Bryant 524J User's Manual
Contents
1. 2679 71 NOTE Dimensions in are millimeters Y e b g E oOooQ d DISCHARGE AIR p zm e 3 8 THREADED ROD FIELD SUPPLIED RETURN AIR TYP 4 PLACES BRACKET FACTORY SUPPLIED FIELD INSTALLED TYP 4 PLACES STEEL CHANNEL FIELD SUPPLIED TYP 2 PLACES z 1 1 1 cm 90900 md 2 d h PR zu OVERHEAD SUSPENSION ACCESSORY WITH HOT WATER COIL i r 1 D oo oO 000 me DISCHARGE AIR dO a Zu 3 8 THREADED ROD RETURN AIR FIELD SUPPLIED TYP 4 PLACES BRACKET FACTORY SUPPLIED FIELD INSTALLED TYP 4 PLACES TH STEEL CHANNEL FIELD SUPPLIED TYP 2 PLACES L i L x oo oO 000 tal gt S ZI d OVERHEAD SUSPENSION ACCESSORY WITH HOT WATER COIL C10728 Fig 7 Preferred Suspension Technique 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 to2. 11 H H21 BLK l DISCONNECT POWER PER u 126 6 22 YEL 12H K22 YEL 2 wi IFM NEC SUPPLY 35 6 23 BLU 134 K23 BLU u 3 PHASE ONLY Zen S 3 PHASE ONLY EQUIP GND TERMINAL BLOCK JUMPER FOR 1B HEAT PUMP WIRING R YI ELECTRIC HEAT ACCESSORY Y2 YW WI w2 w2 c H wir rN C I nc WHT X YI wm CONNECT TO 24VAC AT OMIT FOR HEAT PUMP T WIRING Wi We STAT wm CONDENSING UNIT LEGEND FACTORY WIRING E FIELD CONTROL WIRING CB CIRCUIT BREAKER IFC INDOOR FAN CONTACTOR I FM INDOOR FAN MOTOR TB TERMINAL BLOCK T STAT THERMOSTAT NOTE USE COPPER CONDUCTORS ONLY C10695 Fig 17 Unit Wiring Table 6 Fan Contactor Coil Data UNIT VOLTAGE MAXIMUM 524J vac HOLDING VA 25A 25H 28A 30A 10 Connecting Ductwork Refer to the System Design Manual for the recommended design and layout of ductwork Fig 18 shows recommended duct connection to units with 2 fans A CAUTION 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 o
3. Medium Static Drive Data 60 Hz English UNIT MOTOR DRIVE Motor Pulley Pitch Diameter in Pulley Factory Setting Full Turns Open FAN DRIVE Pulley Pitch Dia in Pulley Bore in Belt No Section Belt Pitch in FAN SPEEDS rpm Factory Setting Range Max Allowable Speed rpm Change per 1 2 Turn of Moveable Motor Pulley Flange MAX FULL TURNS FROM CLOSED POSITION SHAFTS CENTER DISTANCE in 524J 25A Esa esp 524J 28A 524J 30A Is 418 2 38 8 2 38 8 i 2 39 8 2 39 8 798 984 798 984 798 984 1200 1100 1100 2 6 6 67 9 43 9 16 10 99 6 67 9 43 t Four belts shipped with unit Use correct set of 2 belts sized according to the pulley setting 25 524J Table 9C High Static Drive Data 60 Hz English 524J 25A UNIT 524J 25H 524J 28A 524J 30A MOTOR DRIVE Motor Pulley Pitch Diameter in 4 3 5 3 Ti T FAN DRIVE Pulley Pitch Dia in z4 se 8 6 Pulley Bore in 115 46 Belt No Section 2 B Belt Pitch in 37 8 FAN SPEEDS rpm Factory Setting 1024 Range 873 1075 Max Allowable Speed rpm 1100 Change per 1 2 Turn of Moveable Motor Pulley 19 4 16 7 16 7 Flange MAX FULL TURNS FROM 6 CLOSED POSITION SHAFTS CENTER DISTANCE in 8 16 10 02 6 67 9 43 6 67 9 43 T It is possible to adjust drive so that fan speed exceeds maximum allowable DO NOT exceed 1200 rpm Table 9D Standard Drive Data 60 Hz SI 524J 25A UNIT 524J
4. Model Type Packaging 524J Bryant Fan Coil A Standard Puron R 410A Refrigerant Not Used A Not Used Voltage E 460 3 60 A P 208 230 3 60 nn en T 575 3 60 B Painted Cabinet Nominal Tonnage Not Used 25 20 Tons 0 Not Used 28 25 Tons 30 30 Tons Indoor Fan Options 1 Fan Drive and Motor Low Motor Efficency Standard Type of Coil 2 Fan Drive and Motor Med Motor Efficency Standard A Standard DX Coil 3 Fan Drive and Motor High Motor Efficency Standard B High Capacity DX Coil H DX Coil for Heat Pump Duty Coil Options A Al Cu Not Used 0 Not Used Not Used 0 Not Used Not Used 0 Not Used C10837 Fig 3 Model Number Nomenclature POSITION NUMBER 1 2 3 4 5 6 7 8 9 10 TYPICAL 2 6 1 0 G 1 2 3 4 5 POSITION DESIGNATES 1 2 Week of manufacture fiscal calendar 3 4 Year of manufacture 10 2010 5 Manufacturing location G ETP Texas USA 6 10 Sequential number C 0725 Fig 4 Serial Number Nomenclature 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
5. 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 amp INDOOR FAN CONTROL WIRING CONNECTIONS MADE amp 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 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 UINT 524J 25H 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 35 524J 92011 Bryant Heating and Cooling Systems e 7310 W Morris St e Indianapolis IN 46231 CHECK VOLTAGE IMBALANCE LINE TO LINE VOLTS AB AB AC BC 3 AVERAGE VOLTAGE MAXIMUM DEVIATION FROM AVERAGE VOLTAGE OIL PRESSURE SUCTION PRESSURE SUCTION LINE
6. 524J 28A 524J 30A See Legend and Notes on page 36 30 Table 10D 524J High Capacity Fan Performance Data 0 600 kPa External Static Pressure SI EXTERNAL STATIC PRESSURE kPa AIRFLOW UNIT L s 0 Te w an o re uw re fw ue pum pos uw o wm vu vw ve vv 2 54 3 18 524J 25A 3 96 524J 25H 4 94 6 14 2 95 3 55 4 51 570 7 10 524J 28A 3 59 4 78 524J 30A 6 23 7 98 10 10 See Legend and Notes on page 36 Table 10D 524J High Capacity Fan Performance Data 0 600 kPa External Static Pressure SI cont EXTERNAL STATIC PRESSURE kPa ow ARROW ao o 3 91 19 12 4 75 19 73 524J 25A 5 72 524J 25H 524J 28A 524J 30A See Legend and Notes on page 36 31 524J Legend and Notes for Tables 10A and 10C LEGEND FACTORY SUPPLIED PRESSURE DROP ENGLISH Bhp Brake Horsepower Input to Fan ESP External Static Pressure AIRFLOW PRESSURE DROP NOTES UNIT i I Cfm in wg 1 Maximum allowable fan speed for size 25 units is 1200 rpm Maximum allowable fan speed for size 28 and 30 units is 1100 rpm 0 12 2 Fan performance is based on deductions for wet coil clean 2 in filters 524J 25A and unit casing See table at right for factory supplied filter pressure drop 524J 25H 0 19 3 Refer to fan motor and drive tables for additional data 0 26 7 500 0 15 524J 28A 10 000 0 22 12 500 0 30
7. Replace the seal cap tighten A INSTALLER INSTALLATEUR TXV superheat must be checked at initial unit start up and adjusted if necessary Superheat must be 10 15 deg F La surchauffe TXV doit tre v rifi e au moment de la mise en route initiale et ajust e si n cessaire La surchauffe doit tre comprise entre 10 et 15 degr s F 40RU500073 2 0 C10828 Fig 21 Label TXV Adjustment 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 A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result 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 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
8. 0 cee eee 21 Coil Removal 0 0 2 riti niee eee eee 22 Cleaning Cooling Coil 0040 22 Cleaning Insulation sese 22 Replacing Filters 0 0000 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 4 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 safety alert symbol DANGE
9. 05 7 87 10 07 12 73 1028 7 60 1073 1126 See Legend and Notes on page 36 28 Table 10B 524J Standard Fan Performance Data 0 600 kPa External Static Pressure SI EXTERNAL STATIC PRESSURE kPa AIRFLOW UNIT L s 0 Te w m 9 ue um fe lw ue uw um m ue um me lw ive m 2 53 3 15 524J 25A 91 524J 25H 3 9 4 85 6 03 2 68 3 32 524J 28A 4 23 5 33 6 61 3 50 4 51 524J 30A 5 87 7 51 9 49 See Legend and Notes on page 36 Table 10B 524J Standard Fan Performance Data 0 600 kPa External Static Pressure SI cont EXTERNAL STATIC PRESSURE kPa AIRFLOW UNIT L s 3 89 19 03 4 70 19 60 524J 25A 67 524J 25H 5 6 524J 28A 524J 30A See Legend and Notes on page 36 29 524J Table 10C 524J High Capacity Fan Performance Data 0 0 2 4 in wg External Static Pressure English EXTERNAL STATIC PRESSURE in wg AIRFLOW UNIT Cfm ae o s os I 3 40 4 27 5 32 6 62 8 24 3 96 4 76 6 05 7 64 9 52 4 82 6 41 8 36 10 71 13 54 524J 25A 524J 25H 524J 28A 524J 30A See Legend and Notes on page 36 Table 10C 524J High Capacity Fan Performance Data 0 0 2 4 in wg External Static Pressure English cont EXTERNAL STATIC PRESSURE in wg AIRFLOW UNIT Cfm 5 24 1147 6 38 1184 524J 25A 7 67 524J 25H e
10. 7 2514 6 LEFT SIDE FRONT ACCESS FOR CONTROLS MOTOR amp BELT t CONTROL BOX LEGEND 1 i TXV Thermostatic Expansion Valve RO gt EPAR L1 00 TYP 1 28 41 NOTES u 1 Dimensions in are in millimeters 7 8 DIA POWER ENTRY M E 22 4 2 E Direction of airflow L i io a 3 Recommended clearance ld Yi 5 5 9 16 Rear 3 in 914 mm 2 ft 6 in 762 mm D 1665 2 with electric heat accessory 1 1 8 DIA FOR LIQUID CONNECTION 28 6 er Front 2 ft 6 in 762 mm 1 8447 DIA FOR SUCTION CONNECTION ed Right Side 2 ft 6 in 762 mm 3 4 9 16 7 8 DIA FOR TXV BULB CONNECTION Left Side 2 ft 6 in 762 mm 1030 2 A EE Local codes or jurisdiction may prevail E 4 Liquid piping not supplied by Carrier 5 Duct flange is factory supplied and field RETURN AIR EE installed i une iore es 16 1 Em AB 183271 6 40RUS may require alternate or additional 1280 9 357 1 407 9 i field favricated poping access holes IH Y 1 ALTERNATE t RETURN AIR 1787 N 28 6 1 3 4 DIA FOR SUCTION CONNECTION 44 5 VA 28 6 RIGHT SIDE g DIA FOR LIQUID CONNECTION Fig 2 Dimensions Sizes 28 and 30 UNIT Ib kg 524J 28A 1050 477 524J 30A 1062 482 C10835 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 AJAA
11. 9 000 0 19 524J 30A 12 000 0 29 15 000 0 40 Legend and Notes for Tables 10B and 10D LEGEND FACTORY SUPPLIED PRESSURE DROP SI ESP External Static Pressure NOTES UNIT AIRFLOW PRESSURE DROP 1 Maximum allowable fan speed for size 25 units is 20 r s Maximum L s Pa allowable fan speed for size 28 and 30 units is 18 3 r s 2 Fan performance is based on deductions for wet coil clean 51 mm 2900 32 filters and unit casing See table at right for factory supplied filter 524J 25A 3800 47 pressure drop 524J 25H 3 Refer to fan motor and drive tables for additional data 4700 64 3500 36 524J 28A 4700 55 5900 76 4250 47 524J 30A 5650 71 7050 98 32 33 524J 2011 Bryant Heating and Cooling Systems e 7310 W Morris St e Indianapolis IN 46231 Printed in U S A Edition Date 01 11 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 34 Catalog No 11524J 07 Replaces 11524J 05 START UP CHECKLIST SPLIT SYSTEMS WITH 524J UNITS I PRELIMINARY INFORMATION II OUTDOOR MODEL NO INDOOR MODEL NO SERIAL NO SERIAL NO ADDITIONAL ACCESSORIES PRE START UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE Y N IF SO WHERE WILL THIS DAMAGE PREVENT UNIT START UP Y N CHECK POWER SUPPLY DOES IT AGREE WITH UNIT Y N HAS THE GROUND WIRE BEEN CONNECTED Y N HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY
12. Duct Flange Installation 18 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 s TXV bulb located on suction tube per Fig 20 s the capillary tube to the bulb free of kinks and not subject to pinching s the bulb well secured to the suction tube with strap Also refer to condensing unit or outdoor heat pump section instructions before starting a split system A split system start up checklist is provided at the end of these instructions IMPORTANT IMPORTANT EQUALIZER LINE CONDUITE D EQUILIBRAGE SIGHT GLASS HUBLOT UPPER SPLIT BU BLOC SUPERIEUR AIR FLOW CIRCULATION D DAR Fig ISDIAMSMIN 10DIAMS 15x DIA MIN 10x DIA MIN soLENoID VALVE B DIAMS MIN BxDIA MIN VARNE A SOLENOIDE pate FILTER BLOC DRIER NES EUR TXV SENSING FILTRE PER DESSICCATEUR AIRFLOW CIRCULATION DAR 15DIAMS MIN 19 DIAMS EQUALIZER LINE 15x DIA MIN 10xDIA MIN I CoNDUITE D QUILIBRAGE 8 DIAMS MIN 8x DIA MIN INDOOR COIL CHANGEUR INT RIEUR Ne Th
13. MPT Steam Coil Out MPT Hot Water Coil In MPT Hot Water Coil Out MPT Condensate PVC FILTERS Quantity Size mm Access Location STEAM COIL Max Working Pressure kPag at 126 C Total Face Area sq m Rows Fins m HOT WATER COIL Max Working Pressure kPag Total Face Area sq m Rows Fins m Water Volume L m3 LEGEND DX Direct Expansion TXV Thermostatic Expansion Valve Er Field installed accessory only 25H 70 326 44 2 381 3775 2831 4719 3 73 3 73 29 1 29 1 R 410A 1 59 1 59 Enhanced Copper Tubes Aluminum Sine Wave Fins 4482 1 85 2 2 Face 50 50 591 2 178 2 5 g 1 21 5 1 11 5 1 2 1 2 1 11 4 ODM 1 IDF Throwaway Factory Supplied 4 406 x 610 x 51 4 406 x 508 x 51 Right or Left Side 138 1 24 1 394 1034 1 24 2 335 52 6 0 052 Units are shipped without refrigerant charge TOP ALTERNATE RETURN AIR INTAKE T ACCESS FOR CONTROLS MOTOR AND BELT 17 5 1 4 438 2 o c 1 3 11 16 93 71 3 118 6 10 3 4 179 41 12101 9 1 4 1 16 1401 31 1 6 3 8 17 6 3 8 1 5 8 I 17 4 1 2 1467 4 141 31 DUC
14. 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 COMPRESSOR AMPS L1 L2 L3 NOTES Y N AC Printed in U S A 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 COMP A1 BC V COMP B1 d Edition Date 01 11 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 36 CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES ARE THE SIGHT GLASSES SHOWING OIL LEVEL AT g to 1 4 FULL Catalog No 11524J 07 Replaces Il524J 05
15. 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 4 e PLUG 1708 EX vl 4 Y a l A_ L PLUG CONDENSATE 4 a Pa DRAIN ar LEGEND Accessory Line pk i Alternate Air Intake and Discharge O gt Air Intake and Discharge Note Maintain recommended clearances per Fig 1 and Fig 2 C10684 Fig 6 Typical Unit Positioning 524J 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 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 SIZE 25 EF LA Ll 7 11 1 27 RI 2425 7 1 OVERHEAD SUSPENSION ACCESSORY UNIT SIZES 28 30 L 8 g ioe REE
16. 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 Rear 3 ft 914 mm 21 5 ft 762 mm with electric heat accessory e Front 21 5 ft 762 mm e Right Side 31 ft 1067 mm Left Side 21 2 ft 762 mm 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 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 N
17. drain connection The pan slope must be changed to pitch towards the side of the unit with the drain connection See Fig 13 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 Re tighten screws The pan should have a pitch of at least 4 in over its length toward the drain connection 14 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 2 matched fan belts 524J 25A 30A units For instructions on changing fan rotation changing drive speeds and adjusting drives see Pulley and Drive Adjustment in the Service section Power Supply and Wiring Check the unit data 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 A WARNING 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 cons
18. located in the side of the fan contactor control box according to Fig 17 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 17 gp a n FAN CONTACTOR 24V DI mace T i BLOCK POWER WIRING m KNOCKOUT T C10694 Fig 16 Fan Contactor Box and Terminal Block Cover Removed Typical 15 524J Table 4 Electrical Data Standard Motors FAN MOTOR POWER SUPPLY VOLTAGE we 3s szasa oem sn som ee es i ssi 7565 78 o om 20 See Legend and Notes below 1 Table 5 Electrical Data Alternate Motors FAN MOTOR POWER SUPPLY VOLTAGE UNIT V PH Hz Minimum 208 230 3 60 187 253 7 5 5 59 21 4 19 4 26 9 24 3 45 40 524 J 25H 460 3 60 414 506 7 5 5 59 9 7 12 1 20 5659 m 5 208 230 3 60 187 253 10 0 7 46 28 0 25 2 35 0 31 5 60 50 524J 30A 7 46 See Legend and Notes below Legend and Notes for Tables 4 and 5 LEGEND Example Supply voltage is 230 3 60 FLA Full Load Amps max voltage deviation from average voltage MOCP Maximum Overcurrent Protection 96 Voltage Imbalance 100 x Motors are designed for satisfactory operation within 10 of avoragevoiags normal voltage shown Voltages should not exceed the limits A BC shown in the Voltage Limits column AB 393v L BC 403 v NOTES A AC 396
19. 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 underground refrigerant piping 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 524J 25A 28A 30A 524J 25H Must be enlarged from 11 g in 28 6mm to 13 4 in 44 5mm NOTE Access hole knockouts 1 4 are factory supplied FIELD FABRICATED HOLE DIAMATERS USE HOLE in mm NUMBERS Nos Nog No7 A B Bes ee 0 T 9 11 8 28 6 11 8 28 6 13 4 44 5 3 25 82 6 6 125 155 6 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
20. v 1 Minimum circuit amps MCA and MOCP values are calcu lated in accordance with The NEC Article 440 393 403 396 1192 2 Motor FLA values are established in accordance with Under Average Voltage A writers Laboratories UL Standard 1995 3 Unbalanced 3 Phase Supply Voltage T 996 Never operate a motor where a phase imbalance in supply Determine maximum deviation from average voltage voltage is greater than 2 Use the formula in the example AB 397 393 4v see column to the right to determine the percentage of volt BC 403 397 6v age imbalance AC 397 396 1v 4 Installation with Accessory Electric Heaters Maximum deviation is 4 v Size the Field Power Wiring between the heater TB1 and the Determine percent of voltage imbalance 524J indoor fan motor per NEC Article 430 28 1 or 2 depends on length of conduit between heater enclosure and e 6 524J power entry location Install wires in field installed eo altagplmbelanee 397 conduit 1 5 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately 16 C 5 H P AND ABOVE RCUIT BREAKER FIELD uh jo O21 BLK
21. 1 2 1 11 4 ODM 1 IDF Throwaway Factory Supplied 4 16 x 20x2 4 20 x 24x2 4 16 x 24x2 4 20 x 25x2 Either Side 20 13 33 15 0 15 0 1 10 1 10 1 10 150 13 33 15 0 15 0 2 8 5 2 12 5 2 12 5 13 9 14 3 1 90 Units are shipped without refrigerant charge 524J Table 1B 524J A Physical Data SI Cooling Units UNIT 524J NOMINAL CAPACITY kW OPERATING WEIGHT kg Base Unit with TXV Plenum FANS Qty Diam mm Nominal Airflow L s Airflow Range L s Nominal Motor kW Standard Motor 208 230 3 60 and 460 3 60 575 3 60 Motor Speed r s 208 230 3 60 and 460 3 60 575 3 60 REFRIGERANT Operating charge kg approx per circuit DIRECT EXPANSION COIL Max Working Pressure kPag Face Area sq m No of Splits No of Circuits per Split Split Type Percentage Rows Fins m PIPING CONNECTIONS Quantity Size in DX Coil Suction ODF DX Coil Liquid Refrigerant ODF Steam Coil In MPT Steam Coil Out MPT Hot Water Coil In MPT Hot Water Coil Out MPT Condensate PVC 30A 105 482 148 2 457 3775 4119 5663 2831 4719 3539 5899 4247 7079 3 73 5 60 7 46 3 73 5 60 7 46 29 1 29 1 29 1 29 1 29 3 29 3 R 410A 1 59 2 04 2 27 Enhanced Copper Tubes Aluminum Sine Wave Fins 4481 1 85 2 30 2 77 2 2 2 18 20 24 Face 50 50 4 591 4 591 4 591 2 11 g 2 13 g 2 13 g 2 5 g 1 21 2 1 1 2 1 2 1 2 1 11 4 ODM 1 I
22. 1 g Nipple 75 g L 11 g Long Radius Elbow 5 g Street Elbow 5 g Nipple 61 2 L 5 Long Radius Elbow 5 g Street Elbow 5 g Nipple 91 5 L 5 g Long Radius Elbow 11 g Nipple 5 g L 11 g Long Radius Elbow 11 g Nipple 11 L 11 g Long Radius Elbow 11 g Nipple 3L 11 g Long Radius Elbow 5 g Nipple 27 g L 5 g 45 Elbow 5 g Nipple 15 g L 5 g Long Radius Elbow 5 g Nipple 27 g L 5 g 45 Elbow 5 g Nipple 41 4 L 5 g Long Radius Elbow 11 g Nipple 5 L 11 g 45 Elbow 11 g Nipple 83 4 L 11 g Long Radius Elbow 13 g Street Elbow 13 g Nipple 11 L 13 g Long Radius Elbow 5 g Street Elbow 5 g Nipple 11 5 L 5 g Long Radius Elbow 5 g Street Elbow 5 g Nipple 191 5 L 5 s Long Radius Elbow 13 g Nipple 43 45 L 13 g Long Radius Elbow 13 g Nipple 231 4 L 13 g Long Radius Elbow Qty Part No 524J Table 3 Fitting Requirement cont UNIT ACCESS HOLE NO CONNECTION TYPE CIRCUIT Suction 524J 30A See Fig 8 for access hole location by number FITTINGS REQUIRED in 13 g Street Elbow 13 g Nipple 3 L 13 g Long Radius Elbow 5 g Street Elbow 5 g Nipple 73 4 L 5 g Long Radius Elbow 5 g Street Elbow 5 g Nipple 181 2 L 5 g Long Radius Elbow 13 g Nipple 43 46 L 13 g Long Radius Elbow 13 g Nipple 191 4 L 13 g Long Radius Elbow Lower Fittings are listed in order from header or tee stub connection out to access hole in corner support post Condensate Drain Install a trapp
23. 25H 524J 28A 524J 30A MOTOR DRIVE Motor Pulley Pitch Diameter mm 109 2 134 6 or 30 FAN DRIVE Pulley Pitch Dia mm 279 Pulley Bore mm 49 2 Belt No Section 2 Bt Belt Pitch mm 2 FAN SPEEDS r s Factory Setting 12 5 Max Allowable Speed r s 18 3 Change per 1 5 Turn of Moveable Motor Pulley 0 255 0 218 0 218 Flange MAX FULL TURNS FROM 6 CLOSED POSITION SHAFTS CENTER DISTANCE mm 232 279 169 240 169 240 t Four belts shipped with unit Use correct set of 2 belts sized according to the pulley setting 26 Table 9E Medium Static Drive Data 60 Hz SI 524J 25A 54 ised 524J 28A 524J 30A 109 2 134 6 109 2 134 6 109 2 134 6 UNIT MOTOR DRIVE Motor Pulley Pitch Diameter mm Pulley Factory Setting Full Turns Open FAN DRIVE Pulley Pitch Dia mm Pulley Bore mm Belt No Section Belt Pitch mm FAN SPEEDS r s Factory Setting Range Max Allowable Speed r s Change per Turn of Moveable Motor Pulley Flange MAX FULL TURNS FROM CLOSED POSITION SHAFTS CENTER DISTANCE mm 2 986 1062 2 1011 13 3 16 4 13 3 16 4 0 255 0 255 232 279 169 240 3 0 239 49 2 2 Bt 2 986 2 1011 14 7 13 3 16 4 18 3 0 255 6 169 240 t Four belts shipped with unit Use correct set of 2 belts sized according to the pulley setting Table 9F High Static Drive Data 60 Hz SI UNIT MOTOR DRIVE Motor Pulley Pitch Diameter mm Pulley Fa
24. 5 10 0 S215T 13 8 1755 10 0 D215T 13 8 1745 10 0 S215T 13 8 1750 10 0 D215T 13 8 524J Table 8C Fan Motor Data Standard Motor SI 524J 25A UNIT 524J 25H 524J 28A 524J 30A 208 230 3 60 and 460 3 60 Speed r s 29 08 Shaft kW 7 46 Frame NEMA S215T Shaft Dia mm 34 9 575 3 60 Speed r s 29 25 Shaft kW 7 46 Frame NEMA S215T Shaft Dia mm 34 9 LEGEND NEMA National Electrical Manufacturers Association Table 8D Fan Motor Data Alternate Motor SI 208 230 3 60 and 460 3 60 Speed r s 29 17 Frame NEMA S215T Shaft Dia mm 34 9 575 3 60 Speed r s 29 17 Frame NEMA D215T Shaft Dia mm 34 9 LEGEND NEMA National Electrical Manufacturers Association 24 Table 9A Standard Drive Data 60 Hz English UNIT MOTOR DRIVE Motor Pulley Pitch Diameter in Pulley Factory Setting Full Turns Open FAN DRIVE Pulley Pitch Dia in Pulley Bore in Belt No Section Belt Pitch in FAN SPEEDS rpm Factory Setting Range Max Allowable Speed rpm Change per 1 2 Turn of Moveable Motor Pulley Flange MAX FULL TURNS FROM CLOSED POSITION SHAFTS CENTER DISTANCE in 524J 25A Sa SE 524J 28A 524J 30A i s is 2 42 8 2 42 8 2 43 8 2 43 8 679 863 682 841 674 831 1200 1100 1100 6 9 12 10 99 6 67 9 43 6 67 9 43 t Four belts shipped with unit Use correct set of 2 belts sized according to the pulley setting Table 9B
25. 524J PACKAGED AIR HANDLING UNITS 60 Hz WITH PURON R 410A REFRIGERANT SIZES 25 28 30 Installation Start Up and Service Instructions TABLE OF CONTENTS SAFETY CONSIDERATIONS 1 PRE INSTALLATION 0 000000 2 Moving and Storage 0 0 0 eee eee eee 2 Rigging Mm 2 INSTALLATION ee eee eee eee 2 18 General unserer 2 Uner ting ss 2 AGEESSOMIES 5rd reca eed po iniecta id epo cepe ga ic 2 Unit Positioning 0 0 0 eee eee eee eee 9 Unit Isolation lessen 11 Refrigerant Piping Access 22222222 11 Refrigerant Piping 00000 11 Condensate Drain 000 02 eee eee 14 Fan Motors and Drives 0005 15 Power Supply and Wiring sss 15 Connecting Ductwork 0000 17 Return Air Filters 17 STARE UP 4 gies doen Maen ne RE A 19 SERVICE seine en een 19 32 Panels M m 19 Fan Motor Lubrication 000 20 Fan Shaft Bearings 0000 20 Centering Fan Wheel 00 20 Fan Shaft Position Adjustment 20 Individual Fan Wheel Adjustment 21 Fan Belts 112 tes ice essen 21 Fan Rotation 00 cee eee eee eee ee eee 21 Fan Pulley Alignment 0 4 21 Pulley and Drive Adjustment 21 Condensate Drains 0 eee ee eee 21 Return Air Filters 2 0 0 0 0 0
26. DF FILTERS Throwaway Factory Supplied Quantity Size mm Hone x 508 x 51 4 508 x 610 x 51 4 x 610 x 51 4 508 x 635 x 51 Access Location Either Side STEAM COIL Max Working Pressure kPag at 126 C 138 Total Face Area sq m 1 24 1 39 1 39 Rows Fins m 1 394 1 394 1 394 HOT WATER COIL Max Working Pressure kPag 1034 Total Face Area sq 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 KR Field installed accessory only Table 1C 524J 25H Physical Data English Heat Pump Units UNIT 524J NOMINAL CAPACITY Tons OPERATING WEIGHT Ib Base Unit with TXV Plenum FANS Qty Diam in Nominal Airflow cfm Airflow Range cfm Nominal Motor Hp Standard Motor 208 230 3 60 and 460 3 60 575 3 60 Motor Speed rpm 208 230 3 60 and 460 3 60 575 3 60 REFRIGERANT Operating charge Ib approx per circuit DIRECT EXPANSION COIL Max Working Pressure psig Face Area sq ft No of Splits No of Circuits per Split Split Type Percentage Rows Fins in PIPING CONNECTIONS Quantity Size in DX Coil Suction ODF DX Coil Liquid Refrigerant ODF Steam Coil In MPT Steam Coil Out MPT Hot Water Coil In MPT Hot Water Coil Out MPT Condensate PVC FILTERS Quantity Size in Access Loca
27. OMINAL CAPACITY Tons OPERATING WEIGHT Ib Base Unit with TXV Plenum FANS Qty Diam in Nominal Airflow cfm Airflow Range cfm Nominal Motor Hp Standard Motor 208 230 3 60 and 460 3 60 575 3 60 Motor Speed rpm 208 230 3 60 and 460 3 60 575 3 60 REFRIGERANT Operating charge Ib approx per circuit DIRECT EXPANSION COIL Max Working Pressure psig Face Area sq ft No of Splits No of Circuits per Split Split Type Percentage Rows Fins in PIPING CONNECTIONS Quantity Size in DX Coil Suction ODF DX Coil Liquid Refrigerant ODF Steam Coil In MPT Steam Coil Out MPT Hot Water Coil In MPT Hot Water Coil Out MPT Condensate PVC FILTERS Quantity Size in Access Location STEAM COIL Max Working Pressure psig at 260 F Total Face Area sq ft Rows Fins in HOT WATER COIL Max Working Pressure psig Total Face Area sq ft Rows Fins in Water Volume gal ft3 LEGEND DX Direct Expansion TXV Thermostatic Expansion Valve ax Field installed accessory only 30A 30 1050 1062 325 2 15 2 18 8000 10000 12000 6000 10000 7500 12500 9000 15000 5 0 7 5 10 0 5 0 7 5 10 0 1745 1745 1745 1745 1755 1755 R 410A 3 5 4 5 5 0 Enhanced Copper Tubes Aluminum Sine Wave Fins 650 19 88 24 86 29 83 2 2 2 18 20 24 Face 50 50 4 15 4 15 4 15 2 11 8 2 13 8 2 13 8 2 5 g 1 21 2 1 1 2 1 2
28. R 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 524J A 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 A WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause in 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 A WARNING 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 4 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet meta
29. T FLANG 17 3 3 8 SEE NOTE 5 Leod 1390 5 DUCT FLANGE 1 2 TYP SEE NOTE 5 nme I TYP 2 PLACES ALTERNATE p gt z ENTRANCE Ty E ES ar FOR POWER WIRING i o Jr ALTERNATE DRAIN LOCATION ALTERNATE ENTRANCE n TANE j FOR COIL OF 1 CONNECTIONS i eS f a he a a ee ee ee a s MN o 17 6 1 2 9 1469 9 dol M 5 P M l i Tou es 6 3 4 COENA TE DRAN 171 51 3 1 8 6 10 3 4 41 31 19 41 1210181 j 5 IS 2 4 3 16 1716 3 12260 6 LEFT SIDE FRONT ACCESS FOR CONTROLS MOTOR AND BELT LEGEND ft 1 02 IP TXV Thermostatic Expansion Valve NOTES m 1 8 DIA POWER ENTRY 122 2 1 1 2 i 138 1 id i i 1 1 8 DIA FOR LIQUID CONNECTION 128 6 1 3 4 DIA FOR SUCTION CONNECTION 4 81 44 5 11423 L O 3 6 15 16 7 1 8 DIA FOR TXV BULB CONNECTION 938 2 22 2 2 5 1 16 183 1 17 9 3 16 537 7 17 7 1716 1 2 1 16 484 1 RETURN AIR Be 11 1716 1 4 1 16 La 1280 9 407 9 oO i i i t L 1 8 ALTERNATE near RETURN AIR 1 3 4 DIA FOR SUCTION CONNECTION 44 5 1 1 8 DIA FOR LIQUID CONNECTION 44 5 RIGHT SIDE Fig 1 Dimensions Size 25 om En 1 Dimensions in are in millimeters 2 Direction of airflow 3 Recommended clearance Rear 3 in 914 mm 2 ft 6 in 762 mm wi
30. 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 UJ 3 H O C10838 FIELD FABRICATED HOLE POSITION DIMENSIONS in mm 10 38 263 7 Fig 8 Refrigerant Piping Access Holes 11 524J Ro EQUALIZER LINE w gt q olo UPPER SENSING T eS p SPLIT BULB E fond SOLENOID 0 aA PRS VALVE SIGHT AIRFLOW 15DIAMS ji TV I Y Gass MIN Q DIAMS J gt gt SN x EQUALIZER S 5 LINE FILTER LOWER e DRIER SPLIT o i AIRFLOW m d 8DIAMS 7 CU MN INDOOR COIL AD LEGEND TXV Thermostatic Expansion Valve NOTE Componen
31. ctory Setting Full Turns Open FAN DRIVE Pulley Pitch Dia mm Pulley Bore mm Belt No Section Belt Pitch mm FAN SPEEDS r s Factory Setting Range Max Allowable Speed r s Change per 1 Turn of Moveable Motor Pulley Flange MAX FULL TURNS FROM CLOSED POSITION SHAFTS CENTER DISTANCE mm 524J 25A 524J 25H 524J 28A 524J 30A 109 2 134 6 109 2 134 6 109 2 134 6 16 9 20 0t 14 6 17 9 idi 207 255 169 240 3 0 203 49 2 2 B 960 17 1 14 6 7 9 18 3 0 278 6 169 240 t It is possible to adjust drive so that fan speed exceeds maximum allowable DO NOT exceed 20 r s 27 524J UNIT 524J 25A 524J 25H 524J 28A 524J 30A AIRFLOW Cfm Table 10A 524J Standard Fan Performance Data 0 0 2 4 in wg External Static Pressure English EXTERNAL STATIC PRESSURE in wg 569 639 711 781 846 905 641 702 763 824 885 943 770 823 876 930 983 841 888 982 1030 914 957 1042 1084 See Legend and Notes on page 36 UNIT 524J 25A 524J 25H 524J 28A 524J 30A AIRFLOW Cfm Table 10A 524J Standard Fan Performance Data 0 0 2 4 in wg External Static Pressure English cont EXTERNAL STATIC PRESSURE in wg 954 5 22 1142 5 67 990 6 30 1176 6 84 1 2 00 o o os 1w Rem Bhp Rom Bhp Rem Bhp Rpm Bhp Rem Bhp Rpm Bhp Rpm 532 Bhp 3 60 4 23 5 24 6 51 8 08 3 60 4 45 5 68 7 14 8 86 12 73 4 70 6
32. e 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 7 in the installation start up and service instruction Super heat must be adjusted in field Les tubes capillaires du capteur doivent tre achemin partir du d tendeur thermostatique situ a l int rieur de l appareil au travers de l un des trous d acc s de conduites Attacher le capteur sur une portion verticale de la conduite de succion l ext rieur de l appareil Voir la Figure 7 dans le manuel d installation de mise en marche et d entretien La surchauffe doit tre ajust e sur place C10827 Fig 20 Label TXV Bulb Location Adjusting TXV for Superheat The unit mounted thermostatic expansion valve s is are factory set to provided superheat at the bulb location in 10 F to 15 F 5 5 C to 8 3 C range Actual system load conditions may require adjustment of the factory setting To adjust the TXV superheat setting 1 Remove the seal cap from the bottom of the TXV body 2 To increase superheat turn the stem clockwise To de crease the superheat turn the stem counterclockwise Do not turn the stem more than one full turn 3 Wait until suction pressure and superheat stabilize This may take more than 30 minutes 4 Continue adjustment until superheat reaches 10 F to 15 F 5 5 C to 8 3 C 5
33. ed condensate drain line to unit connection as shown in Fig 12 The unit drain connection is a PVC stub See Fig 13 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 FROM PLUG CONDENSATE PLUG PAN 3 MIN 76 PLUG PLUG EXISTING FLOOR DRAIN SINK OR HOPPER UNIT CONDENSATE CONN 3 MIN 76 1 MIN ps v1 Am NOT LESS THAN 18 457 LONG AND TWO SIZES LARGER THAN WASTE PIPE TRAP TRAP TO SEWER NOTE Dimensions in are in millimeters C10691 Fig 12 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 PVC STUB UNIT DRAIN CONNECTION ADJUSTMENT SLOTS BOTH ENDS OF UNIT C10692 Fig 13 Drain Pan Slope Adjustment As shipped the unit s condensate drain pan is NOT sloped towards the
34. f 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 CONNECTIONS 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 CONNECTIONS Connect outdoor air 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 factory installed 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 17 524J C10696 Fig 18 Typical Fan Discharge Connections for Multiple Fan Units DUCT FLANGES C10697 Fig 19
35. ist 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 A WARNING FIRE HAZARD Failure to follow this warning could result in intermittent operation or performance satisfaction Do not connect aluminum wire between disconnect switch and fan coil unit Use only copper wire See Fig 14 ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY Fig 14 Disconnect Switch and Unit A93033 Install disconnect switch and power wiring in accordance with all applicable local codes See Fig 14 16 and the unit label diagram Connect power wiring with l 4 in ring terminal FAN SCROLL FAN CONTACTOR BOX MOTOR AND DRIVE WIRE ACCESS FAN DRIVE CONDENSATE PULLEY CONNECTION HORIZONTAL COIL FILTER TXV BULB ELEMENTS ACCESS REFRIGERANT FILTER PIPING ACCESS RETAINER CLIP CONDENSATE DRAIN CONNNECTION VERTICAL LEGEND TXV Thermostatic Expansion Valve C10693 Fig 15 Wiring and Service Access Side Panel Removed 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 15 and 16 Wire the thermostat to the 24 v control circuit terminal block
36. ith the unit Replacing Filters Filters can be removed and installed 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 27 3 Remove old filters by lifting and tilting them out of the filter track See Fig 15 and 28 Use the factory supplied filter hook to slide filters within reach for re moval The filter hook is shipped inside the unit in the filter track 4 Reverse the procedure to install new filters A CAUTION UNIT OPERATION HAZARD Failure to follow this caution could cause equipment damage Do not operate unit without air filters 22 FILTER RETAINER CLIP C10703 Fig 27 Remove Filter Retainer Clip C10704 Fig 28 Filter Removal Replacement Table 8A Fan Motor Data Standard Motor English UNIT 208 230 3 60 and 460 3 60 Speed rpm Hp Frame NEMA Shaft Dia in 575 3 60 Speed rpm Hp Frame NEMA Shaft Dia in LEGEND NEMA National Electrical Manufacturers Association Table 8B Fan Motor Data Alternate Motor English 524J 25A ppp 524J 28A 524J 30A UNIT 208 230 3 60 and 460 3 60 Speed pm Hp Frame NEMA Shaft Dia in 575 3 60 Speed rpm Frame NEMA Shaft Dia in 213T D215T LEGEND NEMA National Electrical Manufacturers Association 23 524J 25A AJESH 524J 28A 524J 30A 174
37. l 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 A 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 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 con densate drain duct connections and required clear ances 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
38. oduces a greater load on motor Do not exceed rated capacity of motor Condensate Drains Keep condensate drains free of dirt and foreign matter Return Air Filters Refer to Replacing Filters section for filter accessibility and removal Replace with clean filters of the sizes listed in Tables 1A 1F After draining as much water as possible from coils add sufficient antifreeze to prevent residual water in the coil from freezing Add a sufficient quantity of non corrosive antifreeze to the entire system to prevent all water within the system from freezing 21 524J 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 Cleaning Cooling Coil Remove return air filters 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 immobilized 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 w
39. ollar 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 LOCKING COLLAR BEARING C10699 Fig 23 Fan Shaft Bearing SLOT C10700 Fig 24 Fan Motor Mounting 20 Individual Fan Wheel Adjustment Loosen the 2 locking bolts holding fan wheel hub to shaft See Fig 22 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 re tightening bolts Press down on belt with one finger midway between fan and motor pulleys to check deflection The correct deflection is g in 3 2 mm See Fig 24 If complete belt replacement is required during servicing loosen the motor plate mounting bolts Fig 24 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 25 FAN HOUSING AIR DISCHARGE N CUTOFF PLATE FAN WHEEL C10701 Fig 25 Fan Rotation To reverse the directi
40. on 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 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 26 to check proper pulley alignment 4 If pulleys are not in correct alignment loosen the mo tor holddown bolts and slide the motor axially until the pulleys are aligned 5 Tighten motor holddown bolts ADJUSTABLE FLANGES STRAIGHT EDGE MUST BE PARALLEL WITH BELT SETSCREWS PULLEYS FIXED FLANGES SINGLE GROOVE TWO GROOVES MOTOR AND FAN SHAFTS MUST BE PARALLEL C10702 Fig 26 Fan Pulley Adjustments 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 26 A CAUTION UNIT OPERATION HAZARD Failure to follow this caution could cause equipment damage Increasing fan speed pr
41. 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 19 524J Fan Motor Lubrication Fan motor supplied with unit is permanently lubricated and requires no further lubrication Fan Shaft Bearings Size 25 30 units have pillow block bearings Fig 22 that must be lubricated with suitable bearing grease approximately every 3 months See Table 7 for suitable lubricants Table 7 Lubricant Data MANUFACTURER LUBRICANT Mobil Mobilplex EP No 2 Sunoco Prestige 42 Texaco Multifak 2 Texaco Regal AFB 2 Preferred lubricant contains rust and oxidation inhibitors FAN WHEEL HUB BEARING GREASE FITTING LOCKING COLLAR C10698 Fig 22 Fan Shaft Bearings and Fan Wheel Typical FAN PULLEY S BELTS MOTOR PULLEY S 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 23 To replace locking collar push collar up against inner face of bearing Turn c
42. t location arrangemetshown for field installation of sight glasses solenoid valves filter driers and TXV sensing bulbs The TXVs and equilizer lines are factory installed C10726 Fig 9 Face Split Coil Suction and Liquid Line Piping Typical VAPOR LINE LIQUID LINE CONNECTION 45 STRAP SUCTION VAPOR CONNECTION CONDENSATE DRAIN TXV BULB CONNECTION LEGEND FIRST ON LAST OFF B TXV Thermostatic Expansion Valve VERTICAL INSTALLATION NOTE The 8 o clock position is shown above C10689 Fig 11 TXV Sensing Bulb Location CONDENSATE DRAIN CONNECTION FIRST ON LAST OFF A HORIZONTAL INSTALLATION C10688 Fig 10 Typical Evaporator Coil Connections 524J 12 UNIT 524J 25A 524J 28A 524J 30A 524J 25H UNIT Table 2 Factory Installed Nozzle and Distributor Data COIL TYPE STD TXV Qty Part No DISTRIBUTOR Qty Part No FEEDER TUBES PER DISTRIBUTOR Qty Size in NOZZLE Feeder tube size is 1 4 in 6 35 mm NOTE Hot gas bypass applications require field supplied auxiliary side connector See Fig 8 for access hole location by number T Fittings are listed in order from header or tee stub connection out to access hole in corner support post Table 3 Fitting Requirements ACCESS HOLE NO CONNECTION TYPE CIRCUIT 524J 25A 3 Liquid Upper 524J 25H Liquid Upper 524J 28A 3 Liquid Upper 13 FITTINGS REQUIRED in 11 g Street Elbow 1
43. th 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 UNIT WEIGHT UNIT Ib kg 524J 25A 730 331 524J 25H 720 326 C10834 524J TOP ALTERNATE RETURN AIR INTAKE JT CONTROL BOX p r Kusel ACCESS FOR CONTROLS Bc MOTOR amp BELT 5 10 T Le 3 7 16 4 87 3 3 178 k 7 8 3 4 79 4 2355 9 NETT M rS UOS T 1 5 8 j al 1 4 1 2 I 1 6 7 8 H 41 3 419 1 479 6 DUCT FLANGE SEE NOTE 5 DUCT FLANGE SEE NOTE 5 1 2 TYP TYP 2 PLACES 12 7 1 1 ALTERNATE ENTRANCE Tr es E E M m FOR POWER i ALTERNATE WIRING FILTER ALTERNATE x a ACCESS MOTOR BELT ACCESS 8 ALTERNATE 1 DRAIN LOCATION IP 3 i u o RETURN AIR INTAKE ALTERNATE 1 4 ui xl ENTRANCE F FOR COIL CONNECTIONS RETURN x AIR NE 4 lo o 2 11 16 lo 627 11 L Q E 3 ur A CONDENSATE DRAIN RID 1 5 8 O D 41 31 31 8 B 3 4 79 4 2355 91 I 2 8 5 8 e4 a 8 3 828
44. tion STEAM COIL Max Working Pressure psig at 260 F Total Face Area sq ft Rows Fins in HOT WATER COIL Max Working Pressure psig Total Face Area sq ft Rows Fins in Water Volume gal ft LEGEND DX Direct Expansion TXV Thermostatic Expansion Valve Xx Field installed accessory only 25H 20 720 140 2 15 8000 6000 10000 5 0 5 0 1745 1745 R 410A 3 5 3 5 Enhanced Copper Tubes Aluminum Sine Wave Fins 650 19 9 2 2 Face 50 50 4 15 2 11 g 2 5 g 1 21 5 1 115 1 2 1 2 1 11 4 ODM 1 IDF Throwaway Factory Supplied 4 16 x 20x 2 4 16 x 24x 2 Right or Left Side 20 13 33 1 10 150 13 33 2 8 5 13 9 1 85 Units are shipped without refrigerant charge 524J Table 1D 524J 25H Physical Data SI Heat Pump Units UNIT 524J NOMINAL CAPACITY kW OPERATING WEIGHT kg Base Unit with TXV Plenum FANS Qty Diam mm Nominal Airflow L s Airflow Range L s Nominal Motor kW Standard Motor 208 230 3 60 and 460 3 60 575 3 60 Motor Speed r s 208 230 3 60 and 460 3 60 575 3 60 REFRIGERANT Operating charge kg approx per circuit DIRECT EXPANSION COIL Max Working Pressure kPag Face Area sq m No of Splits No of Circuits per Split Split Type Percentage Fins m PIPING CONNECTIONS Quantity Size in DX Coil Suction ODF DX Coil Liquid Refrigerant ODF Steam Coil In
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