Bryant 542E User Manual
installation, operation,
and maintenance instructions
542E
Sizes 024 thru 06(f
PACKAGED HEAT PUMPS
NOTE: Installation must conform to the guidelines pre
sented in these unit Installation Instructions. Read and
become familiar with these instructions before starting in
stallation.
Models 542D and 542E Packaged Heat Pumps are fully selfcontained combination heating/cooling units designed for
outdoor installation. Model 542E may be installed either on
a rooftop or ground level slab. Model 542D is used in con
junction with an accessory roof mounting curb and incorpor
ates a down-discharge/return-air plenum as an integral part
of the unit.
These packaged heat pumps are factory-charged and sealed.
Installation is easy—simply connect condensate drain, air
ducts, high- and low-voltage wiring, and install a field-sup
plied air filter in the return-air ductwork (except for Model
542D which has factory-supplied high-capacity air filters) to
obtain heating during the heating season, cooling and
dehumidification during the cooling season, and filtering of
the conditioned space.
All units can be connected into existing duct systems that
are properly sized and designed to handle an airflow of 400 to
450 ft^lmin per each 12,000 Btuh of unit capacity.
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.
Important-Read Before Installing
1. Check all local and other applicable codes for informa
tion concerning proximity to property lines, height
above roof, obstructions, or other special installation re
quirements.
2. Make certain that power supply available (volts, hertz,
and phase) corresponds to that specified on unit rating
plate.
3. Check electrical supply provided by utility to be sure
that service capacity is sufficient to handle load imposed
by unit being installed.
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.
GENERAL
Models 542D and 542E Packaged Heat Pumps have been de
signed and tested in accordance with ARI Standard 240-77
and 270-75, and are UL-listed.
These instructions contain the following sections:
I. Moving and Setting Unit in Place
II. Condensate and Defrost Disposal
III. Duct Connections
IV. Electrical Connections
V. Preparing Unit for Startup
& 542D060
Cancels: New
Figure 1—Model 542E
Figure 2—Model 542D060 Mounted On
Accessory Roof Mounting Curb
VI. Refrigerant Leaks
VII. Startup and Adjustments
VIII. Sequence of Operation
IX. Care and Maintenance
I. MOVING AND SETTING UNIT IN PLACE
CAUTION: Pjvc ■aiition.' Mui.-iT hf lakcii 1o prevunl d.itnage
wlic-n nio\ing the unit. The unit intfrl remain in at) upright
position during all rigging and moving oper;ition.-!, lie .-iure
to |)j-olect the top and ■iide-! of the unit by using spreaders
when rigging the unit to be lifted. Model 5i2n mu.st be
rigged for lifting as .shown in Figure 7. Model .542E must he
rigged for lifting ;is shovsn in Figure
The unit must be installed level for proper condensate
drainage. Be sure that the ground level pad, field-fabricated
support, or accessory roof mounting curb is level before set
ting the unit in place.
When selecting an installation site, try to locate the unit on
the side opposite the prevailing wind to assure proper opera
tion 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
blockage of the outdoor coil and assure proper drainage of
defrosted ice.
A. Rooftop Installation
When installing a Model 542D downflow unit or a Model
542E end-discharge unit with an accessory downflow
40542DP6-A
12/15/79
A79110
flplt
A79111
BDP Company, Division of Carrier Corp.
Top of unit ...............................
Duct side of unit
Compressor access door access end
side
........
......................
............................. 30 Bottom of unit above
. CONTROL ACCESS DOOR^ 7
COMPRESSOR
ACCESS DOOR
Size
024 & 030
036
042, 048, & 060
48 Blower access door end..
12 End opposite blower
■ anticipated snow level.. ■6
A
60-3/16
60-3/16
68-3/16
542E REQUIRED CLEARANCE (Inches)
..30
.112
\ /-4oia r-i DIÁ
,MPT DRAIN
^CONNECTION
542E DIMENSIONS (Inches)
B
32-3/16 24-13/16 21
32-3/16
40-3/16 30-13/16 21
c D E F
24-13/16 21 13-3/4
HIGH-VOLTAGE
INLET WITH MULTIPLE.
KNOCKOUTS
11-1/2 13-5/16 54
16-3/8 17-5/16
13-5/16
i-E
.«
------------------
-SUPPLY-AIR
61-3/16 5-1/8 ' 7-1/2
A
ELECTRIC HEAT
HIGH-VOLTAGE INLET WITH
MULTIPLE KNOCKOUTS
G H
54
6-7/8 6-15/16
4-5/8
U-N"
“T
M
_L
J
6-15/16
A79071
Sizes K
024 & 030
036
042, 048, & 060
18-1/8 3
18-1/8 3
25
L
3-3/8 20-3/32
M N P
15-3/32
15-3/32 12-9/16
12-9/16 13 ,28-9/16
15-1/8 16-19/32 34-9/16 44-1/4 2
Figure 3--542E Dimensional Drawing
TABLE l-RATINGS, PERFORMANCE, & RECOMMENDED FILTER SIZES
MODEL
SIZE
SERIES A
Rated Heating Capacity® 47°F (Btuh)*
Total Power Consumption (Watts)*
COP*
Rated Heating Capacity® 17°F (Btuh)*
Total Power Consumption (Watts)*
COP*
Rated Cooling Capacity @ 95°F (Btuh)*
Total Power Consumption (Watts)*
EER
Rated Indoor Airflow (Ft3/Min)*
Rated External Static Pressure (In. wc)*
ARI Sound Rating Humbert
Recommended Minimum Filter Size (Sq ln.)t
Standard-Type
Cleanable- or High-Capacity-Type
* Rated in accordance with ARI Standard 240-77.
t
Rated in accordance with ARI Standard 270-75.
i Recommended field-supplied filter sizes shown are
**Two 20 X 20 X 2 high-capacity filters are furnished
with Model 542D060.
024
26,000
2850 3300 3850
2.7 2.7 2.7
14,000 16,000 18,000
2300 2650 3000 3650
1.8
25,500 30,000 35,000
3350
7.6
850
0.3
19
408 504 624
265
based on a velocity of 300 ft/min at the rated indoor airfow.
plenum, the accessory roof mounting curb must be installed
on and flashed into the roof before unit installation. The in
structions for installing the curb are packaged with the
curb.
CAUTION: Be sure that the roof will support the additional
weight. Refer to Figure 5 or 6 for weight information. On a
downflow installation with a-Model 542D or a Model 542E
with an accessory downflow plenum where the accessory roof
mounting curb is not being used, the field-fabricated support
must be level and must properly support the unit and downflow plenum.
When installing a Model 542E without an accessory down
flow plenum, place the unit on a level base that provides
proper support. On flat roofs, be sure that the unit is at least
R S T
7.5
37-1/8
542E
4700 5100 6300 6300
2.7 2.8 2.7 2.7
22,000 25,000 31,500 31,500
43,000 47,000 58,000 58,000
8.1
1550 1700 2000 2000
744
484
13 28-9/16 37-1/8 2 7/8 27-3/8
030 036 042 048 060
A A A
30,000 35,000 43,000 48,000 58,000
1.8 1.8 1.8 1,8 1.8
3800 4650 5300 6100
7.9
1050 1300
0.3 0.3 0.3 0.3 0.3
19 19 18 18 20 20
328 406
U
2
7/8 27-3/8
7/8 33-11/16
4150 5200 5200
7.7
816 960
530 624
V
542D
060
A A A
58,000
1.8
7700 7700
7.5 7.5
0.3
**
**
4 inches above the highest expected water level on the roof
to prevent flooding. Consult local codes for installation re
quirements.
NOTE: See Figure 10 for a typical rooftop installation. B. Ground-Level Installation
The unit must be placed on a solid level concrete pad that is
a minimum of 4 inches thick and that extends approximate
ly 2 inches beyond the casing on all four sides of the unit.
The unit does not need to be secured to the pad except when
required by local codes.
NOTE: See Figure 11 for a typical ground level installation. C. Clearances
The required minimum operating and service clearances are
-2-
542D060 REQUIRED CLEARANCES (Inches)
Top of unit
Compressor access door End opposite blower
side
Side opposite compressor Bottom of unit above
access door
.......
.........................48 Blower access door end__30
........................................
..........................
30 accessend
12 anticipated snow level
.....
___
12
6
-FRESH AIR
INLET HOOD
l-MPT DRAIN
^CONNECTION
Figure 4—542D060 Dimensional Drawing
542E
Size
024
030
036
042
048
060
Shipping
Wt (lbs)
320 310 78 75 77 80
334 324 81 78 81 84
348 338 85 82 84 87
453 443
465 455 114 110 113
490 480 120 116 120 124
Operating
Wt (lbs)
Corner Wt (lbs)
A B
111 107
D
C
110 115
118
Figure 5—542E Corner Weights
shown in Figure 3 for Model 542E and Figure 4 for Model
542D.
CAUTION: Any air restriction at the outdoor air inlet tthe
entire surface of the outdoor coil) can be detrimental to com
pressor life.
The fan discharge is through the top of the unit. Do not
locate the unit under a complete overhead obstruction. Mini
mum clearance under a partial overhang (such as a normal
house roof overhang) is 48 inches.
Be sure that the unit is located so that water, ice, or snow
from an overhang or roof will not fall directly on the top of
the unit and damage it. Be sure that grass, shrubs, or other
plants do not interfere with the airflow into or out of the
unit.
II. CONDENSATE AND DEFROST DISPOSAL
NOTE: Condensate and defrost water disposal methods must
comply with local codes, restrictions, and practices.
Models 542D and 542E are designed to dispose of cooling
cycle condensate water through a 3/4-inch MPT plastic
HIGH-VOLTAGE INLET
A79072
Top View
Model 5420
A79116-A,
Shipping Wt (lbs) 703
Operating Wt (lbs)
Unit Corner Wts (lbs)
ROOF MOUNTING CURB P/N 304851-302
Shipping Wt (lbs) 120
Operating Wt (lbs)
Curb Corner Wt (lbs) A
Combined Operating Wt (lbs)
Curb Corner Wts with
Unit on Curb
UNIT-MODEL 542D060
A B
144
27.5 27.5 29 29
UNIT&CURB
A B
154 164
556
C D
134
138
113
B C D
669
C
181 170
140
D
Figure 6—542D060 Corner Weights
drain fitting. To prevent damage during the shipping and
moving of the unit, this fitting is shipped inside the unit
compressor compartment (secured with tape). Locate this
fitting and insert the nonthreaded end into the drain hose
located in the compressor compartment. See Figure 12.
It is recommended that a 3-inch trap be installed in the
drain line to avoid improper drainage and to prevent leakage
of indoor air to the outdoors. See Figure 9. Make sure that
the outlet of the trap is at least 2 inches lower than the unit
drain pan connection to prevent the pan from overflowing.
-3-
TABLE ll-ELECTRICAL DATA-MODEL 542E-SIZES 024 THRU 042
MODEL
SIZE
SERIES A A A
Unit Volts-Phase (60Hz)
Operating Voltage Range 197-253 197-253 197-253 187-253
Total Unit Amps
Max Branch Circuit Fuse Size (Amps) 30
Unit Ampacity for Wire Sizing 20.2 27.5 29.2
Minimum Wire Size (AWG)*
Maximum Wire Length (Ft)* 115 85 80 95
024
208-230-1
16.7
10
030 036
208-230-1
22.7
45
10
208-230-1
542E
208/230-3
23.9 14.8
45 25
10
17.8
12
042
A
230-1
207-253 187-253
28.7 21.0
50
34.9
8
112
208/230-3
40
25.2
10
107
TABLE MI-ELECTRICAL DATA-MODELS 542E048, 542D060, & 542E060
MODEL
SIZE
SERIES
Unit Volts—Phase (60Flz) 230-1
Operating Voltage Range 207-253
Total Unit Amps
Max Branch Circuit Fuse Size (Amps) 60
Unit Ampacity for Wire Sizing 38.9
Minimum Wire Size (AWG)* 8 10
Maximum Wire Length (Ft)* 101 100
*Only use 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 fable. 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.
USE SPREADER BARS TO PROTECT UNIT
31.9
542E 542E
048 060
A A
208/230-3 460-3
187-253
22.4 10.9 40.9 26.1
45 20 60
27.1
414-506 207-253 187-253
13.2
14
181 123
USE SPREADER BARS TO PROTECT UNIT
230-1
49.8
6 8
542D & 542E
208/230-3
50
31.3
137
060
A
460-3
414-506
13.7
25
16.4
12
229
ONE INCH FROM PLENUM FOR
PROPER FIT ON CURB AND PLATFORM
CHAIN RETAINER FOR
PROPER BALANCE
Figure 7—542D060 Suggested Rigging
Prime the trap with water and check the condensate line for
leaks.
CAUTION; Do not undersize the condensate drain line.
During the heating defrost cycle, defrost water from the
melting ice on the outdoor coil flows through the slots in the
heat pump base directly below the outdoor coil. If a field-supplied drain pan is to be used to catch the defrost water, this
pan should be at least 2 inches high and extend at least 2 in
ches beyond the width and length of the unit.
If the installation requires draining the condensate and/or
defrost away from the unit, connect a minimum of 7/8-inch
OD copper tubing, 3/4-inch galvanized pipe, or 7/8-inch
plastic pipe. The drainage lines should pitch downward at a
slope of at least 1 inch in every 10 feet of horizontal run.
Both 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 a
gravel apron is being used, it should extend at least 24 in
ches around the mounting pad to ensure proper drainage.
III. DUCT CONNECTIONS
Flanges are provided on the 542E supply- and return-air
A79148
Figure 8—542E Suggested Rigging
openings on the side of the unit. See Figure 3 for connection
sizes and locations. See Figures 10 and 11 for illustrations of
typical installations.
Flanges are provided on the 542D supply- and return-air
openings on the bottom of the unit. See Figure 4 for connec
tion sizes and locations.
NOTE: The minimum installation requirements of the duct
system must be in accordance with the standards of the Na
tional Fire Protection Association for installation of air con
ditioning and ventilating systems of other than residence
type, NFPA No. 90; or residence type, NFPA No. 90B; and/or
local codes and ordinances.
CAUTION: When the duct system fastening holes are being
drilled into the 542E side instead of the unit duct flanges
provided, use care to avoid puncturing the coil tubes.
The following criteria must be followed when selecting, siz
ing, and installing ductwork:
1. When electric heater is installed, a minimum clearance
of one inch to combustible materials must be main
tained for the first 36 inches of duct.
2. It is recommended that flexible connectors be used be-
-4-
tween the ductwork and unit to prevent transmission of
vibration. The duct system can be screwed or bolted to
the unit duct flanges. Suitable gaskets should be used to
insure an airtight seal. When a supplemental electric
resistance heater is being used, use fireproof material
for the connector between the ductwork and unit sup
ply-air duct flange. If flexible duct (which is not heat re
sistant) is being used, use a sheet metal duct sleeve in
side the flexible duct for at least the first 36 inches of
duct.
3. An external field-supplied air filter must be installed in
the 542E return-air ductwork. Recommended filter sizes
are shown in Table I. Filters should be installed where
they are easily accessible for service.
NOTE: Model 542D has factory-supplied high-capacity air
filters. High-capacity air filters are also factory-supplied
when the accessory plenum, horizontal economizer, or highcapacity filter rack is being used with Model 542E.
4. Avoid abrupt duct size increases of decreases.
5. Size all ductwork for required heat pump airflow.
6. Adequately insulate and weatherproof all ductwork
located outdoors. Ducts passing thru an unconditioned
space must be insulated and covered with a vapor bar
rier in accordance with the latest issue of SMACNA and
NESCA minimum installation standards for heating
and air conditioning systems.
7. Secure all ducts to the building structure.
8. All openings in the building structure must be properly
flashed, weatherproofed, and vibration-isolated in ac
cordance with local codes and good building practices.
IV. ELECTRICAL CONNECTIONS
WARNING: Tlit- iiiiit l aliinet have.-in uninrerrupted or
unbroken electrical ground to mininii/o por.ional injury if aii
electrical fault should occur. This may consist of elec.rical
wire connected to the unit ground lug in the control com
partment, or conduit approved for electrical ground when in
stalled in accordance with the National Electrical Code and
local electrical codes. A failure to follow this warning can re
sult, in the installer being liable for the personal injury .of
others. ■ , ■ ,
CAUTiON: A failure to follow these precautions could result
in danaage to the. unit being installed:
1. All electrical connections must be made in accordance
with the National Electrical Code and local electrical
codes governing such wiring.
2. Copper conductor is the only type of wire that is to be
connected between the field-supplied electrical discon
nect switch and the unit. DO NOT USE ALUMINUM
WIRE.
3. High-voltage power to the unit must be within the
operating voltage range indicated on the unit rating
plate. On 3-phase units, phases must be balanced within
2%. Consult the local power company for correction of
improper voltage and/or phase balance.
4. When the low-voltage control wires are run in the same
conduit as the high-voltage wires, the low-voltage wires
must be insulated for the highest voltage contained
within the conduit.
ACOUSTIC a INSULATION
DUCT LINER
Figure 10—542E Typical Rooftop
Installation on Pitched Roof
5. When drilling thru any panel to mount electrical hard
ware, conduit, etc; ensure that the drill does not damage
internal components.
6. If aluminum ,conductors are used between the electrical
service panel (power source) and the field-supplied
electrical disconnect switch, the wire gauge selected
must have a current capacity that is not less than the
; copper wire specified and must not create a; voltage drop
in excess of 2% of the unit rated voltage.
A. High-Voltage Connections
A separate electrical line with a field-supplied, waterproof,
fused disconnect, switch mounted at, or within sight of, the
unit must be used for this installation. Refer to the unit rat
ing plate for maximum fuse size and minimum amps
(ampacity) for wire sizing. Tables II and III show recom
mended wire sizes and lengths based on rating plate data.
NOTE: The field-supplied fused disconnect may be mounted
over the unit high-voltage inlet hole directly on the control
corner panel adjacent to the blower access panel. See Figure
3 or 4. Be sure that the disconnect box does not interfere
with the removal of the blower access panel. When mount
ing the disconnect box, align the knockout in the box with
the unit high-voltage inlet hole. Route the wiring from the
disconnect box thru the aligned holes. This connection must
be watertight to prevent water from entering the control
box.
Proceed as follows to complete the high-voltage connections
to the unit:
1. Run high-voltage power leads from fused disconnect
thru high-voltage inlet hole in control corner panel. See
Figure 3 or 4.
2. Connect ground lead to chassis ground connection, and
connect high-voltage power leads to unit high-voltage
pitgail leads. Single-phase units have two black pigtail
leads. Three-phase units have two black and one red pig
tail lead. See Figure 12, Figure 13, and unit wiring
label. Use a suitable wire splice connector or wirenut to
make each high-voltage connection. Tape each com
pleted connection.
B. Low-Voltage Connections
Recommended heat pump room thermostats for heat pump
operation with or without supplemental electric heaters are
P/N 34427DP115 (subbase included) for automatic system
changeover and P/N34427DP118 (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 in
cluded) can be used for heat pump operation without supple
mental electric heaters. This thermostat provides for
manual system changeover and does not have an emergency
heat switch.
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