Carrier 542E User Manual

installation, operation,
		542E
and maintenance instructions		Sizes 024 thru 060
PACKAGED HEAT PUMPS		& 542D060
Cancels: 40542DP6-A		40542DP16-A
		6/1/80

NOTE TO INSTALLER: Leave these instructions with the unit after installation.

NOTE: The installation of this unit must conform to the guidelines presented in these unit Installation Instructions. Read and become familiar with this publication before start­ ing installation.

INTRODUCTION

Models 542D and 542E Packaged Heat Pumps are fully selfcontained combinatipn heating/cooling units designed for outdoor installation. Model 542E may be installed either on a rooftop or ground-level slab. See Figure 1. Model 542D is used with an accessory roof-mounting curb (P/N 304851302) and incorporates a down-discharge/return-air plenum as an integral part of the unit. See Figure 2.

These units are factory-charged with R-22 refrigerant. Installation is simple: connect condensate drain, air ducts, highand low-voltage.wiring, and install a field-supplied air filter (except for model 542D which has factory-supplied air filters).

All units can be connected into existing duct systems that are properly sized and designed to handle an airflow of 350 to 450 ffimin per each 12,000 Btuh of rated unit capacity. See Table I for indoor airflow requirements.

Accessory UL-listed, field-installed, supplemental electric heat packages are available in a variety of KW and voltage options. These electric resistance heaters mount inside the unit blower compartment.

A full line of rooftop system accessories is available for field installation. These accessories include plenums with facto­ ry-supplied air filters (plenum not required with Model 542D), roof-mounting curbs, horizontal and downflow economizers, barometric relief dampers, concentric diffuser boxes, and flexible duct packages. Filter racks with air filters are available for rooftop or ground-level installation.

NOTE: When installing any accessory item, see the Installa­ tion Instructions packaged with the accessory.

IMPORTANT-READ BEFORE INSTALLING

1. This installation must conform with all applicable local and national codes.

2.The power supply (volts, hertz, and phase) must corres­ pond to that specified on unit rating plate.

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

4.Refer to the 542D or 542E dimensional drawing for loca­ tions of electrical inlets, condensate drain, duct connec­ tions, and required clearances before setting unit in place.

5.Styrofoam shipping blocks located between compressor and divider panel and between accumulator and divider panel must be removed. A failure to remove these blocks can result in undesirable vibration noises being transmitted into the conditioned space.

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A79110

Figure 1—Model 542E

A79111

Figure 2—Model 542D060 Mounted on

Accessory Roof-Mounting Curb

GENERAL

Models 542D and 542E Packaged Heat Pumps have been designed and tested in accordance with ARI Standards 24077 and 270-75, and these units are UL-listed.

This publication contains the following sections:

I.Moving and Setting Unit in Place II. Condensate and Defrost Disposal HI. Duct Connections

IV. Electrical Connections

V. Preparing Unit for Startup

VI. Startup and Adjustments

VII. Sequence of Operation

VIII. Care and Maintenance

BDP Company, Division of Carrier Corp.

542E REQUIRED CLEARANCE (Inches)			OUTDOOR FAN
Top of unit..................................	48	Blower access door end______ 30
Duct side of unit.........................	12	End opposite blower
Compressor access door		access end...........................	12
side.........................................	30 Bottom of unit above
		anticipated snow level....	6

CONTROL ACCESS DOOR

COMPRESSOR

ACCESS DOOR

ELECTRIC HEAT

HIGH-VOLTAGE INLET WITH

MULTIPLE KNOCKOUTS

A79071

542E DIMENSIONS (Inches)

Size

A

B

c

D

E

F

G

H

J

024 & 030

60-3/16

32-3/16

24-13/16

21

11-1/2

13-5/16

57

6-7/8

6-15/16

036

60-3/16

32-3/16

24-13/16

21

13-3/4

13-5/16

57

4-5/8

6-15/16

042, 048, & 060

68-3/16

40-3/16

30-13/16

21

16-3/8

17-5/16

65

5-1/8

7-1/2

Sizes

K

L

M

N

P

R

S

T

TJ

V

024 & 030

18-1/8

1-1/2

15-3/32

12-9/16

14-1/2

28-9/16

37-1/8

2

7/8

27-7/8

036

18-1/8

1-1/2

15-3/32

12-9/16

14-1/2

28-9/16

37-1/8

2

7/8

27-7/8

042, 048, & 060

25

1-1/2

20-3/32

15-1/8

18-1/2

34-9/16

44-1/4

2

7/8

35-3/16

Figure 3—542E Dimensional Drawing

TABLE l-RATiNGS, PERFORMANCE, & RECOMMENDED FILTER SIZES

MODEL			542E					5420
SIZE	024	030	036		042	048	060	060
SERIES	A	A	A		A	A	A	A
Rated Heating Capacity @ 47°F (Btuh)* **	26,000	30,000	35,000		42,000	48,000	58,000	58,00011
Total Power Consumption (Watts)*	2850	3450	3850		4600	5100	6300	6300tt
COP*	2.7	2.5	2.7		2.7	2.8	2.7	2.7t-
Rated Heating Capacity® 17°F (Btuh)*	13,500	16,000	18,000		21,000	25,000	31,000	31,00011
Total Power Consumption (Watts)*	2350	2900	3000		3700	4150	5300	530011
COP*	1.7	1.6	1.8		1.7	1.8	1.7	1.711
Rated Cooling Capacity @ 95°F (Btuh)*	25,500	30,000	35,000		41,000	47,000	57,000	57,00011
Total Power Consumption (Watts)*	3350	3900	4650		5150	6100	7600	7600-t
EER	7.6	7.7	7.5		8.0	7.7	7.5	7.511
Rated Indoor Airflow (Ft^/Min)*	850	1050	1300		1535	1700	2000	200011
Rated External Statio Pressure (In. wc)*	0.10	0.15	0.15		0.15	0.20	0.20	0.2011
ARI Sound Rating Humbert	19	19	19		18	18	20	20
Recommended Minimum Filter Size (Sq ln.)t	408	504	624		737	816	960	**
Standard-Type
								**
Cleanable-or High-Capacity-Type	265	328	406		479	530	624

* Rated in accordance with ARI Standard 240-77. t Rated in accordance with ARI Standard 270-75.

f Recommended field-supplied filter sizes shown are based on a velocity of 300 ft/min at the rated indoor airflow. **Two 20 X 20 X 1 air filters are furnished with Model 542D060.

ttTo achieve the performance ratings indicated, the fresh-air and exhaust openings of the plenum section must be sealed airtight, the fresh-air damper must be insulated, and the plenum section must be supported by a curb around an opening to the indoor airspace.

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Figure 4—542D060 Dimensional Drawing

TABLE ll-ELECTRICAL DATA-MODEL 542E-SIZES 024 THRU 042

MODEL				542E
SIZE	J024	J030	J036 1 P036			B042 1 P042
SERIES	A	A		A			A
Unit Volts—Phase (60Hz)	208-230-1	208-230-1	208-230-1		208/230-3	230-1		208/230-3
Operating Voltage Range	197-253	197-253	197-253		187-253	207-253		187-253
Total Unit Amps	16.7	22.7	23.9		14.8	28.7		21.0
Max Branch Circuit Fuse Size (Amps)	30	45	45		25	50		40
Unit Ampacity for Wire Sizing	20.2	27.5	29.2		17.8	34.9		25.2
Minimum Wire Size (AWG)*	10	10	10		12	8		10
Maximum Wire Length (Ft)*	115	85	80		95	112		107

TABLE lll-ELECTRICAL DATA-MODELS 542E048, 542D060, & 542E060

MODEL		542E		542E	542D & 542E
SIZE	B048	P048	E048	060	P060		E060
SERIES		A		A		A
Unit Volts—Phase (60Hz)	230-1	208/230-3	460-3	230-1	208/230-3		460-3
Operating Voltage Range	207-253	187-253	414-506	207-253	187-253		414-506
Total Unit Amps	31.9	22.4	10.9	40.9	30.1		13.7
Max Branch Circuit Fuse Size (Amps)	60	45	20	60	50		25
Unit Ampacity for Wire Sizing	38.9	27.1	13.2	49.8	35.6		15.7
Minimum Wire Size (AWG)*	8	10	14	6	8		12
Maximum Wire Length (Ft)*	101	100	181	123	119		229

* Use only copper wire for field connections to unit. Wire size is based on 60 or 75°C copper conductor at 86°F (30°C) ambient tempera­ ture and ampacity shown in table. If other than 60 or 75°C copper conductor is used, if ambient temperature is above 86°F, or if voltage drop of wire exceeds 2% of unit rated voltage, determine wire size from ampacity shown and the National Electrical Code. Wire lengths shown are measured one way along the wire path between unit and service panel for minimum voltage drop.

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USE SPREADER BARS TO PROTECT UNIT

USE SPREADER BARS TO PROTECT UNIT

A79148

Figure 5—542E Suggested Rigging

I. MOVING AND SETTING UNIT IN PLACE

CAUTION: Use spreader bars when rigging the unit to be lifted to protect the top and sides. Model 542E must be rigged for lifting as shown in Figure 5. Model 542D must be rigged for lifting as shown in Figure 6. Use extreme caution to prevent damage when moving the unit. It must remain in an upright position during all rigging and moving opera­ tions. The unit must be level for proper condensate drainage; therefore, the ground-level pad or accessory roof­ mounting curb must be level before setting the unit in place. When a field-fabricated support is used instead of the ac­ cessory curb, ensure that the support is level and properly supports the unit and plenum.

When selecting an installation site, locate the unit on the side opposite the prevailing wind to assure proper operation of the defrost cycle and to avoid snow drifts that could block the outdoor coil. Be sure that the unit is installed at least 6 inches above the highest probable snow level to prevent block­ age of the outdoor coil and to assure proper drainage of de­ frosted ice.

A. Rooftop Installation

CAUTION: When installing the unit on a rooftop, be sure that the roof will support the additional weight. Refer to the Product Data Sheet (PDS) for Models 542D and 542E to obtain total weight and corner weight information.

When installing a Model 542D Downflow Unit or a Model 542E End-discharge Unit with an accessory downflow plenum, the accessory roof-mounting curb must be installed on, and flashed into, the roof before unit installation. The instructions for installing the curb are packaged with the curb.

When installing a Model 542E without downflow plenum, place the unit on a level base that provides proper support. On flat roofs, be sure that the unit is located at least 4 inches above the highest expected water level on the roof to prevent flooding. Consult local codes for additional installation requirements.

B. Ground-Level Installation

Place the unit on a solid, level concrete pad that is a minimum of 4 inches thick and that extends approximately 2 inches beyond the casing on all four sides of the unit. Do not secure the unit to the pad except when required by local codes.

C. Clearances

The required minimum operating and service clearances are shown in Figures 3 and 4. (Refer to the 542D clearances when installing Model 542E with an accessory downflow plenum.)

Figure 6—542D060 Suggested Rigging

CAUTION: Do not restrict outdoor airflow. An air restric­ tion at either the outdoor-air inlet (the entire surface of the outdoor coil) or the fan discharge can be detrimental to com­ pressor life.

The outdoor fan discharges through the top of the unit. Ensure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under a complete overhead obstruction. The minimum clearance under a partial overhang (such as a normal house roof overhang) is 48 inches.

Do not locate the unit where water, ice, or snow from an overhang or roof will damage or flood the unit by falling on the top. Do not locate the unit where grass, shrubs, or other plants will interfere with the airflow either into or out of the unit.

II. CONDENSATE AND DEFROST DISPOSAL

NOTE: Ensure that defrost and condensate water disposal methods comply with local codes, restrictions, and practices.

Models 542D and 542E dispose of condensate water through a 3/4-inch MPT plastic drain fitting. To prevent damage dur­ ing the shipping and moving of the unit, this fitting and a plastic drain pipe are shipped inside the unit compressor compartment (secured with tape). Locate this fitting and 'nsert the nonthreaded end into the plastic drain pipe. See Figure 8. Insert the plastic pipe over the drain on the drain pan. The pipe and fitting must lay flat against the base for proper drainage. The residual curvature in the pipe must be in a horizontal plane.

Install a 3-inch trap at the drain fitting to ensure proper drainage. See Figure 7. Make sxire that the outlet of the trap is at least 2 inches lower than the unit drain pan connection to prevent the pan from overflowing. Prime the trap with water.

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		CAPACITOR(S)
REVERSING VALVE	HIGH-PRESSURE	(COMPRESSOR a	BLOWER MOTOR
ASSEMBLY		FAN MOTOR)
LOW-PRESSURE	SERVICE FITTING		RELAY
			BLOWER MOTOR
SERVICE FITTING			CAPACITOR
			DEFROST
ACCUMULATOR			RELAY
			DEFROST
			TIMER
ACCUMULATOR			TRANSFORMER
FUSIBLE			LOW-VOLTAGE
PLUG
			TERMINAL
DEFROST			BOARD
			LOW-VOLTAGE
THERMOSTAT
			INLET HOLE
METERING			CHASSIS
			GROUND
DEVICE			CONNECTION
LOW-PRESSURE SWITCH		QUICK-START PTC	■HIGH-
INDOOR COIL DRAIN PAN			VOLTAGE
		THERMISTOR
			PIGTAIL

4 MPT PLASTIC DRAIN FITTING	COMPRESSOR	LEADS
^(SHIPPED TAPED INSIDE
COMPRESSOR COMPARTMENT)

A79243

Figure 8—Partial Side'View With Compressor & Control Access Panels Removed (Model 542E036, 208V-230V—1)

During the heating defrost cycle, defrost water from the melting ice on the outdoor coil flows through the holes in the heat pump base directly below the outdoor coil. When using a field-supplied drain pan to catch the defrost water, be sure that this pan is at least 2 inches high and extends at least 2 inches beyond the width and length of the unit.

If the installation requires draining the condensate and/or defrost water away from the unit, connect a drain tube(s), using a minimum of 7/8-inch OD copper tubing, 3/4-inch galvanized pipe, or 7/8-inch plastic pipe. Do not undersize the tuhe(s). Pitch the drain tube(s) downward at a slope of at least 1 inch in every 10 feet of horizontal run. Be sure to check the drain tube(s) for leaks.

Condensate and defrost water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground-level installations. When using a gravel apron, make sure it slopes away from the unit.

III. DUCT CONNECTIONS

Model 542E has duct flanges on the supplyand return-air openings on the side of the unit. See Figure 3 for connection sizes and locations.

Model 542D has duct flanges on the supplyand return-air openings on the bottom of the unit. See Figure 4 for connec­ tion sizes and locations.

WARNING: The design and installation of the duct system must be in. accordance with the standards of the National Fire Protection Association for installation of nonresidencetype air conditioning and ventilating systems, NFPA No. 90; or residence-type, NFPA No. 90B; and/or local codes and ordinances.

Adhere to the following criteria when selecting, sizing, and installing the duct system:

1. Select and size ductwork, supply-air registeis, and return-air grilles according to ASHRAE recommenda­ tions and as presented in BDP training materials.

CAUTION: When the duct system fastening holes are being drilled into the side of Model 542E instead of the unit duct flanges, use extreme care to avoid puncturing the coil or coil tubes.

2. Use a flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transi­ tion may be screwed or bolted to duct flanges. Use suita­ ble gaskets to ensure a weather and airtight seal.

NOTE: When using a supplemental electric heater, main­ tain a minimum clearance of one inch to combustible materials for the first 36 inches of duct and use fireproof material for the transition between the ductwork and unit supply-air duct flange. When using flexible duct (which is not heat resistant), use a 36-inch long sheet metal duct be­ tween the supply outlet and the flexible duct. Observe the warning on the unit rating plate.

3.Install an external, field-supplied air filter(s) in the return-air ductwork where it is easily accessible for ser­ vice. Recommended filter sizes are shown in Table I. (Model 542D has factory-supplied air filters.)

4.Size all ductwork for required indoor airflow of heat pump being installed. This airflow will be adequate for safe electric heater operation (except when using 20KW heater with 030-size unit airflow must be at least 1000 fU/min). Avoid abrupt duct size increases or decreases.

5.Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing thru an uncon­ ditioned space, and use a vapor barrier in accordance with the latest issue of SMACNA and NESCA minimum installation standards for heating and air conditioning systems. Secure all ducts to the building structure.

6.Flash, weatherproof, and vibration-isolate all openings in building structure in accordance with local codes and good building practices.

HIGH-VOLTAGE		-FIELD SPLICE
PIGTAIL LEADS
BLK
BLK	^
		1	POWER
RED			SUPPLY

/ r	F1ELD-SUPPL1E(
/ r-Tok
3-PHASE	SWITCH
UNITS ONLY		A79244

Figure 9—Field High-Voltage Connections

IV. ELECTRICAL CONNECTIONS

WARNING: The unit cabinet must have an uninterruptedj 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 the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with the National Electrical Code and local electrical codes. A failure to follow this warning could result in the installer being lia­ ble for the personal injury of others.

CAUTION: A failure to follow these precautions could result in damage to the unit being installed;

1. Make all electrical connections in accordance with the National Electrical Code and local electrical codes governing such wiring.

2.Use only copper conductor for connections between the field-supplied electrical disconnect switch and the unit. DO NOT USE ALUMINUM WIRE.

3.Ensure that high-voltage power to the unit is within the operating voltage range indicated on the unit rating plate. On 3-phase units, ensure that phases are balanced within 2%. Consult the local power company for correc­ tion of improper voltage and/or phase balance.

4.Insulate low-voltage wires for the highest voltage con­ tained within the conduit when low-voltage control

wires are run in the same conduit as high-voltage wires.

5.Do not damage internal components when drilling thru any panel to mount electrical hardware, conduit, etc.

6.Make sure that the service conductors used between the electrical service panel and the field-supplied electrical disconnect switch do not have a current capacity less than the copper wire specified, and do not create a total voltage drop in excess of 2% of the rated voltage of the unit.

NOTE: When using aluminum conductor from the electrical service panel (power supply) to the disconnect switch (where local codes permit the use of aluminum wire), make the con­ nections in accordance with the National Electrical Code. Prepare all aluminum wire immediately before installation by “brush-scratching” the wire, then coating the wire with a corrosion inhibitor (such as Pentrox A). Be sure that the entire connection is completely covered to prevent an electrochemical reaction that will cause the connection to fail very quickly. Do not reduce the effective size of the wire by cutting off strands to fit the wire into a connector. Always use properly sized connectors.

A. High-Voltage Connections

The unit must have a separate electrical service with a fieldsupplied, waterproof fused disconnect switch at, or within sight of, the unit. Refer to the imit rating plate for max­ imum fuse size and minimum circuit amps (ampacity) for

wire sizing. Tables II and III show recommended wire sizes and lengths based on rating plate data.

The field-supplied disconnect switch box may be mounted on the unit over the high-voltage inlet hole in the control cor­ ner panel. See Figure 3 or 4. Be sure that the disconnect box does not interfere with the removal of the blower access panel.

Proceed as follows to complete the high-voltage connections to the unit:

1.Connect ground lead to chassis-ground connection when using a separate ground wire.

2.Connect high-voltage power leads to unit high-voltage pigtail leads. Single-phase units have two black pigtail leads. Three-phase units have two black and one red pig­ tail lead. See Figure 8, Figure 9, and unit wiring label. Use a suitable wire splice connector or wirenut to make each high-voltage connection. Tape each completed con­

nection.

B. Special Procedures for 208-V Operation WARNING: Make sure that the power supply to the unit is switched OFF before making any wiring changes.

When operating sizes 018 thru 036 single-phase units or sizes 036 thru 060 208/230-volt three-phase units at 208 volts, disconnect the red transformer-primary lead from the contactor. See the unit wiring label and Figure 8. Remove the tape and cover from the terminal on the end of the blue transformer-primary lead. Save the cover. Connect the blue lead to the contactor terminal from which the red lead was disconnected.

Using the cover removed from the blue lead, insulate the loose terminal on the red lead. Wrap the cover with electri­ cal tape so that the metal terminal can not be seen.

NOTE: If a blower motor speed is changed, insulate all unused motor leads following the same procedures described for the transformer leads.

C. Low-Voltage Connections

The recommended heat pump room thermostats for heat pump operation with or without supplemental electric heaters are P/N 34427DP115 (subbase included) for auto­ matic system changeover and P/N 34427DP118 (subbase included) for manual system changeover. These thermostats have an emergency heat (EM. HT.) switch and red indicator light.

Heat pump room thermostat P/N 34427DP87 (subbase included) can be used for heat pump operation without sup­ plemental electric heaters. This thermostat provides for manual system changeover and does not have an emergency heat switch.

NOTE: When a supplemental electric heat package is being used, see the Installation Instructions packaged with the heater to complete system low-voltage wiring connections.

Locate the room thermostat on an inside wall in the space to be conditioned where it will not be subjected to either a cool­ ing or heating source, or direct exposure to sunlight. Mount the thermostat 4 to 5 feet above the floor.

Use No. 18 AWG color-coded, insulated (35°C minimum) wires to make the low-voltage connections between the ther­ mostat and the unit. If the thermostat is located more than 100 feet from the unit (as measured along the low-voltage wires), use No. 16 AWG color-coded, insulated (35°C minimum) wires.

A grommeted, low-voltage inlet hole is located in the panel adjacent to the control access panel. See Figure 3 or 4. Run the low-voltage leads from the thermostat, thru the inlet hole, and to the low-voltage terminal board. See Figure 8. Connect the low-voltage thermostat leads to the terminal

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