Bryant 548C Series Installation, Start-Up And Service Instructions Manual
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Bryant 548C Series Installation, Start-Up And Service Instructions Manual

Bryant 548C Series Installation, Start-Up And Service Instructions Manual

Single package rooftop heat pump units
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IMPORTANT - READ BEFORE INSTALLING
1. Read and become familiar with these installation in-
structions before installing this unit (Fig. 1).
2. Be sure the installation conforms to all applicable local
and national codes.
3. These instructions contain important information for the
proper maintenance and repair of this equipment. Re-
tain these instructions for future use.
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
I. Locate the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
II. Unit Duct Connections . . . . . . . . . . . . . . . . . . . . . . 3
III. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IV. Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-24
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 24,25
I. Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
III. Outdoor-Fan Adjustment . . . . . . . . . . . . . . . . . . . . 26
IV. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 26
V. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30

SAFETY CONSIDERATIONS

Recognize safety information. This is the safety-alert symbol
( ). When you see this symbol on the unit and in instruc-
tions or manuals, be alert to the potential for personal
injury.
Understand the signal words - DANGER, WARNING and
CAUTION. These words are used with the safety-alert sym-
bol. Danger identifies the most serious hazards which will
result in severe personal injury or death. Warning indicates
a condition that could result in personal injury. Caution is
used to identify unsafe practices which would result in minor
personal injury or product and property damage.
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch
to unit. Electrical shock could cause personal injury.
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
HEAT PUMP UNITS
Page
Cancels: New
Fig. 1 - Typical Unit
1. The power supply (volts, hertz, and phase) must corre-
spond to that specified on unit rating plate.
2. The electrical supply provided by the utility must be suf-
ficient to handle load imposed by this unit.
3. Refer to Locate the Unit section on this page and Fig. 2
for locations of electrical inlets, condensate drain, duct
connections, and required clearances before setting unit
in place.
4. This installation must conform with local building codes.
Refer to local plumbing or wastewater codes and other
applicable local codes.
5. Approved for outdoor installation on wood flooring
or on class A, B, or C (U.S.A. Standard) roof covering
materials.

INSTALLATION

Unit is shipped in the vertical airflow configuration (see Fig.
1). To convert to horizontal discharge, remove horizontal duct
opening covers. Using the same screws, install covers with
insulation-side down (facing outside) on the unit over verti-
cal duct openings. Seals around duct openings must be tight.
All units can be connected into existing duct systems that are
properly sized and designed to handle an airflow of 142 to
236 L/s (300 to 500 cfm) per each 3.5 kW (12,000 Btuh) of
rated cooling capacity.
NOTE: When installing any accessory item, see the manu-
facturer's installation instructions packaged with the acces-
sory. A qualified installer or agency must use only factory-
authorized kits or accessories when modifying this unit.
I. LOCATE THE UNIT
A. Clearance
Maintain clearance around and above unit to provide proper
airflow and service access (see Fig. 2 and 3).
A minimum clearance to combustibles is not required around
ductwork on vertical discharge units. On horizontal dis-
charge units, a minimum clearance of 25 mm (1 in.) is re-
quired for the first 305 mm (12 in.) of ductwork.
548C (50 Hz)
Sizes 090,120
Nominal Capacities:
23.1, 28.7 kW
(6.6, 8.2 Tons)
IIE 548C-90-1
2/15/92

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  • Page 1: Table Of Contents

    548C (50 Hz) installation, start-up and Sizes 090,120 service instructions Nominal Capacities: SINGLE PACKAGE ROOFTOP 23.1, 28.7 kW (6.6, 8.2 Tons) HEAT PUMP UNITS Cancels: New IIE 548C-90-1 2/15/92 IMPORTANT — READ BEFORE INSTALLING 1. Read and become familiar with these installation in- structions before installing this unit (Fig.
  • Page 2 STD UNIT ECONOMIZER CORNER CORNER CORNER CORNER ‘‘H’’ ‘‘J’’ ‘‘K’’ WEIGHT WEIGHT WEIGHT (A) WEIGHT (B) WEIGHT (C) WEIGHT (D) UNIT 548C090 ⁄ ⁄ 1050 ⁄ 548C120 ⁄ ⁄ 1253 ⁄ NOTES: 1. Dimensions in [ ] are in millimeters. Center of gravity.

  • Page 3: Unit Duct Connections

    II. UNIT DUCT CONNECTIONS On vertical units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. On horizontal units, duct flanges should be attached to horizontal openings and all ductwork should be secured to flanges. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.
  • Page 4 NOTES: ROOF CURB ‘‘A’’ UNIT SIZE 1. Roof curb accessory is shipped ACCESSORY unassembled. 2. Insulated panels. 389028 203 [356] 3. Dimensions in [ ] are in millimeters. 548C090 & 120 4. Roof curb: galvanized steel. 389028 204 5. Attach ductwork to curb (flanges of duct [610] rest on curb).
  • Page 5 MAXIMUM ALLOWABLE DIFFERENCE Fig. 5 — Unit Leveling Tolerance ‘‘A’’ ‘‘B’’ ‘‘C’’ WEIGHT UNIT 548C090 77.42 1967 41.50 1054 42.12 1070 548C120 77.42 1967 41.50 1054 50.12 1273 NOTES: 1. Dimension in ( ) is in millimeters. 2. Hook rigging shackles through holes in base rail, as shown in detail ‘‘A’’. Holes in base rails are centered around the unit center of gravity.
  • Page 6 Table 1a — Specifications (SI) UNIT 548C NOMINAL CAPACITY (kW) 23.1 28.7 OPERATING WEIGHT (Kg) Unit With Economizer ROOF CURB WEIGHT (Kg) 350 mm Curb 600 mm Curb COMPRESSOR Hermetic Quantity Oil (ml) (each compressor) 1627 2071 REFRIGERANT R-22 Operating Charge (Kg) Circuit 1 Circuit 2 OUTDOOR FAN...
  • Page 7 Table 1b — Specifications (English) UNIT 548C NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit With Economizer ROOF CURB WEIGHT (lb) 14-in. Curb 24-in. Curb COMPRESSOR Hermetic Quantity Oil (oz) (each compressor) REFRIGERANT R-22 Operating Charge (lb-oz) Circuit 1 8-14 Circuit 2 8-10 OUTDOOR FAN Propeller Type...

  • Page 8: Field Connections

    zontal discharge units, a minimum clearance of 25 mm IV. FIELD CONNECTIONS (1 in.) is required for the first 300 mm (12 in.) of A. Condensate Disposal ductwork. Units must have an external trap added. See Fig. 7. A ⁄ -in.
  • Page 9 the % voltage imbalance. Operation on improper line volt- 3. For units with electric heat, refer to Table 3 to deter- age or excessive phase imbalance constitutes abuse and mine appropriate power wiring figure (Fig. 12 - 14), and may cause damage to electrical components. Such op- route power lines as indicated in appropriate figure.
  • Page 10 CONNECTION BOARD LEGEND AHA — Adjustable Heat Anticipator — Cooling Compensator — Plug — Terminal Block — Thermostat-Cooling — Thermostat-Heating Field Wiring Factory Wiring NOTE: The W2 wiring is required with optional 2-module heater package. Fig. 10 — Low-Voltage Connections With Economizer or Two-Position Damper LEGEND AHA —...
  • Page 11 Table 3 — Electrical Data VOLTAGE COMPR ELECTRIC HEAT POWER SUPPLY ELECTRIC HEAT ELECTRIC HEAT RANGE (each) UNIT NOMINAL POWER WIRING PART NO. 548C V-PH-HZ Nominal FIG. NO. 389001- Max RLA Hp FLA MOCP† 10.5 15.2 21.4 12.5 18.0 44.0 400-3-50 41.0 21.0...
  • Page 12 Fig. 13 — Electric Heater Power Wiring Connections — 548C, Single Point Kit 389008-203 and 389008-209 Fig. 14 — Electric Heater Power Wiring Connections — 548C, Single Point Kit 389008-205 and 389008-211 LEGEND FOR FIG. 12 - 14 EQUIP — Equipment —...
  • Page 13 Control Voltage Connections Table 5 — Heat Anticipator Settings Install a factory-approved room thermostat. See Table 4. Lo- UNIT VOLTAGE cate the thermostat on an inside wall in the space to be con- ditioned where it will not be subjected to either a cooling or HEATER kW ANTICIPATOR SETTING PART NO.
  • Page 14 Accessory Economizer and Two-Position Damper The economizer/two-position damper hood assembly is pack- aged and shipped in the accessory. Accessory filter door pack- age (part number 389031-201 on 090 units, and part number 389031-202 on 120 units) must be used with economizer and two-position damper.
  • Page 15 Example: Given — Negative Pressure . 0.19 mm/Hg (0.1 in. wg) Outdoor Air ..519 L/s (1100 cfm) Determine — Setting = 150 mm (6 in.) Fig. 19 — Minimum Position Setting FILTER ACCESS DOOR SCREEN...
  • Page 16 13. Connect OAT per Fig. 28. BAROMETRIC CONDENSER RELIEF DAMPER SECTION 14. Open main unit control box and remove inner control box cover. Mount economizer control board in the low- voltage section using 4 screws located in the control box (see Fig. 29). 15.
  • Page 17 19. Remove indoor-fan motor access panel (located next to the compressor access panel). Save screws. Using wire- nuts, attach the DAT to the 2 black wires that were connected to the economizer board in Step 18. 20. Using the wire tie provided, attach the DAT to the in- door blower as shown in Fig.

  • Page 18: Pre-Start-Up

    Unit is now ready for initial start-up. PRE-START-UP Crankcase heaters are energized as long as there is power to the unit. Energize heaters 24 hours prior to unit start-up. START-UP Proceed as follows to inspect and prepare the unit for initial startup: I.
  • Page 19 LEGEND — Contactor — Heater Contactor — Indoor-Fan Contactor OFC — Outdoor-Fan Contactor RVS — Reversing Valve Solenoid — Heating Stage — Contact Energized — Cooling Stage NOTES: 1. In heating mode, economizer damper blade will move to the mini- mum position, and unit will operate as described for units without economizer, regardless of outdoor air temperature.

  • Page 20: Cooling Section Start-Up And Adjustments

    the outdoor-fan motor will be energized. On units with econo- D. Cooling Sequence of Operation (See Fig. 31) mizer, the economizer damper blade will move to the mini- With Accessory Economizer mum position. The unit will now operate in the heating mode. Upon a request for cooling from the space thermostat, termi- If the space thermostat is satisfied during a defrost cycle, the nals Y1 and G will be energized with 24 v.

  • Page 21: Indoor Airflow And Airflow Adjustments

    Adjust indoor-fan speed to meet jobsite conditions and tem- III. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS perature rise in Tables 1a and 1b. Tables 7 and 8 show fan CAUTION: For cooling operation, the recommended R/s and rpm at motor pulley settings. Table 9 shows maxi- airflow is 142 to 236 L/s (300 to 500 cfm) per each 3.5 mum amp draw of belt drive motor.
  • Page 22 Table 10 — 548C090 Air Delivery (SI) — Horizontal Discharge Units STANDARD 1.12 kW MOTOR, 1.79 MAXIMUM BkW, 10.30 TO 14.70 R/s DRIVE RANGE External Static Pressure (Pa) AIRFLOW (L/s) 1100 0.35 0.50 10.6 0.68 11.7 0.85 12.7 1.03 13.6 1.25 14.4 1.46...
  • Page 23 Table 14 — 548C090 Air Delivery (English) — Horizontal Discharge Units STANDARD 1.5 HP MOTOR, 2.40 MAXIMUM BHP, 620 TO 880 RPM DRIVE RANGE External Static Pressure (in. wg) AIRFLOW (Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 2200 0.42 0.62...

  • Page 24: Care And Maintenance

    A. Belt Drive Motors Fan motor pulleys are factory set for speed shown in Tables 1a and 1b. NOTE: Before adjusting fan speed, make sure the new fan speed will provide an air temperature rise range as shown in Tables 1a and 1b. To change fan speed: 1.

  • Page 25: Air Filter

    tion 75 to 100 mm (3 to 4 in.) from the inner coil section. WARNING: Failure to follow these warnings could re- See Fig. 36. sult in serious personal injury: 5. Use a water hose or other suitable equipment to flush 1.

  • Page 26: Lubrication

    II. LUBRICATION B. Low Charge Cooling Using Cooling Charging Chart, Fig. 38 and 39, vary refrig- A. Compressors erant until the conditions of the appropriate chart are met. Each compressor is charged with correct amount of oil at the Note the charging charts are different from the type nor- factory.
  • Page 27 Fig. 38 — Cooling Charging Charts, 548C090 Fig. 39 — Cooling Charging Charts, 548C120 —27—...

  • Page 28: Troubleshooting

    TROUBLESHOOTING —28—...
  • Page 29 —29—...
  • Page 30 ECONOMIZER TROUBLESHOOTING CHART SYMPTOM CAUSE REMEDY Damper does not open. Indoor fan is not on Determine reason. No power to control board Check for 24-v power from Pin 1 to Pin 2 on P4. If none, de- termine reason. No 12-vdc power between T6 and T8 on Replace control board.
  • Page 32 Copyright 1992 Carrier Corporation CATALOG NO. 000-376...

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