Bryant 538J-18-1 User Manual
installation, start-up and
service instructions
LIGHT COMMERCIAL
CONDENSING UNITS
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
I. Complete Pre-Installation Checks . . . . . . . . . . . . . . 1
II. Rig and Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III. Complete Refrigerant Piping Connections . . . . . . . 3
IV. Make Electrical Connections
V. Accessory Installation. . . . . . . . . . . . . . . . . . . . . . . . 4
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
I. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
II. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
III. Cleaning Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . 4
538J
Sizes 018-060
Cancels: New II 538J-18-1
1/15/02
I. COMPLETE PRE-INSTALLATION CHECKS
A. Unpack Unit
Move unit to final location. Remove unit packaging being
careful not to damage service valves or grilles.
B. Inspect Shipment
File claim with shipping company if shipment is damaged or
incomplete. Check unit nameplate to ensure unit matches
job requirements.
C. Consider System Requirements
Consult local b uilding codes and NEC for special installation
requirements.
Allow sufficient space for air flow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1 and 2. Unit can be
mounted on a level pad directly on base legs or mounted on
raised pads at support points. See Fig. 2 for center of gravity.
SAFETY CONSIDERATIONS
Installing and servicing air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install or service air-conditioning equipment.
Untrained personnel may perform basic maintenance such
as cleaning an d rep l ac ing f ilt er s. All oth er ope ra tio n s sho ul d
be performed by trained service personnel. When working on
air-conditioning equipment, observe safety precautions in
literature, and on tags and labels attached to unit.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for brazing operations. Have a fire extinguisher available. Read these instructions thoroughly. Consult local building codes and National Electrical Cod e (NEC,
U.S.A. Standard) for special installation requirements.
INSTALLATION
WARNING: Before installing or servicing system,
always turn off main power to system. There may be
more than one disconnect switch. Turn off accessory
heater power if applicable. Electrical shock can cause
personal injury.
C
O
O
LIN
G
Fig. 1 — Typical Condensing Unit
WEIGHT
OPERATING
15.88 130 58.9
15.88 136 61.6
19.05 161 73.0
19.05 185 83.9
22.22 222 100.5
22.22 249 112.9
8
8
4
4
8
/
/
/
5
5
3
285.8 0-0
295.3 0-0
295.3 0-0
4
8
8
/
/
/
1
5
5
168.3 0-11
171.5 0-11
171.5 0-11
8
4
4
/
/
/
5
3
3
8
/
/
/
3
7
7
295.3 0-0
403.2 0-0
8
8
/
/
5
7
171.5 0-11
209.5 0- 4 406.4 0-0
206.4 0- 3
4
4
8
/
/
/
3
1
1
352.4 0-8
347.7 0-8
16
/
8
/
7
11
Support Feet
MINIMUM MOUNTING PAD DIMENSIONS
ft-in. mm
538J
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
817.6 1-1
817.6 1-1
8
8
8
8
16
/
/
/
1
1
1
444.5 1-8
444.5 1-8
444.5 1-8
2
2
2
/
/
/
1
1
1
16
/
/
/
1
3
3
444.5 1-8
752.5 2-8
752.5 2-8
2
8
8
/
/
/
1
5
5
UNIT SIZE
048 and 060 2- 0 x 4-2 609.6 x 1270.0
018,024,030 and 036 1-11 x 3-6 584.2 x 1066.8
clearance on compressor end and coil side. With multi-unit application, arrange units so discharge of
one does not enter inlet of another.
coil end, and 3 ft (914.4 mm) minimum clearance on compressor end and fan side. With fan facing
wall, allow 8″ (203.2 mm) minimum clearance on fan side and coil end, and 3 ft (914.4 mm) minimum
2. Dimensions in parenthesis are in millimeters.
NOTES:
1. Required clearances: With coil facing wall, allow 6″ (156.4 mm) minimum clearance on coil side and
3. Center of gravity .
436.6 1-5
436.6 1-5
436.6 1-5
16
16
/
/
/
3
3
3
595.3 1-5
595.3 1-5
595.3 1-5
16
16
/
/
/
7
7
7
369.9 1-4 406.4 1-11
369.9 1-4 406.4 1-11
369.9 1-4 406.4 1-11
16
16
/
/
/
9
9
9
938.2 1-2
938.2 1-2
938.2 1-2
16
16
/
/
/
15
15
15
638.2 3-0
638.2 3-0
ABCD E FGHJKLM
ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm lb kg
638.2 3-0
8
8
/
/
/
1
1
1
436.6 1-5
498.5 2-5
498.5 2-5
8
16
16
16
16
8
8
16
/
/
/
5
5
3
595.3 1-5
774.7 1-7
774.7 1-7
2
2
16
/
/
/
1
1
7
468.3 2- 6
468.3 2- 6
16
16
/
/
7
7
369.9 1-4 406.4 1-11
433.4 1-6
433.4 1-6
16
16
16
/
/
/
9
1
1
938.2 1-2
1131.9 1-5
1131.9 1-5
16
/
16
16
/
/
15
9
9
638.2 3-0
944.6 3-8
944.6 3-8
8
16
16
/
/
/
1
3
3
Fig. 2 — 538J018-060 — Dimensional Drawing
SIZE
UNIT
538J
024 2-1
030 2-1
036 2-1
048 3-1
018 2-1
060 3-1
—2—
II. RIG AND MOUNT UNIT
A. Mounting on Ground
Mount unit on a solid, level concrete pad. Position unit so
water or ice from roof does not fall directly i nto unit. Fieldfabricated stacking kits can be used when units are to be
stacked. If conditions or local codes require unit to be fastened to a pad, 6 field-supplied tiedown bolts should be used
and fastened through slots provided in unit mounting feet.
B. Mounting on Roof
Mount unit on level platform or frame at least 6 in. above
roof surface. Isolate unit and tubing from structure.
C. Rigging
CAUTION: Be sure unit panels are securely in
place prior to rigging.
Keep unit upright. Lift unit using sling. Use cardboard or
padding under sling, and spreader bars to prevent sling
damage to unit. See Fig. 3. See Fig. 2 for center of gravity reference. Install unit so coil does not face into prevailing
winds. If this is not possible and constant winds above
25 mph are expected, use field-fabricat ed wind baffle.
NOTE: Accessory wind baffles should be used on all units
with accessory low-ambient control.
Field-fabricat ed snow stan d may be used to rai se unit when
operation will be required during the winter. Units may also
be wall mounted using the accessory wall mounting kit.
III. COMPLETE REFRIGERATION PIPING CONNECTIONS
Outdoor units may be connected to indoor units using fieldsupplied tubing of refrigerant grade and condition. See
Tables 1A and 1B for correct line sizes. Do not use less than
10 ft (3 m) of interconnecting tubing.
CAUTION: DO NOT BURY MORE THAN 36 IN.
(922 mm) OF REFRIGERANT PIPE IN THE
GROUND. If any section of pipe is buried, there must
be a 6 in. (154 m) ver tic al r ise to the valv e con nec tion s
on the outdoor unit. If more than the recommended
length is buried, refrigerant m ay migra te to the coole r,
buried section duri ng extended periods of system shutdown. This causes refrigerant slugging and could damage compressor at start-up.
Fig. 3 — Lifting Unit with Sling
A. Check AccuRater® Control
The AccuRater refrigerant control is required for cooling system capacity optimization. An AccuRater device with fieldreplaceable piston should be supplied with the indoor unit.
Refer to AccuRater metering de vice table in separate indoor
unit installation instructi ons to determine the corre ct AccuRater piston size required for the condenser/evaporator system being installed.
Note that one of 2 types of the AccuRater devices can be
used. Use Type A only if Type B is unavailable. See Fig. 4. Do
not interchange components between AccuRater device
types. Matching of outdoor unit with indoor unit may require
field replacement of piston. Replace piston, if required,
before connecting refrigerant lines. Piston replacement
instructions are included in the indoor unit installation
instructions. After system installation is complete, see
Refrigerant Charging section on page 8 to check and/or
adjust refrigerant charge.
The 538J series units may also be installed with units using
a thermostatic expansion valve (TXV). If a TXV is used, be
sure to remove the pi ston from the i ndoor coil. See i nstallation instruction s shipped with the TXV for proper posi tioning and adjustment.
When more than 50 ft (15.2 m) of interconnecting tubing and
more than 30 ft (9.1 m) of vertical lift is used, refer to Part 3
of the System Desig n Manual for design details, or contac t
your local distributor.
If either refrig era nt tu b ing or i ndoor co il is e xp ose d to a tmo spheric condit ions for long er than 5 minu tes , it must be evac uated to 1000 microns to eliminate contamination and
moisture in the system.
Run refrigerant tubes as directly as possible, avoiding
unnecessary turns and bend s. Suspend refrigerant tubes so
they do not damage insulation on vapor tube and do not
transmit vibration to the structure. Also, when passing
refrigerant tubes through the wall, seal opening so that
vibration is not transmitted to structure. Leave some slack
in refrigerant tubes between structure and outdoor unit to
absorb vibration. Refer to separate indoor unit installati on
instructions for additiona l information.
TYPE A (FIELD-INSTALLED BYPASS TYPE)
TYPE B (RECOMMENDED)
NOTE: Arrow on AccuRater body points in free-flow direction, away
from the indoor coil.
Fig. 4 — AccuRater Metering Device Components
—3—
B. Make Piping Sweat Connections
Remove plastic caps from liquid and suction service valves.
Use refrigerant gr ade tubi ng. Service val ves are closed from
the factory and ready for brazing. After wrapping the service
valve with a wet cloth, the tubing set can be brazed to the
service valve using either silver bearing or non-silver bearing brazing material. Consult local code requirements.
Refrigerant tubing and indoor coil are ready for leak testing.
NOTE: Unit is shipped with a full factory charge of R-22
refrigerant as indicated on nameplate.
Pass nitrogen or other inert gas through piping while brazing to prevent formation of copper oxide.
CAUTION: To avo id da ma ge whil e b ra zing, serv ice
valves should be wrapped in a heat-sinking material
such as a wet cloth .
CAUTION: When brazing tubing sets to the service valves, a brazing shield must be used to prevent
damage to the painted unit surface.
C. Provide Safety Relief
A fusible plug is located in unit suction line; do not cap this
plug. If local code requires addition al safety devices, insta ll
as directed.
IV. MAKE ELECTRIAL CONNECTIONS
WARNING: Unit cabinet must have an uninter-
rupted, unbroken electrical ground to minimize the
possibility of personal injury if an electrical fault
should occur. This ground ma y co nsist of electrical wir e
connected to the unit ground lug in control compartment, or conduit approved for electrical ground when
installed in accordance with NEC, ANSI/NFP A (Ame rican National Standards Institute/National Fire Protection Association) 70, and local electrical codes. Failure
to follow this warning could result in the installer
being liable for personal injury to others.
CAUTION: Unit failu re as a result of oper ation on
improper line voltage or excessive phase imbalance
constitutes abuse and may cause damage to electrical
components. Such operation will invalidate any applicable warranty.
A. Power Wiring
Unit is factory-w ired for voltage shown on nameplate. Provide adequate, fused disconnect switch within sight of unit,
readily accessible but out of reach of children. Provi sion for
locking the switch open (off) is advisable to prevent power
from being turn ed on w hile unit is be ing s erviced . Di sco nnect
switch, fuses, and field wiring must be in compliance with
NEC (U.S.A. Standard) and applicable local codes. Use minimum 60 C wire for field power connection.
Route power wires through opening in the unit side panel
and connect in unit control box as shown on unit label diagram and Fig. 5 and 6. Unit must be grounded.
B. Control Circuit Wiring
Control voltage is 24 v. See Fig. 5 and unit label diagram for
field-supplied wiring details. Route control wire through
opening in the unit side panel to connection in unit control
box.
NOTE: For wire runs up to 50 ft (15 m), use no. 18 AWG
(American Wire Gage) insulate d wire (35 C minimum). For
50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire. For
more than 75 ft (23 m), use no. 14 AWG insulated wire. See
Table 2 for conversion to European wire sizes.
NOTE: Oper ation of unit on imp rope r lin e vol tage c onst itute s
abuse and co uld af fect any appl ic able warran ty. See Table 3.
Do not install unit in system where voltage may fluctuate
above or below permissible limits.
See Table 3 for recommended fuse sizes. When making electrical connections, provide cle arance at unit for refrigerant
piping connections.
Use indoor unit transfo rmer a s 24-v (40-v a min imum) supply
for system as shown in Fig. 5 or use accessory transformer.
WARNING: Before performing service or maintenance, be sure the indoor unit main power switch is off
and indoor blower has completely stopped. Failure to
do so may result in electrical shock or injury from
rotating fan blades.
C. Connections to Duct-Free Fan Coil Units
The 538J units are designed for easy match-up to 619C,
619F, 619ENX018 and 619ENX024 duct-free fan coils. These
units provide 24 -v power for the outdoor u nit from the fan
coil. Connect the Y and C terminals of the indoor unit to the
blue and brown wires of the outdoor unit with 20 gage (minimum) thermostat wire.
V. ACCESSORY INSTALLATION
Install all unit a ccessories per accessory installation instructions prior to start-up.
Do not use accessory Time Guard® II device when combining
a 538J unit with 619E indoor units.
When ambient temp erature will fall be low 55 F (1 3 C), a ccessory low ambient controller (part no. 53DS900060) is
required. When accessory low ambient kit is used, unit
should also be equipped with accessory winter start kit and
field-fabricated wind baffles.
—4—
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