Bryant 524J25A, 524J28A, 524J30A, 524J Series Installation, Start-up And Service Instructions Manual

524J
PACKAGED AIR--HANDLING UNITS, 60 Hz
WITH PURONR(R--410A) REFRIGERANT
SIZES 25, 28, 30

Installation, Start--Up

and Service Instructions

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 1...................

PRE--INSTALLATION 2.........................

Moving and Storage 2..........................

Rigging 2....................................

INSTALLATION 2–18..........................

General 2....................................

Uncrating 2..................................

Accessories 2.................................

Unit Positioning 9.............................

Unit Isolation 11..............................

Refrigerant Piping Access 11....................

Refrigerant Piping 11..........................

Condensate Drain 14...........................

Fan Motors and Drives 15.......................

Power Supply and Wiring 15....................

Connecting Ductwork 17.......................

Return--Air Filters 17..........................

START--UP 19.................................

SERVICE 19–32...............................

Panels 19....................................

Fan Motor Lubrication 20.......................

Fan Shaft Bearings 20..........................

Centering Fan Wheel 20........................

Fan Shaft Position Adjustment 20................

Individual Fan Wheel Adjustment 21..............

Fan Belts 21.................................

Fan Rotation 21...............................

Fan Pulley Alignment 21.......................

Pulley and Drive Adjustment 21..................

Condensate Drains 21..........................

Return--Air Filters 21..........................

Coil Removal 22..............................

Cleaning Cooling Coil 22.......................

Cleaning Insulation 22.........................

Replacing Filters 22...........................

START--UP CHECKLIST 35--36..................

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock or other conditions which may cause personal
injury or property damage. Consult a qualified installer,
service agency, or your distributor or branch for
information or assistance. The qualified installer or
agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual
instructions package

Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloths for brazing operations and
have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and appropriate
national electrical codes (in USA, ANSI/NFPA70,
National Electrical Code (NEC); in Canada, CSA C22.1)
for special requirements.

It is important to recognize safety information. This is the
safety--alert symbol

unit and in instructions or manuals, be alert to the
potential for personal injury.

Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. 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 hazards 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.

. When you see this symbol on the

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause in personal
injury or death.

Before performing service or maintenance operations
on unit, always turn off main power switch to unit and
install lockout tag. Unit may have more than one
power switch.

!

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause in personal
injury,death and/or equipment damage.

R

524J

Puron
higher pressures than standard R--22 systems. Do not
use R--22 service equipment or components on Puron
refrigerant equipment.

PERSONAL INJURY AND ENVIRONMENTAL
HAZARD

Failure to follow this warning could cause in 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.

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
524J units.

(R--410A) refrigerant systems operate at

!

WARNING

!

CAUTION

PRE--INSTALLATION

1. The power supply (v, ph, and Hz) must correspond to
that specified on unit rating plate.

2. The electrical supply provided by the utility must be
sufficient to handle load imposed by this unit.

3. Refer to Installation, General section (page 2) and
Fig. 1 and Fig. 2 for locations of electrical inlets, con­densate drain, duct connections, and required clear­ances before setting unit in place.

4. This installation must conform with local building
codes and with the NEC (National Electrical Code) or
ANSI (American National Standards Institute)/NFPA
(National Fire Protection Association) latest revision.
Refer to provincial and local plumbing or wastewater
codes and other applicable local codes.

Moving and Storage -- To transfer unit from truck to
storage site, use a fork truck. Do not stack units more than
2 high during storage. If unit is to be stored for more than
2 weeks before installation, choose a level, dry storage
site free from vibration. Do not remove plastic wrap or
skid from unit until final installation.

Rigging -- All 524J Series units can be rigged by using the
shipping skid. Units are shipped fully assembled. Do not

remove shipping skids or protective covering until unit is
ready for final placement; damage to bottom panels can
result. Use slings and spreader bars as applicable to lift
unit.

INSTALLATION

General -- Allow the following clearances for service

access and airflow:

1

S Rear: 3 ft (914 mm) [2

accessory]

1

S Front: 2
S Right Side: 3
S Left Side: 2

For units equipped with an economizer, refer to the
accessory installation instructions for additional clearance
requirements. Be sure floor, wall, or ceiling can support
unit weight (Tables 1A – 1D). See Fig. 1 and Fig. 2 for
dimensions.

Uncrating -- Move unit as near as possible to final
location before removing shipping skid.

/2ft (762 mm)

1

/2ft (1067 mm)

1

/2ft (762 mm)

/2ft (762 mm) with electric heat

!

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution could cause equipment
damage.

Ensure voltage listed on unit data plate agrees with
electrical supply provided for the unit.

Remove metal banding, top skid, and plastic wrap.
Examine unit for shipping damage. If shipping damage is
evident, file claim with transportation agency. Remove
base skid just prior to actual installation.

Check nameplate information against available power
supply and model number description in Fig. 3.

NOTE: Be sure to remove the styrofoam shipping pad
from the thermostatic expansion valve (TXV). Verify that
it has been removed. See Fig. 5.

Accessories -- Refer to instructions shipped with each
accessory for specific information.

2

Table 1A — 524J***A Physical Data, English — Cooling Units

UNIT 524J* 25A 28A 30A

NOMINAL CAPACITY (Tons) 20 25 30

OPERATING WEIGHT (lb)

Base Unit with TXV 730 1050 1062

Plenum 225 325 325

FANS

Qty...Diam. (in.) 2...15 2...18 2...18

Nominal Airflow (cfm) 8000 10000 12000

Airflow Range (cfm) 6000 – 10000 7500 – 12500 9000 – 15000

Nominal Motor Hp (Standard Motor)

208/230--- 3 ---60 and 460 --- 3---60 5.0 7.5 10.0

5 7 5 --- 3 --- 6 0 5.0 7.5 10.0

Motor Speed (rpm)

208/230--- 3 ---60 and 460 --- 3---60 1745 1745 1745

5 7 5 --- 3 --- 6 0 1745 1755 1755

REFRIGERANT R--- 410A

Operating charge (lb)
(approx per circuit)*

DIRECT--- EXPANSION COIL Enhanced Copper Tubes, Aluminum Sine---Wave Fins

Max Working Pressure (psig) 650

Face Area (sq ft) 19.88 24.86 29.83

No. of Splits 2 2 2

No. of Circuits per Split 18 20 24

Split Type...Percentage Face...50/50

Rows...Fins/in. 4...15 4...15 4...15

PIPING CONNECTIONS,

Quantity...Size (in.)

DX Coil — Suction (ODF) 2...11/

DX Coil — Liquid Refrigerant (ODF) 2...5/

Steam Coil, In (MPT) 1...21/

Steam Coil, Out (MPT) 1...1/

Hot Water Coil, In (MPT) 1...2

Hot Water Coil, Out (MPT) 1...2

Condensate (PVC) 1...11/4ODM/1 IDF

FILTERS Throwaway — Factory Supplied

Quantity...Size (in.)

Access Location Either Side

STEAM COIL**

Max Working Pressure (psig at 260° F) 20

Tota l F a ce Ar e a ( s q ft) 13.33 15.0 15.0

Rows...Fins/in. 1...10 1...10 1...10

HOT WATER COIL**

Max Working Pressure (psig) 150

Tota l F a ce Ar e a ( s q ft) 13.33 15.0 15.0

Rows...Fins/in. 2...8.5 2...12.5 2...12.5

Water Volume

(gal) 13.9 14.3

(ft3) 1.90

LEGEND

DX — Direct Expansion
TXV — Thermostatic Expansion Valve

* Units are shipped without refrigerant charge.
** Field installed accessory only.

3.5

8

4...16 x 20 x 2

4...16 x 24 x 2

4.5 5.0

2...13/

8

8

2

2

4...20 x 24 x 2

4...20 x 25 x 2

2...13/

8

524J

3

524J

Table 1B —524J***A Physical Data, SI — Cooling Units

UNIT 524J* 25A 28A 30A

NOMINAL CAPACITY (kW) 70 87 105

OPERATING WEIGHT (kg)

Base Unit with TXV 331 477 482

Plenum 102 148 148

FANS

Qty...Diam. (mm) 2...381 2...457 2...457

Nominal Airflow (L/s) 3775 4119 5663

Airflow Range (L/s) 2831 – 4719 3539 – 5899 4247 – 7079

Nominal Motor kW (St andard Motor)

208/230--- 3 ---60 and 460 --- 3---60 3.73 5.60 7.46

5 7 5 --- 3 --- 6 0 3.73 5.60 7.46

Motor Speed (r/s)

208/230--- 3 ---60 and 460 --- 3---60 29.1 29.1 29.1

5 7 5 --- 3 --- 6 0 29.1 29.3 29.3

REFRIGERANT R--- 410A

Operating charge (kg)

(approx per circuit)*

DIRECT--- EXPANSION COIL Enhanced Copper Tubes, Aluminum Sine---Wave Fins

Max Working Pressure (kPag) 4481

Face Area (sq m) 1.85 2.30 2.77

No. of Splits 2 2 2

No. of Circuits per Split 18 20 24

Split Type...Percentage Face...50/50

Rows...Fins/m 4...591 4...591 4...591

PIPING CONNECTIONS,

Quantity...Size (in.)

DX Coil — Suction (ODF) 2...11/

DX Coil — Liquid Refrigerant (ODF) 2...5/

Steam Coil, In (MPT) 1...21/

Steam Coil, Out (MPT) 1...1/

Hot Water Coil, In (MPT) 1...2

Hot Water Coil, Out (MPT) 1...2

Condensate (PVC) 1...11/4ODM/1 IDF

FILTERS Throwaway — Factory Supplied

Quantity...Size (mm.)

Access Location Either Side

STEAM COIL**

Max Working Pressure (kPag at 126°C) 138

Tota l F a ce Ar e a ( s q m) 1.24 1.39 1.39

Rows...Fins/m 1...394 1...394 1...394

HOT WATER COIL**

Max Working Pressure (kPag) 1034

Tota l F a ce Ar e a ( s q m) 1.24 1.39 1.39

Rows...Fins/m 2...335 2...335 2...335

Water Volume

(L) 52.6 54.1

(m3) 0.052 0.054

LEGEND

DX — Direct Expansion
TXV — Thermostatic Expansion Valve

* Units are shipped without refrigerant charge.
** Field installed accessory only.

1.59

8

4...406 x 508 x 51

4...406 x 610 x 51

2.04 2.27

2...13/

8

8

2

2

2...13/

4...508 x 610 x 51

4...508 x 635 x 51

8

4

Table 1C — 524J*25H Physical Data, English — Heat Pump Units

UNIT 524J* 25H

NOMINAL CAPACITY (Tons)

OPERATING WEIGHT (lb)

Base Unit with TXV 720

Plenum 140

FANS

Qty...Diam. (in.) 2...15

Nominal Airflow (cfm) 8000

Airflow Range (cfm) 6000 --- 10000

Nominal Motor Hp (Standard Motor)

208/230--- 3 ---60 and 460 --- 3---60 5.0

5 7 5 --- 3 --- 6 0 5.0

Motor Speed (rpm)

208/230--- 3 ---60 and 460 --- 3---60 1745

5 7 5 --- 3 --- 6 0 1745

REFRIGERANT

Operating charge (lb)
(approx per circuit)*

DIRECT--- EXPANSION COIL

Enhanced Copper Tubes, Aluminum Sine---Wave Fins

Max Working Pressure (psig) 650

Face Area (sq ft) 19.9

No. of Splits 2

No. of Circuits per Split 2

Split Type...Percentage Face....50/50

Rows...Fins/in. 4...15

PIPING CONNECTIONS,

Quantity...Size (in.)

DX Coil — Suction (ODF) 2...1

DX Coil — Liquid Refrigerant (ODF) 2...

Steam Coil, In (MPT) 1...2

Steam Coil, Out (MPT) 1...1

Hot Water Coil, In (MPT) 1...2

Hot Water Coil, Out (MPT) 1...2

Condensate (PVC) 1...1

FILTERS

Throwaway — Factory Supplied

Quantity...Size (in.) 4...16 x 20 x 2

Access Location RightorLeftSide

STEAM COIL**

Max Working Pressure (psig at 260° F) 20

Tota l F a ce Ar e a ( s q ft) 13.33

Rows...Fins/in. 1...10

HOT WATER COIL**

Max Working Pressure (psig) 150

Tota l F a ce Ar e a ( s q ft) 13.33

Rows...Fins/in. 2...8.5

Water Volume

(gal) 13.9

(ft3) 1.85

LEGEND

DX — Direct Expansion
TXV — Thermostatic Expansion Valve

*

Units are shipped without refrigerant charge.

** Field installed accessory only.

20

R--- 410A

3.5/3.5

1/

8

5/

8

1/

2

1/

2

1/

ODM/1 IDF

4

4...16 x 24 x 2

524J

5

524J

Table 1D — 524J*25H Physical Data, SI — Heat Pump Units

UNIT 524J* 25H

NOMINAL CAPACITY (kW)

OPERATING WEIGHT (kg)

Base Unit with TXV 326

Plenum 44

FANS

Qty...Diam. (mm) 2...381

Nominal Airflow (L/s) 3775

Airflow Range (L/s) 2831--- 4719

Nominal Motor kW (St andard Motor)

208/230--- 3 ---60 and 460 --- 3---60 3.73

5 7 5 --- 3 --- 6 0 3.73

Motor Speed (r/s)

208/230--- 3 ---60 and 460 --- 3---60 29.1

5 7 5 --- 3 --- 6 0 29.1

REFRIGERANT

Operating charge (kg)
(approx per circuit)*

DIRECT--- EXPANSION COIL

Enhanced Copper Tubes, Aluminum Sine---Wave Fins

Max Working Pressure (kPag) 4482

Face Area (sq m) 1.85

No. of Splits 2

No. of Circuits per Split 2

Split Type...Percentage Face...50/50

Fins/m 591

PIPING CONNECTIONS,

Quantity...Size (in.)

DX Coil — Suction (ODF) 2...1

DX Coil — Liquid Refrigerant (ODF) 2...

Steam Coil, In (MPT) 1...2

Steam Coil, Out (MPT) 1...1

Hot Water Coil, In (MPT) 1...2

Hot Water Coil, Out (MPT) 1...2

Condensate (PVC) 1...1

FILTERS

Throwaway — Factory Supplied

Quantity...Size (mm)

Access Location RightorLeftSide

STEAM COIL**

Max Working Pressure (kPag at 126°C) 138

Tota l F a ce Ar e a ( s q m) 1.24

Rows...Fins/m 1...394

HOT WATER COIL**

Max Working Pressure (kPag) 1034

Tota l F a ce Ar e a ( s q m) 1.24

Rows...Fins/m 2...335

Water Volume

(L) 52.6

(m3) 0.052

LEGEND

DX — Direct Expansion
TXV — Thermostatic Expansion Valve

*

Units are shipped without refrigerant charge.

** Field installed accessory only.

70

R--- 410A

1.59/1.59

1/

8

5/

8

1/

2

1/

2

1/

ODM/1 IDF

4

4...406 x 610 x 51

4...406 x 508 x 51

6

LEGEND

TXV — Thermostatic Expansion Valve
NOTES:

1. Dimensions in [ ] are in millimeters.

2. Direction of airflow.

3. Recommended clearance:

• Rear: 3 in. [914 mm] (2 ft, 6 in. [762 mm]
with electric heat accessory)

• Front: 2 ft, 6 in. [762 mm]

• Right Side: 2 ft, 6 in. [762 mm]

• Left Side: 2 ft, 6 in. [762 mm]

• Local codes or jurisdiction may prevail.

4. Liquid piping not supplied by Carrier.

5. Duct flange is factory supplied and field
installed.

524J

Fig. 1 -- Dimensions – Size 25

7

UNIT

524J*25A 730 (331)
524J*25H 720 (326)

UNIT WEIGHT

lb (kg)

C10834

524J

LEGEND

TXV — Thermostatic Expansion Valve
NOTES:

1. Dimensions in [ ] are in millimeters.

2. Direction of airflow.

3. Recommended clearance:

• Rear: 3 in. [914 mm] (2 ft, 6 in. [762 mm]
with electric heat accessory)

• Front: 2 ft, 6 in. [762 mm]

• Right Side: 2 ft, 6 in. [762 mm]

• Left Side: 2 ft, 6 in. [762 mm]

• Local codes or jurisdiction may prevail.

4. Liquid piping not supplied by Carrier.

5. Duct flange is factory supplied and field
installed.

6. 40RUS may require alternate or additional
field favricated poping access holes

Fig. 2 -- Dimensions – Sizes 28 and 30

8

UNIT

524J*28A
524J*30A

lb (kg)

1050 (477)
1062 (482)

C10835

Model Type

524J = Bryant Fan Coil
Puronr R--- 410A Refrigerant

Voltage

E = 460/3/60
P = 208 / 230/3/60
T = 575/3/60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

5 2 4 J E 2 5 A 0 0 0 A 2 0 A A A

_____________

____

Not Used

A = Not Used

Service Options

A=None

B = Painted Cabinet

Packa ging

A=Standard

Nominal Tonnage

25 = 20 Tons
28 = 25 Tons
30 = 30 Tons

Typ e o f C oi l

A = Standard DX Coil
B = High Capacity DX Coil
H = DX Coil for Heat Pump Duty

Not Used

0=Not Used

Not Used

0=Not Used

POSITION NUMBER
TYPICAL

Not Used

0 = Not Used

Indoor Fan Options

1 = Fan Drive and Motor - Low / Motor Efficency - Standard
2 = Fan Drive and Motor - Med / Motor Efficency - Standard
3 = Fan Drive and Motor - High / Motor Efficency - Standard

Coil Options

A=Al/Cu

Not Used

0 = Not Used

C10837

Fig. 3 -- Model Number Nomenclature

12345678910
2610G12345

SETANGISEDNOITISOP

)radnelac lacsif( erutcafunam fo keeW1−2

Year of manufacture (“10” = 2010)3−4

)ASU ,saxeT ,PTE = G( noitacol gnirutcafunaM5

rebmun laitneuqeS6−10

C!0725

Fig. 4 -- Serial Number Nomenclature

524J

TXV COIL

REMOVE FOAM BLOCK

LEGEND

TXV — Thermostatic Expansion Valve

C10683

Fig. 5 -- Foam Block Location

Unit Positioning -- The unit can be mounted on the floor

for vertical application with return air entering the face of
the unit and supply air discharging vertically through the
top of the unit. The unit can also be applied in a
horizontal arrangement with return air entering

horizontally and the supply air discharging horizontally.
When applying the unit in a horizontal arrangement,
ensure the condensate drain pan is located at the bottom
center of the unit for adequate condensate disposal. See
Fig. 6 for condensate connections for each unit position.

PLUG

PLUG

Note: Maintain recommended clearances

CONDENSATE
DRAIN

LEGEND

Accessory Line
Alternate Air Intake and Discharge

Air Intake and Discharge

per Fig. 1 and Fig. 2

C10684

Fig. 6 -- Typical Unit Positioning

9

Typical positioning and alternate return air locations are
shown in Fig. 6. Alternate return air locations can be used
by moving the unit panel from the alternate return air
location to the standard return air location. Refer to
overhead suspension accessory drawing (Fig. 7) for

OVERHEAD SUSPENSION ACCESSORY — UNIT SIZE 25

524J

preferred suspension technique. The unit needs support
underneath to prevent sagging.

IMPORTANT: Do NOT attempt to install unit with return
air entering top panel of unit. Condensate will not drain from
unit.

OVERHEAD SUSPENSION ACCESSORY — UNIT SIZES 28, 30

NOTE: Dimensions in [ ] are millimeters

Fig. 7 -- Preferred Suspension Technique

C10728

10

Unit Isolation -- Where extremely quiet operation is
essential, install isolators between floor and base of unit,
or between ceiling and top section of unit.

Be sure that unit is level and adequately supported. Use
channels at front and sides of unit for reference points
when leveling.

Refrigerant Piping Access -- The 524J Series units come
with standard knockouts for refrigerant piping. These
knockouts are located on both sides of the unit for
installation flexibility. The standard knockouts provide
sufficient access to the unit’s coils for all 524J*25A, 28A
and 30A units. The 524J*25H requires additional holes
which must be field--fabricated to accommodate the
piping. See Fig. 8 for positions and dimensions for the
additional access holes required. Recommended access
hole use is also listed for all units. Note that Fig. 8 shows
the access holes on the control--box side of the unit; this is
the side of the unit with the coil headers, so it is used most
often for piping access.

IMPORTANT: Do not bury refrigerant piping
underground.

Refrigerant Piping -- See Tables 1A–1D for refrigerant
pipe connection sizes. For ease in brazing, it is
recommended that all internal solder joints be made
before unit is placed in final position.

The 524J direct--expansion units have internal
factory--installed thermostatic expansion valves (TXVs),
distributors, and nozzles for use with R--410A. See Table 2
for part numbers. Knockouts are provided in the unit corner
posts for 524J refrigerant piping. See Fig. 8, which also lists
recommended knockouts and access holes to use for each
524J unit size. Recommended fittings are listed in Table 3.

The sensor bulb capillary tubes must be routed from the
TXVs inside the unit through one of the piping access
holes. Clamp the TXV sensor bulb on a vertical portion of
the suction line, outside the unit. See Fig. 9.

NOTE: Be sure to remove the styrofoam shipping pad
from the TXV. Verify that it has been removed. See Fig. 5.

IMPORTANT: Never attach the sensor to the suction
manifold. Do NOT mount the sensor on a trapped portion
of the suction line.

The 524J Series evaporator coils have a face--split design.
Ensure that lower circuit of coil is first on/last off when
connected to the condensing unit and/or system controls.
See Fig. 10.

External TXV equalizer connections are provided and
factory--brazed into the coil suction manifolds.

If suction line must be horizontal, clamp bulb to suction
line at least 45 degrees above bottom, at approximately
the 4 o’clock or 8 o’clock position. See Fig.11.

524J

7
6
5

4
3

2
1

UNIT

524J*25A, 28A, 30A 1,2, 3, 4 — — — — — —

524J*25H 3*,5,6,7 11/8(28.6) 11/8(28.6) 13/4(44.5) 3.25 (82.6) 6.125 (155.6) 10.38 (263.7)

*Must be enlarge d from 11/8in. (28.6mm) to 13/4in. (44.5mm)
N O TE : Acc e s s ho l e k no cko u t s 1 --- 4 ar e fact o r y --- s u p p l i e d .

USE HOLE
NUMBERS

FIELD-- FABRIC ATED HOLE DIAMATERS

in. ( mm)

No. 5 No. 6 No. 7 A B C

A

FIELD-- FABRIC ATED HOLE POSITION DIMENSIONS

B

C

in. ( mm)

Fig. 8 -- Refrigerant Piping Access Holes

11

C10838