installation, start-up and
service instructions
COMMERCIAL AIR-COOLED
CONDENSING UNITS
569C
576B
Cancels: II 569C-72-4
II 569C-72-5
8/15/00
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation
instructions 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.
Retain these instructions for future use.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
I. Locate the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III. Compressor Mounting. . . . . . . . . . . . . . . . . . . . . . . . 2
IV. Unit Refrigerant Piping Connections. . . . . . . . . . . . 2
V. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 5
VI. Accessory Installation. . . . . . . . . . . . . . . . . . . . . . . . 8
Fig. 1 — Typical Unit (569C072 Shown)
Recognize safety information. This is the safety-alert sym-
bol. ( ) When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for per-
sonal injury.
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
I. Start-Up and Adjustments . . . . . . . . . . . . . . . . . . . . 9
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 9
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.
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
III. Condenser-Fan Adjustment . . . . . . . . . . . . . . . . . . 10
IV. Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V. Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . 11
VI. Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VII. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 11
VIII. Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . 12
IX. High Flow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch
to unit. Electrical shock could cause personal injury.
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . 13,14
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2
1. The power supply (volts, hertz, and phase) must cor-
respond to that specified on unit rating plate.
SAFETY CONSIDERATIONS
2. The electrical supply provided by the utility must be
sufficient to handle load imposed by this unit.
WARNING: Improper installation, adjustment,
alteration, service, maintenance, or use can cause
explosion, fire, electric shock, or other occurrences
which may injure you or damage your property. Con-
sult a qualified installer or service agency for informa-
tion or assistance. The qualified installer or agency
must use only factory-authorized kits or accessories
when repairing this product.
3. Refer to the Locate the Unit section on page 2 and
Fig. 2 and 3 for locations of electrical inlets, required
clearances, and weight distribution based on recom-
mended support points 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.
Table 1 — Physical Data
UNIT
569C072
569C090
569C120
576B090
576B102
576B120
1
1
1
NOMINAL CAPACITY (tons)
6
7 /
10
7 /
8 /
10
2
2
2
OPERATING WEIGHT (lb)
Aluminum Coils (Std)
Copper Coils (Optional)
340
386
392
460
426
503
510
578
564
632
564
632
RIGGING WEIGHT (lb)
Aluminum Coils (Std)
Copper Coils (Optional)
390
436
420
488
445
522
560
628
614
682
614
682
REFRIGERANT*
Operating Charge†
Typical (lb)
R-22
11.4
2.0
13.6
2.0
16.5
2.0
14.3
2.0
16.4
2.0
16.4
2.0
Shipping Charge (lb)
Reciprocating,
Hermetic
COMPRESSOR
Scroll, Hermetic
Reciprocating, Semi-Hermetic
1...06DH824
(See Note)
6
Qty...Type
1...H26A72Q
1...ZR94KC
1...ZR125KC
1...06DA818
1...06DA824
Qty Cylinders (ea)
Speed (rpm)
Oil Charge (oz) (ea)
2
NA
3500
85
NA
3500
110
4
6
3500
65
1750
88
1750
128
1750
128
CONDENSER AIR FAN
Qty...Rpm
Propeller; Direct Drive
1...850
1...1100
1...1100
1...1100
26
1...1100
1...1100
Diameter (in.)
26
26
26
26
26
1
3
3
3
3
3
Motor Hp (NEMA)
/
/
/
/
/
/
3
4
4
4
4
4
Watts
Nominal Cfm Total
444
3800
976
6500
960
7000
930
6500
930
6500
930
6500
CONDENSER COIL
Rows...Fins/in.
Enhanced Copper Tubes, Aluminum Lanced Fins
2...17
Face Area (sq ft)
12.24
11.26
18.0
20.50
18.87
18.0
18.0
16.56
18.0
16.56
Storage Capacity (lb)**
16.56
16.56
CONNECTIONS (sweat)
Suction (in.)
Liquid (in.)
1
1
1
1
1
1
1 /
1 /
1 /
1 /
1 /
1 /
8
8
8
8
8
8
1
1
5
1
5
5
/
/
/
/
/
/
2
2
8
2
8
8
CONTROLS
Pressurestat Settings (psig)
High Cutout
Cut-in
Low Cutout
Cut-in
426
7
320 20
7
22
3
5
LEGEND
**Storage capacity of condenser coil with coil 80% full of liquid R-22 at
124 F.
NOTE: Unit 576B120 has one step of unloading. Full load is 100% of
capacity, and one step of unloading is 67% capacity. Unit 576B120 has
the following unloader settings: load is 70 1 psig and unload is 60
2 psig.
NEMA — National Electrical Manufacturers Association
*Unit is factory supplied with holding charge only.
†Typical operating charge with 25 ft of interconnecting piping.
—3—
DIMENSIONS (ft-in.)
ELECTRICAL CONNECTIONS
CONNECTION SIZES
UNIT
A
B
C
D
E
F
3
AA
BB
CC
DD
1 / ″ Dia Field Power Supply Hole
8
With Aluminum Coils (Standard)
2″ Dia Power Supply Knockout
1
3
1
5
5
569C072
569C090
569C120
576B090
576B102
576B120
1-6 /
1-8
1-9
1-6
1-7
1-7
1-2 /
—
1-2 /
1-4 /
2-9 /
2
4
2
4
16
16
16
16
16
16
16
1
2 / ″ Dia Power Supply Knockout
2
1
13
5
7
1-6 /
2-9
/
1-3
1-3
1-3
1-3
1-3
2- /
3-5 /
16
16
7
/ ″ Dia Field Control Wiring Hole
8
5
7
1-8
2-0
2- /
3-5 /
16
16
16
16
SERVICE VALVE CONNECTIONS
3
13
5
7
1-4 /
2-9
/
2- /
3-5 /
4
16
16
16
13
13
5
7
UNIT
SUCTION
LIQUID
1-5
1-5
2-9
2-9
/
/
2- /
3-5 /
1
1
1
5
1
5
5
569C072
569C090
569C120
576B090
576B102
576B120
1 / ″
/ ″
5
7
8
2
2- /
3-5 /
1
1 / ″
/ ″
8
2
With Copper Coils (Optional)
1
1 / ″
/ ″
8
8
1
5
5
569C072
569C090
569C120
576B090
576B102
576B120
1-8
1-3
1-6
1-7
—
1-2 /
1-3
1-3
1-3
1-3
1-3
1-4 /
2-9 /
4
16
16
16
16
16
16
16
1
1 / ″
/ ″
8
2
1
13
5
7
1-9 /
2-9
/
2- /
3-5 /
2
16
16
1
1 / ″
/ ″
8
8
5
7
1-10
2-0
2- /
3-5 /
1
16
16
16
16
1 / ″
/ ″
8
8
1
1
13
5
7
1-7 /
1-4 /
2-9
/
2- /
3-5 /
2
2
2
2
16
16
16
WEIGHT CHART (lb)
1
13
13
5
7
1-7 /
1-4
1-4
2-9
2-9
/
/
2- /
3-5 /
STD UNIT
CORNER W
CORNER X
Al
1
5
7
UNIT
1-7 /
2- /
3-5 /
Al
Cu
Al
Cu
Cu
569C072
569C090
569C120
576B090
576B102
576B120
340
392
426
510
564
564
386
460
503
578
632
632
86
91
106
120
126
143
161
161
53
84
99
89
97
97
65
100
126
106
114
114
96
114
133
133
CORNER Y
CORNER Z
UNIT
Al
Cu
Al
Cu
569C072
569C090
569C120
576B090
576B102
576B120
77
105
117
133
141
141
82
113
127
142
150
150
124
113
113
173
193
193
133
127
127
187
207
207
NOTE: Al indicates weight with aluminum-fin coil (standard);
Cu indicates weight with copper-fin coil (optional).
NOTES:
1. Dimensions in [ ] are in millimeters.
2.
3.
Center of Gravity. See chart for dimensions.
Direction of airflow.
4. Minimum clearance (local codes or jurisdiction may prevail):
a. Bottom to combustible surfaces, 0 inches.
b. Either left or rear side of condensing unit must have 36-in. clearance for proper airflow;
the remaining side(s) must have 12-in. clearance each.
c. Overhead, 60 in., to assure proper condenser fan operation.
d. Between units, control box side, 42 in. per NEC (National Electrical Code).
e. Between unit and ungrounded surfaces, control box side, 36 in. per NEC.
f. Between unit and block or concrete walls and other grounded surfaces, control box side,
42 in. per NEC.
5. With the exception of the clearance for the condenser coil as stated in Note 4b, a removable
fence or barricade requires no clearance.
6. Units may be installed on combustible floors made from wood or Class A, B, or C roof cover-
ing material.
7. Certified dimension drawings available on request.
Fig. 2 — Base Unit Dimensions
—4—
Table 2 — Refrigerant Piping Sizes
LINEAR LENGTH OF PIPING — FT (M)
NOTICE TO RIGGERS
HOOK RIGGING SHACKLES THROUGH HOLES IN BASE RAIL, ON ALL FOUR SIDES.
HOLES IN BASE RAILS ARE CENTERED AROUND THE UNIT CENTER OF GRAVITY. USE
WOODEN TOP SKID, WHEN RIGGING, TO PREVENT RIGGING STRAPS FROM DAMAGING
UNIT.
CAUTION: ALL PANELS MUST BE IN PLACE WHEN RIGGING.
0-25
25-50
(7.6-15.2)
50-75
(15.2-22.9)
75-100
(0-7.6)
(22.9-30.5)
UNIT
Line Size (in. OD)
L
S
L
S
L
S
L
S
1
1
5
1
5
5
1
1
1
1
1
1
1
569C072
569C090
569C120
576B090
576B102
576B120
/
/
/
/
/
/
1 /
/
/
/
/
/
/
1 /
/
/
/
/
/
/
1 /
/
/
/
/
/
/
1 /
2
2
8
2
8
8
8
8
8
8
8
8
2
2
8
2
8
8
8
8
8
8
8
8
2
8
8
8
8
8
8
8
8
8
8
8
2
8
8
8
8
8
8
8
8
8
8
8
1
1
5
1
5
5
1
5
5
5
5
5
1
5
5
5
5
5
3
1 /
1 /
1 /
1 /
1
3
3
3
1 /
1 /
1 /
1 /
1
1
1
3
1 /
1 /
1 /
1 /
1
1
3
3
1 /
1 /
1 /
1 /
1
1
3
3
1 /
1 /
1 /
1 /
LEGEND
L — Liquid Line
S — Suction Line
NOTES:
1. Pipe sizes are based on a 2° F (1° C) loss for liquid and suction
lines.
2. Pipe sizes are based on the maximum linear length shown for
each column, plus a 50% allowance for fittings.
3. Charge units with R-22 in accordance with unit installation
instructions.
RIGGING WEIGHT*
A
B
C
UNIT
lb
kg
in. mm in. mm in. mm
45.0 1143 38.5 978 35.5 904
45.0 1143 38.5 978 43.5 1105
45.0 1143 38.5 978 43.5 1105
45.0 1143 38.5 978 43.5 1105
45.0 1143 38.5 978 43.5 1105
45.0 1143 38.5 978 43.5 1105
569C072
569C090
569C120
576B090
576B102
576B120
390
420
445
560
614
614
177
192
203
255
280
280
Table 3 — Liquid Line Data
LIQUID LINE
MAX
ALLOWABLE
LIQUID LIFT
Max Allowable
Pressure Drop
Max Allowable
Temp Loss
UNIT
Ft
86
60
70
60
65
65
M
psi
7
7
7
7
kPa
48.3
48.3
48.3
48.3
48.3
48.3
F
2
2
2
2
2
2
C
1
1
1
1
1
1
*Weights are for aluminum coils.
569C072
569C090
569C120
576B090
576B102
576B120
26.2
18.3
21.3
18.3
19.8
19.8
Fig. 3 — Rigging Label
7
7
NOTE: Values shown are for units operating at 45 F (7.2 C) saturated
suction and 95 F (35 C) entering air.
V. ELECTRICAL CONNECTIONS
WARNING: The unit cabinet must have an
uninterrupted, unbroken electrical ground to minimize
the possibility of personal injury if an electrical fault
should occur. This ground may consist of electrical wire
connected to the unit ground lug in the control
compartment or conduit approved for electrical ground
when installed in accordance with the NEC and local
electrical codes. Failure to adhere to this warning could
result in personal injury.
Fig. 4 — Typical Compressor Mounting (576B Units)
B. Filter Drier and Moisture Indicator
CAUTION: Failure to follow these precautions
could result in damage to the unit being installed:
The filter drier is factory installed. Moisture indicator is a
field-installed accessory and should be installed just after
liquid line shutoff valve at the evaporator coil. Do not use a
receiver. A receiver is not supplied with the unit and should
not be used.
A. Field Power Supply (Fig. 5-7)
1. Make all electrical connections in accordance with
NEC ANSI/NFPA (American National Standards
Institute/ National Fire Protection Association) 70,
latest edition, and local electrical codes governing
such wiring. Refer to unit wiring diagram.
NOTE: Unit is shipped with R-22 holding charge. System
pressure must be relieved before removing caps. Recover
refrigerant prior to brazing.
Pass nitrogen or other inert gas through piping while braz-
ing to prevent formation of copper oxide.
2. Use only copper or copper-clad conductor fan connec-
tions between field-supplied electrical disconnect
switch and unit. DO NOT USE ALUMINUM WIRE.
Maximum wire size is no. 2 AWG (American Wire
Gage).
Install field-supplied thermostatic expansion valve(s) in
evaporator section. It is r ecom m en d ed that a field supplied
liquid line solenoid be positioned in the main liquid line
(near the evaporator coil). It should be wired to close when
compressor stops to minimize refrigerant migration during
the ‘‘OFF’’ cycle.
3. Voltage to compressor terminals during operation
must be within voltage range indicated on unit name-
plate (also see Table 4). On 3-phase units, voltages
between phases must be balanced within 2% and
—5—
the current within 10%. Use the formula shown in
Table 4, Note 2, to determine the percent voltage
imbalance. Operation on improper line voltage or
excessive phase imbalance constitutes abuse and may
cause damage to electrical components. Such opera-
tion would invalidate any applicable warranty.
4. Insulate low-voltage wires for highest voltage con-
tained within conduit when low-voltage control wires
are run in same conduit as high-voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, con-
duit, etc.
All units except 208/230-v units are factory wired for the
voltage shown on the nameplate. If the 208/230-v unit is to
be connected to a 208-v power supply, the transformer must
be rewired by moving the black wire from the 230-v terminal
on the transformer and connecting it to the 200-v terminal
on the transformer.
LEGEND
Contactor
C
NEC
—
—
National Electrical Code
Field Wiring
Factory Wiring
Refer to unit label diagram for additional information.
Pigtails are provided for field wire connections. Use factory-
supplied splices or UL (Underwriters’ Laboratories)
approved copper/aluminum connector.
Splice Connection (Factory Supplied)
Fig. 5 — Power Wiring Connections
insulated wire (35 C minimum). For over 75 ft, use no. 14
AWG insulated wire (35 C minimum). All wire larger than
no. 18 AWG cannot be directly connected to the thermostat
and will require a junction box and splice at the thermostat.
When installing units, provide a disconnect per NEC. All
field wiring must comply with NEC and local requirements.
Install field wiring as follows:
1. Install conduit through side panel openings.
1. Connect thermostat wires to screw terminals of low
voltage connection board.
2. Install power lines to terminal connections as shown
in Fig. 5.
2. Pass the control wires through the hole provided in
the corner post. See Fig. 7.
B. Control Voltage Connections
3. Feed wire through raceway built into the corner post
and into the 24-v thermostat connection board. The
24-v thermostat connection is located on the left side
of the low voltage connection compartment. The race-
way provides the UL required clearance between the
high- and low-voltage wiring.
Install an accessory thermostat assembly according to instal-
lation instructions included with the accessory. Locate ther-
mostat assembly on a solid wall in the conditioned space to
sense average temperature in accordance with thermostat
installation instructions.
Route thermostat cable or equivalent single leads of colored
wire from subbase terminals to low-voltage connections on
unit (shown in Fig. 6) as described in Steps 1 through 4 below.
4. Total combined amperage draw of the field-installed
liquid line solenoid valve and indoor fan contactor
must not exceed 22 va. If the specified va must be
exceeded, use a remote relay to switch the load.
NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated
wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG
LEGEND
AHA — Adjustable Heat Anticipator
LLSV
LPS
TB
—
—
—
—
—
—
Liquid Line Solenoid Valve
Low-Pressure Switch
Ter minal Block
Terminal (Marked)
Spice
Factory Wiring
Field Control Wiring
To Indicate Common Potential Only,
Not To Represent Wiring
C
—
—
—
Contactor, Compressor
Circuit Breaker
CB
CC
Cooling Compensator
TC
Thermostat-Cooling
Time-Delay Relay
CLO — Compressor Lockout
HPS — High-Pressure Switch
TDR
TH
Thermostat-Heating
IFC
—
Indoor (Evaporator) Fan Contactor
TRAN — Transformer
→
Fig. 6 — Typical Control Wiring Connections (569C Shown)
801
—6—
Table 4 — Electrical Data
VOLTAGE RANGE
COMPRESSOR
OFM
FLA
POWER SUPPLY
NOMINAL VOLTAGE
(V-Ph-Hz)
UNIT
Min
Max
RLA
LRA
MCA
MOCP
208/230-3-60
460-3-60
575-3-60
187
414
518
254
508
632
21.8
10.0
9.0
158
79
65
1.9
1.0
1.9
30.1
13.5
14.1
40
20
20
569C072
208/230-3-60
460-3-60
187
414
518
187
414
518
254
508
632
254
508
632
28.8
14.7
10.8
37.8
17.2
14.3
195
95
3.8
1.9
1.9
3.1
1.4
1.4
39.8
20.3
15.4
51.1
23.4
19.8
50
25
20
70
30
25
569C090
569C120
575-3-60
80
208/230-3-60
460-3-60
575-3-60
239
125
90
208/230-3-60
380-3-60
187
342
414
518
187
342
414
518
187
342
414
518
254
418
508
632
254
418
508
632
254
418
508
632
31.5
19.0
15.7
12.6
39.7
24.0
19.9
15.9
39.7
24.0
19.9
15.9
160
75
3.1
2.2
1.4
1.4
3.1
2.2
1.4
1.4
3.1
2.2
1.4
1.4
42.5
26.0
21.0
17.2
52.7
32.2
26.3
21.3
52.7
32.2
26.3
21.3
50
35
25
20
70
40
35
25
70
40
35
25
576B090
576B102
576B120
460-3-60
80
575-3-60
64
208/230-3-60
380-3-60
460-3-60
575-3-60
208/230-3-60
380-3-60
460-3-60
575-3-60
198
93
99
79
198
93
99
79
LEGEND
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
CSA
FLA
—
—
—
—
—
Canadian Standards Association
Full Load Amps
BC = 464 v
AC = 455 v
HACR
LRA
MCA
Heating, Air Conditioning and Refrigeration
Locked Rotor Amps
452 + 464 + 455
3
Average Voltage
=
Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
NEC
OFM
RLA
UL
—
—
—
—
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps
1371
3
=
=
Underwriters’ Laboratories
457
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance:
7
457
NOTES:
% Voltage Imbalance
=
=
100 x
1. In compliance with NEC requirements for multimotor and combina-
tion load equipment (refer to NEC Articles 430 and 440), the over-
current protective device for the unit shall be fuse or HACR breaker.
The Canadian units may be fuse or circuit breaker.
1.53%
This amount of phase imbalance is satisfactory as it is below the maxi-
mum allowable 2%.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is
greater than 2%. Use the following formula to determine the percent
of voltage imbalance.
IMPORTANT: If the supply voltage phase imbalance is more than 2%,
contact your local electric utility company immediately.
3. The 575-v units are CSA only.
% of Voltage Imbalance =
4. The 380-v units are not UL or CSA listed.
max voltage deviation from average voltage
100 x
average voltage
—7—
PRE-START-UP
WARNING: Failure to observe the following warn-
ings could result in serious personal injury:
1. Follow recognized safety practices and wear
protective goggles when checking or servicing
refrigerant system.
2. Do not operate compressor or provide any elec-
tric power to unit unless compressor terminal
cover is in place and secured.
3. Do not remove compressor terminal cover until
all electrical sources have been disconnected.
4. If refrigerant leak is suspected around compres-
sor terminals, recover refrigerant whenever
possible and relieve all pressure from system
before touching or disturbing anything inside
terminal box.
5. Never attempt to repair soldered connection
while refrigerant system is under pressure.
6. Do not use torch to remove any component.
System contains oil and refrigerant under
pressure. To remove a component, wear protec-
tive goggles and proceed as follows:
Fig. 7 — Field Control Wiring Raceway
(576B Unit Shown)
a. Shut off electrical power to unit.
b. Recover refrigerant. Relieve all pressure
from system.
VI. ACCESSORY INSTALLATION
c. Cut component-connecting tubing with tub-
ing cutter and remove component from unit.
At this time any required accessories should be installed on
the unit. Refer to Table 5 for available accessories. Control
wiring information is provided in the unit wiring book.
d. Carefully unsweat remaining tubing stubs
when necessary. Oil can ignite when exposed
to torch flame.
Table 5 — Accessory List
ACCESSORY
Proceed as follows to inspect and prepare the unit for initial
start-up:
Gage Panel
Winter-Start Relay Package
Weatherprobe™ II Low Ambient Kit
Hail Guard Package (072)
Hail Guard Package (090,102,120)
Thermostats
1. Field electrical power source must agree with unit
nameplate rating.
2. Check voltage imbalance as shown in Table 4, Note 2.
Subbase
3. Check that all internal wiring connections are tight
and that all barriers, covers, and panels are in place.
4. Ensure all service valves are open. On 576B units, be
sure all compressor service valves are backseated.
5. Verify that compressor holddown bolts have been
loosened and that flat/snubber washers can be
rotated by applying finger pressure (snug, but not
tight).
6. On 569C and 576B units, verify compressor crank-
case heater is securely in place. Crankcase heater
must operate for a least 24 hours before start-up.
7. Note that compressor oil level is visible in the sight
glass (576B units only).
8. Check for leaks in refrigerant system by using soap
bubbles and/or electronic leak detector.
9. Check that liquid line solenoid valve is located at
evaporator coil as shown in Filter Drier and Moisture
Indicator section, page 5.
10. Check that both outdoor and indoor units are prop-
erly mounted in accordance with installation instruc-
tions and applicable codes.
—8—
START-UP
thermostat is also energized, allowing the field-supplied
and -installed (24v) indoor (evaporator) fan contactor to func-
tion. A field-supplied and -installed liquid line valve (con-
nected between Terminals G and C at the outdoor unit), will
also open. This allows the system to function in cooling; the
LPS will not open if compressor is not running. As cooling
demand is satisfied, the thermostat contacts break, deener-
gizing the contactor causing the system to shut off. The liq-
uid line solenoid (LLS) valve closes, minimizing the potential
for refrigerant migration at this time. The compressor does
not restart until the thermostat again calls for cooling. If a
demand for cooling occurs within 5 minutes after the ther-
mostat is satisfied, the system will not restart due to the fea-
ture of Time Guard II device. After the 5-minute time period,
the system will restart as normal upon thermostat demand.
I. START-UP AND ADJUSTMENTS
CAUTION: Complete the required procedures
given in the Pre-Start-Up section and unit start-up
checklist at the end of this publication before starting
the unit. Do not jumper any safety devices when oper-
ating the unit.
Do not operate the compressor when the outdoor tem-
perature is below 25 F (24 C) (unless accessory low
ambient kit is installed).
A. Checking Cooling Control Operation
Start and check the unit for proper cooling control operation
as follows:
The system is protected with a Cycle-LOC device so that the
compressor will not start if a high-pressure or low-pressure
fault occurs. To reset the Cycle-LOC device, set the thermo-
stat to eliminate the cooling demand then return to the orig-
inal set point. This should be done only once, and if system
shuts down due to the same fault, determine the problem
before attempting to reset the Cycle-LOC device.
1. Place room thermostat SYSTEM switch in OFF posi-
tion. Observe that blower motor starts when FAN
switch is placed in ON position and shuts down when
FAN switch is placed in AUTO. position.
2. Place SYSTEM switch in COOL position and FAN
switch in AUTO. position. Set cooling control below
room temperature. Observe that compressor and con-
denser- and evaporator-fan motors start. Observe
that cooling cycle shuts down when control setting is
satisfied.
The crankcase heaters must be energized for a minimum of
24 hours before starting a 569C and 576B unit.
D. Oil Charge
576B Units
Allow unit to run for about 20 minutes. Stop unit and check
compressor oil level. Add oil only if necessary to bring oil into
view in sight glass. Use only approved compressor oil.
B. Unit Controls
All units have the following internal-protection controls:
Compressor Overload
Approved oils are:
This overload interrupts power to the compressor when
either the current or internal motor winding temperature
become excessive, and automatically resets when the inter-
nal temperature drops to a safe level. This overload may
require up to 60 minutes (or longer) to reset. If the internal
overload is suspected of being open, disconnect the electrical
power to the unit and check the circuit through the overload
with an ohmmeter or continuity tester.
Suniso 3GS
WF32-150
If oil is added, run unit for an additional 10 minutes. Stop
unit and check oil level. If level is still low, add oil only after
determining that piping system is designed for proper oil
return and that system is not leaking oil.
569C Units
Time Guard® II Device
The 569C units do not have a sight glass and are factory
charged with the correct amount of oil.
The unit is equipped with accessory Time Guard II recycle
timer. The device will cause a 5-minute delay between com-
pressor starts.
All Units
Do not reuse drained oil or use any oil that has been exposed
to the atmosphere. Procedures for adding or removing oil are
given in the Standard Service Techniques Manual, Chapter
1, Refrigerants.
Cycle-LOC™ Device
When high-pressure or low-pressure fault occurs, the Cycle-
LOC device will protect the system by not allowing the com-
pressor to start.
CARE AND MAINTENANCE
Low-Pressure Switch/ (LPS)
To ensure continuing high performance and to minimize the
possibility of premature equipment failure, periodic mainte-
nance must be performed on this equipment. This cooling
unit should be inspected at least once each year by a quali-
fied service person.
When the suction line pressure drops below 7 psig (48 kPa),
the LPS opens 24-v power to the compressor contactor and
stops the compressor. When the pressure reaches 22 psig
(152 kPa), the switch resets and the compressor is allowed to
restart.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
High-Pressure Switch (HPS)
When the refrigerant high-side pressure reaches 426 psig
(2937 kPa), the HPS opens 24-v power to the compressor con-
tactor and stops the compressor. When the pressure drops to
320 psig (2206 kPa), the switch resets and the compressor is
allowed to restart.
WARNING: The ability to properly perform main-
tenance on this equipment requires certain expertise,
mechanical skills, tools, and equipment. If you do not
possess these, do not attempt to perform any mainte-
nance on this equipment other than those procedures
recommended in the User’s Manual. FAILURE TO
HEED THIS WARNING COULD RESULT IN SERI-
OUS PERSONAL INJ URY AND POSSIBLE DAM-
AGE TO THIS EQUIPMENT.
C. Sequence of Operation
At start-up, the thermostat calls for cooling. When all
safety devices are satisfied, the compressor contactor (fan
contactor) will energize causing the compressor and outdoor
(condenser) fan motor to operate. Terminal “G” at the
—9—
SERVICE
WARNING: When servicing unit, shut off all elec-
trical power to unit to avoid shock hazard or injury
from rotating parts.
I. CLEANING
Inspect unit interior at the beginning of each cooling season
and as operating conditions require.
A. Condenser Coil
Inspect coil monthly. Clean condenser coil annually, or as
required by location and outdoor-air conditions.
Clean coil as follows:
Fig. 9 — Propping Up Top Panel
1. Turn off unit power and tag disconnect.
2. Remove and save top panel screws on condensing
unit.
3. Remove condenser coil corner post. See Fig. 8. To hold
top panel open, place coil corner post between top
panel and side panel. See Fig. 9.
4. Remove bracket holding coil sections together at
return end of condenser coil. Carefully separate the
outer coil section 3 to 4 in. from the inner coil section.
See Fig. 10.
5. Use a water hose or other suitable equipment to flush
down between the 2 coil sections to remove dirt and
debris. Clean the outer surfaces with a stiff brush in
the normal manner.
6. Reposition the outer coil section, attach the bracket
removed in Step 4, and remove the coil corner post
from between the top panel and side panel. Secure
the sections together. Install the coil corner post and
replace all screws (removed in Step 2).
Fig. 10 — Separating Coil Sections
II. LUBRICATION
A. Compressors
III. CONDENSER-FAN ADJUSTMENT (Fig. 11)
1. Shut off unit power supply, and tag disconnect.
Each compressor is charged with the correct amount of oil at
the factory. Refer to the Oil Charge section on page 9 for
additional information.
2. Remove condenser-fan assembly (grille, motor, motor
cover, and fan).
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 11.
5. Tighten set screws.
B. Fan Motor Bearings
Fan motor bearings are of the permanently lubricated type.
No further lubrication is required.
6. Replace condenser-fan assembly.
NOTE: Fan height adjustments are as follows:
UNIT
in.
mm
569C072
4.50
114
All Units
(except 569C072)
6.42
163
Fig. 8 — Cleaning Condenser Coil
Fig. 11 — Outdoor (Condenser) Fan Adjustment
—10—
IV. CAPACITY CONTROL (576B120 Only)
7. Remove compressor from unit.
A suction pressure-actuated unloader controls 2 cylinders
and provides capacity control. Unloaders are factory set (see
Table 1), but may be field adjusted:
8. Clean system. Add new liquid line filter drier.
9. Install new compressor in unit.
10. Connect suction and discharge lines to compressor.
Ensure that compressor holddown bolts are in place.
A. Control Set Point
The control set point (cylinder load point) is adjustable from
0 to 85 psig. To adjust, turn control set point adjustment nut
(Fig. 12) clockwise to its bottom stop. In this position, set
point is 85 psig. Then, turn adjustment counterclockwise to
desired control set point. Every full turn counterclockwise
decreases set point by 7.5 psig.
11. Install crankcase heater.
12. Connect wiring.
13. Evacuate and recharge unit, per Step VII.
14. Restore unit power.
VI. CRANKCASE HEATER
B. Pressure Differential
The crankcase heater prevents refrigerant migration and
compressor oil dilution during shutdown when compressor is
not operating.
The pressure differential (difference between cylinder load
and unload points) is adjustable from 6 to 22 psig. To adjust,
turn pressure differential adjustment screw (Fig. 12) coun-
terclockwise to its back stop position. In this position, differ-
ential is 6 psig. Then, turn adjustment screw clockwise to
desired pressure differential. Every full turn clockwise
increases differential by 1.5 psig.
Close both compressor service valves if applicable when
crankcase heater is deenergized for more than 6 hours.
VII. REFRIGERANT CHARGE
Unit panels must be in place when unit is operating during
charging procedure. Unit is shipped with a holding charge
only. Weigh in 7 lbs of R-22 to start unit. Refer to GTAC II,
Module 5, Charging, Recovery, Recycling, and Reclamation
for additional information.
See Troubleshooting Guide on page 13 for additional
information.
A. Low Charge Cooling
Using Cooling Charging Charts, Fig. 13 and 14, vary refrig-
erant until the conditions of the appropriate chart are met.
Note the charging charts are different from type normally
used. The charts are based on charging the units to the cor-
rect sub-cooling for the various operating conditions. Accu-
rate pressure gage and temperature sensing device are
required.
Connect the pressure gage to the service port on the liquid
line service valve. Mount the temperature sensing device on
the liquid line, close the liquid line service valve, and insu-
late it so that outdoor ambient temperature does not affect
the reading. Indoor-air cfm must be within the normal oper-
ating range of the unit.
Operate unit a minimum of 15 minutes. Ensure that temper-
ature and pressure have stabilized. Plot liquid pressure and
temperature on chart and add or reduce charge as required.
Do not vent refrigerant to the atmosphere. Recover any
excess charge. Operate the unit until the system stabilizes.
Adjust charge to conform with charging chart, using liquid
pressure and temperature to read chart.
Fig. 12 — Compressor Capacity Control Unloader
V. COMPRESSOR REMOVAL
See Table 1 for compressor information.
Follow safety codes and wear safety glasses and work gloves.
B. Refrigerant Leaks
1. Shut off power to unit and install lockout. Remove
unit access panel (front of unit).
Proceed as follows to repair a refrigerant leak and to charge
the unit:
2. Remove refrigerant from system using refrigerant
removal methods described in GTAC II, Module 5,
Charging, Recovery, Recycling, and Reclamation.
1. Locate the leak and ensure that refrigerant system
pressure has been relieved.
3. Disconnect compressor wiring at compressor termi-
nal box.
2. Repair leak following accepted practices.
NOTE: Install a new filter drier in the liquid line whenever
the system has been opened for repair.
4. Remove bolts from suction flange and discharge ser-
vice valve (576B units).
3. Add a small charge of R-22 refrigerant vapor to sys-
tem and leak-test unit.
CAUTION: Excessive movement of copper lines at
compressor may cause higher levels of vibration when
unit is restored to service.
4. Evacuate refrigerant system up to 500 micons. If
additional leaks are not found.
5. Charge unit with R-22 refrigerant.
5. Remove crankcase heater from compressor base
(576B units only).
NOTE: Do not vent refrigerant to the atmosphere. Recover
any excess charge.
6. Remove compressor holddown bolts.
—11—
VIII. REFRIGERANT SERVICE PORTS
IX. HIGH FLOW VALVES
Each unit has 3 service ports: one on the suction line, one on
the liquid line, and one on the compressor discharge line. Be
sure caps on the ports are tight.
Located on the compressor hot gas and suction tubes are
High Flow Valves. Large black plastic caps distinguish these
valves with O-rings located inside the caps. These valves can
not be accessed for service in the field. Ensure the plastic
caps are in place and tight or the possibility of refrigerant
leakage could occur.
Fig. 14 — Cooling Charging Chart — 569C090, 120
and 576B090,102,120
Fig. 13 — Cooling Charging Chart — 569C072
—12—
TROUBLESHOOTING GUIDE
CAUSE
SYMPTOM
REMEDY
Compressor does not run —
Contactor open
Power off.
Restore power.
Replace with correct fuses after finding cause
and correcting.
Fuses blown.
Replace transformer if primary windings are
receiving power and no output.
Check thermostat setting.
Check for refrigerant undercharge or system
leak.
Transformer open/shorted.
Thermostat circuit open.
Low-pressure switch open.
Check for refrigerant over charge or
obstruction of outdoor airflow.
High-pressure switch open.
Connections loose.
Tighten all connections.
Compressor motor thermostat open.
Compressor leads loose, broken.
Single phasing.
Check for excessive motor temperature.
Check connections with power off.
Replace blown fuse.
Compressor does not run —
Contactor closed
Allow compressor motor windings to cool down to reset
overload. Determine cause for overload opening.
Compressor internal overload open.
Compressor cycles on high-
pressure switch —
Condenser fan on
High-pressure switch faulty.
Airflow restricted. Dirty coil.
Air recirculating.
Replace switch.
Remove obstruction, clean condenser coil.
Clear airflow area.
Recover, evacuate and recharge as required. Refer to
Carrier GTAC-II, Module 5, Charging, Recovery,
Recycling, and Reclamation.
Noncondensables in system.
Refrigerant overcharge.
Recover as required.
Check or replace filter drier, expansion
valve, etc.
Refrigerant system restrictions.
Compressor cycles on high-
pressure switch —
Fan slips on shaft.
Motor not running.
Tighten fan hub screws.
Check power and capacitor / and / hp motor.
1
3
3
4
Condenser fan off
Motor bearings seized.
Motor overload open.
Motor burned out, windings open.
Filter drier plugged.
Expansion valve power head
defective.
Replace motor.
Check overload rating. Check for fan blade obstruction.
Replace motor.
Compressor cycles on low-
pressure switch —
Evaporator fan running
Replace filter drier.
Replace power head.
Low refrigerant charge.
Expansion valve restricted/plugged.
Evaporator coil iced up.
Evaporator coil dirty.
Find leak, repair, evacuate system, and recharge.
Remove and replace expansion valve.
Check refrigerant charge.
Clean coil fins.
Airflow restricted —
Low suction pressure
Indoor-air filter dirty.
Clean or replace filters.
Check damper operation and position.
Tighten all connections.
Replace relay.
Indoor-air dampers closed.
Electrical connections loose.
Fan relay defective.
Indoor (evaporator) fan stopped —
Low suction pressure
Motor overload open.
Motor defective.
Check power supply.
Replace motor.
Fan belt broken or slipping.
Refrigerant charge low.
Head pressure low.
Replace or tighten belt.
Add charge.
Check refrigerant charge.
Clean or replace filters.
Compressor runs but
cooling insufficient —
Suction pressure low
Indoor-air filters dirty.
Expansion valve power head
defective.
Replace power head.
Expansion valve restricted/plugged.
Evaporator coil partially iced.
Evaporator airflow restricted.
Remove and replace expansion valve.
Check low-pressure setting.
Remove obstruction.
Compressor runs but
cooling insufficient —
Suction pressure high
Heat load excessive.
Check for open doors or windows.
NOTE: See Fig. 15 and 16 for component arrangements.
—13—
LEGEND FOR FIG. 15 AND 16
LPS — Low-Pressure Switch
C
— Contactor, Compressor
Terminal (Marked)
NEC — National Electrical Code
CAP — Capacitor
OFC — Outdoor (Condenser) Fan Contactor
OFM — Outdoor (Condenser) Fan Motor
CB
CH
— Circuit Breaker
— Crankcase Heater
Terminal (Unmarked)
Terminal Block
OL
QT
TB
— Overload Relay
— Quadruple Terminal
— Terminal Block
CLO — Compressor Lockout
COMP — Compressor Motor
COTP — Compressor Temperature Protection
EQUIP — Equipment
Factory Wiring
TDR — Time-Delay Relay
TRAN— Transformer
Field Power Wiring
GND — Ground
HPS — High-Pressure Switch
→
Fig. 15 — Typical 569C Component Arrangement
Fig. 16 — Typical 576B Component Arrangement
→
Copyright 2000 Bryant Heating & Cooling Systems
801
CATALOG NO. 5356-903
START-UP CHECKLIST
I. PRELIMINARY INFORMATION
OUTDOOR: MODEL NO. __________________________________ SERIAL NO.____________________________________
INDOOR: AIR HANDLER MANUFACTURER _____________________________________________________________
MODEL NO. ___________________________________ SERIAL NO.____________________________________
ADDITIONAL ACCESSORIES ______________________________________________________________________________
II. PRE-START-UP
OUTDOOR UNIT
IS THERE ANY SHIPPING DAMAGE? _______
(Y/N) _______
IF SO, WHERE: _________________________________________________________________________________________
______________________________________________________________________________________________________
WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) _______
CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? (Y/N) _______
HAS THE GROUND WIRE BEEN CONNECTED? (Y/N) _______
HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (Y/N) _______
ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (Y/N) _______
HAVE COMPRESSOR HOLDDOWN BOLTS BEEN LOOSENED, WHERE APPLICABLE (Snubber washers are snug, but not tight)?
(Y/N) _______
CONTROLS
ARE THERMOSTAT AND INDOOR-FAN CONTROL WIRING
CONNECTIONS MADE AND CHECKED?
(Y/N) _______
ARE ALL WIRING TERMINALS (including main power supply) TIGHT?
HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS?
(Y/N) _______
(Y/N) _______
INDOOR UNIT
HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE?
ARE PROPER AIR FILTERS IN PLACE? (Y/N) _______
HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT?
DO THE FAN BELTS HAVE PROPER TENSION? (Y/N) _______
(Y/N) _______
(Y/N) _______
(Y/N) _______
HAS CORRECT FAN ROTATION BEEN CONFIRMED?
PIPING
IS LIQUID LINE SOLENOID VALVE LOCATED AT THE EVAPORATOR COIL AS REQUIRED?
(Y/N) _______
HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, CONDENSER, EVAPORATOR,
TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS
WITH A LEAK DETECTOR?
(Y/N) _______
LOCATE, REPAIR, AND REPORT ANY LEAKS. ________________________________________________________________
ARE ALL 576B COMPRESSOR SERVICE VALVES FULLY OPENED (BACKSEATED)?
(Y/N) _______
HAVE LIQUID LINE SERVICE VALVE AND SUCTION LINE SERVICE VALVE BEEN OPENED?
(Y/N) _______
IS THE OIL LEVEL IN COMPRESSOR CRANKCASE ON 576B UNIT IN VIEW IN THE COMPRESSOR SIGHT GLASS?
(Y/N) _______
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS:
AB _______ V
AC _______ V
BC _______ V
(AB + AC + BC)/3 = AVERAGE VOLTAGE =V
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = __________ V
VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) = __________ %
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM!
CALL LOCAL POWER COMPANY FOR ASSISTANCE.
CL-1
III. START-UP
CHECK EVAPORATOR-FAN SPEED AND RECORD. _______
CHECK CONDENSER-FAN SPEED AND RECORD. _______
AFTER AT LEAST 15 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
OIL PRESSURE (576B only)
SUCTION PRESSURE
SUCTION LINE TEMP
DISCHARGE PRESSURE
DISCHARGE LINE TEMP
ENTERING CONDENSER-AIR TEMP
LEAVING CONDENSER-AIR TEMP
EVAP ENTERING-AIR DB (dry bulb) TEMP
EVAP ENTERING-AIR WB (wet bulb) TEMP
EVAP LEAVING-AIR DB TEMP
EVAP LEAVING-AIR WB TEMP
COMPRESSOR AMPS (L1/L2/L3)
_____ / _____ / _____
HAS REFRIGERANT CHARGE BEEN ADJUSTED PER UNIT CHARGING CHART? _______________
NOTES:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
Copyright 2000 Bryant Heating & Cooling Systems
801
CL-2
CATALOG NO. 5356-903
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