TO INDOOR UNIT A01513 Fig 15 Wiring Diagram 024 036 048 15 DUAL CAPACITY CONNECTION DIAGRAM 208 230 1 60 POWER SUPPLY EQUIP GND 1 21314 SE RVS C HI LPS P FORCED DEFROST HPS DEFFOST TME MIN OAT PL5 TO INDOOR UNIT A02212 Fig 16 Wiring Diagram 060 2003 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 16 Printed in U S A iib98b244 Catalog No 5359 810
3. lt Thermistor x Connection DEFROST Defrost Time HE UU Selectors PEEL To Run ello Capacitor Thermostat 9 Low Voltage geass 80 O D F Connection Connector ES 5 Heater Oe eO Connection A D HK38EA001 Reserved for Future Use 01192 Fig 12 Control Board Control Box Side of Unit THERMISTOR PLACED UNDERNEATH BASE PAN ATTACHED TO BASE PAN WITH ADHESIVE A02218 Fig 14 View from Top of Base Pan XIII FINAL CHECKS IMPORTANT Before leaving job be sure to do the following 14 1 Ensure that all wiring and tubing is secure in unit before adding panels and covers Securely fasten all panels and covers 2 Tighten service valve stem caps to 1 12 turn past finger tight 3 Leave Owner s Manual with owner Explain system opera tion and periodic maintenance requirements outlined in manual 4 Fill out Dealer Installation Checklist and place in customer file CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending upon geographic areas such as coastal applications DUAL CAPACITY n CONNECTION DIAGRAM S BLK
4. 1 the temperature increases the resistance decreases Thermistors FIELD CONNECTIONS are used to sense outdoor ambient and coil temperature Refer to The two speed control received 24vac low voltage control system Fig 13 for resistance values versus temperature inputs through the screw connections on the left side of the control board TWO SPEED COMPRESSOR If the outdoor ambient or coil thermistor should fail a fault code appears at two speed control IMPORTANT Outdoor Air Thermistor Placement Mount out The two speed compressor contains motor windings that provide door air thermistor underneath unit base pan lip on control box side 2 pole 3500 RPM operation of the unit Attach to base pan with adhesive tape COMPRESSOR INTERNAL RELIEF IMPORTANT If outdoor air thermistor is not properly placed The compressor is protected by an internal pressure relief IPR underneath base pan unit may see nuisance thermistor out of range which relieves discharge gas into compressor shell when differen faults tial between suction and discharge pressures exceeds 525 psi The compressor is also protected by an internal overload attached to motor windings Connection T Low High Speed Contactor Reversing Valve Connection ms c t sev Low Pressure Switch Connector High Pressure Switch Connector
5. 8 51 SENSOR CONNECTION 52 24 VAC HOT 24 VAC COM See notes 1 2 3 4 and 10 A01502 NON PROGRAMMABLE N A THERMOS TAT MODEL 2S OUTDOOR SENSOR 2 COOL STAGE 1 See notes 1 2 3 5 and 10 A01505 HEAT STAGE 1 WI NON PROGRAMMABLE VARIABLE SPEED THERMOSTAT CONDENSING TWO SPEED MODEL 2S FURNACE AIR CONDITIONER COOL STAGE 2 HEAT STAGE 2 HEATSTAGE2 Ow2 COOL STAGE 1 Y 4 24 VAC HOT HEAT STAGE 1 W W1I COOL STAGE 2 24 VAC COMM FAN N A 5 OUTDOOR SENSOR CONNECTION 24 VAC COMM See notes 1 2 3 5 and 10 A01503 NA gum CONNECTION See notes 1 2 3 and 4 Fig 11 Typical 24V Wiring Diagram Cont Dg PROGRAMMABLE THERMOSTAT MODEL 2S 24 VAC HOT FAN COOL STAGE 1 COOL STAGE 2 HEAT STAGE 1 HEATSTAGE2 2 24 VAC COMM N A OUTDOOR SENSOR CONNECTION FV4A TWO SPEED OR 40FK AIR CONDITIONER FAN COIL 9 REMOVE J2 JUMPER FOR HEAT STAGING See notes 1 2 3 5 and 7 THERMIDISTAT CONTROL MODEL RH HEAT STAGE 2 HEAT STAGE 1 COOL STAGE 1 COOL STAGE 2 FAN 24 VAC HOT DEHUMIDIFY DHUM 24 VAC COMM HUMIDIFY N A OUTDOOR SENSOR A01493 VARIABLE SPEED RROGRAMMADEE CONDENSING TWO SPEED MODEL 25 FURNACE AIR CONDITIONER HEAT STAGE 1 CO
6. TWO SPEED AIR CONDITIONER 24 VAC HOT 8 24 HEAT STAGE 1 COOL STAGE 2 FAN N A OUTDOOR SENSOR CONNECTION Fig 11 Typical 24V Wiring Diagram cp See notes 1 2 3 and 5 A01500 PROGRAMMABLE VARIABLE SPEED THERMOSTAT SINGLE STAGE TWO SPEED 80 NON CONDENSING FURNACE MODEL 2S FURNACE AIR CONDITIONER s NON PROGRAMMABLE BOARD COOL STAGE 1 Y1 W2 THERMOSTAT me Y MODEL 25 FURNACE TWO SPEED COOL STAGE 1 L3 BOARD AIR CONDITIONER HEAT STAGE 1 Fm 3 HEATSTAGE2 Ow2 t COOL STAGE 2 Y Y2 HEAT STAGE 1 W W1 H W N A O W2 24 VAC HOT R FAN avacuor H 4R8LE 24 VAC COM 24 VAC COMM N A OUTDOOR DEHUM SENSOR 9 101 CONNECTION N A See notes 1 2 3 and 5 A01501 OUTDOOR TWO STAGE SENSOR 4 NON PROGRAMMABLE FURNACE WITH CONNECTIONS qs THERMOSTAT PSC BLOWER TWO SPEED MODEL 25 MOTOR AIR CONDITIONER See note 1 2 3 4 and 10 24 VAC HOT RE 2 A01504 VARIABLE SPEED 24 VAC COMM c 80 NON CONDENSING FURNACE 9 AFS HEAT STAGE 1 W W1 PROGRAMMABLE BOARD MODEL 2S COOL STAGE 2 Y Y2 FURNACE TWO SPEED COOL STAGE 1 BOARD AIR CONDITIONER FAN G HEAT STAGE 2 OW2 4 HEAT STAGE 1 sTAGE 2 Y Y2 FAN HEAT STAGE 2 o w2 COOL STAGE 1
7. OUTDOOR UNIT CONNECTED TO FACTORY APPROVED INDOOR UNIT Outdoor unit contains correct system refrigerant charge for opera tion with indoor unit of same size when connected by 15 ft of field supplied or factory accessory tubing Check refrigerant charge for maximum efficiency A CAUTION Installation of filter drier in liquid line is required B INSTALL LIQUID LINE FILTER DRIER Installation of filter drier in liquid line is required Refer to Fig 7 and install filter drier as follows 1 Braze 5 in connector tube to liquid service valve Wrap filter drier with damp cloth 2 Braze filter drier between connector tube and liquid tube to indoor coil Flow arrow must point toward indoor coil C REFRIGERANT TUBING Connect vapor tube to fitting on outdoor unit vapor service valves Connect liquid tube to filter drier See Fig 7 and Table 1 Use refrigerant grade tubing SENSING BULB SUCTION TUBE X 4 O CLOCK Fig 6 Positioning of Sensing Bulb 8 O CLOCK 02000 CAUTION avoid valve damage while brazing vice valves must be wrapped in heat sink material such as a wet cloth D SWEAT CONNECTION Service valves are closed from factory and ready for brazing After wrapping service valve and filter drier with a wet cloth braze sweat connections using industry accepted methods and materials Do not use soft solder materials which melt below 800 F Consult local code requirements Re
8. CUUM Y CHARGE SYSTEM Fig 9 Triple Evacuation Method A95425 C CONNECT CONTROL WIRING Route 24v control wires through control wiring grommet and connect to leads provided in control box See Fig 11 Use No 18 AWG color coded insulated 35 C minimum wire If thermostat is located more than 100 ft from unit as measured along the control voltage wires use No 16 AWG color coded wire to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads The outdoor unit requires a minimum of 27va 24vac control power IMPORTANT Check factory wiring and wire connections to ensure terminations are secured properly Check wire routing to ensure wires are not in contact with tubing sheet metal etc TABLE 2 ACCESSORY USAGE ACCESSORY Coastal Filter REQUIRED FOR LONG LINE APPLICATIONS 50 175 FT REQUIRED FOR SEACOAST APPLICATIONS WITHIN 2 MILES Yes Support Feet Recommended Puron Balance Port Hard Shutoff TXV Yest For tubing line sets between 50 and 175 ft horizontal or 20 ft vertical differential refer to Service Manual for Air Conditioners and Heat Pumps Using Puron Refrigerant Crankcase heater and start assist are standard on two speed units T All two speed units require hard shut off TXV DISCONNECT E C AND OR LOCAL CODES CONTACTOR FIELD POWER A WIRING GROUND LUG A91306 Fi
9. DOWN KNOCKOUT LOCATIONS MINIMUM MOUNTING UNIT SIZE DIMENSIONS 024 036 060 19 X 24 26 X 32 Fig 3 Mounting Unit to Pad V INSTALL TXV Puron fan coils and furnace coils come factory equipped with a bi flow hard shut off TXV specifically designed for Puron two speed units No TXV changeout is required An existing R 22 TXV must be replaced with a factory approved TXV specifi cally designed for Puron two speed units NOTE FK4 and FC4 fan coils are equipped with an R 22 TXV If an FK4 or an FC4 fan coil is used with a Puron air conditioner the R 22 TXV must be replaced with a factory approved Puron TXV CAUTION If indoor unit is equipped with piston A remove indoor coil piston and replace with factory approved TXV metering device A TXV INSTALLATION 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 See Fig 4 SENSING BULB EQUALIZER TUBE THERMOSTATIC EXPANSION VALVE Fig 4 TXV Installed AMAN ROM UA BULB INSULATION TAPE XS ONY AKAN XXX XS Q A01418 Fig 5 TXV Kit Contents INSTALLING TXV IN PLACE OF PISTON 1
10. E 2 Y FAN R N A Phun HUMIDIFY HUM N A ouroon 8 SENSOR 4 CONNECTION 2 FK4C FV4A OR 40FK FAN COIL J1 JUMPER REMOVE FOR HEAT STAGING SINGLE STAGE FURNACE HUMIDIFIER 24 VAC J2 JUMPER See notes 1 2 3 6 8 10 and 12 A01495 TWO SPEED AIR CONDITIONER See notes 1 2 3 4 and 7 A01496 TWO SPEED AIR CONDITIONER R OUTDOOR 7 SENSOR notes 1 2 3 6 and 8 A01497 THERMIDISTAT CONTROL MODEL RH COOL STAGE 1 OUTDOOR THERMIDISTAT CONTROL MODEL RH COOL STAGE 1 HEAT STAGE 2 HEAT STAGE 2 O W2 HEAT STAGE 1 COOL STAGE 2 FAN REL 24 VAC COMM C D N A HUMIDIFY HUM _ N A B SENSOR m CONNECTION S2 H HEAT STAGE 1 TWO STAGE FURNACE WITH PSC TWO SPEED BLOWER MOTOR AIR CONDITIONER See notes 1 2 3 6 8 and 10 01498 VARIABLE SPEED 80 NON CONDENSING FURNACE opp BOARD 11 FURNACE l TWO SPEED BOARD AIR CONDITIONER I poete 24 24 DEHUMIDIFY N A OUTDOOR HUMIDIFY SENSOR CONNECTIONS S cooLsmE2 FAN G I HUMIDIFIER L Li 24 VAC OUTDOOR an _ SENSOR See notes 1 2 3 6 8 10 and 11 01499
11. I CHECK CHARGE WARNING Service valve gage ports are not equipped with Schrader valves To prevent personal injury make A sure gage manifold is connected to the valve gage ports before moving valves off fully back seated position Wear safety glasses and gloves when handling refrigerant A COOLING ONLY PROCEDURE 1 Operate unit a minimum of 15 minutes before checking charge 2 Measure liquid service valve pressure by attaching an accurate gage to service port 3 Measure liquid line temperature by attaching an accurate thermistor type or electronic thermometer to liquid line near outdoor coil 4 Refer to Table 4 for required subcooling temperature 5 Refer to Table 3 Find the point where required subcooling temperature intersects measured liquid service valve pres sure 6 To obtain required subcooling temperature at a specific liquid line pressure add refrigerant if liquid line tempera ture is higher than indicated or reclaim refrigerant if temperature is lower Allow a tolerance of 3 F TABLE 3 REQUIRED LIQUID LINE TEMPERATURE F REQUIRED SUBCOOLING TEMPERATURE CF LIQUID PRESSURE AT SERVICE VALVE PSIG 189 195 B UNIT CHARGE Factory charge and charging method are shown on pink charging label Puron refrigerant cylinders contain a dip tube which allows liquid refrigerant to fl
12. N OPTION LOCK FURNACE INTO LOW FIRE OPERATION AND LET O W2 CONTROL HIGH FIRE OPERATION REFER TO FURNACE INSTALLATION INSTRUCTIONS FOR PROPER SETUP TO ACTIVATE DEHUMIDIFY FEATURE ON CURRENT STYLE VARIABLE SPEED 80 PERCENT NON CONDENSING FURNACE DISCONNECT GREEN DEHUM WIRE FROM G ON FURNACE CONTROL BOARD AND CONNECT TO DEHUMIDIFY TERMINAL DHUM ON THERMIDISTAT THE DE JUMPERS MUST BE REMOVED TO ENABLE THE DEHUMIDIFICATION FEATURE ON FURNACE 10 X START UP CAUTION To prevent compressor damage or personal injury observe the following A Do not overcharge system with refrigerant Do not operate unit in a vacuum or at negative pressure Do not disable low pressure switch CAUTION To prevent personal injury wear safety glasses protective clothing and gloves when handling A refrigerant and observe the following Back seating service valves are not equipped with Schrader valves Fully back seat counter clockwise valve stem before removing gage port cap A CAUTION Do not vent refrigerant to atmosphere Re cover during system repair or final unit disposal Follow these steps to properly start up the system 1 The outdoor unit is equipped with a crankcase heater which operates when the compressor is off Energize crankcase heater 24 hr before starting unit To energize heater only set indoor thermostat to OFF position and close power disconnect to unit NOTE Starting the compressor w
13. OL STAGE 2 FAN 24 VAC HOT N A OUTDOOR SENSOR CONNECTION See notes 1 2 3 and 5 A01507 Fig 11 Typical 24V Wiring Diagram Cont 9 FK4C FV4A TWO SPEED OR 40FK AIR CONDITIONER FAN COIL REMOVE J2 JUMPER FOR HEAT STAGING wai REMOVE J1 JUMPER See notes 1 2 3 6 7 8 and 9 A01494 LEGEND 24 V FACTORY WIRING 24 V FIELD WIRING FIELD SPLICE CONNECTION RELAY SPDT PILOT DUTY 24 V COIL HN61KK324 OR EQUIVALENT HUMIDISTAT OPENS ON HUMIDITY RISE HL38MG026 AIRFLOW SELECTOR A97466 WIRING DIAGRAM NOTES 11 12 WIRING MUST CONFORM TO NEC OR LOCAL CODES UNDERLINED LETTER ON THERMOSTAT TERMINAL INDICATES USAGE FOR EXAMPLE O W2 MEANS O IS ENERGIZED IN COOLING MODE REFER TO INDOOR UNIT INSTALLATION INSTRUCTIONS FOR ANY ADDITIONAL FEATURES AND WIRING INFORMA TION NON PROGRAMMABLE MODEL 2S01 B WHEN USED IN AIR CONDITIONING INSTALLATION THE R19 JUMPER MUST BE CUT AND REMOVED PROGRAMMABLE MODEL 2801 B MUST HAVE DIP SWITCH C ON WHEN USED IN AIR CONDITIONER APPLICATIONS THERMIDISTAT DIP SWITCH NO 1 SHOULD BE SET IN OFF POSITION FOR AIR CONDITIONER APPLICATIONS FACTORY DEFAULT AS AN OPTION O W2CAN CONTROL SECOND STAGE HEAT THERMIDISTAT DIP SWITCH NO 2 SHOULD BE SET IN THE ON POSITION FOR DUAL CAPACITY COMPRESSOR OPERATION TO ACTIVATE DEHUMIDIFY FUNCTION ON 4 OR FV4 REMOVE 11 JUMPER AT FAN CONTROL BOARD 10 AS A
14. R OPERATION When the compressor operates in high capacity operation the motor rotates clockwise Both the lower and upper pistons are eccentric with the rotating crankshaft and both compress refriger ant When the compressor operates in low capacity the motor reverses direction rotates counterclockwise The lower piston becomes idle and the upper piston compresses refrigerant The start and run windings are reversed TABLE 5 CONTROL FUNCTION LED CODE SIGNAL DEFINITION IMPORTANCE No demand Stand by Constant flash No pause 1 flash w pause 2 flashes w pause 3 flashes w pause 4 flashes w pause 3 flashes pause 4 flashes 5 flashes pause 1 flash 5 flashes pause 2 flashes 6 flashes w pause Constant light No pause No flash Function light signal order of importance in case of multiple signal request 1 is most important Low speed operation High speed operation Outdoor thermistor failure Outdoor coil thermistor failure Thermistor out of range Low pressure switch trip High pressure switch trip Compressor V JV trip Board failure TABLE 6 DUAL CAPACITY COMPRESSOR WINDING RESISTANCE AT 70 20 WINDING 024 036 048 06 Start S C 2 280 1 850 1 457 0 740 0 770 0 745 0 552 0 356 F CRANKCASE HEATER OPERATION The two speed control energizes crankcase heater during unit off cycle G OUTDOOR FAN MOTOR OPERATION The outd
15. Remove any existing refrigerant and ensure coil has not been exposed to atmospheric pressure for more than 15 minutes 2 Remove indoor coil inlet tube at piston body inlet Use back up wrench to prevent damage 3 Remove piston retainer begin careful not to damage scaling surface of O ring 4 Remove and discard factory installed piston Replace re tainer if O ring is damaged UA Reinstall piston retainer in piston body ON Replace indoor coil inlet tube Use back up wrench to prevent damage A CAUTION To prevent damage to the unit use a brazing shield and wrap TXV with wet cloth 7 Sweat swivel adapter see Fig 5D to inlet of indoor coil and attach to TXV see Fig 5A 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 8 Install vapor elbow see Fig 5B with equalizer adapter to suction tube of line set and suction connection to indoor coil Adapter has a 1 4 male connector or attaching equalizer tube 9 Connect equalizer tube of TXV to 1 4 in equalizer fitting on vapor line adapter 10 Attach TXV bulb to horizontal section of suction line using bulb straps provided See Fig 5C Insulate bulb with factory supplied insulation tape See Fig 5E See Fig 6 for correct positioning of sensing bulb 11 Proceed with remainder of unit installation REPLACING R 22 TXV OR NON BALANCE POR
16. T PURON TXV Remove any existing refrigerant and ensure coil has not been exposed to atmospheric pressure for more than 15 minutes Hiro 2 Remove coil access panel and fitting panel from front of cabinet Remove TXV support clamp using the 5 16 in nut driver Save the clamp 4 Remove 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 approved 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 See Fig 5A To avoid damage to tubing or valve use wrench and backup wrench 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 strap See Fig 5C See Fig 6 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 I
17. cover IMPORTANT Maximum liquid line size is 3 8 in O D for all residential applications IMPORTANT Always install the factory supplied air conditioner liquid line filter drier Obtain replacement filter driers from your local distributor or branch NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL nt TEN 7 F LIQUID TUBE Y 3 r js VAPOR TUBE INSULATION THROUGH THE WALL PGE OST INSULATION 4 VAPOR TUBE HANGER STRAP AROUND VAPOR TUBE ONLY 0 o o o 1 MIN LIQUID TUBE Fig 2 Connecting Tubing Installation SUSPENSION A01383 INSTALLATION I CHECK EQUIPMENT AND JOB SITE A UNPACK UNIT Move to final location Remove carton taking care not to damage unit B INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment is damaged or incomplete Locate unit rating plate on unit corner panel It contains information needed to properly install unit Check rating plate to be sure unit matches job specifications INSTALL ON A SOLID LEVEL MOUNTING PAD If conditions or local codes require the unit be attached to pad tie down bolts should be used and fastened through knockouts provided in unit base pan Refer to unit mounting pattern in Fig 3 to determine base pan size and knockout hole location On rooftop applications mount on level
18. ctuate above or below permissible limits NOTE Use copper wire only between disconnect switch and unit NOTE Install branch circuit disconnect of adequate size per NEC to handle unit starting current Locate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC A ROUTE GROUND AND POWER WIRES Remove access panel to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box Size wires per NEC but not smaller than minimum wire size shown in Product Data Sheet WARNING The unit cabinet must have as uninter rupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes Failure to follow this warning can result in an electric shock fire or death B CONNECT GROUND AND POWER WIRES Connect ground wire to ground connection in control box for safety Connect power wiring to leads provided as shown in Fig 10 5000 4500 4000 LEAK IN 3500 Z 3000 e 62500 2000 VACUUM TIGHT es TOO WET p TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES A95424 Fig 8 Deep Vacuum Graph EVACUATE v BREAK VACUUM WITH DRY NITROGEN Y WAIT Y Y BREAK VACUUM WITH DRY NITROGEN Y Y Y CHECK FOR TIGHT DRY SYSTEM IF IT HOLDS DEEP VA
19. d two stage cooling are satisfied the compressor will shut off NOTE If unit has not operated within the past 12 hours or following a unit power up upon the next thermostat high or low speed demand unit operates for a minimum of 5 minutes in high speed NOTE When two speed unit is operating at low speed system vapor suction pressure will be higher than a standard single speed system or high speed operation This normal operation is due to the reduced capacity operating with typically larger indoor and outdoor coils NOTE Outdoor fan motor will continue to operate for one minute after compressor shuts off when outdoor ambient is greater than or equal to 100 F B STATUS FUNCTION LIGHTS A system control STATUS function light is located on the outdoor unit control board see Fig 12 The STATUS light provides signals for several system operations See Table 5 for codes and definitions Table 5 also provides the order of signal importance NOTE Only one code will be displayed on the outdoor unit control board the most recent with the highest priority C FACTORY DEFAULTS Factory defaults have been provided in the event of failure of outdoor air thermistor coil thermistor and or furnace interface jumper D ONE MINUTE SPEED CHANGE TIME DELAY When compressor changes speeds from high to low or low to high there is a 1 minute time delay before compressor restarts The outdoor fan motor remains running E COMPRESSO
20. erious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation WARNING Before installing modifying or servicing system main electrical disconnect switch must be in the A OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Electrical shock can cause personal injury or death CAUTION Puron R 410A systems operate at higher pressures than standard R 22 systems Be certain that AN service equipment is rated for Puron Some R 22 service equipment may not be acceptable Check with your distributor INSTALLATION RECOMMENDATIONS NOTE In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment 1 Locate unit away from windows patios decks etc where unit operation sound may disturb customer 2 Ensure that vapor and liquid tube diameters are appropriate to capacity of unit NC Cancels 598B 24 3 II 598B 24 4 5 03
21. frigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints IMPORTANT Check factory tubing on both indoor and outdoor unit to ensure tubes are not rubbing against each other or any sheet metal Pay close attention to feeder tubes making sure wire ties on feeder tubes are secure and tight E LEAK CHECKING Leak test all joints in indoor outdoor and refrigerant tubing F EVACUATE REFRIGERANT TUBING AND INDOOR COIL A CAUTION Never use the system compressor as a vacuum pump Refrigerant tubes and indoor coil should be evacuated using the recommended deep vacuum method of 500 microns The alternate triple evacuation method may be used if the procedure outlined below is followed Always break a vacuum with dry nitrogen DEEP VACUUM METHOD The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and liquid water See Fig 8 TRIPLE EVACUATION METHOD The triple evacuation method should only be used when vacuum pump is capable of pumping down to 28 in of mercury and system does not contain any liquid water Refer to Fig 9 and proceed as follows 1 Pump system down to 28 in of mercury and allow pump to continue operating for an additional 15 minutes 2 Close service valves and shut
22. g 10 Line Power Connections VIII INSTALL ELECTRICAL ACCESSORIES A GENERAL Refer to the individual instructions packaged with kits or acces sories when installing Available electrical accessories include latent capacity control See Fig 11 for typical accessory wiring diagrams B LATENT CAPACITY CONTROL LCC The purpose of an LCC is to provide a dehumidification mode to assure a 75 percent or less system sensible heat ratio If indoor unit installed contains an blower such as an 4 or FV4A fan coil or a 315 or 355MAV gas furnace no is required Indoor products with ECM blowers have enough CFM range to provide proper airflow for low speed cooling If indoor unit installed has a standard PSC blower motor the low speed airflow available is too great to assure 75 percent or less system sensible heat ratio The LCC for standard blower products consists of a standard humidistat which opens contacts on humidity rise and a pilot duty relay with 24v coil NOTE If an LCC is desired low speed airflow must be main tained so that a minimum of 300 CFM ton can be supplied during high speed LCC operation LCC OPERATION FOR TYPICAL PSC FAN COILS The standard blower operation for systems with typical PSC fan coils is covered in Fig 11 The blower runs in high speed regardless if compressor operation is high or low speed When the LCC is wired according to Fig 11 and humidity rises the humidistat contacts
23. h high and low pressure switches If the control senses the opening of a high or low pressure switch it will respond as follows THERMISTOR CURVE De energize the compressor low or high speed contactor 2 Keep the outdoor fan operating for 15 minutes 3 Display the appropriate error code on the status light see Table 5 4 After a 15 minute delay if Yl or Y2 inputs are on and the LPS or HPS is reset energize appropriate compressor contactor either low or high 5 If LPS or HPS has not closed after a 15 minute delay the 0 0 20 40 60 80 100 120 outdoor fan is turned off If the open switch closes anytime TEMPERATURE DEG F after the 15 minute delay then resume operation on call for Y1 and or Y2 ASIASI J MAJOR COMPONENTS Fig 13 Resistance Values Versus Temperature TWO SPEED CONTROL COMPRESSOR CONTROL CONTACTORS The two speed control board controls the following functions Low high capacity contactor coils 24 volts The electronic Low and high compressor contactor operation control board controls the operation of the low speed C L and the Outdoor fan motor operation Crankcase heater operation high speed C H contactors Compressor protection K TEMPERATURE THERMISTORS Pressure switch monitoring RESISTANCE KOHMS 2 Thermistors are electronic devices which sense temperature As Time delays
24. installation and start up instructions TWO SPEED PLUS AIR CONDITIONING UNIT NOTE Read the entire instruction manual before starting the Installation This symbol indicates a change since the last issue SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thor oughly 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 N 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 s
25. ithout a minimum of 12 hours of crankcase heat prior to initial start up may result in compressor chattering noise and possible damage to the compressor 2 Fully back seat open liquid and vapor tube service valves 3 Unit is shipped with valve stem s front seated and caps installed Replace stem caps after system is opened to refrigerant flow back seated Replace caps finger tight and tighten additional 1 12 turn 20 ft Ib torque with wrench 4 Close electrical disconnects to energize system 5 Set room thermostat at desired temperature Be sure set point is below indoor ambient and is set low enough to energize desired speed NOTE Bryant electronic thermostats are equipped with a 15 minute staging timer This timer prevents the two speed system from operating at high speed until unit has been operating in low speed for 15 minutes unless there is at least a 5 F difference between room temperature and thermostat set point To force high speed after a minimum of 2 minutes in low speed adjust the set point at least 5 below room ambient 6 Set room thermostat to COOL and fan control to AUTO or ON as desired Wait for appropriate time delay s and 2 minute minimum low speed run time Operate unit for 15 minutes Check refrigerant charge NOTE If unit has not operated within the past 12 hours or following a unit power up upon the next thermostat high or low speed demand unit operates for a minimum of 5 minutes in high speed X
26. nstall vapor elbow with equalizer adapter to vapor line of line set and vapor connection to indoor coil See Fig 5B Adapter has a 1 4 in male connector for attaching equalizer tube See Fig 5B 14 Connect equalizer tube of TXV by 1 4 in equalizer fitting on vapor line adapter Use backup wrench to prevent damage to equalizer fitting 15 Proceed with the remainder of unit installation B LONG LINE APPLICATIONS For refrigerant piping arrangements with equivalent lengths greater than 50 ft or when elevation difference between indoor and or outdoor unit is more than 20 ft follow all requirements of the Long Line Guideline section in the Application Guideline and Service Manual for Residential Split System Air Conditioners and Heat Pumps Using Puron Refrigerant VI MAKE PIPING CONNECTIONS WARNING Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid personal injury or death Use all service ports and open all flow control devices including solenoid valves CAUTION Do not leave system open to atmosphere any longer than minimum required for installation POE oil in compressor is extremely susceptible to moisture absorption Always keep ends of tubing sealed during installation CAUTION If ANY refrigerant tubing is buried provide 6 in vertical rise at service valve Refrigerant tubing lengths up to 36 in may be buried without further special consideration Buried refrigera
27. nt tubing lengths greater than 36 in are NOT recommended CAUTION To prevent damage to unit or service valves observe the following Use a brazing shield Wrap service valves with wet cloth or use a heat sink material Outdoor units may be connected to indoor section using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition Tubing diameters listed in Table 1 are adequate for equivalent lengths up to 50 ft For tubing requirements beyond 50 ft substantial capacity and performance losses can occur Follow the recommendations in the Application Guideline and Service Manual for Residential Split System Air Conditioners and Heat Pumps Using Puron Refrigerant to minimize losses Refer to Table 1 for field tubing diameters Refer to Table 2 for accessory requirements 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 TABLE 1 REFRIGERANT CONNECTIONS AND RECOMMENDED LIQUID AND VAPOR TUBE DIAMETERS IN LIQUID Connection Tube Connection Tube Connection Tube Diameter Diameter Diameter Diameter Diameter Diameter 3 8 3 8 5 8 5 8 5 8 3 4 3 8 3 8 3 4 3 4 3 4 7 8 3 8 3 8 7 8 7 8 7 8 7 8 3 8 3 8 7 8 1 1 8 7 8 1 1 8 Notes 1 Tube diameters are for lengths up to 50 equivalent ft 2 Do not apply capillary tube indoor coils to these units A
28. off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Close service valve and allow system to stand for 1 hr During this time dry nitrogen will be able to diffuse throughout the system absorbing moisture 5 Repeat this procedure as indicated in Fig 9 System will then contain minimal amounts of contaminants and water vapor LIQUID LINE FILTER DRIER LIQUID SERVICE TUBE A95509 Fig 7 Filter Drier with Sweat Adapter Tube and Liquid Tube G FINAL TUBING CHECK IMPORTANT Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment Ensure tubes are not rubbing against each other or any sheet metal Pay close attention to feeder tubes making sure wire ties on feeder tubes are secure and tight Vil MAKE ELECTRICAL CONNECTIONS WARNING To avoid personal injury or death do not A supply power to unit with compressor terminal box cover removed Be sure field wiring complies with local and national fire safety and electrical codes and voltage to system is within limits shown on unit rating plate Contact local power company for correction of improper voltage See unit rating plate for recommended circuit protection device NOTE Operation of unit on improper line voltage constitutes abuse and could affect unit reliability See unit rating plate Do not install unit in system where voltage may flu
29. oor unit control energizes outdoor fan any time compres sor is operating The outdoor fan remains energized during the 1 minute speed change time delay and if a pressure switch or compressor overload should trip Outdoor fan motor will continue to operate for one minute after the compressor shuts off when the outdoor ambient is greater than or equal to 100 F H COMPRESSOR VOLTAGE FAILURE 6 FLASHES The control senses the voltage of the compressor run winding If compressor voltage Vc is less than 90v when control board is calling for compressor operation control shuts compressor off for 15 minutes with outdoor fan running After 15 minutes provided there is a call for Y1 or Y2 control attempts to start compressor During this time a code of 6 flashes appears at control board If Vc trip occurs 3 consecutive times during a 1 request then low capacity operation is locked out and control responds to Y2 requests until a reset occurs If 3 consecutive trips occur in a combination of and Y2 or all Y2 requests then both low and high capacity operation will be locked out The compressor voltage failure 6 flashes can be caused by compressor internal overload trip refer to Table 6 for correct winding resistance no 240 volt power supply to outdoor unit failed compressor contactor s failure of start relay to pick up properly improper wiring I PRESSURE SWITCH PROTECTION The outdoor unit is equipped wit
30. open and de energize the relay If relay is EE de energized the system operates on high speed compressor and high speed airflow until humidistat closes Fig 11 shows the wiring with a Bryant Thermidistat which controls temperature and humidity level without the need for an additional humidistat and relay LCC OPERATION FOR TYPICAL PSC FURNACES The standard blower operation of systems with typical PSC furnaces is covered in Fig 11 The blower runs in high or low speed in conjunction with compressor high or low speed opera tion When the LCC is wired according to Fig 11 humidity rises the humidistat contacts open and de energize the relay If relay is de energized the system operates on high speed compressor and low speed airflow until humidistat closes Fig 11 shows the wiring with a Bryant Thermidistat which controls temperature and hu midity level without the need for an additional humidistat and relay IX MAKE AIRFLOW SELECTIONS A AIRFLOW SELECTION FOR 315AAV 355MAV FUR NACES The 315AAV 355MAV Non Condensing Variable Speed Fur naces provide high and low speed blower operation to match the capacities of the compressor at high and low speeds To select the recommended airflow and for adjustments to the manual switches labeled SW1 A C and CF on the control board refer to the furnace Installation Start Up and Operating Instructions The 315AAV utilizes a control center that allows the installing technician to select
31. ow from cylinder in upright position Charge Puron units with cylinder in upright position and a commercial type metering device in manifold hose Charge refrigerant into suction line NOTE Unit is to be charged in high capacity only Charging in low capacity may cause compressor chattering and possible damage to the compressor TABLE 4 SUBCOOLING TEMPERATURES UNIT 024 036 048 060 TXV TYPE EXPANSION DEVICE HIGH CAPACITY ONLY SUBCOOLING AT SERVICE VALVE NOTE If subcooling charging conditions are not favorable charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively EXAMPLE To calculate additional charge required for a 25 ft line set 25 ft 15 ft 10 ft x 0 6 oz ft 6 oz of additional charge XII SYSTEM FUNCTIONS AND SEQUENCE OF OPERA TION The outdoor unit control system has special functions The following is an overview of the two speed control functions A COOLING OPERATION This product utilizes a 2 stage cooling indoor thermostat With a call for first stage cooling Yl the outdoor fan and low capacity compressor are energized If low capacity cannot satisfy cooling demand high capacity is energized Yl and Y2 or Y2 only by the second stage of indoor thermostat After second stage is satisfied the unit returns to low speed operation until first stage is satisfied or until second stage is required again When both one stage an
32. 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 CAUTION Do not allow POE lubricant to come into AN contact with roofing material POE may deteriorate cer tain types of synthetic roofing Roof mounted units exposed to winds above 5 mph may require wind baffles Consult the Application Guideline and Service Manual for Residential Split System Air Conditioners and Heat Pumps using Refrigerant for wind baffle construction NOTE Unit must be level to within 2 53 8 in ft per compressor manufacturer specifications 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 IV OPERATING AMBIENTS The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F 38 IN DIA TIEDOWN KNOCKOUTS 2 PLACES IN BASEPAN 97375 DIMENSIONS IN TIE
33. the proper airflows The A C switch determines the airflow during high speed compressor operation Airflow for hight and low speed can be calculated at either 350 CFM per ton or 400 CFM per ton based on the positions of SW1 5 B AIRFLOW SELECTION FOR FK4C OR FV4A FAN COILS The FK4C and FV4A provides high and low speed blower operation to match the capacities of compressor at high and low speeds To select recommended airflow refer to the FK4C or FV4A Installation Instructions The FK4C and FV4A utilize an EASY SELECT control board that allows the installing technician to select proper airflows For adjustments to control board and recommended A C SIZE and CFM ADJUST selections refer to the fan coil Installation Instructions This fan coil has an adjustable blower off delay factory set at 90 sec for high and low speed blower operation THERMIDISTAT CONTROL MODEL RH VARIABLE SPEED CONDENSING FURNACE TWO SPEED AIR CONDITIONER HEAT STAGE 2 COOL STAGE 1 HEAT STAGE 1 COOL stace 2 Y Y2 FAN 8 DEHUMIDIFY 24 VAC COMM cr HUMIDIFY HUM N A B OUTDOOR st SENSOR CONNECTION S2 NON PROGRAMMABLE THERMOSTAT MODEL 2 24 VAC HOT RE 24 VAC COMM 4 COOL STAGE 2 HEAT STAGE 1 HEAT STAGE 2 pwa COOL STAGE 1 v 3 4 N A OUTDOOR SENSOR CONNECTION THERMIDISTAT CONTROL MODEL RH N A COOL STAGE 1 HEAT STAGE 1 COOL STAG
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