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 . 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,
CAUTION, and NOTE. These words are used with the safetyalert 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.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause 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.
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.
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.
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.
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.
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. 1A and Fig. 1B 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 2
clearance and airflow. 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. 1A and Fig. 1B
for dimensions.
Uncrating — Move unit as near as possible to final
location before removing shipping skid.
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. 2.
NOTE: Be sure to remove the styrofoam shipping pad from
the thermostatic expansion valve (TXV). Verify that it has
been removed. See Fig. 3.
Accessories — Refer to instructions shipped with each
accessory for specific information.
1
/2 ft at front and side of unit for service
2
Table 1A — 524J***A Physical Data, English — Cooling Units
UNIT 524J*07A08A12A14A16A
8
2
2
1
2250-
3750
1...11/
/
2
8
2
1
/
2
10121/
3000-
5000
2...11/
8
1
/4 ODM/1 IDF
3750-
6250
2...11/
2...5/
1...21/
1..11/
2
8
8
2
2
15
4500-
7500
2...11/
8
1...2
1...2
4...16 x 20 x 2
4...16 x 24 x 2
NOMINAL CAPACITY (Tons)67
OPERATING WEIGHT (lb)
Base Unit with TXV381385405670685
Plenum175175175225225
208/230-1-601.32.4———
208/230-3-60 and 460-3-602.42.42.42.93.7
575-3-601.02.02.03.03.0
Motor Speed (rpm)
208/230-1-6017251725———
208/230-3-60 and 460-3-6017251725172517251725
575-3-6017251725172517251725
REFRIGERANTR-410A
Operating charge (lb)
(approx per circuit
†
3.03.01.5/1.52.0/2.02.5/2.5
DIRECT-EXPANSION COILEnhanced Copper Tubes, Aluminum Sine-Wave Fins
Max Working Pressure (psig)450
Face Area (sq ft)6.678.3310.013.2517.67
No. of Splits11 2 2 2
No. of Circuits per Split121591216
Split Type...Percentage——Face...50/50
Fins/in.1515151515
PIPING CONNECTIONS,
Quantity...Size (in.)
DX Coil — Suction (ODF)1...1
1
/
8
DX Coil — Liquid Refrigerant (ODF)1...5/
Steam Coil, In (MPT)1...21/
Steam Coil, Out (MPT)1...11/
Hot Water Coil, In (MPT)1...11/
Hot Water Coil, Out (MPT)1...1
Condensate (PVC)1...1
FILTERSThrowaway — Factory Supplied
Quantity...Size (in.)4...16 x 24 x 2
Access LocationEither Side
STEAM COIL**
Max Working Pressure (psig at 260°F)20
Total Face Area (sq ft)6.676.676.6713.3313.33
Rows...Fins/in.1...91...91...91...101...10
HOT WATER COIL**
Max Working Pressure (psig)150
Total Face Area (sq ft)6.676.676.6713.3313.33
Rows...Fins/in.2...8.52...8.52...8.52...8.52...8.5
Water Volume
Table 1B — 524J***A Physical Data, SI — Cooling Units
UNIT 524J*07A08A12A14A16A
NOMINAL CAPACITY (kW)2126354352
OPERATING WEIGHT (kg)
Base Unit with TXV173175184304311
Plenum808080102102
FANS
Qty...Diam. (mm)1...3811...3811...3812...3812...381
Nominal Airflow (L/s)11331604188823602831
Airflow Range (L/s)850-14161203-20061416-23601770-29492124-3539
Nominal Motor kW (Standard Motor)
208/230-1-600.971.79———
208/230-3-60 and 460-3-601.791.791.792.162.16
575-3-600.751.491.492.242.24
Motor Speed (r/s)
208/230-1-6028.828.8———
208/230-3-60 and 460-3-6028.828.828.828.828.8
575-3-6028.828.828.828.828.8
REFRIGERANTR-410A
Operating charge (kg)
(approx per circuit)
†
DIRECT-EXPANSION COILEnhanced Copper Tubes, Aluminum Sine-Wave Fins
Max Working Pressure (kPag)3102
Face Area (sq m)0.620.770.930.931.64
No. of Splits11 2 2 2
No. of Circuits per Split121591216
Split Type...Percentage——Face...50/50
Fins/m591591670591591
PIPING CONNECTIONS,
Quantity...Size (in.)
DX Coil — Suction (ODF)1...1
DX Coil — Liquid Refrigerant (ODF)1...5/
Steam Coil, In (MPT)1...21/
Steam Coil, Out (MPT)1...11/
Hot Water Coil, In (MPT)1...11/
Hot Water Coil, Out (MPT)1...1
Condensate (PVC)1...1
FILTERSThrowaway — Factory Supplied
Quantity...Size4...406 x 610 x 51
Access LocationEither Side
STEAM COIL**
Max Working Pressure (kPag at 126°C)138
Total Face Area (sq m)0.620.620.621.241.24
Rows...Fins/m1...3551...3551...3551...3941...394
HOT WATER COIL**
Max Working Pressure (kPag)1034
Total Face Area (sq m)0.620.620.621.241.24
Rows...Fins/m2...3352...3352...3352...3352...335
Water Volume
Table 1C — 524J***H Physical Data, English — Heat Pump Units
UNIT 524J*07H08H12H
NOMINAL CAPACITY (Tons)
67
OPERATING WEIGHT (lb)
Base Unit with TXV385385427
Plenum175175175
FANS
Qty...Diam. (in.)1...151...151...15
Nominal Airflow (cfm)240030004000
Airflow Range (cfm)1800-30002250-37503000-5000
Nominal Motor Hp (Standard Motor)
208/230-1-601.32.4—
208/230-3-60 and 460-3-602.42.42.4
575-3-601.02.02.0
Motor Speed (rpm)
208/230-1-6017251725—
208/230-3-60 and 460-3-60172517251725
575-3-60172517251725
REFRIGERANT
Operating charge (lb)
(approx per circuit)
†
DIRECT-EXPANSION COIL
3.03.02.0/2.0
Enhanced Copper Tubes, Aluminum Sine-Wave Fins
Max Working Pressure (psig)450
Face Area (sq ft)8.338.3310.0
No. of Splits112
No. of Circuits per Split15159
Split Type...Percentage———
Rows...Fins/in.3...153...153...15
PIPING CONNECTIONS,
Quantity...Size (in.)
DX Coil — Suction (ODF)1...1
DX Coil — Liquid Refrigerant (ODF)1...5/
Steam Coil, In (MPT)1...21/
Steam Coil, Out (MPT)1...11/
Hot Water Coil, In (MPT)1...11/
Hot Water Coil, Out (MPT)1...11/
1
/
8
8
2
2
2
2
Condensate (PVC)1...11/4 ODM/1 IDF
FILTERS
Quantity...Size (in.)4...16 x 24 x 2
Access LocationEither Side
STEAM COIL**
Max Working Pressure (psig at 260°F)
Total Face Area (sq ft)6.676.676.67
Rows...Fins/in.1...91...91...9
HOT WATER COIL**
Max Working Pressure (psig)150
Total Face Area (sq ft)6.676.676.67
Rows...Fins/in.2...8.52...8.52...8.5
Water Volume
Table 1D —524J***H Physical Data, SI — Heat Pump Units
UNIT 524J*07H08H12H
NOMINAL CAPACITY (kW)
OPERATING WEIGHT (kg)
Base Unit with TXV175175194
Plenum808080
FANS
Qty...Diam. (mm)1...3811...3811...381
Nominal Airflow (L/s)113316041888
Airflow Range (L/s)850-14161203-20061416-2360
Nominal Motor kW (Standard Motor)
208/230-1-600.971.79—
208/230-3-60 and 460-3-601.791.791.79
575-3-600.751.491.49
Motor Speed (r/s)
208/230-1-6028.828.8—
208/230-3-60 and 460-3-6028.828.822.8
575-3-6028.828.822.8
REFRIGERANT
Operating charge (kg)
(approx per circuit)
†
DIRECT-EXPANSION COIL
Max Working Pressure (kPag)3102
Face Area (sq m)0.770.770.93
No. of Splits112
No. of Circuits per Split12159
Split Type...Percentage———
Rows...Fins/m3...5913...5913...591
PIPING CONNECTIONS,
Quantity...Size (in.)
DX Coil — Suction (ODF)1...1
DX Coil — Liquid Refrigerant (ODF)1...5/
Steam Coil, In (MPT)1...21/
Steam Coil, Out (MPT)1...11/
Hot Water Coil, In (MPT)1...11/
Hot Water Coil, Out (MPT)1...11/
Condensate (PVC)1...11/4 ODM/1 IDF
FILTERS
Quantity...Size (mm)4...406 x 610 x 51
Access LocationEither Side
STEAM COIL**
Max Working Pressure (kPag at 126°C)138
Total Face Area (sq m)0.620.620.62
Rows...Fins/m1...3551...3551...355
HOT WATER COIL**
Max Working Pressure (kPag)1034
Total Face Area (sq m)0.620.620.62
524J = Bryant Fan Coil
Puronr R---410A Refrigerant
A=Standard
Typ e o f C oil
Service Options
B = High Capacity DX Coil
H = DX Coil for Heat Pump Duty
A = Standard DX Coil
A=None
B = Painted Cabinet
Indoor Fan Options
1 = Fan Drive and Motor - Low / Motor Efficency - Standard
2 = Fan Drive and Motor - Med / Motor Efficency - Standard
Not Used
A = Not Used
Not Used
0 = Not Used
Not Used
0 = Not Used
Coil Options
A=Al/Cu
Not Used
0 = Not Used
Not Used
0 = Not Used
3 = Fan Drive and Motor - High / Motor Efficency - Standard
Voltage
E = 460/3/60
P = 208/ 230/3/60 (Size 16 and Indoor Fan 3 Units Only)
J = 208/ 230/1/60 (07 and 08 Units Only)
T = 575/3/60
____
Nominal Tonnage
07 = 6 Tons
08 = 7.5 Tons
14 = 12.5 Tons
12 = 10 Tons
16 = 15 Tons
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POSITION NUMBER
TYPICAL
Year of manufacture (”08” = 2008)3−4
LEGEND
TXV — Thermostatic Expansion Valve
Fig. 2 — Model Number Nomenclature
Fig. 3 — Serial Number Nomenclature
Fig. 4 — Foam Block Location
9
Unit Positioning — The unit can be mounted on the
LEGEND
Accessory Line
Alternate Air Intake and Discharge
Air Intake and Discharge
Note:
Maintain recommended clearances
per Figs. 1A–1B
UNIT SIZES 14 - 16
NOTE: Dimensions in [ ] are millimeters
UNIT SIZES 07 - 12
OVERHEAD SUSPENSION ACCESSORY
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. 5 for condensate connections for each unit
position.
Typical positioning and alternate return air locations are shown
in Fig. 5. 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. 6) for 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.
Fig. 5 — Typical Unit Positioning
Fig. 6 — Preferred Suspension Technique
10
Unit Isolation — Where extremely quiet operation is
UNIT
USE HOLE
NUMBERS
524J*07A, 08A
524J*07H, 08H
1, 3
524J*12A, 14A, 16A
524J*12H
1, 2, 3, 4
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*07A, 08A, 12A, 14A and 16A units
as well as the 524J*07H, 08H, 12H units. See Fig. 7 for the
positions. Recommended access hole use is also listed for all
units. Note that Fig. 7 shows the access holes on the controlbox 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 refriger-
ant 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. 7, 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. 8.
NOTE: Be sure to remove the styrofoam shipping pad from
the TXV. Verify that it has been removed. See Fig. 4.
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. 8.
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. 9.
4
3
2
1
Fig. 7 — Refrigerant Piping Access Holes
11
UPPER
LEGEND:
TXV – Thermostatic Expansion Valve
NOTE: Component location arrangement shown for field installation of
sight glasses, solenoid valves, filter driers, and TXV sensing bulbs.
The TXVs and equilizer lines are factory installed.
FIRS T ON/L AST OFF = B
VERTICAL INSTALLATION
FIRS T ON/LAST OFF = A
HORIZONTAL INSTALLATION
LEGEND
TXV — Thermostatic Expansion Valve
NOTE: The 8 o’clock position is shown above.
SPLIT
AIRFLOW
TXV
SENSING
BULB
15 DIAMS
MIN
10
DIAMS
8 DIAMS
MIN
EQUALIZER LINE
FILTER
DRIER
TXV
SOLENOID
VALV E
SIGHT
GLASS
UPPER
SPLIT
AIRFLOW
LOWER
SPLIT
AIRFLOW
TXV
SENSING
BULB
15 DIAMS
MIN
TXV
SENSING
BULB
15 DIAMS
MIN
10
DIAMS
10
DIAMS
8 DIAMS
MIN
8 DIAMS
EQUALIZER LINE
TXV
EQUALIZER
LINE
TXV
MIN
INDOOR
COIL
FILTER
DRIER
SOLENOID
VALV E
SIGHT
GLASS
Single Circuit Coil Piping Configuration - 524J*07, 08
For single compressor condensing units.
Fig. 8 — Face-Split Coil Suction and Liquid Line Piping (Typical)
NOTE: Hot gas bypass applications require field-supplied auxiliary side connector.
Table 3 — Fitting Requirements
UNIT
ACCESS
HOLE NO.
†
1Suction—
524J*07A
524J*07H
3Liquid—
1Suction—
524J*08A
524J*08H
3Liquid—
1SuctionLower
2LiquidLower
524J*12A
3LiquidUpper
4SuctionUpper
1SuctionLower
2LiquidLower
524J*12H
3LiquidUpper
4SuctionUpper
†
See Fig. 7 for access hole location by number.
‡
Fittings are listed in order from header or tee stub connection out to access hole in corner support post.
CONNECTION
TYPE
CIRCUIT
FEEDER TUBES
PER DISTRIBUTOR
Qty...Size (in.)
1
/
4
1
/
4
1
/
4
3
/
16
1
/
4
3
/
16
3
/
16
3
/
16
1
1
/8 Street Elbow
1
/8 Nipple, 105/8 L
1
1
/8 Long Radius Elbow
1
5
/8 Street Elbow
5
/8 Nipple, 85/8 L
5
/8 Long Radius Elbow
1
/8 Street Elbow
1
1
/8 Nipple, 85/8 L
1
1
/8 Long Radius Elbow
1
5
/8 Street Elbow
5
/8 Nipple, 85/8 L
5
/8 Long Radius Elbow
1
/
(2) 1
5
/8 Street Elbow
5
/8 Nipple, 81/2 L
5
/8 Long Radius Elbow
5
/8 Street Elbow
5
/8 Nipple, 131/2 L
5
/8 Long Radius Elbow
1
/8 Nipple, 53/4 L
1
1
/8 Long Radius Elbow
1
1
/8 Nipple, 12 L
1
1
/8 Long Radius Elbow
1
1
/
(2) 1
5
/8 Street Elbow
5
/8 Nipple, 51/2 L
5
/8 Long Radius Elbow
5
/8 Street Elbow
5
/8 Nipple, 101/2 L
5
/8 Long Radius Elbow
1
1
/8 Nipple, 55/8 L
1
/8 Long Radius Elbow
1
1
/8 Nipple, 12 L
1
1
/8 Long Radius Elbow
1
†
NOZZLE
Qty...Part No.
1...G4
1...G5
1...G5
1...G5
2...G3
2...G3
2...G3
2...G4
FITTINGS REQUIRED
(in.)
Street Elbow
8
Street Elbow
8
‡
13
Table 3 — Fitting Requirements (cont)
UNIT
ACCESS
HOLE NO.
†
CONNECTION
TYPE
CIRCUIT
1SuctionLower
2LiquidLower
524J*14A
3LiquidUpper
4SuctionUpper
1SuctionLower
2LiquidLower
524J*16A
3LiquidUpper
4SuctionUpper
†
See Fig. 7 for access hole location by number.
‡
Fittings are listed in order from header or tee stub connection out to access hole in corner support post.
FITTINGS REQUIRED
(in.)
1
1
/8 Street Elbow
1
/8 Nipple, 75/8 L
1
1
/8 Long Radius Elbow
1
5
/8 Street Elbow
5
/8 Nipple, 17/16 L
5
/8 Long Radius Elbow
5
/8 Street Elbow
5
/8 Nipple, 111/2 L
5
/8 Long Radius Elbow
1
/8 Nipple, 55/8 L
1
1
/8 Long Radius Elbow
1
1
/8 Nipple, 13 L
1
1
/8 Long Radius Elbow
1
1
1
/8 Street Elbow
1
/8 Nipple, 723/4 L
1
1
/8 Long Radius Elbow
1
5
/8 Street Elbow
5
/8 Nipple, 13/8 L
5
/8 Long Radius Elbow
5
/8 Street Elbow
5
/8 Nipple, 111/2 L
5
/8 Long Radius Elbow
1
/8 Nipple, 55/8 L
1
1
/8 Long Radius Elbow
1
1
/8 Nipple, 13 L
1
1
/8 Long Radius Elbow
1
‡
14
Condensate Drain — Install a trapped condensate drain
NOTE: Dim ensions in [ ] ar e in millime ters.
line to unit connection as shown in Fig. 11. The unit drain connection is a PVC stub. See Fig. 12. Some areas may require an
adapter to connect to either galvanized steel or copper pipe.
For these applications, install a field-supplied threaded PVC
adapter.
3” MIN.
[76]
Fig. 11 — Condensate Drains
NOTE: A trap must be installed in the condensate drain line to
ensure that the static pressure of fans is balanced with the
water column in the drain line and that condensate can drain
completely from pan. Without a trap, air can be drawn up drain
line until water level in condensate pan becomes equal to static
pressure created by fans, preventing complete drainage. Conditions will worsen as filters become dirty.
Install clean-out plugs in trap. Pitch drain line downward to an
open floor drain or sump. Provide service clearance around
drain line to permit removal of unit panels. Observe all local
sanitary codes.
Fig. 12 — Drain Pan Slope Adjustment
As shipped, the unit’s condensate drain pan is NOT sloped towards the drain connection. The pan slope must be changed to
pitch towards the side of the unit with the drain connection. See
Fig. 12. Loosen the 2 screws next to the drain outlet at both
ends of the unit, push drain pan down in the slots near the drain
connection, and up in the slots on the opposite end. Retighten
screws. The pan should have a pitch of at least
1
/4-in. over its
length toward the drain connection.
Fan Motors and Drives — Motor and drive packages
are factory installed in all units. The motor and drive packages
consist of the following items:
1 — fan motor
1 — adjustable motor pulley
1 — fan pulley
1 — fan belt (524J*07A-12A and 524J*07H-12H units)
2 — matched fan belts (524J*14A-16A units)
For instructions on changing fan rotation, changing drive
speeds and adjusting drives, see Pulley and Drive Adjustment
in the Service section.
15
Power Supply and Wiring — Check the unit data
COPPER
WIRE ONLY
ELECTRIC
DISCONNECT
SWITCH
ALUMINUM
WIRE
A
LE GEN D
TXV —
Thermostatic Expansion Valve
23
22
21
1
3
1
2
1
1
1
0
5
°
C
6
00
VR
J
A
W
plate to ensure that available power supply matches electrical
characteristics of the unit. Provide a disconnect switch with an
integrated lock-out feature of size required to provide adequate
fan motor starting current. See Tables 4-6 for unit electrical
data.
FAN SCROLL
MOTOR
ND DRIVE
FAN
CONTACTOR
BOX
WIRE
ACCESS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not use gas piping as an electrical ground. 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 unit ground lug in control compartment,
or conduit approved for electrical ground when installed in
accordance with NEC (National Electrical Code); ANSI/
NFPA 70, latest edition (in Canada, Canadian Electrical
Code CSA [Canadian Standards Association] C22.1), and
local electrical codes.
FIRE HAZARD
Failure to follow this warning could result in intermittent
operation or performance satisfaction.
Do not connect aluminum wire between disconnect switch
and condensing unit. Use only copper wire.
(See Fig. 13.)
CONDENSATE
DRAIN
CONNECTION
(HORIZONTAL)
FILTER
ELEMENTS
FILTER
RETAINER
CLIP
FAN DRIVE
PULLEY
COIL
TXV BULB
ACCESS
REFRIGERANT/
CHILLED WATER
PIPING ACCESS
CONDENSATE
DRAIN
CONNNECTION
(VERTICAL)
Fig. 14 — Wiring and Service Access
(Side Panel Removed)
The 524J size 07-16 units that have motors wired for 460-v,
3-ph, 60 Hz operation can be field-converted to 208/230-v,
3-ph, 60 Hz operation. Rewire the motor according to the
diagram plate on the motor. After reconfiguring the motor,
mark the motor specifying 208-v or 230-v operation replacing
the 460-v sticker information on the units’ corner post.
Fan motors are factory-installed on all units. Indoor-fan
contactors are located in the fan contactor box behind the side
access panel (see Fig. 14 and 15). Wire the thermostat to the
24-v control circuit terminal block located in the side of the fan
contactor control box, according to Fig. 16 or the unit label
diagram. If the air handler is part of a split system, complete the
wiring from the condensing unit to the thermostat shown in
Fig. 16.
Install disconnect switch and power wiring in accordance with
all applicable local codes. See Fig. 14-16 and the unit label
diagram. For units with motor sizes less than 5 Hp (3.7 kW),
connect power wiring to unit with no. 10 ring terminal. For
units with motor sizes of 5 Hp (3.7 kW) or more, connect
power wiring with
ages shown. Voltages should not exceed the limits shown in the Voltage Limits column.
dance with NEC (National Electrical Code), Article 440.
Laboratories) Standard 1995.
Never operate a motor where a phase imbalance in supply voltage is
greater than 2%. Use the following formula to determine the percentage of
voltage imbalance.
EXAMPLE: Supply voltage is 400-3-50.
AB = 393 v
BC = 403 v
AC = 396 v
Determine maximum deviation from average voltage
(AB) 397 – 393 = 4 v
(BC) 403 – 397 = 6 v
(AC) 397 – 396 = 1 v
Maximum deviation is 6 v.
Determine percent voltage imbalance.
This amount of phase imbalance is satisfactory because it is below the maximum allowable 2%.
FLA— Full Load Amps
MOCP
—
Maximum Overcurrent Protection
max voltage deviation from average voltage
average voltage
Average Voltage =
393 + 403 + 396
3
=
119 2
3
=
397
% Voltage Imbalance = 100 x
6
397
=1.5%
IMPORTANT: If the supply voltage phase imbalance is more than
2%, contact your local electric utility company immediately.
LEGEND
NOTE: Use copper conductors only.
EQUIP—Equipment
GND—Ground
HC—Heating Contactor
HTR—Electric Heater
IFC—Indoor-Fan Contactor
IFM—Indoor-Fan Motor
TB—Termi nal Bl oc k
T’STAT—Thermostat
Factory Wiring
Field Control Wiring
Fig. 16 — Unit Wiring
18
Table 6 — Fan Contactor Coil Data
UNIT
524J*
07A, 07H, 08A, 08H
12A 12H, 14A, 16A
VOLTAGE
(vac)
2410
MAXIMUM
HOLDING
VA
Connecting Ductwork — Refer to the System Design
Manual for the recommended design and layout of ductwork.
Figure 17 shows recommended duct connection to units with 2
fans.
UNIT OPERATION HAZARD
Failure to follow this caution could cause equipment
damage.
Do not operate unit without ductwork or discharge plenum
unless fan speed has been adjusted for external static
pressure of zero in. wg. Failure to do so may result in
motor overload.
DISCHARGE CONNECTIONS — Duct flanges are
factory-supplied; they are shipped inside the unit attached to
the hairpin end of the coil tube sheet for field installation.
Using the existing screws, install the duct flanges on the unit’s
fan deck. Each fan discharge requires 2 flanges; each flange
must be bent in the middle to conform to the discharge
opening. See Fig. 19. After flanges are installed, connect them
to the supply duct using a canvas connection to prevent
vibration. It is important that this connection be properly
fabricated to prevent high air friction losses and air noise.
RETURN CONNECTION — When using return-air
ductwork, route return-air duct to the unit’s return air inlet near
the filter rack, using a canvas connection to prevent
transmission of unit vibration. If the duct blocks off the unit’s
access panel, provide a slip joint in the ductwork to permit
removal for servicing.
OUTDOOR-AIR INLET CONNECTION — Connect outdoorair inlet to field-installed accessory economizer. Refer to
Economizer Installation Instructions.
Return-Air Filters — Type and size of filters are shown
in Tables 1A – 1D and are factory-supplied and factoryinstalled. In all units with 2 fans, a filter replacement tool
(hook) is shipped inside the unit for field use when replacing
filters. See the Service section for instructions on filter element
replacement.
Fig. 17 — Typical Fan Discharge Connections for Multiple Fan Units
19
Fig. 18 — Duct Flange Installation
START-UP
Before starting unit, check the following and correct as necessary:
• Is unit solidly supported?
• Is fan adjusted for speed and pulley alignment?
• Are pulleys, motor, and bearings securely mounted?
• Are there any loose parts that will rattle or vibrate?
• Is condensate drain pan pitched for correct drainage?
• Are coil baffle plates tight against coil to prevent air
bypass?
• Are all panels securely fastened?
• Are all electrical connections correct and tight?
Also refer to condensing unit instructions before starting a split
system. A split system start-up checklist is provided at the end
of these instructions.
SERVICE
Inspection and maintenance should be performed at regular intervals and should include the following:
• Complete cleaning of cabinet, fan wheel, cooling coil,
condensate pan and drain, heating coils, and return-air
grille (if present).
• Inspection of panels and sealing of unit against air
leakage.
• Adjustment of fan motor, belt, bearings, and wheels.
• Cleaning or replacement of filters.
• Testing for cooling/heating system leaks.
• Checking of all electrical connections.
Most unit service can be performed by removing one or both of
the unit’s side panels. Coil cleaning or removal or insulation
cleaning may require removal of a rear, top, or bottom panel,
depending on the unit’s orientation. When service is
completed, replace unit panels.
Panels — Panels are fastened to unit frame with sheet metal
screws. Fan and coil compartment must be sealed tightly after
service to prevent air from bypassing the cooling coil.
Fan Motor Lubrication — Fan motor supplied with
unit is permanently lubricated and requires no further
lubrication.
Fan Shaft Bearings — Bearings on size 07-12 units are
sealed, permanently lubricated bearings that require no further
lubrication. Size 14-16 units have pillow-block bearings
(Fig. 20) that must be lubricated with suitable bearing grease
approximately every 3 months. See Table 7 for suitable
lubricants.
Table 7 — Lubricant Data
MANUFACTURERLUBRICANT
MobilMobilplex EP No. 2
SunocoPrestige 42
TexacoMultifak 2
TexacoRegal AFB-2*
*Preferred lubricant, contains rust and oxidation inhibitors.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause 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.
Fig. 19 — Fan Shaft, Bearings, and Fan Wheel (Typical)
20
Centering Fan Wheel — If fan and fan shaft assembly
are not properly centered, blades may scrape against the blower
side scroll plate or may create an objectionable whistling noise.
It may be necessary to adjust individual fan wheels or move entire fan shaft. See the following two sections.
Fan Shaft Position Adjustment — Loosen
setscrew or locking collar of each fan shaft bearing. Slide shaft
into correct position and replace locking collar (Fig. 20). To
replace locking collar, push collar up against inner face of
bearing. Turn collar in direction of fan rotation until tight, and
tighten setscrew. Tightening locking collar in direction of fan
rotation results in further tightening of collar should setscrew
work itself loose.
Individual Fan Wheel Adjustment — Loosen the
2 locking bolts holding fan wheel hub to shaft. See Fig. 19.
Position fan wheel in center of the fan housing and tighten
locking bolts. Clearance between wheel and housing should be
the same on both sides.
Fan Belts — Motor mounting plate and motor support
angles are slotted to permit both vertical and horizontal
adjustment. Adjust belt(s) for correct deflection by loosening
motor plate mounting bolts, moving motor/plate assembly
forward or back, and retightening bolts. Press down on belt
with one finger midway between fan and motor pulleys to
check deflection. For units with motor sizes up to and
including 3.7 Hp (2.76 kW), correct deflection is
(4.8 mm). For larger motor sizes, correct deflection is
(3.2 mm). See Fig.
21.
3
/16-in.
1
/8-in.
If complete belt replacement is required during servicing,
loosen the motor plate mounting bolts (Fig. 21), move motor/
plate assembly towards fan pulley, and pull belt(s) off pulleys.
Reverse the procedure with new bolts and readjust deflection.
Fan Rotation — Correct fan rotation with respect to fan
outlet is shown in Fig. 22.
To reverse the direction of rotation of a 3-phase fan motor,
reverse any 2 of the power leads. Refer to the connection
diagram on the inside of motor terminal box cover for proper
reversing procedure of single-phase motor.
Fig. 20 — Fan Shaft Bearing
Fig. 21 — Fan Motor Mounting
21
Fig. 22 — Fan Rotation
Fan Pulley Alignment — Align as follows:
1. Loosen setscrews on pulleys.
2. Align pulleys visually and tighten setscrews on fan pulley
to lock it in place.
3. Use the methods shown in Fig. 23 to check proper pulley
alignment.
4. If pulleys are not in correct alignment, loosen the motor
holddown bolts and slide the motor axially until the
pulleys are aligned.
5. Tighten motor holddown bolts.
Pulley and Drive Adjustment — To obtain desired
fan speed, refer to the fan motor and drive data in Tables
8A-11D and adjust fan motor pulley as follows:
1. Remove belt from fan motor pulley after loosening motor
from motor base.
2. Loosen setscrew in moveable flange of pulley. Screw
moveable flange toward fixed flange to increase the fan
speed and away from fixed flange to reduce speed.
Before tightening setscrew, make certain that setscrew is
over nearest flat surface of pulley hub (Fig. 23).
UNIT OPERATION HAZARD
Failure to follow this caution could cause equipment
damage.
Increasing fan speed produces a greater load on motor. Do
not exceed rated capacity of motor.
Fig. 23 — Fan Pulley Adjustments
Return-Air Filters — Refer to Replacing Filters section
for filter accessibility and removal. Replace with clean filters of
the sizes listed in Tables 1A-1D.
Coil Removal — Remove unit panels and corner posts as
required. Disconnect coil connections and remove fastening
screws. Remove coil through end or side sections of unit.
Remove any heavy dirt that may have accumulated on underside of coil. Coil can be cleaned more easily with a stiff brush,
vacuum cleaner, or compressed air when coil is dry. If coil is
wet or if water is to be used for cleaning, guard against splashing water on electrical components or damaging surrounding
area. Clean coil baffles as applicable and check for tight fit to
be sure air does not bypass coil.
Cleaning Insulation — The insulation contains an im-
mobilized antimicrobial agent that helps prevent the growth of
bacteria and fungi. Clean the inner surface of the insulation
according to the separate maintenance instructions shipped
with the unit.
Condensate Drains — Keep condensate drains free of
dirt and foreign matter.
22
Replacing Filters — Filters can be removed and in-
FILTER
RETAINE
CLIP
SLIDE
stalled from either side of the unit. Install new filters in units
that have one fan as follows:
1. Remove the side access panel (retain screws).
2. Remove the filter retainer clip (see Fig. 24).
3. Remove old filters by lifting and tilting them out of the
filter track. See Fig. 14 and 25.
4. Reverse the procedure to install new filters.
To install new filters in larger units that have 2 fans, follow the
preceding steps, but use the factory-supplied filter hook to slide
filters within reach for removal. The filter hook is shipped inside the unit in the filter track.
UNIT OPERATION HAZARD
Failure to follow this caution could cause equipment
damage.
Do not operate unit without air filters.
Fig. 25 — Filter Removal/Replacement
Fig. 24 — Remove Filter Retainer Clip
23
Table 8A — Fan Motor Data, Standard Motor — English
UNIT
524J*07A
524J*07H
524J*08A
524J*08H
524J*12A
524J*12H
524J*14A524J*16A
208/230-1-60
Speed (rpm)17251725———
Hp1.32.4———
Frame (NEMA)56Y56Y———
Shaft Dia (in.)
5
/
8
5
/
8
———
208/230-3-60 and 460-3-60
Speed (rpm)17251725172517251725
Hp2.42.42.42.93.7
Frame (NEMA)56Y56Y56Y56Y56Y
Shaft Dia (in.)
5
/
8
5
/
8
5
/
8
7
/
8
7
/
8
575-3-60
Speed (rpm)17251725172517251725
Hp1.02.02.03.03.0
Frame (NEMA)5656HZ56HZ56HZ56HZ
Shaft Dia (in.)
5
/
8
7
/
8
7
/
8
7
/
8
7
/
8
LEGEND
NEMA — National Electrical Manufacturers Association
Table 8B — Fan Motor Data, Alternate Motor — English
Table 10D — 524J High-Capacity Fan Performance Data —
0-600 kPa External Static Pressure — SI (cont)
EXTERNAL STATIC PRESSURE (kPa)
350400450500550600
See Legend and Notes on page 33.
32
Legend and Notes for Tables 10A and 10C
LEGEND
Bhp— Brake Horsepower Input to Fan
ESP— External Static Pressure
NOTES:
1. Maximum allowable fan speed is 1200 rpm for all sizes.
2. Fan performance is based on deductions for wet coil, clean 2-in.
filters, and unit casing. See table at right for factory-supplied filter
pressure drop.
3. Refer to fan motor and drive tables for additional data.
Legend and Notes for Tables 10B and 10D
LEGEND
ESP — External Static Pressure
NOTES:
1. Maximum allowable fan speed is 20 r/s for all sizes.
2. Fan performance is based on deductions for wet coil, clean
51-mm filters, and unit casing. See table at right for factory-supplied filter pressure drop.
3. Refer to fan motor and drive tables for additional data.
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? (Y/N) _____
CONTROLS
ARE THERMOSTAT(S) AND INDOOR FAN CONTROL WIRING
CONNECTIONS MADE AND CHECKED? (Y/N) _____
ARE ALL WIRING TERMINALS (including main power supply) TIGHT? (Y/N) _____
HAVE OUTDOOR UNIT CRANKCASE HEATERS BEEN ENERGIZED FOR 24 HOURS? (Y/N) ______
INDOOR UNIT
HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE? (Y/N) _____
ARE PROPER AIR FILTERS IN PLACE? (Y/N) _____
HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT? (Y/N) ______
DO THE FAN BELTS HAVE PROPER TENSION? (Y/N) _____
PIPING
524J***A, 524J***H
HAS FOAM SHIPPING BLOCK BEEN REMOVED FROM THE TXV (Thermostatic Expansion Valve)? (Y/N) ______
ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR UNIT (524J***A) OR OUTDOOR UNIT (524J***H)
COILS AS REQUIRED?(Y/N) _______
HAVE LEAK CHECKS BEEN MADE AT COMPRESSORS, CONDENSERS, INDOOR COILS,
TXVs (Thermostatic Expansion Valves) SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS
WITH A LEAK DETECTOR?(Y/N) _____
LOCATE, REPAIR, AND REPORT ANY LEAKS._______________________________________________________________
HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)(Y/N) ____
ARE THE COMPRESSOR OIL SIGHT GLASSES SHOWING CORRECT LEVELS? (Y/N) _____
CL-1
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.
III. START-UP
CHECK INDOOR FAN MOTOR SPEED AND RECORD.
AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
OIL PRESSURE
SUCTION PRESSURE
SUCTION LINE TEMP
DISCHARGE PRESSURE
DISCHARGE LINE TEMP
ENTERING OUTDOOR UNIT AIR TEMP
LEAVING OUTDOOR UNIT AIR TEMP
INDOOR UNIT ENTERING AIR DB TEMP
INDOOR UNIT ENTERING AIR WB TEMP
INDOOR UNIT LEAVING AIR DB TEMP
INDOOR UNIT LEAVING AIR WB TEMP