Bryant 548J Installation and user guide

548J
SINGLE PACKAGE HEAT PUMP/ELECTRIC HEAT
NOMINAL 3 TO 8.5 TONS
WITH PURONR(R--410A) REFRIGERANT
Service and Maintenance Instructions
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 1....................
UNIT ARRANGEMENT AND ACCESS 3...........
SUPPLY FAN (BLOWER) SECTION 4..............
HEAT PUMP REFRIGERATION SYSTEM 8.........
PURONR(R--410A) REFRIGERANT 13.............
COOLING CHARGING CHARTS 14................
CONVENIENCE OUTLETS 19....................
HEAT PUMP CONTROLS 20......................
PROTECTIVE CONTROLS 20.....................
COMMERCIAL DEFROST CONTROL 21...........
ELECTRIC HEATERS 24.........................
SMOKE DETECTORS 26.........................
RTU--MP CONTROL SYSTEM 33..................
ECONOMIZER SYSTEMS 47.....................
WIRING DIAGRAMS 56.........................
PRE--START-UP 58..............................
START-UP, GENERAL 58.........................
START-UP, RTU--MP CONTROL 59................
OPERATING SEQUENCE 62......................
FASTENER TORQUE VALUES 67.................
APPENDIX I. MODEL NUMBER SIGNIFICANCE 68...
APPENDIX II. PHYSICAL DATA 69................
APPENDIX III. FAN PERFORMANCE 71...........
APPENDIX IV. ELECTRICAL INFORMATION 82....
APPENDIX V. WIRING DIAGRAM LIST 96.........
APPENDIX VI. MOTORMASTER SENSOR
LOCATIONS 97.................................
UNIT START-UP CHECKLIST 99..................
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical
components. Only trained and qualified service personnel
should install, repair, or service air-conditioning
equipment. Untrained personnel can perform the basic
maintenance functions of replacing filters. Trained service
personnel should perform all other operations.
When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to
the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations.
Have fire extinguishers available for all brazing
operations.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have
fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and National
Electrical Code (NEC) for special requirements.
Recognize safety information. This is the safety--alert
symbol . When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for
personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert
symbol. DANGER identifies the most serious hazards
which will result in severe personal injury or death.
WARNING signifies a hazard which could result in
personal injury or death. CAUTION is used to identify
unsafe practices which may 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.

2
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
Before performing service or maintenance operations
on unit, turn off main power switch to unit. Electrical
shock and rotating equipment could cause injury.
!WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
Units with convenience outlet circuits may use
multiple disconnects. Check convenience outlet for
power status before opening unit for service. Locate
its disconnect switch, if appropriate, and open it.
Tag--out this switch, if necessary.
!WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal
injury, death and/or equipment damage.
Puron (R--410A) refrigerant systems operate at higher
pressures than standard R--22 systems. Do not use
R--22 service equipment or components on Puron
refrigerant equipment.
!WARNING
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could cause personal
injury or death. Relieve pressure and recover all
refrigerant before system repair or final unit disposal.
Wear safety glasses and gloves when handling
refrigerants. Keep torches and other ignition sources
away from refrigerants and oils.
!WARNING
CUT HAZARD
Failure to follow this caution may result in personal
injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing, safety
glasses and gloves when handling parts and servicing
air conditioning units.
CAUTION
!
548J

3
UNIT ARRANGEMENT AND ACCESS
General
Fig. 1 and Fig. 2 show general unit arrangement and
access locations.
INDOOR BLOWER
ACCESS
CONTROL BOX
COMPRESSORS
(D08-09 only)
C09190
Fig. 1 -- Typical Access Panel Location (Front)
FILTER ACCESS PANEL
INDOOR COIL ACCESS PANEL
C08449
Fig. 2 -- Typical Access Panel Locations (Rear)
Routine Maintenance
These items should be part of a routine maintenance
program, to be checked every month or two, until a
specific schedule for each can be identified for this
installation:
Quarterly Inspection (and 30 days after initial start)
SReturn air filter replacement
SOutdoor hood inlet filters cleaned
SBelt tension checked
SBelt condition checked
SPulley alignment checked
SFan shaft bearing locking collar tightness checked
SOutdoor coil cleanliness checked
SCondensate drain checked
Seasonal Maintenance
These items should be checked at the beginning of each
season (or more often if local conditions and usage
patterns dictate):
Air Conditioning/Heat Pump
SOutdoor fan motor mounting bolts tightness
SCompressor mounting bolts
SOutdoor fan blade positioning
SControl box cleanliness and wiring condition
SWire terminal tightness
SRefrigerant charge level
SIndoor coil cleaning
SSupply blower motor amperage
Electric Heating
SPower wire connections
SFuses ready
SManual--reset limit switch is closed
Economizer or Outside Air Damper
SInlet filters condition
SCheck damper travel (economizer)
SCheck gear and dampers for debris and dirt
Air Filters and Screens
Each unit is equipped with return air filters. If the unit has
an economizer, it will also have an outside air screen. If a
manual outside air damper is added, an inlet air screen
will also be present.
Each of these filters and screens will need to be
periodically replaced or cleaned.
Return Air Filters
Return air filters are disposable fiberglass media type.
Access to the filters is through the small lift--out panel
located on the rear side of the unit, above the
evaporator/return air access panel. (See Fig. 1.)
To remove the filters:
1. Grasp the bottom flange of the upper panel.
2. Lift up and swing the bottom out until the panel dis-
engages and pulls out.
3. Reach inside and extract the filters from the filter
rack.
4. Replace these filters as required with similar replace-
ment filters of same size.
To re--install the access panel:
1. Slide the top of the panel up under the unit top panel.
2. Slide the bottom into the side channels.
3. Push the bottom flange down until it contacts the top
of the lower panel (or economizer top).
IMPORTANT: DO NOT OPERATE THE UNIT
WITHOUT THESE FILTERS!
548J

4
Outside Air Hood
Outside air hood inlet screens are permanent
aluminum--mesh type filters. Check these for cleanliness.
Remove the screens when cleaning is required. Clean by
washing with hot low--pressure water and soft detergent
and replace all screens before restarting the unit. Observe
the flow direction arrows on the side of each filter frame.
Economizer Inlet Air Screen
This air screen is retained by spring clips under the top
edge of the hood. (See Fig. 3.)
DIVIDER
BAROMETRIC
RELIEF
CLEANABLE
ALUMINUM
FILTER FILTER
HOOD
FILTER
CLIP
OUTSIDE
AIR
C08634
Fig. 3 -- Filter Installation
To remove the filter, open the spring clips. Re--install the
filter by placing the frame in its track, then closing the
spring clips.
Manual Outside Air Hood Screen
This inlet screen is secured by a retainer angle across the
top edge of the hood. (See Fig. 4.)
C07156
Fig. 4 -- Screens Installed on Outdoor--Air Hood
(Sizes 08D--09D Shown)
To remove the screen, loosen the screws in the top retainer
and slip the retainer up until the filter can be removed.
Re--install by placing the frame in its track, rotating the
retainer back down and tighten all screws.
SUPPLY FAN (BLOWER) SECTION
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal
injury or death.
Before performing service or maintenance operations
on the fan system, shut off all unit power and tag--out
the unit disconnect switch. Do not reach into the fan
section with power still applied to unit.
!WARNING
Supply Fan (Direct--Drive)
For unit sizes 04, 05 and 06, the Standard Static supply
fan system consists of a direct--drive forward--curved
centrifugal blower wheel attached to the motor shaft. The
motor has taps to provide the servicer with the selection of
one of five motor torque/speed ranges to best match wheel
performance with attached duct system. See Fig. 5 (548J
Direct--Drive Fan Assembly) and Fig. 6 (EMC Motor
Connectors).
EMC Motor
Motor Plug Position
(95° from vertical)
95°
EMC Power
Transformer
(460, 575v)
C09260
Fig. 5 -- 548J Direct--Drive Supply Fan Assembly
L2
YEL
Gnd
GRN/YEL
L1
BLU
C
12345
LGN
Motor
Power
Connections
Speed
Taps
Com
BRN
VIO
Default Connection
C09261
Fig. 6 -- EMC Motor Connectors
548J

5
460, 575-v Units
208/230-v Units
C09263
Fig. 7 -- EMC Unit Wiring
ECM Motor – The direct--drive motor is an X13
Electronically Commutated motor (ECM). An ECM
contains electronic circuitry to convert single--phase line
AC voltage into a 3--phase DC voltage to power the motor
circuit. The motor circuit is a DC brushless design with a
permanent magnet rotor. On the X13 design, the
electronic circuitry is integral to the motor assembly and
cannot be serviced or replaced separately.
208/230--v units use a 230--v motor. 460--v units use a
230--v motor with a stepdown transformer (mounted on
the end of the fan housing, see Fig. 5). 575--v units use a
460--v motor with an autotransformer. Motor power
voltage is connected to motor terminals L and N (see
Fig. 6 and Fig. 7); ground is connected at terminal G.
The motor power voltage is ALWAYS present; it is not
switched off by a motor contactor.
Motor operation is initiated by the presence of a 24--v
control signal to one of the five motor communications
terminals. When the 24--v signal is removed, the motor
will stop. The motor control signal is switched by the
defrost board’s IFO output.
Evaluating motor speed – The X13 ECM is a constant
torque motor design. The motor speed is adjusted by the
motor control circuitry to maintain the programmed shaft
torque. Consequently there is no specific speed value
assigned to each control tap setting. At the Position 5 tap,
the motor speed is approximately 1050 RPM (17.5 r/s) but
it will vary depending on fan wheel loading.
Selecting speed tap – The five communications terminals
are each programmed to provide a different motor torque
output. See Table 1. Factory default tap selection is
Position 1 for lowest torque/speed operation.
Table 1 – 548J Standard Static Motor Tap Programing
(percent of full--load torque)
Unit Size Ta p 1 Ta p 2 Ta p 3 Ta p 4 Ta p 5
04 32 38 45 50 100
05 46 58 61 69 100
06 73 82 85 90 100
Factory Default: Tap 1 (VIO)
To select another speed:
1. Disconnect main power to the unit.
2. Remove the motor signal lead (VIO) at the motor
communications terminal.
3. Reconnect the motor signal lead to the desired speed
terminal.
4. Connect main power to the unit.
Motor “rocking” on start--up – When the motor first starts,
the rotor (and attached wheel) will “rock” back and forth
as the motor tests for rotational direction. Once the correct
rotation direction is determined by the motor circuitry, the
motor will ramp up to specified speed. The “rocking” is a
normal operating characteristic of ECM motors.
Troubleshooting the ECM motor – Troubleshooting the
X13 ECM requires a voltmeter.
1. Disconnect main power to the unit.
2. Remove the motor power plug (including the control
BRN lead) and VIO control signal lead at the motor
terminals.
3. Restore main unit power.
4. Check for proper line voltage at motor power leads
BLK (from L terminal) and YEL (from N terminal).
548J

6
Table 2 – Motor Test Volts
Unit Voltage Motor Voltage Min---Max Volts
208/230 230 190--- 250
460 230 210--- 250
575 460 420--- 500
5. Apply a jumper at unit control terminals R to G to
initiate a demand for motor operation. Check for 24--v
output at defrost board terminal IFO.
6. Check for proper control signal voltage at motor
signal leads VIO and BRN. Signal should be 22 to
28--v.
7. Disconnect unit main power.
8. Reconnect motor power and control signal leads at
the motor terminals.
9. Restore unit main power.
Motor should start and run. If it does not, remove the
motor assembly. Replace with same motor part number;
do not substitute with an alternate design as torque/speed
programming will not be same as on original factory
motor.
Replacing the ECM Motor – Before removing the ECM
belly--band mounting ring, measure the distance between
the base of the motor shaft and the edge of the mounting
ring. Remove the motor mounting band and transfer to the
replacement motor. Position the mounting band at
distance measured in first step. Snug the mounting bolt
but do not tighten yet.
Insert the motor shaft into the fan wheel hub. Then secure
the three motor mount arms to the support cushions.
Torque the arm mounting screws to 60 in--lbs (6.8 N--m).
Center the fan wheel in the fan housing. Torque the fan
wheel hub setscrew to 120 in--lbs (13.6 N--m).
Ensure the motor terminals are located at a position below
the 3 o’clock position (see Fig. 5). Tighten the motor
belly--band bolt to 80 in--lbs (9.0 N--m).
Supply Fan (Belt--Drive)
The belt--drive supply fan system consists of a
forward--curved centrifugal blower wheel on a solid shaft
with two concentric type bearings, one on each side of the
blower housing. A fixed--pitch driven pulley is attached to
the fan shaft and an adjustable--pitch driver pulley is on
the motor. The pulleys are connected using a “V” type
belt. (See Fig. 8.)
C07087
Fig. 8 -- Belt Drive Motor Mounting
Belt
Check the belt condition and tension quarterly. Inspect the
belt for signs of cracking, fraying or glazing along the
inside surfaces. Check belt tension by using a spring--force
tool (such as Browning’s Part Number “Belt Tension
Checker” or equivalent tool); tension should be 6--lbs at a
5/8--in. deflection when measured at the centerline of the
belt span. This point is at the center of the belt when
measuring the distance between the motor shaft and the
blower shaft.
NOTE: Without the spring--tension tool, place a straight
edge across the belt surface at the pulleys, then deflect the
belt at mid--span using one finger to a 1/2--in. deflection.
Adjust belt tension by loosening the motor mounting plate
front bolts and rear bolt and sliding the plate toward the
fan (to reduce tension) or away from fan (to increase
tension). Ensure the blower shaft and the motor shaft are
parallel to each other (pulleys aligned). Tighten all bolts
when finished.
To replace the belt:
1. Use a belt with same section type or similar size. Do
not substitute a “FHP” type belt. When installing the
new belt, do not use a tool (screwdriver or pry--bar) to
force the belt over the pulley flanges, this will stress
the belt and cause a reduction in belt life.
2. Loosen the motor mounting plate front bolts and rear
bolts.
3. Push the motor and its mounting plate towards the
blower housing as close as possible to reduce the cen-
ter distance between fan shaft and motor shaft.
4. Remove the belt by gently lifting the old belt over
one of the pulleys.
5. Install the new belt by gently sliding the belt over
both pulleys and then sliding the motor and plate
away from the fan housing until proper tension is
achieved.
6. Check the alignment of the pulleys, adjust if necessary.
7. Tighten all bolts.
8. Check the tension after a few hours of runtime and
re--adjust as required.
548J

7
Adjustable--Pitch Pulley on Motor
The motor pulley is an adjustable--pitch type that allows a
servicer to implement changes in the fan wheel speed to
match as--installed ductwork systems. The pulley consists
of a fixed flange side that faces the motor (secured to the
motor shaft) and a movable flange side that can be rotated
around the fixed flange side that increases or reduces the
pitch diameter of this driver pulley. (See Fig. 9.)
C07075
Fig. 9 -- Supply--Fan Pulley Adjustment
As the pitch diameter is changed by adjusting the position
of the movable flange, the centerline on this pulley shifts
laterally (along the motor shaft). This creates a
requirement for a realignment of the pulleys after any
adjustment of the movable flange. Also reset the belt
tension after each realignment.
Check the condition of the motor pulley for signs of wear.
Glazing of the belt contact surfaces and erosion on these
surfaces are signs of improper belt tension and/or belt
slippage. Pulley replacement may be necessary.
To change fan speed:
1. Shut off unit power supply.
2. Loosen belt by loosening fan motor mounting nuts.
(See Fig. 8.)
3. Loosen movable pulley flange setscrew. (See Fig. 9.)
4. Screw movable flange toward fixed flange to increase
speed and away from fixed flange to decrease speed.
Increasing fan speed increases load on motor. Do not
exceed maximum speed specified.
5. Set movable flange at nearest keyway of pulley hub
and tighten setscrew to torque specifications.
To align fan and motor pulleys:
1. Loosen fan pulley setscrews.
2. Slide fan pulley along fan shaft. Make angular align-
ment by loosening motor from mounting.
3. Tighten fan pulley setscrews and motor mounting
bolts to torque specifications.
4. Recheck belt tension.
Bearings
This fan system uses bearings featuring concentric split
locking collars. The collars are tightened through a cap
screw bridging the split portion of the collar. The cap
screw has a Torx T25 socket head. To tighten the locking
collar: Hold the locking collar tightly against the inner
race of the bearing and torque the cap screw to 65--70
in--lb (7.4--7.9 Nm). See Fig. 10.
C08121
Fig. 10 -- Tightening Locking Collar
Motor
When replacing the motor, also replace the external--tooth
lock washer (star washer) under the motor mounting base;
this is part of the motor grounding system. Ensure the
teeth on the lock washer are in contact with the motor’s
painted base. Tighten motor mounting bolts to 120 +/-- 12
in--lbs.
Changing fan wheel speed by changing pulleys: The
horsepower rating of the belt is primarily dictated by the
pitch diameter of the smaller pulley in the drive system
(typically the motor pulley in these units). Do not install a
replacement motor pulley with a smaller pitch diameter
than provided on the original factory pulley. Change fan
wheel speed by changing the fan pulley (larger pitch
diameter to reduce wheel speed, smaller pitch diameter to
increase wheel speed) or select a new system (both
pulleys and matching belt(s)).
Before changing pulleys to increase fan wheel speed,
check the fan performance at the target speed and airflow
rate to determine new motor loading (bhp). Use the fan
performance tables or use the Packaged Rooftop Builder
software program. Confirm that the motor in this unit is
capable of operating at the new operating condition. Fan
shaft loading increases dramatically as wheel speed is
increased.
To reduce vibration, replace the motor’s adjustable pitch
pulley with a fixed pitch pulley (after the final airflow
balance adjustment). This will reduce the amount of
vibration generated by the motor/belt--drive system.
548J

8
HEAT PUMP REFRIGERATION
SYSTEM
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal
injury, death and/or equipment damage.
This system uses PuronRrefrigerant which has
higher pressures than R--22 and other refrigerants. No
other refrigerant may be used in this system. Gauge
set, hoses, and recovery system must be designed to
handle Puron refrigerant. If unsure about equipment,
consult the equipment manufacturer.
!WARNING
Outdoor Coil
The 548J outdoor coil is fabricated with round tube
copper hairpins and plate fins of various materials and/or
coatings (see “Appendix I -- Model Number Significance”
to identify the materials provided in this unit). All unit
sizes use composite--type two--row coils. Composite
two--row coils are two single--row coils fabricated with a
single return bend end tubesheet.
Indoor Coil
The indoor coil is traditional round--tube, plate--fin
technology. Tube and fin construction is of various
optional materials and coatings (see Model Number
Format). Coils are multiple--row.
Outdoor Coil Maintenance and Cleaning
Recommendation
Routine cleaning of coil surfaces is essential to maintain
proper operation of the unit. Elimination of contamination
and removal of harmful residues will greatly increase the
life of the coil and extend the life of the unit. The
following maintenance and cleaning procedures are
recommended as part of the routine maintenance activities
to extend the life of the coil.
Remove Surface Loaded Fibers
Surface loaded fibers or dirt should be removed with a
vacuum cleaner. If a vacuum cleaner is not available, a
soft non--metallic bristle brush may be used. In either
case, the tool should be applied in the direction of the fins.
Coil surfaces can be easily damaged (fin edges can be
easily bent over and damage the coating of a protected
coil) if the tool is applied across the fins.
NOTE: Use of a water stream, such as a garden hose,
against a surface loaded coil will drive the fibers and dirt
into the coil. This will make cleaning efforts more
difficult. Surface loaded fibers must be completely
removed prior to using low velocity clean water rinse.
Periodic Clean Water Rinse
A periodic clean water rinse is very beneficial for coils
that are applied in coastal or industrial environments.
However, it is very important that the water rinse is made
with very low velocity water stream to avoid damaging
the fin edges. Monthly cleaning as described below is
recommended.
PERSONAL INJURY AND UNIT DAMAGE
HAZARD
Failure to follow this caution may result in personal
injury or equipment damage.
Only approved cleaning is recommended.
CAUTION
!
Routine Cleaning of Indoor Coil Surfaces
Periodic cleaning with Totaline®environmentally sound
coil cleaner is essential to extend the life of coils. This
cleaner is available from our Replacement Components
Division as part number P902--0301 for one gallon
container, and part number P902--0305 for a 5 gallon
container. It is recommended that all coils, including
standard aluminum, pre--coated, copper/copper or
E--coated coils be cleaned with the Totaline
environmentally sound coil cleaner as described below.
Coil cleaning should be part of the unit’s regularly
scheduled maintenance procedures to ensure long life of
the coil. Failure to clean the coils may result in reduced
durability in the environment.
Avoid the use of
Scoil brighteners
Sacid cleaning prior to painting
Shigh pressure washers
Spoor quality water for cleaning
Totaline environmentally sound coil cleaner is
nonflammable, hypoallergenic, non bacterial, and a
USDA accepted biodegradable agent that will not harm
the coil or surrounding components such as electrical
wiring, painted metal surfaces, or insulation. Use of
non--recommended coil cleaners is strongly discouraged
since coil and unit durability could be affected.
Clean coil as follows:
1. Turn off unit power, tag disconnect.
2. Remove top panel screws on outdoor coil end of unit.
3. Remove coil corner post. See Fig. 11. To hold top
panel open, place coil corner post between top panel
and center post. See Fig. 12.
548J

9
OUTDOOR
COIL
C09219
Fig. 11 -- Cleaning Condenser Coil (Size 04--07 shown)
C08206
Fig. 12 -- Propping Up Top Panel
4. For Sizes 04--07: Remove screws securing coil to
compressor plate and compressor access panel.
5. For Sizes 08--09: Remove fastener holding coil sec-
tions together at return end of condenser coil. Care-
fully separate the outdoor coil section 3 to 4 in. from
the inner coil section. See Fig. 13.
OUTDOOR
COIL
C09220
Fig. 13 -- Separating Coil Sections
6. 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.
7. Secure inner and outer coil rows together with a
field--supplied fastener.
8. Reposition the outer coil section and remove the coil
corner post from between the top panel and center
post. Reinstall the coil corner post and replace all
screws.
Totaline Environmentally Sound Coil Cleaner
Application Equipment
S21/2gallon garden sprayer
SWater rinse with low velocity spray nozzle
UNIT DAMAGE HAZARD
Failure to follow this caution may result in corrosion
and damage to the unit.
Harsh chemicals, household bleach or acid or basic
cleaners should not be used to clean outdoor or indoor
coils of any kind. These cleaners can be very difficult
to rinse out of the coil and can accelerate corrosion at
the fin/tube interface where dissimilar materials are in
contact. If there is dirt below the surface of the coil,
use the Totaline environmentally sound coil cleaner as
described above.
CAUTION
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced
unit performance.
High velocity water from a pressure washer, garden
hose, or compressed air should never be used to clean
a coil. The force of the water or air jet will bend the
fin edges and increase airside pressure drop.
CAUTION
!
Totaline Environmentally Sound Coil Cleaner
Application Instructions
1. Proper eye protection such as safety glasses is recom-
mended during mixing and application.
2. Remove all surface loaded fibers and dirt with a vacu-
um cleaner as described above.
3. Thoroughly wet finned surfaces with clean water and
a low velocity garden hose, being carefull not to bend
fins.
4. Mix Totaline environmentally sound coil cleaner in a
21/2gallon garden spryer according to the instruc-
tions included with the cleaner. The optimum solution
temperature is 100°F(38°C).
NOTE: Do NOT USE water in excess of 130°F(54°C), as
the enzymatic activity will be destroyed.
5. Thoroughly apply Totaline environmentally sound
coil cleaner solution to all coil surfaces including
finned area, tube sheets and coil headers.
6. Hold garden sprayer nozzle close to finned areas and
apply cleaner with a vertical, up--and--down motion.
548J

10
Avoid spraying in horizontal pattern to minimize poten-
tial for fin damage.
7. Ensure cleaner thoroughly penetrates deep into finned
areas.
8. Interior and exterior finned areas must be thoroughly
cleaned.
9. Finned surfaces should remain wet with cleaning
solution for 10 minutes.
10. Ensure surfaces are not allowed to dry before rinsing.
Reapply cleaner as needed to ensure 10--minute satur-
ation is achieved.
11. Thoroghly rinse all surfaces with low velocity clean
water using downward rinsing motion of water spray
nozzle. Protect fins from damage from the spray
nozzle.
Indoor Coil
Cleaning the Indoor Coil
1. Turn unit power off. Install lockout tag. Remove in-
door coil access panel.
2. If economizer or two--position damper is installed, re-
move economizer by disconnecting Molex plug and
removing mounting screws.
3. Slide filters out of unit.
4. Clean coil using a commercial coil cleaner or dish-
washer detergent in a pressurized spray canister. Wash
both sides of coil and flush with clean water. For best
results, back--flush toward return--air section to re-
move foreign material. Flush condensate pan after
completion.
5. Reinstall economizer and filters.
6. Reconnect wiring.
7. Replace access panels.
Refrigeration System Components
Each heat pump refrigeration system includes a
compressor, accumulator, reversing valve, dual--function
outdoor coil with vapor header check valve, cooling liquid
line with filter drier and check valve, dual--function
indoor coil with vapor header check valve, and heating
liquid line with check valve and strainer. Unit sizes
04A--07A have a single compressor--circuit; unit sizes
08D and 09D have two compressor--circuits. See Fig. 14
for typical unit piping schematic (unit size 09D (4--row
indoor coil) with two compressor--circuits is depicted).
Dual--function outdoor and indoor coils are designed to
provide parallel coil circuits during evaporator--function
operation and converging coil circuits during
condenser--function operation.
Refrigerant flow metering in the evaporator--function
sequence is provided by multiple Acutrols – fixed--bore
metering devices that are located in the tee nipples
between the liquid header and the entrance to each coil
circuit. The Acutrol metering device is swaged into the
nipple tube between the liquid header end and the
side--port tube. See Fig. 15. During evaporator--function
operation, flow is straight through the nipple and into each
evaporator circuit. Flow continues through the parallel
evaporator circuits and into the vapor header.
COMPRESSOR
ACCUMULATOR
HPS
COMPRESSOR
ACCUMULATOR
HPS
Filter
Drier 2B
1B
LPS/LOC
Acutrol DFT 1
Cooling Liquid Lines
DFT 2
2A
1A
1D
2D
Outdoor Coil
Indoor Coil
Comp 2
Comp 1
2C
1C Strainer
Heating Mode Liquid Lines
Acutrol
C09228
Fig. 14 -- Typical Unit Piping Schematic (09D unit with 4--row indoor coil)
548J

11
To
Evaporato
r
Coil
Circuits
From
Liquid
Header
Metering
Orifice
C09229
Fig. 15 -- Heat Pump Acutrol — Flow as Evaporator
Function
Converging circuit flow in the condenser--function
operation is accomplished with the check valve in the
vapor header and the liquid transfer header connected to
the side ports on all but one of the Acurator tee nipples in
each circuit. During condenser--function operation, hot gas
from the compressor discharge enters the header until it
reaches the check valve which blocks further flow. The
hot gas exits the header through the tubes above the check
valve and enters these coil circuits. At the outlet of these
desuperheating and condensing circuits, the refrigerant
enters the Acurater tees from the coil end. The refrigerant
exits the tee at the side port and enters the liquid transfer
header (see Fig. 16). The refrigerant moves through the
liquid transfer header and exits through the remaining
tubes, through the side ports on the Acutrol tees (see
Fig. 17) and back into the coil circuits where additional
condensing occurs. These circuits exit into the vapor
header behind the check valve and exit through the
remaining tube on the vapor header. In this last pass
through the coil, the refrigerant is subcooled. Subcooled
liquid exits at the last Acutrol tee (see Fig. 18) where the
side port is connected to the specific mode liquid line.
From
Condenser
Coil Circuits
To
Transfer
Header
C09230
Fig. 16 -- Heat Pump Acutrol — Flow as Condenser
Function/Exiting First Pass
To
Condensing
Circuit
From
Transfer
Header
C09231
Fig. 17 -- Heat Pump Acutrol — Flow as Condenser
Function/Entering Second Pass
From
Subcoole
r
Circuit
To
Liquid
Line
DFT Location
(Outdoor Coils only)
C09232
Fig. 18 -- Heat Pump Acutrol — Flow as Condenser
Function/ Exiting Subcooler Pass
Each liquid line has a check valve to prevent backflow
through the liquid line in its opposite mode. This ensures
correct flow direction through filter driers and strainers
and prevents emptying of off--mode liquid lines into
evaporator--function coil circuits.
Reversing Valve and Check Valve Position
SeeFig.14onpage10.
Table 3 – Cooling Mode (each circuit)
Component Status/Position
Reversing Valve Energized
Check Valve A Closed
Check Valve B Open
Check Valve C Closed
Check Valve D Open
Table 4 – Heating Mode (each circuit)
Component Status/Position
Reversing Valve De---energized
Check Valve A Open
Check Valve B Closed
Check Valve C Open
Check Valve D Closed
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12
Table 5 – Defrost Mode
04A--- 07A and 08D---09D/Circuit 2:
Component Status/Position
Defrost Thermostat Closed
Outdoor Fan(s) Off
Reversing Valve Energized
Check Valve A Closed
Check Valve B Open
Check Valve C Closed
Check Valve D Open
Troubleshooting Refrigerant Pressure Problems
and Check Valves
Refer to Fig. 14, on page 10, and the Cooling Mode and
Heating Mode tables (Tables 3 and 4) on page 11.
Coil Metering Devices
The metering devices are multiple fixed–bore devices
(Acutrolt) swaged into the horizontal outlet tubes from
the liquid header, located at the entrance to each
evaporator coil circuit path. These are non–adjustable.
Service requires replacing the entire liquid header
assembly.
Check for possible blockage of one or more of these
metering devices by creating a low load condition on the
evaporator--function coil and then observing the frosting
pattern on the finned portion of the coil.
To check the indoor coil, disconnect the supply fan signal
(04A--06A direct--drive fans) or contactor (IFC) coil, then
start the circuit in a Cooling Mode (jumper R to Y1 or
Y2) and observe the frosting pattern on the face of the
indoor coil. A frost pattern should develop uniformly
across the face of the indoor coil starting at each tube at
the Acutrol nipple locations.
To check the outdoor coil, disconnect the outdoor fan
motor. Start the circuit in a Heating Mode (jumper R to
W1 or W2) and observe the frost pattern on the face of the
outdoor coil.
Failure to develop frost at an outlet tube can indicate a
plugged or a missing orifice.
Refrigerant System Pressure Access Ports
There are two access ports in each circuit -- on the suction
tube near the compressor and on the discharge tube near
the compressor. These are brass fittings with black plastic
caps. The hose connection fittings are standard 1/4 SAE
Male Flare couplings.
The brass fittings are two--piece High Flow valves, with a
receptacle base brazed to the tubing and an integral
spring--closed check valve core screwed into the base.
(See Fig. 19.) This check valve is permanently assembled
into this core body and cannot be serviced separately;
replace the entire core body if necessary. Service tools are
available from RCD that allow the replacement of the
check valve core without having to recover the entire
system refrigerant charge. Apply compressor refrigerant
oil to the check valve core’s bottom o--ring. Install the
fitting body with 96 +/--10 in--lbs of torque; do not
overtighten.
1/2-20 UNF RH
30°
0.596
.47
5/8” HEX
SEAT CORE
WASHER DEPRESSOR PER ARI 720
+.01/-.035
FROM FACE OF BODY
7/16-20 UNF RH
O-RING
45°
1/2" HEX
This surface provides a metal to metal seal when
torqued into the seat. Appropriate handling is
required to not scratch or dent the surface.
(Part No. EC39EZ067)
C08453
Fig. 19 -- CoreMax Access Port Assembly
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13
PURONR(R--410A) REFRIGERANT
This unit is designed for use with Puron (R--410A)
refrigerant. Do not use any other refrigerant in this
system.
Puron (R--410A) refrigerant is provided in pink (rose)
colored cylinders. These cylinders are available with and
without dip tubes; cylinders with dip tubes will have a
label indicating this feature. For a cylinder with a dip
tube, place the cylinder in the upright position (access
valve at the top) when removing liquid refrigerant for
charging. For a cylinder without a dip tube, invert the
cylinder (access valve on the bottom) when removing
liquid refrigerant.
Because Puron (R--410A) refrigerant is a blend, it is
strongly recommended that refrigerant always be removed
from the cylinder as a liquid. Admit liquid refrigerant into
the system in the discharge line. If adding refrigerant into
the suction line, use a commercial metering/expansion
device at the gauge manifold; remove liquid from the
cylinder, pass it through the metering device at the gauge
set and then pass it into the suction line as a vapor. Do not
remove Puron (R--410A) refrigerant from the cylinder as a
vapor.
Refrigerant Charge
Amount of refrigerant charge is listed on the unit’s
nameplate. Refer to the GTAC2--5 Charging, Recovery,
Recycling and Reclamation training manual and the
following procedures.
Unit panels must be in place when unit is operating during
the charging procedure. If unit is equipped with a head
pressure control device, bypass it to ensure full fan
operation during charging.
Charge checking and adjustments must be made while the
system is operating in Cooling only.
No Charge
Use standard evacuation techniques for Puron (R--410A)
refrigerant.. After evacuating system, weigh in the
specified amount of refrigerant.
Low--Charge Cooling
Using Cooling Charging Charts, Fig. 20 vary refrigerant
until the conditions of the appropriate chart are met. Note
the charging charts are different from type normally used.
Charts are based on charging the units to the correct
superheat for the various operating conditions. Accurate
pressure gauge and temperature sensing device are
required. Connect the pressure gauge to the service port
on the suction line. Mount the temperature sensing device
on the suction line and insulate it so that outdoor ambient
temperature does not affect the reading. Indoor--air cfm
must be within the normal operating range of the unit.
To Use Cooling Charging Charts
Take the outdoor ambient temperature and read the
suction pressure gauge. Refer to chart to determine what
suction temperature should be. If suction temperature is
high, add refrigerant. If suction temperature is low,
carefully recover some of the charge. Recheck the suction
pressure as charge is adjusted.
SIZE DESIGNATION NOMINAL TONS
REFERENCE
04A 3
05A 4
06A 5
07A 6
08D 7.5
09D 8.5
EXAMPLE:
Model 548J*04A
Outdoor Temperature 85_F(29_C)..................
Suction Pressure 140 psig (965 kPa).................
Suction Temperature should be 55_F(13_C)..........
Compressors
Lubrication
Compressors are charged with the correct amount of oil at
the factory.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to
components.
The compressor is in a PuronRrefrigerant system and
uses a polyolester (POE) oil. This oil is extremely
hygroscopic, meaning it absorbs water readily. POE
oils can absorb 15 times as much water as other oils
designed for HCFC and CFC refrigerants. Avoid
exposure of the oil to the atmosphere.
CAUTION
!
Replacing Compressor
The compressor used with Puron refrigerant contains a
POE oil. This oil has a high affinity for moisture. Do not
remove the compressor’s tube plugs until ready to insert
the unit suction and discharge tube ends.
Compressor mounting bolt torque is 65--75 in--lbs (7.3--8.5
Nm).
548J

14
COOLING CHARGING CHARTS
C09184
Fig. 20 -- Cooling Charging Charts-- 548J*04A
C09185
Fig. 20 (cont.) -- Cooling Charging Charts -- 548J*05A
548J

15
C09186
Fig. 20 (cont.) -- Cooling Charging Charts -- 548J*06A
C09187
Fig. 20 (cont.) -- Cooling Charging Charts -- 548J*07A
548J

16
C09188
Fig. 20 (cont.) -- Cooling Charging Charts -- 548J*08D
C09189
Fig. 20 (cont.) -- Cooling Charging Charts -- 548J*09D
548J

17
Compressor Rotation
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal
injury.
CAUTION
!
On 3--phase units with scroll compressors, it is important
to be certain compressor is rotating in the proper
direction. To determine whether or not compressor is
rotating in the proper direction:
1. Connect service gauges to suction and discharge pres-
sure fittings.
2. Energize the compressor.
3. The suction pressure should drop and the discharge
pressure should rise, as is normal on any start--up.
NOTE: If the suction pressure does not drop and the
discharge pressure does not rise to normal levels:
4. Note that the evaporator fan is probably also rotating
in the wrong direction.
5. Turn off power to the unit.
6. Reverse any two of the unit power leads.
7. Reapply power to the compressor.
The suction and discharge pressure levels should now
move to their normal start--up levels.
NOTE: When the compressor is rotating in the wrong
direction, the unit makes an elevated level of noise and
does not provide cooling.
Filter Drier
Replace whenever refrigerant system is exposed to
atmosphere. Only use factory specified liquid--line filter
driers with working pressures no less than 650 psig. Do
not install a suction--line filter drier in liquid line. A
liquid--line filter drier designed for use with Puron
refrigerant is required on every unit.
Outdoor Fan Location
See Fig. 21.
1. Shut off unit power supply. Install lockout tag.
2. Remove condenser--fan assembly (grille, motor, and
fan).
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 21.
5. Tighten setscrews to 84 in--lbs (9.5 Nm).
6. Replace condenser--fan assembly.
Conduit
0.14 in + 0.0 / -0.03
C08448
Fig. 21 -- Outdoor Fan Adjustment
Troubleshooting Cooling System
Refer to Table 6 for additional troubleshooting topics.
548J

18
Table 6 – Heating and Cooling Troubleshooting
PROBLEM CAUSE REMEDY
Compressor and
Outdoor Fan
Will Not Start.
Power failure. Call power company.
Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Determine root cause.
Defective thermostat, contactor, transformer,
control relay, or capacitor.
Replace component.
Insufficient line voltage. Determine cause and correct.
Incorrect or faulty wiring. Check wiring diagram and rewire correctly.
Thermostat setting too high. Lower thermostat setting below room temperature.
High pressure switch tripped. See problem ‘‘Excessive head pressure.’’
Low pressure switch tripped. Check system for leaks. Repair as necessary.
Freeze-up protection thermostat tripped. See problem ‘‘Suction pressure too low.’’
Compressor Will Not
Start But Outdoor
Fan Runs.
Faulty wiring or loose connections in compressor
circuit.
Check wiring and repair or replace.
Compressor motor burned out, seized, or
internal overload open.
Determine cause. Replace compressor or allow enough time for
internal overload to cool and reset.
Defective run/start capacitor, overload, start
relay.
Determine cause and replace compressor.
Onelegof3-phasepowerdead. Replace fuse or reset circuit breaker. Determine cause.
Compressor Cycles
(Other Than
Normally Satisfying
Thermostat).
Refrigerant overcharge or undercharge. Recover refrigerant, evacuate system, and recharge to nameplate.
Defective compressor. Replace and determine cause.
Insufficient line voltage. Determine cause and correct.
Blocked outdoor coil or dirty air filter. Determine cause and correct.
Defective run/start capacitor, overload, or start
relay.
Determine cause and replace.
Defective thermostat. Replace thermostat.
Faulty outdoor-fan (cooling) or indoor-fan
(heating) motor or capacitor.
Replace.
Restriction in refrigerant system. Locate restriction and remove.
Compressor Operates
Continuously.
Dirty air filter. Replace filter.
Unit undersized for load. Decrease load or increase unit size.
Thermostat set too low (cooling). Reset thermostat.
Low refrigerant charge. Locate leak; repair and recharge.
Air in system. Recover refrigerant, evacuate system, and recharge.
Outdoor coil dirty or restricted. Clean coil or remove restriction.
Compressor Makes
Excessive Noise.
Compressor rotating in the wrong direction. Reverse the 3-phase power leads as described in
Start-Up.
Excessive Head
Pressure.
Dirty outside air or return air filter (heating). Replace filter.
Dirty outdoor coil (cooling). Clean coil.
Refrigerant overcharged. Recover excess refrigerant.
Air in system. Recover refrigerant, evacuate system, and recharge.
Condensing air restricted or air short-cycling. Determine cause and correct.
Head Pressure
Too L o w.
Low refrigerant charge. Check for leaks; repair and recharge.
Compressor scroll plates defective. Replace compressor.
Restrictioninliquidtube. Remove restriction.
Excessive Suction
Pressure.
High heat load. Check for source and eliminate.
Compressor scroll plates defective. Replace compressor.
Refrigerant overcharged. Recover excess refrigerant.
Suction Pressure
Too L o w.
Dirty air filter (cooling). Replace filter.
Dirty or heavily iced outdoor coil (heating). Clean outdoor coil. Check defrost cycle operation.
Low refrigerant charge. Check for leaks; repair and recharge.
Metering device or low side restricted. Remove source of restriction.
Insufficient indoor airflow (cooling mode). Increase air quantity. Check filter and replace if necessary.
Temperature too low in conditioned area. Reset thermostat.
Field-installed filter drier restricted. Replace.
Outdoor ambient below 25_F (cooling). Install low-ambient kit.
Outdoor fan motor(s) not operating (heating). Check fan motor operation.
548J

19
CONVENIENCE OUTLETS
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
Units with convenience outlet circuits may use
multiple disconnects. Check convenience outlet for
power status before opening unit for service. Locate
its disconnect switch, if appropriate, and open it.
Tag--out this switch, if necessary.
!WARNING
Two types of convenience outlets are offered on 548J
models: Non--powered and unit--powered. Both types
provide a 125--volt GFCI (ground--fault circuit--interrupter)
duplex receptacle rated at 15--A behind a hinged waterproof
access cover, located on the end panel of the unit. See
Fig. 22.
Convenience
Outlet
GFCI
Pwd-CO
Fuse
Switch
Pwd-CO
Transformer
Control Box
Access Panel
C08128
Fig. 22 -- Convenience Outlet Location
Installing Weatherproof Cover –
A weatherproof while-in-use cover for the
factory-installed convenience outlets is now required by
UL standards. This cover cannot be factory-mounted due
its depth; it must be installed at unit installation. For
shipment, the convenience outlet is covered with a blank
cover plate.
The weatherproof cover kit is shipped in the unit’s control
box. The kit includes the hinged cover, a backing plate
and gasket.
DISCONNECT ALL POWER TO UNIT AND
CONVENIENCE OUTLET.
Remove the blank cover plate at the convenience outlet;
discard the blank cover.
Loosen the two screws at the GFCI duplex outlet, until
approximately 1/2-in (13 mm) under screw heads are
exposed. Press the gasket over the screw heads. Slip the
backing plate over the screw heads at the keyhole slots
and align with the gasket; tighten the two screws until
snug (do not over-tighten).
Mount the weatherproof cover to the backing plate as
shown in Fig. 23. Remove two slot fillers in the bottom of
the cover to permit service tool cords to exit the cover.
Check for full closing and latching.
RECEPTACLE
NOT INCLUDED
COVER – WHILE-IN-USE
WEATHERPROOF
BASE PLATE FOR
GFCI RECEPTACLE
C09022
Fig. 23 -- Weatherproof Cover Installation
Non--powered type: This type requires the field
installation of a general--purpose 125--volt 15--A circuit
powered from a source elsewhere in the building. Observe
national and local codes when selecting wire size, fuse or
breaker requirements and disconnect switch size and
location. Route 125--v power supply conductors into the
bottom of the utility box containing the duplex receptacle.
Unit--powered type: A unit--mounted transformer is
factory--installed to stepdown the main power supply
voltage to the unit to 115--v at the duplex receptacle. This
option also includes a manual switch with fuse, located in
a utility box and mounted on a bracket behind the
convenience outlet; access is through the unit’s control
box access panel. See Fig. 22.
The primary leads to the convenience outlet transformer
are not factory--connected. Selection of primary power
source is a customer--option. If local codes permit, the
transformer primary leads can be connected at the
line--side terminals on the unit--mounted non--fused
disconnect or HACR breaker switch; this will provide
service power to the unit when the unit disconnect switch
or HACR switch is open. Other connection methods will
result in the convenience outlet circuit being de--energized
when the unit disconnect or HACR switch is open. See
Fig. 24.
Duty Cycle: the unit--powered convenience outlet has a
duty cycle limitation. The transformer is intended to
provide power on an intermittent basis for service tools,
lamps, etc; it is not intended to provide 15--amps loading
for continuous duty loads (such as electric heaters for
overnight use). Observe a 50% limit on circuit loading
above 8--amps (i.e., limit loads exceeding 8--amps to 30
minutes of operation every hour).
Test the GFCI receptacle by pressing the TEST button on
the face of the receptacle to trip and open the receptacle.
Check for proper grounding wires and power line phasing
548J

20
if the GFCI receptacle does not trip as required. Press the
RESET button to clear the tripped condition.
CO8283
UNIT
VOLTAGE
CONNECT
AS
PRIMARY
CONNECTIONS
TRANSFORMER
TERMINALS
208,
230 240 L1: RED +YEL L2: BLU + GRA
H1 + H3
H2 + H4
460 480
L1: RED
Splice BLU + YEL
L2: GRA
H1
H2 + H3
H4
575 600 L1: RED
L2: GRA
H1
H2
Fig. 24 -- Powered Convenience Outlet Wiring
Maintenance: Periodically test the GFCI receptacle by
pressing the TEST button on the face of the receptacle.
This should cause the internal circuit of the receptacle to
trip and open the receptacle. Check for proper grounding
wires and power line phasing if the GFCI receptacle does
not trip as required. Press the RESET button to clear the
tripped condition.
Fuse on powered type: The factory fuse is a Bussman
“Fusetron” T--15, non--renewable screw--in (Edison base)
type plug fuse.
Using unit--mounted convenience outlets: Units with
unit--mounted convenience outlet circuits will often
require that two disconnects be opened to de--energize all
power to the unit. Treat all units as electrically energized
until the convenience outlet power is also checked and
de--energization is confirmed. Observe National Electrical
Code Article 210, Branch Circuits, for use of convenience
outlets.
HEAT PUMP CONTROLS
Controls Terminal Board
The Controls Terminal Board (CTB) is a large printed
circuit board that is located in the center of the unit
control box. This printed circuit board contains multiple
termination strips and connectors to simplify factory
control box wiring and field control connections.
Terminals are clearly marked on the board surface. See
Fig 25.
The CTB contains no software and no logic. But it does
include seven configuration jumpers that are cut to
configure the board to read external optional and
accessory controls, including that the unit is a heat pump.
C09274
Fig. 25 -- Controls Terminal Board (CTB)
Table 7 – Jumper Configuration
Jumper Control Function Note
JMP1 Phase Monitor
JMP2 Occupancy Control
JMP3 Smoke Detector Shutdown
JMP4 Remote Shutdown
JMP5 Heat Pump / Reheat 548J default: Cut
JMP6 Heat Pump / Reheat 548J default: Cut
JMP7 Heat Pump / Reheat 548J default: Cut
Jumpers JMP5, JMP6 and JMP7 are located in notches
across the top of the CTB (see Fig. 25 ). These jumpers
are factory cut on all heat pump units. Visually check
these jumpers to confirm that they have been cut.
PROTECTIVE CONTROLS
Compressor Protection
Overcurrent
The compressor has internal linebreak motor protection.
548J