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Bryant R-22 Application Manual And Service Manual

Air conditioners and heat pumps using r-22 refrigerant
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NOTE: Read the entire instruction manual before starting the
installation.
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SAFETY CONSIDERATIONS .....................................................1
INTRODUCTION ..........................................................................2
INSTALLATION GUIDELINE ....................................................2
Residential New Construction ..................................................2
Add-On Replacement (Retrofit) ...............................................2
Seacoast (For Air Conditioners Only) .....................................2
ACCESSORY DESCRIPTIONS ...................................................2
Compressor Crankcase Heater..................................................2
Evaporator Freeze Thermostat..................................................2
Winter Start Control .................................................................2
Compressor Start Assist-PTC ................................................2
Compressor Start Assist Capacitor/Relay ................................2
Low-Ambient Controller ..........................................................2
MotorMaster™ Control ............................................................2
Low-Ambient Pressure Switch.................................................2
Wind Baffle...............................................................................3
Coastal Filter.............................................................................3
Support Feet ..............................................................................3
Liquid-Line Solenoid Valve .....................................................3
Thermostatic-Expansion Valve.................................................3
Isolation Relay ..........................................................................3
LOW-AMBIENT GUIDELINE.....................................................3
LONG-LINE GUIDELINE............................................................3
Approved Systems ....................................................................3
Interconnecting Tubing Sizing .................................................3
Metering Device Sizing ............................................................6
Charging Information................................................................8
2-Speed Applications ...............................................................8
UNIT IDENTIFICATION .............................................................8
Serial Number Identification ....................................................9
CABINET.....................................................................................10
Remove Top Cover-Before 1/1/92 ......................................10
Information Plate-Reliant Products......................................10
Control-Box Cover-Cube Products......................................10
Remove Top Cover- After 1/1/92 .......................................10
Remove Fan-Motor Assembly-After 1/1/92........................11
ELECTRICAL..............................................................................12
Aluminum Wire ......................................................................12
Contactors................................................................................13
Capacitors................................................................................14
Cycle Protector........................................................................15
Crankcase Heater ....................................................................16
Time-Delay Relay...................................................................16
Pressure Switches....................................................................17
Defrost Thermostats................................................................18
Defrost-Control Board ............................................................18
Application Guide and
Service Manual
AIR CONDITIONERS AND HEAT PUMPS
USING R-22 REFRIGERANT
-1-
Cancels: AP01-3, SM01,02-4
Fan Motors ..............................................................................21
Service Alarm Control Board.................................................21
Outdoor Thermostat(s)............................................................22
Compressor Plug.....................................................................24
Low-Voltage Terminals ..........................................................25
RECIPROCATING COMPRESSOR ..........................................25
Mechanical Failures ................................................................25
Electrical Failures ...................................................................26
System Cleanup After Burnout ..............................................27
Compressor Removal And Replacement ...............................27
COPELAND SCROLL COMPRESSOR ....................................28
Features ...................................................................................28
Troubleshooting ......................................................................28
Discharge Thermostat .............................................................28
Discharge Solenoid Valve ......................................................28
MILLENNIUM SCROLL COMPRESSOR ................................29
Features ...................................................................................29
Compressor Protection............................................................29
Troubleshooting ......................................................................29
Scroll Compressor, 3-Phase Monitor.....................................29
TWO-SPEED SYSTEM ..............................................................29
Cautions and Warnings...........................................................29
System Functions ....................................................................29
Factory Defaults......................................................................33
Major Components..................................................................33
LED Function/Malfunction Lights .........................................34
Troubleshooting ......................................................................34
REFRIGERATION SYSTEM .....................................................35
Refrigeration Cycle.................................................................35
Leak Detection ........................................................................35
Brazing ....................................................................................37
Service Valves ........................................................................38
Reversing Valve......................................................................39
Thermostatic-Expansion Valves (TXV).................................40
Coil Removal ..........................................................................41
Liquid-Line Strainer (Heat Pumps Only) ..............................41
Accumulator ............................................................................43
Contaminant Removal ............................................................43
System Charging.....................................................................43
Checking Charge.....................................................................43
CARE AND MAINTENANCE...................................................45
SAFETY CONSIDERATIONS
Service and repair of these units should be attempted only by
trained service technicians familiar with Bryant standard service
instructions and training manual.
All equipment should be installed in accordance with accepted
practices and unit Installation Instructions, and in compliance with
all national and local codes.
Power should be turned off when servicing or repairing electrical
components. Extreme caution should be observed when trouble-
shooting electrical components with power on. Observe all warn-
ing notices posted on equipment.
SM01,02-5
10-00

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Summary of Contents for Bryant R-22

  • Page 1: Table Of Contents

    CARE AND MAINTENANCE...45 SAFETY CONSIDERATIONS Service and repair of these units should be attempted only by trained service technicians familiar with Bryant standard service instructions and training manual. All equipment should be installed in accordance with accepted practices and unit Installation Instructions, and in compliance with all national and local codes.

  • Page 2: Introduction

    Refrigeration system contains refrigerant under pressure. Extreme caution should be observed when handling refrigerants. Wear safety glasses and gloves to prevent personal injury. During normal system operation, some components are hot and can cause burns. Rotating fan blades can cause personal injury. Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed.

  • Page 3: Wind Baffle

    See Low-Ambient Instructions Recommended Yes‡ Yes** This Long-Line Application Guideline applies to all Bryant residential air conditioner and heat pump split systems that have a nominal capacity of 18,000 to 60,000 Btuh. This guideline provides required system changes and accessories necessary for any residential product having piping requirements greater than 50 ft or installations where indoor unit is located above outdoor unit.
  • Page 4 (5.56 x 9.53) SLOT 4 REQ'D (151.5) (12.7) (11.6) (12.7) (152.4) (6.3) BAFFLE MAT'L: 20 GA STEEL SCREW 10 REQ'D SUPPORT 4 REQ'D BAFFLE 2 REQ'D Fig. 1—Wind Baffle Construction for Reliant Units (3.45) DIA HOLE 2 REQ'D (5.56) DIA HOLE 2 REQ'D SUPPORT MAT'L: 18 GA STEEL (3.45) DIA HOLE...
  • Page 5 Calculate the linear length of vapor tube required, adding any losses for the total number of elbows for application. (See Table 5.) Using this equivalent length, select desired vapor-line size from Table 4. Subtract the nominal percentage loss from outdoor-unit presale-literature Detailed Cooling Capacities data for the given indoor/outdoor combination.

  • Page 6: Metering Device Sizing

    TABLE 3—WIND BAFFLE DIMENSIONS FOR CUBE UNITS (IN.) UNIT SIZE UNIT HEIGHT 21-15/16 23-15/16 25-15/16 Small 27-15/16 29-15/16 31-15/16 33-15/16 21-15/16 23-15/16 25-15/16 27-15/16 Medium 22-1/2 29-15/16 31-15/16 33-15/16 35-15/16 37-15/16 25-15/16 27-15/16 29-15/16 31-15/16 Large 33-15/16 35-15/16 37-15/16 39-15/16 TABLE 4—ESTIMATED PERCENTAGE OF NOMINAL COOLING-CAPACITY LOSSES* UNIT LONG-LINE...

  • Page 7: Liquid-Line Solenoid And Tubing Configuration

    90° STD 90° LONG RAD 45° STD Fig. 3—Tube Bend Losses TABLE 5—FITTING LOSSES IN EQUIVALENT FT REFERENCE DIAGRAM IN FIG. 1 TUBE SIZE OD (IN.) 1-1/8 NOTE: If total equivalent horizontal length is 100 ft or longer, both indoor and outdoor pistons must be increased 1 full piston size, in addition to changes required by Tables 6 and 7.

  • Page 8: Charging Information

    Since long-line applications only involve 3/8-in. liquid lines, the additional refrigerant charge required is 0.6 oz of Refrigerant 22 (R-22) per ft of 3/8-in. liquid line over 15 ft. EXAMPLE: To calculate additional charge required for a 25–ft line set:...

  • Page 9: Serial Number Identification

    Positions 1 and 2—Week of Manufacture Example: 01—First week of a year Fig. 4—Application with Air Conditioner Installed in a Horizontal Configuration Fig. 5—Application with Heat Pump Installed in a Horizontal Configuration 52—Last week of a year Positions 3 and 4—Year of Manufacture Example: 94—1994...

  • Page 10: Cabinet

    Fig. 6—Application with Air Conditioner or Heat Pump Installed with Indoor Unit Above Outdoor Unit CABINET Certain maintenance routines and repairs require removal of cabinet panels. There are 4 basic cabinet designs for air condition- ers and heat pumps. (See Fig. 8.) The horizontal discharge unit will be discussed in a separate section of this manual.

  • Page 11: Remove Fan-Motor Assembly-After 1/1/92

    Fig. 7—Application with Air Conditioner or Heat Pump Installed Above Indoor Unit 6. Lift top cover from unit. 7. Reverse sequence for reassembly. VI. REMOVE FAN-MOTOR ASSEMBLY—AFTER 1/1/92 NOTE: This section applies to all Reliant products made after January 1, 1992 1.

  • Page 12: Electrical

    CAUTION: Aluminum wire may be used in the branch circuit (such as the circuit between the main and unit disconnect), but only copper wire may be used between the unit disconnect and the unit on Bryant systems. TROUBLE- Whenever aluminum wire is used in the branch-circuit wiring with this unit, adhere to the following recommendations.

  • Page 13: Contactors

    SE FL JOS DJ SE FL JO SD J SE FL JOS DJ SE FL JO SD J SE FL JOS DJ SE FL SEFL JOSD JO SD J SEFL JOSD SEFL JOSD SEFL JOSD Fig. 9—Information Plate connection will be exposed to moisture, it is very important to cover the entire connection completely to prevent an electrochemi- cal action that will cause the connection to fail very quickly.

  • Page 14: Capacitors

    Fig. 11—Contactor III. CAPACITORS CAUTION: Capacitors can store electrical energy when power is off. Electrical shock can result if you touch the capacitor terminals and discharge the stored energy. Exercise extreme caution when working near capacitors. With power off, discharge stored energy by shorting across the capacitor terminals with a 15,000-ohm, 2-watt resistor.

  • Page 15: Cycle Protector

    4. Remove PTC from unit. Wait at least 10 minutes for PTC to cool to ambient temperature. 5. Measure resistance of PTC with ohmmeter as shown in Fig.13. The cold resistance (RT) of any PTC device should be approxi- mately 100 – 180 percent of device ohm rating. 12.5–ohm PTC = 12.5–22.5 ohm resistance —...

  • Page 16: Crankcase Heater

    HN67ZA002 HN67ZA003 Cycle-protector device is simple to troubleshoot. Only a voltmeter capable of reading 24v is needed. Device is in control circuit; therefore, troubleshooting is safe with control power (24v) on and high-voltage power off. With high-voltage power off, attach voltmeter leads across T1 and T3 and set thermostat so that Y terminal is energized.

  • Page 17: Pressure Switches

    OPERATING TIME BLK DENOTES CLOSED CONTACTS HN67ZA002 SAFETY CONTROL TERMINAL BOARD CONNECTION Fig. 18—Wiring for Single-Pole Contactor thereby improving the efficiency of the system. The sequence of operation is that on closure of the wall thermostat and at the end of a fixed on-delay of 1 sec, the fan relay is energized.

  • Page 18: Defrost Thermostats

    CAUTION: Wear safety glasses and gloves when work- ing with refrigerants. Apply heat with torch to solder joint and remove switch. Wear safety glasses when using torch. Have quenching cloth available. Oil vapor in line may ignite when switch is removed. Braze in 1/4-in.
  • Page 19 OF2 OF1 30 50 HK32FA003/HK32FA006 2. Using thermocouple temperature-measuring device, route sensor or probe underneath coil (or other convenient loca- tion). Attach to liquid line near defrost thermostat. Insulate for more accurate reading. 3. Turn on power to outdoor unit. 4.
  • Page 20 HK32FA003/HK32FA006 OF2 OF1 30 50 HK32FA003/HK32FA006 13. Shut off unit power and reconnect fan lead. 14. Remove jumper between DFT and R terminals. Reconnect defrost-thermostat leads. Failure to remove jumper causes unit to switch to defrost every 30, 50, or 90 minutes and remain in defrost for full 10 minutes.

  • Page 21: Fan Motors

    6. Short between the speed-up terminals using a small, slotted screwdriver. 7. Unit changes over to defrost within 21 sec (depending on timing-cycle setting). Liquid-line temperature rises to range where defrost-thermostat contacts open. Temperature range is from 75°F to 85°F. Resistance goes from zero to contacts open.

  • Page 22: Outdoor Thermostat(S)

    Speedup Pins either heating or cooling. This enables owner to obtain timely heat-pump service during heating season, reducing supplementary electric heat costs, and during cooling season, reducing period of heat discomfort. The service alarm is an accessory device. Service alarm locks out compressor under certain adverse operating conditions.
  • Page 23 AEROQUIET SYSTEM AND AEROMAX TOP Fan Motor Part No. Fan Blade Part No. HC29GE208 HC31GE230/231 HC33GE208 HC33GE232 HC34GE231 HC34GE460 HC35GE208 HC35GE232 HC37GE208 HC37GE230 HC38GE221 HC39GE232 HC39GE234 HC39GE461 HC40GE230 HC40GE461 Fig. 23—Defrost Thermostat Location TABLE 12—FAN POSITION Brookside LA01EB023 4–5/32 LA01EC019 5–1/8 LA01EA026 4–5/8...

  • Page 24: Compressor Plug

    THERMOSTAT SUBBASE TERMINAL FIELD LINE VOLTAGE SUPPLY WIRE THERMOSTAT INDOOR OUTDOOR SUBBASE UNIT UNIT TERMINAL TERMINAL BOARD BOARD Fig. 26—Wiring Connections for Service Alarm and Cycle Protector heat-pump output drops. Setting at which thermostat closes is variable, depending on design of system. It is set at time of installation and should not be changed without cause.

  • Page 25: Low-Voltage Terminals

    tion shown for the Tecumseh compressor is shown with the triangle formed by the terminals pointing toward the top. The configuration around the fusite terminals is the outline of the terminal covers used on the specific compressors. The slot through which the wires of the plug are routed is oriented on the bottom or slightly to the left or right.

  • Page 26: Electrical Failures

    POWER OFF! OHMMETER 0-10 SCALE In this type of failure, compressor motor runs and turns compres- sor, and compressor is pumping. Usually, an internal problem such as blown head gasket or broken internal-discharge line causes compressor to pump hot discharge gas back into its own shell rather than through system.

  • Page 27: System Cleanup After Burnout

    Most common motor failures are due to either an open, grounded, or short circuit. Directions below are specifically for single-phase units, however, they also apply to 3-phase compressors. When a single-phase compressor fails to start or run, 3 tests can help determine the problem.

  • Page 28: Copeland Scroll Compressor

    5. Scratch matching marks on stubs in old compressor. Make corresponding marks on replacement compressor. 6. Use torch to remove stubs from old compressor and to reinstall them in replacement compressor. 7. Use copper couplings to tie compressor back into system. 8.

  • Page 29: Millennium Scroll Compressor

    BLUE SEALANT THERMAL GREASE Fig. 30—Location of Discharge Thermostat cause a rapid pressure equalization around the compressor, thus reducing the normal shutdown sound created by reverse rotation of the scroll. The solenoid valve is normally closed and is wired across high-voltage line 1 to load terminals of the contactor. (See Fig.
  • Page 30 Fig. 31—CES0130075 3–Phase Monitor Board COMP CONT EQUIP LOGIC CESO130075 *LPS *HPS *LLS INDOOR EXTERNAL POWER SUPPLY 24 V THERMOSTAT Fig. 32—CESO130075 3–Phase Monitor Wiring Diagram —30— CONT CONT CONT LOGIC A00010 A00011...
  • Page 31 HEATING OPERATION (HEAT PUMP ONLY) The 2-speed products utilize a 2-stage-heating indoor thermostat. The first stage of heating is heat-pump operation (Y1). Auxiliary backup heat is controlled by second stage (W2). There is a 2° differential between first and second stage. The control board determines the compressor speed based on ambient temperature.
  • Page 32 TABLE 15—FUNCTION LIGHT CODE AND DISPLAY LOCATION CODE T’STAT 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 X‡ w/pause 6 flashes w/pause† Constant light No pause No flash...

  • Page 33: Factory Defaults

    TWO SPEED THERMOSTAT COIL Fig. 36—Low-Voltage Control Wiring AUXILIARY HEAT (W2) LOCKOUT In some areas, it is necessary to disable the auxiliary heat, except for defrost, until the outdoor ambient is less than the structure’s balance point. This is accomplished by using the low-voltage wiring as shown in Fig.

  • Page 34: Led Function/Malfunction Lights

    C - TRANSFORMER COMMON R - TRANSFORMER LINE W2 - FIRST STAGE AUXILIARY HEAT O - REVERSING VALVE Y2 - SECOND STAGE COOLING/HEAT PUMP Y1 - FIRST STAGE COOLING/HEAT PUMP W3 - SECOND STAGE AUXILIARY HEAT L - MALFUNCTION LIGHT 4 - TON IF NO JUMPER IS INSTALLED, DEFAULT...

  • Page 35: Refrigeration System

    (less expensive than refrigerant). Nitrogen also leaks faster than R-22 and is not absorbed by refrigeration oil. Nitrogen cannot, however, be detected by a leak detector. (See Fig. 43.)
  • Page 36 EQUIP Fig. 40—Low-Speed Windings EQUIP Fig. 41—High-Speed Windings SCHEMATIC DIAGRAM (LADDER FORM) COMP MAIN MAIN START SCHEMATIC DIAGRAM (LADDER FORM) COMP MAIN MAIN START —36— HIGH START A91446 HIGH START A91445...

  • Page 37: Brazing

    COOLING CYCLE OUTDOOR FAN INDOOR INDOOR COIL ACCUMULATOR SUCTION SERVICE PORT AT SERVICE VALVE (CLG CYCLE) STRAINER SUCTION (METERING) SERVICE PORT (BYPASSING) HEAT PUMP ACCESSORY LIQUID LINE SERVICE PORT FILTER DRIER AT SERVICE VALVE (CLG CYCLE) (DUAL FLOW) Fig. 42—Heat Pump Refrigerant-Flow Diagrams CAUTION: Due to the high pressure of nitrogen, it should never be used without a pressure regulator on the tank.

  • Page 38: Service Valves

    SERVICE PORT W/SCHRADER STEM CORE FIELD SIDE SEAT FORGED FRONT SEATING VALVE b. Remove all flux residue with brush and water while material is still hot. 2. Use sil-fos or phos-copper for copper-to-copper only. No flux is required. 3. Silver solder is used on copper-to-brass, copper-to-steel, or copper-to-copper.

  • Page 39: Check-Flo-Rater™ (Bypass-Type) Heat Pumps Only

    FEEDER PISTON TUBES (ORIENT AS SHOWN) STRAINER BRASS HEX NUT TEFLON PISTON SEAL RETAINER If the service valve is to be replaced, a metal barrier must be inserted between the valve and the unit to prevent damaging the unit exterior from the heat of the brazing operations. CAUTION: Wear safety glasses and gloves when han- dling refrigerants.

  • Page 40: Thermostatic-Expansion Valves (Txv)

    NEW SOLENOID COIL 4TH PORT 4 PORT DESIGN If valve is defective: 1. Shut off all power to unit and remove all charge from system. 2. Check valve design. If valve is of the 3-port design and new replacement is of the 4-port design, replacement of the solenoid coil and wire leads is necessary.

  • Page 41: Thermostatic-Expansion Valve (Bi-Flow Txv)

    3. The needle valve on the pin Bryant is spring-loaded, which also exerts pressure on the underside of the diaphragm via the pushrods, which tends to close the valve. Therefore, bulb pressure equals evaporator pressure (at outlet of coil) plus spring pressure.
  • Page 42 DIAPHRAGM BYPASS TXV PUSHRODS FEEDER TUBES INLET OUTLET NEEDLE VALVE SPRING DISTRIBUTOR CHECK VALVE (CLOSED) BYPASS TUBE DIAPHRAGM BYPASS TXV PUSHRODS FEEDER TUBES INLET OUTLET NEEDLE VALVE SPRING DISTRIBUTOR CHECK VALVE (OPEN) BYPASS TUBE CAPILLARY TUBE COIL EXTERNAL EQUALIZER TUBE Fig.

  • Page 43: Accumulator

    If the strainer must be replaced, shut off all power to the unit. See Fig. 49 for strainer location. XI. ACCUMULATOR The accumulator is a device always found in heat pumps and found in some condensing-unit models. Under some light-load condi- tions on indoor coils and on outdoor coil with heat pump in heating mode, some liquid refrigerant is present in suction gas returning to compressor.
  • Page 44 OUTDOOR TEMP (°F) — — — — — — — — — — — — — — — — — — — — — Where a dash appears, do not attempt to charge system under these conditions or refrigerant slugging may occur. SUPERHEAT TEMP (°F) 61.5...

  • Page 45: Care And Maintenance

    TABLE 23—SUBCOOLING AT LIQUID-SERVICE VALVE FOR UNITS PRODUCED THROUGH DECEMBER, 1992 Model 590A 591A/592A Series — — — — — — — — — — — — — — — — — — — — — Model 690A 691A/692A Series —...
  • Page 46 TABLE 24—REQUIRED LIQUID-LINE TEMPERATURE PRESSURE (PSIG) AT SERVICE FITTING 3. Check electrical connections for tightness and controls for proper operation each heating (heat pump only) or cooling season and service as necessary. CAUTION: Because of possible damage to the equip- ment or personal injury, maintenance should be per- formed by qualified personnel only.
  • Page 47 3. Check to be sure tools, loose parts, and debris are removed from the unit. 4. Check to be sure all panels and screws are in place and tight. Desert and Seacoast Locations Special consideration must be given to the installation and main- tenance of condensing units and heat pumps installed in seacoast or desert locations.

  • Page 48: Troubleshooting Chart

    COIL DEFECTIVE PROTECTION CAPACITOR OPEN LOOSE DEFECTIVE RUN COMPRESSOR ELECTRICAL CAPACITOR BEARINGS CONNECTION SUPERHEAT Fig. 52—Air-Conditioner Troubleshooting Chart AIR CONDITIONER NO COOLING OR INSUFFICIENT COOLING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD LOOSE LEAD LOW SUCTION AT FAN MOTOR PRESSURE...

  • Page 49: Heat Pump

    TROUBLESHOOTING–COOLING CYCLE COMPRESSOR WILL NOT RUN OUTDOOR FAN STOPPED OR CONTACTOR CONTACTOR CYCLING ON OPEN CLOSED OVERLOAD OUTDOOR AIR COMPRESSOR POWER SUPPLY RESTRICTED OR POWER SUPPLY OPEN RECIRCULATING DAMAGED OR DEFECTIVE LOOSE LEADS AT LOW-VOLTAGE REVERSING COMPRESSOR TRANSFORMER RESTRICTED OPEN FAULTY START DISCHARGE THERMOSTAT...
  • Page 50 TROUBLESHOOTING–HEATING CYCLE COMPRESSOR WILL NOT RUN DIRTY FILTERS CONTACT CONTACTOR OR INDOOR OPEN CLOSED INDOOR FAN DEFECTIVE LOW- STOPPED OR COMPRESSOR VOLTAGE CYCLING ON POWER SUPPLY TRANSFORMER OVERLOAD REMOTE DAMAGED CONTROL LOOSE LEADS AT REVERSING CENTER COMPRESSOR DEFECTIVE CONTACTOR FAULTY START RESTRICTION IN COIL OPEN OR GEAR (1-PH)
  • Page 51 —51—...
  • Page 52 © 2000 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 —52— Printed in U.S.A. sm01,025 Catalog No. 5356-109...

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