Bryant DURAPAC PLUS SERIES 542J Installation, Start-up And Service Instructions Manual

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installation, start-up and service instructions

SINGLE PACKA GE ROOFT OP HEAT PUM P UNITS

Cancels: II 542J-150-3 II 542J-150-4

Dura

Pac

542J

Plus Series

Sizes 150,180

12 and 15 Tons

3/15/06

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

I. Step 1 — Provide Unit Support. . . . . . . . . . . . . . . . . 1

II. Step 2 — Rig and Place Unit. . . . . . . . . . . . . . . . . . . 1

III. Step 3 — Field Fabricate Ductwork . . . . . . . . . . . . . 1

IV. Step 4 — Make Unit Duct Connections . . . . . . . . . . 3

V. Step 5 — Trap Condensate Drain. . . . . . . . . . . . . . . 3

VI. Step 6 — Make Electrical Connections . . . . . . . . . . 7

VII. Step 7 — Make Outdoor-Air Inlet Adjustments. . . 10

VIII. Step 8 — Install Outdoor-Air Hood. . . . . . . . . . . . . 10

IX. Step 9 — Install All Accessories . . . . . . . . . . . . . . 10

X. Step 10 — Adjust Factory-Installed Options. . . . . 11

XI. Step 11 — Defrost Cycle . . . . . . . . . . . . . . . . . . . . . 18

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-22

SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-29

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .30-35

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained se rvice personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety pre c au ti ons th at ma y a ppl y.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

WARNING: Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

INSTALLATION

IMPORTANT: Units have high ambient operating limits. If

limits are exceeded , the un it will au tomatica lly lock the compressor out of operation. Manual reset will be required to restart the compressor.

I. STEP 1 — PROVIDE UNIT SUPPORT A. Roof Curb

Assemble and install a ccessory roof curb in accordanc e with instructions shipped with the curb. Accessory roof curb and information required to field fabricate a roof curb are shown

in Fig. 1 and 2. Install insulation, cant strips, roofing, and counter flashing as shown. Du ctwork can be secured to roof curb before unit is set in pl ace. Horizontal adapter installation is shown in Fig. 2.

IMPORTANT: Th e gasketing of the unit to the roof curb is critical for watert ight seal. Install ga sket suppli ed with the ro of curb as shown in Fig. 1. Improp erly applied gasket can result in air leaks and poor unit performance.

Curb should be level. This is necessary to permit unit drain to function properly. Unit leveling tolerances is ± ear ft in any dire ction . Refe r to Accessory Roof Curb Installation Instructions for addition al information as required.

B. Alternate Unit Support

When the curb cannot be used, support unit with sleepers using unit curb support area. If sleepers cannot be used, support long sides of unit with a minimum of 3 equally spaced 4-in. x 4-in. pads on each side.

II. STEP 2 — RIG AND PLACE UNIT

Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright, and do not drop. Use spreader bars over unit to prevent sl ing or cabl e damage. Rollers may be used to move unit across a roof. Level by using unit frame as a reference; leveling tolerance is ± linear ft in any direction. See Fig. 1 for additional leveling tolerance information. Unit weight is shown in Table 1.

Four lifting holes are provided in ends of unit base rails as shown in Fig. 3. Refer to rigging inst ructions on unit.

A. Positioning

Provide clearance around and above unit for airflow, safety, and service access (Fig. 4 and 5).

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air .

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

B. Roof Mount

Check building codes for weight distribution requirements.

III. STEP 3 — FIELD FABRICATE DUCTWORK

Secure all ducts to buildi ng structure. Use flexible duct connectors between unit and ducts as required. Insulate and weatherproof all external ductwo rk, join ts, and roof openings with counter flashing and mastic in accordanc e with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

The 542J units with electric heat requi r e a 1-in. clearance for the first 24 in. of ductwork.

/16 in. per lin-

in. per

Page 2

lb density.

Deg. in. Deg. in.

DIMENSIONS (degrees and inches)*

ALL .28 .45 .28 .43

UNIT

below the unit discharge for units equipped with electric heaters.

1. Roof curb accessory is shipped disassembled.

2. Insulated panels: 1″ thick neoprene coated 1

3. Dimensions in ( ) are in millimeters.

NOTES:

4. Direction of airflow.

the indoor section, unit can only be pitched as shown.

5. Roof curb: 16 ga. (VA03-56) stl.

6. A 90 degree elbow must be installed on the supply ductwork

7. To prevent the hazard of stagnant water build-up in the drain pan of

DESCRIPTION

CURB

HEIGHT

Fig. 1 — Roof Curb Details

Standard Curbfor Units

Requiring High Installation

Side Supply and Return

Curb for High Installation

PKG. NO. REF.

CRRFCURB010A00 1′-2″ (305) Standard Curb 14″ High

CRRFCURB011A00 2′-0″ (610)

CRRFCURB012A00 2′-0″ (610)

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3 1/2"

2" X 1/4 SUPPORT TYP. STITCH WELDED

FULLY INSULATED SUPPLY PLENUM 1" INSULATION 1 1/2 # DENSITY, STICK PINNED & GLUED

NOTE: CRRFCURB013A00 is a fully factory preassembled horizontal adapter and includes an insulated transition duct. The pressure drop through the adapter curb is negligible.

For horizontal return applications: The power exhaust and barometric

relief dampers must be installed in the return air duct.

Fig. 2 — Horizontal Supply/Return Adapter Installation

MAXIMUM

UNIT 542J

150 1895 860 3-1 948 180 2205 1000 3-6 1059

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Refer to Table 1 for unit operating weights.

3. Remove boards at ends of unit and runners prior to rigging.

4. Rig by inserting hooks into unit base rails as shown. Use corner post from packaging to protect coil from damage. Use bumper boards for spreader bars.

5. Weights do not include optional EconoMi$erIV. See Table 1 for EconoMi$erIV weight.

6. Weights given are for aluminum indoor coil plate fins and copper outdoor coil plate fins. Weights of other metal combinations are listed in Table 1.

SHIPPING WEIGHT

lb kg ft-in. mm

DIMENSION A

CAUTION: All panels must be in place when rigging.

Fig. 3 — Rigging Details

14 3/4"

ACCESSORY

PACKAGE NO.

CRRFCURB013A00

12" WIDE STANDING SEAM PANELS

CURB

HEIGHT

1′-11″

(584)

DESCRIPTION

Pre-Assembled, Horizontal

Adapter Roof Curb

23"

Outlet grilles must not lie directly below unit discharge. NOTE: A 90-degree elbo w must be provid ed in the du ctwork

to comply with UL (Underwriters Laboratori es ) co d e s f or use with electric heat.

WARNING: For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Insta ll a 90-de gree t urn in th e return ductwor k between the unit and the conditioned space. If a 90-degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Due to electric heater, supply duct will require 90-degree elbow.

IV. STEP 4 — MAKE UNIT DUCT CONNECTIONS

Unit is shipped for thru-the-bottom duct connections. Ductwork openings are shown in Fig. 6. Field-fabricated concentric ductwork may be connected as shown in Fig. 7 and 8.

Attach all ductwork to roof curb and roof curb basepans. Refer to installation instructions shipped with accessory roof curb for more information.

V. STEP 5 — TRAP CONDENSATE DRAIN

See Fig. 4 or 5 and 9 for drain location. Plug is provided in drain hole and must be removed when unit is operating. One

/4-in. half coupling is provided inside unit indoor air section for condensate drain connection. An 81/2 in. x 3/4-in. diameter nipple and a 2-in. x

/4-in. diameter pipe nipple are coupled to standard 3/4-in. diameter elbows to provide a straight path down through holes in unit base rails (see Fig. 10). A trap at least 4-in. deep must be used.

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Table 1 — Physical Data

UNIT SIZE 542J 150 180 NOMINAL CAPACITY (tons) 12

OPERATING WT (lb)

Al/Al* 1615 1925 Al/Al Coated* 1615 1925 Unit Al/Cu* 1745 2075

Cu/Cu* 1815 2165 Electric Heat 65 65 EconoMi$erIV 90 90 Roof Curb† 200 200

COMPRESSOR Semi-Hermetic

Type (Number) 06D-328 (1) 06D-818 (2) Cylinders 64 Oil Change (oz.) (each circuit) 115 88

REFRIGERANT TYPE R-22

Charge (lb)

System 1 26.0 16.5 System 2 — 16.5

OUTDOOR COIL

Rows 33

/8 in., Internally Grooved Copper T ubes, Aluminum or Copper Lanced Fins

Fins/in. 15 15 Total Face Area (sq ft) 21.7 21.7

OUTDOOR FAN Propeller Type, Direct Drive

Nominal Cfm 9,000 9,000 Number...Diameter (in.) 3...22 3...22 Motor Hp (1075 rpm) Watts Input (Total) 1090 1090

INDOOR CO IL

Expansio n D ev i c e Fixed Orifice

/8 in., Internally Grooved Copper Tubes, Aluminum or Copper Lanced Fins, Face Split

Rows 33 Fins/in. 15 15 Total Face Area (sq ft) 17.5 17.5

INDOOR FAN Centrifugal, Adjustable Pitch Belt Drive

Quantity...Size (in.) Nominal Cfm 5000 6000

2...10 x 10 2...12 x 12

Maximum Continuous Bhp 4.25 5.90 Fan Rpm Range 862-1132 799-1010 Maximum Allowable Rpm 1550 1550 Motor Pulley Pitch Diameter (in.) 3.1/4.1 3.7/4.7 Fan Pulley Pitch Diameter (in.) Belt, Quantity...Type...Length (in.) 1...BX...42 1...BX...46 Pulley Center Line Distance (in.) 13.5-15.5 13.3-14.8 Speed Change Per Turn (rpm)

6.0 11.4

54 42

Pulley Maximum Full Turns 6** 6** Factory Pulley Turns Setting 33 Factory Speed Setting (rpm) 1024 926 Fan Shaft Diameter (in.) Motor Hp (Service Factor) 3.7 (1.15) 5.0 (1.15) Motor Frame Size 56H 184T Motor Efficiency 0.84 0.84

17/

HIGH-PRESSURE SWITCH

Cutout (psig) 426 Reset (psig) 320

LOW-PRESSURE/LOSS-OF-CHARGE SWITCH

Cutout (psig) 7 Reset (psig) 22

AIR INLET SCREENS Cleanable

Economi zer, Quantity...Size (in.)

RETURN-AIR FILTERS (TYPE) 10% Efficient — 2-in. Throwaway Fiberglass

Quantity...Size (in.)

DEFROST THERMOSTAT

Defrost Time 30 min (Adjustable to 50 or 90 min)

2...20 x 25 x 1

1...20 x 20 x 1

4...20 x 20 x 2

4...16 x 20 x 2

Closes (F) 28 Opens (F) 65

LEGEND

Al — Aluminum Cu — Copper

*Indoor coil fin material/outdoor coil fin material.

†Weight of 14 in. roof curb.

**Pulley cannot be run at 0 or

/2 turns open.

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NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in millimeters.

3. Center of Gravity.

4. Direction of airflow.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

•Rear: 7′-0″ (2 134) for coil removal. This dimension can be reduced to 4′-0″ (1219) if conditions per mit coil removal from the top.

• Left side: 4′-0″ (1219) for proper outdoor coil airflow.

• Front: 4′-0″ (1219) for control box access.

• Right side: 4′-0″ (1219) for proper operation of damper and power exhaust (if so equipped).

• Top: 6′-0″ (1829) to assure proper outdoor fan operation.

• Local codes or jurisdiction may prevail.

7. With the exception of clearance for the outdoor coil and the damper/power exhaust as stated in note no. 6, a removable fence or barricade requires no clearance.

8. Dimensions are from outside of cor ner post. Allow

″ (8) on each side for top cover drip edge.

0′-

9. A 90 degree elbow must be installed on the supply ductwork below the unit discharge for units equipped with electric heat.

STANDARD UNIT

WEIGHT

ECONOMI$ERIV

WEIGHT

1615 lb (733 kg) 90 lb (41 kg)

Fig. 4 — Base Unit Dimensions — 542J150

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NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in millimeters.

3. Center of Gravity.

4. Direc tion of airflow.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

• Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to 4′-0″ (1219) if conditions per mit coil removal from the top.

• Left side: 4′-0″ (1219) for proper outdoor coil airflow.

•Front: 4′-0″ (1219) for control box access.

• Right side: 4′-0″ (1219) for proper operation of damper and power exhaust (if so equipped).

• Top: 6′-0″ (1829) to assure proper outdoor fan operation.

• Local codes or jurisdiction may prevail.

7. With the exception of clearance for the outdoor coil and the damper/power exhaust as stated in note no. 6, a removable fence or barricade requires no clearance.

8. Dimensions are from outside of corner post. Allow

″ (8) on each side for top cover drip edge.

0′-

9. A 90 degree elbow must be installed on the supply ductwork below the unit discharge for units equipped with electric heat.

STANDARD UNIT

WEIGHT

ECONOMI$ERIV

WEIGHT

1925 lb (874 kg) 90 lb (41 kg)

Fig. 5 — Base Unit Dimensions — 542J180

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NOTE: Do not drill in this area, as damage to basepan may result in water leak.

Fig. 6 — Air Distribution — Thru-the-Bottom

(542J180 Shown)

VI. STEP 6 — MAKE ELECTRIC CONNECTIONS A. Field Power S upply

Unit is factory wired for voltage shown on nameplate. When installing units, provide a disconnect of adequate size

per NEC (National Electrical Code) requirements (Table 2). All field wiring must comply with NEC and local

requirements. Route power lines through control box access panel or unit

basepan (Fig. 4 and 5) to connections as shown on unit wiring diagram and Fig. 11.

Transformers no. 1 and 2 are wired for 230-v unit. If 208/ 203-v unit is to be run with 208-v power supply, the transformers must be rewired as follows:

1. Remove cap from red (208 v) wire.

2. Remove cap from orange (230 v) spliced wire.

3. Replace orange wire with red wire.

4. Recap both wires.

IMPORTANT: BE CERTAIN UNUSED WIRES ARE CAPPED. Failure to do so may damage the transformers.

Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2% and the current must be balanced w ith in 10%.

Use the following formula to determine the percentage of voltage imbalance.

Perce nt ag e of Voltage Imbalance

NOTE: Do not drill in this area, as damage to basepan may result in water leak.

Fig. 7 — Concentric Duct Air Distribution

(542J180 Shown)

Shaded area indicates block-off panels.

NOTE: Dimensions A, A′ and B, B′ are obtained from field-supplied ceiling diffuser.

Fig. 8 — Concentric Duct Details

= 100 x

max voltage deviation from average voltage

average voltage

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

455 + 464 + 455

1371

= 457

Determine maximum deviation from average voltage:

(AB) 457 – 452 = 5 v (BC) 464 – 457 = 7 v

(AC) 457 – 455 = 2 v Maximum deviation is 7 v. Determine the percent voltage imbal ance:

Percentage of Voltage Imbalance= 100 x

457

= 1.53%

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.

Unit failure as a res ult of ope ra tio n o n imp ro per line volt age or excessive phase imbalance constitutes abuse and may cause damage to electrical components.

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INDOOR FAN MOTOR ACCESS

FILTER ACCESS

3/4" FPT DRAIN CONNECTION

1-3/8" DRAIN HOLE

Fig. 9 — Condensate Drain Details

Fig. 10 — Condensate Drain Piping Details

LEGEND

EQUIP GND — Equipment Ground kcmil — Thousand Circular Mils NEC — National Electrical TB — Terminal Block

NOTE: The maximum wire size for TB1 is 350 kcmil f or all unit v olt ages.

Fig. 11 — Field Power Wiring Connections

B. Field Control Wiring

Install a Bryant-approved accessory thermostat assembly according to th e installation instru ctions included with the accessory. Refer to unit Price Pages or contact your local Bryant representative for more information. Locate

thermostat assembly on a solid wall in the conditioned space to sense average temperature.

Route thermostat cable or equivalent single leads of no. 18 AWG (American Wire Gage) colored wire from subbase te rminals through conduit in unit to low-voltage connections as shown on unit label wiring diagram and in Fig. 12.

NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wi re larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

Set heat anticipator settings as indicated in T able 3. Settings may be changed sligh tly to pr ovide a great er degree of comfort for a particular installation.

C. Optional Non-Fused Disconnect

On units with the optional non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 13 for wiring for 100 and 200 amp disconnect switches. Units with an MOCP (maximum overcurrent protection) under 100 will use the 100 amp disconnect switch. Units with an MOCP over 100 will use the 200 amp disconnect switch. Refer to the applicable disconnect wiring diagram.

To prevent breakage during shipping, the disconnect handle and shaft are shipped and packaged inside the unit control box. Install the disconnect handle before unit operation. To install the handle and shaft, perform the following procedure:

1. Open the control box door and r e mo ve t he handle and shaft from shipping location.

2. Loosen the Allen bolt located on the disconnect switch. The bolt is locat ed on the sq uare hole a nd is used to hold the shaft in place. The shaft cannot be inserted until the Allen bolt is moved.

3. Insert the disconnect shaft into the square hole on the disconnect switch. The end of the shaft is specially cut and the shaft can only be inserted in the correct orientation.

4. Tighten the Allen bolt to lock the shaft into position.

5. Close the control bo x door.

6. Attach the handle to the external access door with the two screws provided. When the handle is in the ON position, the handle will be vertical. When the handle is in the OFF position, the handle will be horizontal.

7. Turn the handle to the OFF position and close the door. The handle should fit over th e end of the shaf t when the door is closed.

8. The handle must be in the OFF position to open the control box door.

D. Optional Convenience Outlet

On units with optional convenience outlet, a 115-v GFI (ground fault interrupt) convenience outl et rece ptacle is pr ovided for field wiring. Field wiring should be run thro ugh th e

/8-in. knockout provided in the basepan near the return air

opening.

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Table 2 — Electrical Data

UNIT

542J

150

180

VOLTAGE

(3 Ph,

60 Hz)

208/230 187 253 39.7 228 — — 3 1.7 3.7 10.5/10.5

208/230 187 253 28.2 160 28.2 160 3 1.7 5 15.8/15.8

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty

460 414 508 19.9 114 — — 3 0.8 3.7 4.8

460 414 508 14.1 80 14.1 80 3 0.8 5 7.9

LEGEND

FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — M aximum Overcurrent Protection NEC — National Electrical Code RLA — Rated Load Amps

*Heater capacity (kW) is based on heater voltage of 208 v, 240 v, and

480 v. If po wer distribution voltage to unit varies from rated heater voltage, heater kW will vary accordingly.

†Fuse or HACR circuit breaker. This is the maximum size permissible;

smaller fuse size may be used where conditions permit.

COMPRESSOR OUTDOOR

No. 1 No. 2

FAN

MOTOR

FLA

(ea)

INDOOR FAN

MOTOR

Hp FLA FLA LRA FLA kW MCA MOCP† RLA LRA

POWER

EXHAUST

——

4.6 18.8

——

2.3 6.0

——

4.6 18.8

——

2.3 6.0

ELECTRIC HEAT* POWER SUPPLY

—/— —/— 65/ 65 100/100 64/ 64 39/ 45 14/19 114/122 125/150 64/ 64 72/ 82 26/34 155/168 175/175 94/107

117/135 42/56 211/200 225/225 147/167

—/— —/— 70/ 70 100/100 69/ 69 39/ 45 14/19 119/126 125/150 69/ 69 72/ 82 26/34 159/173 175/175 100/112

117/135 42/56 216/205 225/225 152/173

— — 32 50 31 18 15 54 60 31 39 32 81 90 50 66 55 98 110 82

— — 34 50 34 18 15 57 70 34 39 32 83 90 53 66 55 100 110 84

—/— —/— 84/ 84 110/110 89/ 89

117/135 42/56 231/219 250/225 153/173

—/— —/— 89/ 89 110/110 94/ 94

117/135 42/56 235/224 250/225 158/179

— — 42 50 44 66 55 108 110 85

— — 44 50 47 66 55 110 125 88

DISCONNECT

SIZING

387/387

406/406

189

195

499/48572/ 82 26/34 174/187 175/200 101/112

518/50472/ 82 26/34 179/191 200/200 106/118

23839 32 91 100 54

24439 32 93 100 57

NOTES:

1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. The Canadian units may be fuse or circuit breaker.

2. MCA calculation for units with electric heaters over 50 kW = (1.25 x IFM amps) + (1.00 x heater FLA).

Fig. 12 — Field Control Thermostat Wiring

Table 3 — Heat Anticipator Settings

UNIT 542J

UNIT

VOLTAGE

208/230-3-60

150

460

208/230

180

460

HEATER

14/19 .40 — 26/34 .40 .40 42/56 .66 .40

15 .40 — 32 .40 .40 55 .40 .66

26/34 .40 .66 42/56 .66 .40

32 .40 .40 55 .40 .66

6T3 4T2 2T1 LOAD

5L3 3L2 1L1 LINE

STAGE 1 STAGE 2

NOTE: The disconnect takes the place of TB-1 as shown on the unit

wiring diagram label and the component arrangement label.

Fig. 13 — Optional Non-Fused Disconnect Wiring

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Page 10

VII. STEP 7 — MAKE OUTDOOR-AIR INLET ADJUSTMENTS A. Manual Outdoor-Air Damper

All units (except those equipped with a factory-installed EconoMi$erIV ) h ave a ma nual out door-air damper to provide ventilation air . Damper can be preset to admit up to 25% outdoor air into return-air compartment. To adjust, loosen securing screws and move damper to desired setting. Then retighten screws to secure damper (Fig. 14).

VIII. STEP 8 — INSTALL OUTDOOR-AIR HOOD IMPORTANT: If the unit is equipped with the optional

EconoMi$erIV component, move the outdoor-air temperature sensor prior to installing the outdoor-air hood. See the Optional EconoMi$erIV section for more information.

The same type of factory-installed hood is used on units with 25% air ventilation and units with an EconoMi$erIV.

NOTE: The hood top panel, upper and lower filter retainers, hood drain pan, and filter support bracket are secured opposite the outdoor coil end of the unit. The screens, hood side panels, remaining section of filter support bracket, seal strip, and all other hardware ar e in a package located inside t he return-air filter access panel (Fig. 15).

1. Attach seal strip to upper filter retainer. See Fig. 16.

2. Assemble hood top panel and side panels, upper filter retainer, and hood drain pan (Fig. 17).

3. Secure lower filter retainer and long section of filter support bracket to unit. See Fig. 17.

4. Loosen sheet metal screws for base unit top panel located above o utdoor-air inlet opening, and remove

screws for hood side panels located on the sides of the outdoor-air inlet opening.

5. Match notches in hood top panel to unit top panel screws. Insert hood flange between unit top panel flange and unit. Tighten screws.

6. Hold hood side panel flanges flat against unit, and install screws removed in Step 4.

7. Insert outdoor-air inlet screens and spacer in channel created by lower filter retainer and filter support bracket.

8. Attach remaining short section of filter support bracket.

IX. STEP 9 — INSTALL ALL ACCESSORIES

After all the factory-installed options have been adjusted, install all field-instal led accessories. Refer to the accessory installation instructions included with each accessory.

Fig. 14 — 25% Outdoor-Air Section Details

HOOD TOP PANEL

Fig. 16 — Seal Strip Location

(Air Hood Cross-Sectional View)

LOWER FILTER RETAINER

FILTER SUPPORT BRACKET

HOOD SIDE PANELS (2)

LOWER FILTER RETAINER

Fig. 15 — Outdoor-Air Hood Component Location

HOOD DRAIN PAN

UPPER FILTER RETAINER

NOTE: The outdoor-air hood comes with a baffle which is not used on these units. Discard the baffle.

Fig. 17 — Outdoor-Air Hood Details

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Page 11

A. Motormaster® I Control Installation

Install Field-Fabricated Wind Baffles Wind baffles must be field-fabricated for all units to ensure

proper cooling cycle operation at low ambient temperatures. See Fig. 18 for baffle details. Use 20-gage, galvanized sheet metal, or similar corrosion-resistant metal for baffles. Use field-supplied screws to at tach baffles t o unit. Screws shou ld

/4-in. diameter and 5/8-in. long. Drill required screw holes

for mounting baffles.

CAUTION: To avoid damage to the refrigerant coils and electrical components, use recommended screw sizes only. Use care when drilling holes.

Install Motormaster I Controls Only one Motormaster I control is required per unit. The

Motormaster I control must be used in c onjunction with the accessory 0° F low ambien t kit (purchased separately). The Motormaster I device controls outdoor fan no. 1 while ou tdoor fans no. 2 and 3 are sequenced off by the accessory 0° F low ambient kit.

Accessory 0° F Low Ambient K it — Install the accessory 0° F low ambient kit per instruction supplied with accessory.

Sensor Assembl y — Install the sensor assembly in the location shown in Fig. 19.

Motor Mount — To ensure proper fan height, replace the existing motor mount with the new motor m ount provided with accessory .

Transfor mer (460-V Units On ly) — On 460-volt units a transformer is required. The transformer is provided with the accessory and must be field-installed.

Motormaster I Control — Recommended mounting location is on the inside of the panel to the left of the control box. The control should be mounted on the inside of the panel, vertically, with leads protruding from bottom of extrusion.

MOTORMASTER SENSOR LOCATION

NOTES:

1. All sensors are located on the eighth hairpin up from the bottom.

2. Field-installed tubing insulation is required to be installed over the TXV bulb and capillary tube for proper operation at low ambients. Tubing insulation is only required on the portion of suction line located between indoor and outdoor section.

HAIRPIN END

Fig. 19 — Motormaster I Sensor Locations

X. STEP 10 — ADJUST FACTORY-INSTALLED OPTIONS A. Optional EconoMi$erIV

See Fig. 20 and 21 for EconoMi$erIV component locati ons. NOTE: These instructions are for installing the optional

EconoMi$erIV only. Refer to the accessory EconoMi$erIV or EconoMi$er2 installation instructions when field in stalling an EconoMi$erIV or EconoMi$er2 accessory.

To complete installation of t he optional EconoMi$erIV, perform the following procedure.

1. Remove the EconoMi$er IV hood. Refer to Step 8 — Install Outdoor-Air Hood on page 10 for info rmation on removing and in stalling the outdoor-air hood.

2. Relocate outdoor air temperature sensor from shipping position to operation pos ition on EconoMi $erIV. See Fig. 20.

IMPORTANT: Failure to relocate the sensor w ill res ult in the EconoMi$erIV not operating properly.

3. Re-install economizer hood.

4. Install all EconoMi$erIV accessories. EconoMi$erIV wiring is shown in Fig. 22.

Outdoor air leakage is shown in Table 4. Return air pressure drop is shown in Tabl e 5.

Table 4 — Out door Air Damper Leakage

NOTE: Dimensions in ( ) are in mm.

Fig. 18 — Wind Baffle Details

DAMPER STATIC PRESSURE (in. wg)

0.2 0.4 0.6 0.8 1.0 1.2

LEAKAGE (cfm) 35 53 65 75 90 102

Table 5 — Return Air Pressure Drop (in. wg)

CFM

4500 5000 5400 6000 7200 7500

0.040 0.050 0.060 0.070 0.090 0.100

—11—

Page 12

SCREWS

ECONOMI$ERIV

FRAME

TOP

SCREWS

OUTDOOR AIR TEMPERATURE SENSOR (INSTALLED OPERATION POSITION)

LOW TEMPERATURE COMPRESSOR LOCKOUT SWITCH

ECONOMI$ERIV

SUPPLY AIR TEMPERATURE SENSOR LOCATION

Fig. 20 — EconoMi$erIV Component Locations —

End View

ACTUATOR

CONTROLLER FLANGE

AND SCREWS (HIDDEN)

1 R T

R T

c a V 4

M O C

4 2

c a V

H X E

t e

V 0

V 2

s o

e p

V C

x a

V 0

V 2

V C

Q A

V 2

e r

l o

+ R S

Fig. 21 — EconoMi$erIV Component Locations —

Side View

DCV — Demand Controlled Ventilation

LEGEND

IAQ — Indoor Air Quality LALS— Low Temperature Compressor

Lockout Switch

OAT — Outdoor-Air Temperature POT — Potentiometer

Potentiometer Default Settings: Power Exhaust Middle Minimum Pos. Fully Closed DCV Max. Middle DCV Set Middle Enthalpy C Setting

NOTES:

1. 620 ohm, 1 watt 5% resistor should be rem oved only when using differential enthalpy or dry bulb.

2. If a separate field -supplied 24 v transform er is used for the IAQ sensor power supply, it cannot have the secondary of the transformer grounded.

3. For field-installed remote minimum position POT, remove black wire jumper between P and P1 and set control minimum position POT to the minimum position.

Fig. 22 — EconoMi$erIV Wiring

—12—

Page 13

B. EconoMi$erIV Standard Sensors

Outdoor Air Temperature (OAT) Sensor The outdoor air temperature sensor (HH57AC074) is a 10 to

20 mA device used to measure the outdoo r-air temperature. The outdoor-air temperature is used to determine when the EconoMi$erIV can be used for free cooling. The sen sor must be field-relocat ed. See Fig. 20. The operat ing range of temperature measurement is 40 to 100 F.

Supply Air Temperature (SAT) Sensor The supply air temperature sensor is a 3 K thermistor

located at the inlet of the indoor fan. See Fig. 21. This sensor is factory installed. The operating range of temperature measurement is 0° to 158 F. See Table 6 for sensor temperature/resistance values.

The temperature sensor l ooks like an eyelet terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture.

Low Temperature Compressor Lockout Switch The EconoMi$erIV is equipped with an ambient tempera-

ture lockout switch located in the outdoor air stream which is used to lockout the compressors below a 42 F ambient temperature. See Fig. 20.

Table 6 — Supply Air Sensor Temperature/

Resistance Values

TEMPERATURE (F) RESIST ANCE (ohms)

–58 200,250 –40 100,680 –22 53,010

–4 29,091 14 16,590 32 9,795 50 5,970 68 3,747 77 3,000

86 2,416 104 1,597 122 1,080 140 746 158 525 176 376 185 321 194 274 212 203 230 153 248 116 257 102 266 89 284 70 302 55

C. EconoMi$erIV Control Modes

Determine the EconoMi$erIV control mode before set up of the control. Some modes of operation may require different sensors. Refer to Table 7. The EconoMi$erIV is supplied from the factory with a supply air temp erat ure sen sor, a low temperature compressor lockout switch, and an outdoor air temperature sensor. This allows for operation of the EconoMi$erIV with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the EconoMi$erIV and unit.

Outdoor Dry Bulb Changeover The standard controller is shippe d from the factory config-

ured for outdoor dry bulb changeover control. The outdoor air and su pply air temperature sensors are included as standard. For this control mode, the outdoor temperature is compared to an adjustable set point selected on the control. If the outdoor-air temperature is above the set point, the EconoMi$erIV will adjust the outdoor-air dampers to minimum position. If the outdoor-air temperature is below the set point, the position of the outdoor-air dampers will be controlled to provid e fr ee co o lin g us ing out do or ai r. When in this mode, the LED next to the free cooling set point potentiometer will be on. The changeover temp erature set poi nt is controlled by the free cooling set poi nt potentiomete r located on the control. See Fig. 23. The scal e on the p otentio meter i s A, B, C, and D. See Fig. 24 for the corresponding temp erature changeover values.

Differential Dry Bulb Control For differential dry bulb control the standard outdoor dry

bulb sensor is used in conjunction with an additional accessory return air sensor (part number CRTEMPSN002A00). The accessory sensor must be mounted in the return airstream. See Fig. 25.

In this mode of operation, the outdoor-air temperature is compared to the return-air temperature and the lower temperature airstream is used for cooling. When using this mode of changeover control, turn the free cooling/enthalpy set point potentiometer fully clockwise to the D setting. See Fig. 23.

APPLICATION

Outdoor Air Dry Bulb None. The outdoor air dry bulb sensor is factory installed. CRTEMPSN002A00*

Differential Dry Bulb CRTEMPSN002A00* ( 2) CRTEMP S N002 A 00*

Single Enthalpy HH57AC078 None. The single enthalpy sensor is factory installed.

Differential Enthalpy

for DCV Control using a

Wall-Mounted CO

for DCV Control using a

Duct-Mounted CO

*CRENTDIF004A00 an d CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may conta in parts that will not be need ed for

installation.

†CGCDXSEN004A00 is an accessory CO

**CGCDXASP001A00 is an accessory aspirator box required for duct-mounted applicatio ns.

Sensor

sensor.

Table 7 — EconoMi$er IV Sensor Usage

ECONOMI$ERIV WITH OUTDOOR AIR

DRY BULB SENSOR

Accessories Required Accessories Required

HH57AC078

and

CRENTDIF004A00*

CGCDXSEN004A00

CGCDXSEN004A00†

and

CGCDXASP001A00**

ECONOMI$ERIV WITH SINGLE

ENTHALPY SENSOR

CRENTDIF004A00*

—13—

Page 14

Fig. 23 — EconoMi$erIV Controller Potentiometer

and LED Locations

LED ON

18 17

16 15 14 13 12 11 10

LED OFF

LED ON

LED OFF

LED ON

LED OFF

LED ON

LED OFF

DEGREES FAHRENHEIT

Fig. 24 — Outside Air Temperature

Changeover Set Points

1 R T

R T

c Va 4

OM C

c Va

e S

1 N

n i

s o P

IAQ

SENSOR

1 P

1 T

V 0 1

F E

V 2

V C D

Q A

V 2

e e

D + R

RETURN AIR

TEMPERATURE

OR ENTHALPY

SENSOR

Fig. 25 — Return Air Temperature or Enthalpy

Sensor Mounting Location

100

Outdoor Enthalpy Changeover For enthalpy control, accessory enthalpy sensor (part num-

ber HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. See Fig. 20. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor-air damper moves to its minimum position. The outdoor enthalpy changeover set point is set with the ou tdoor enthalpy set poi nt potentiometer on the EconoMi$er IV controller. The set points are A, B, C, and D. See Fig. 26. The factory-installed 620-ohm jumper must be in place across terminals SR and SR+ on the EconoMi$erIV controller. See Fig. 23 and 27.

Differential Ent halpy Control For differential enthalpy control, the EconoMi$er IV cont rolle r

uses two enthalpy sensors (HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return airstream on the EconoMi$erIV frame. The EconoMi$erIV controller compares t he outdoor air enthalp y to the return air entha lpy to dete rmine Econo Mi$erIV use. The controller s elects the lower enthal py air (return or outdoor) for cooling. For example, when the outdoor air has a lower enthalpy than the return air and is below the set point, the EconoMi$erIV opens to bring in outdoor air for free c ooling.

Replace the standard outside air dry bulb temperature sensor with the acc essor y enth alpy senso r in th e same mou nting location. See Fig. 20. Mount th e return air enthalpy sen sor in the return airstream . See Fig. 25. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on th e EconoMi$erIV controller. When using this mode of changeover control, turn the enthalpy set point potentiometer fully clockwise to the D setting.

NOTE: Remove 620-ohm resistor if differential enthalpy sensor is installed.

Indoor Air Quality (IAQ) Sensor Input The IAQ input can be used for demand control ventilation

control based on the level of CO2 measured in the sp ace or return air duct.

Mount the accessory IAQ sensor according to manufacturer specifica t io n s. The IAQ se n so r sh ould be wired to the AQ and AQ1 terminals of the controller. Adjust the DCV potentiometers to correspond to the DCV voltage output of the indoor air quality sensor at the user-determined set point. See Fig. 28.

If a separate field-supplied transformer is used to power the IAQ sensor, the sensor must not be grounded or the EconoMi$erIV control board will be damaged.

Exhaust Set Point Adjustment The exhaust set point will determine when the exhaust fan

runs based on d am p er po sit i on ( if accessory powe r ex ha ust is installed). The set point is modified with the Exhaust Fan Set Point (EXH SET) potentiometer. See Fig. 23. The set point represents the damper position above which the exhaust fan will be turned on. When there is a call for exhaust, the E con o Mi $er I V co ntro ller provides a 45 ± 15 sec ond delay before exhaust fan activation to allow the dampers to open. This delay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

—14—

Page 15

CONTROL

CURVE

A B C D

CONTROL POINT

APPROX. °F (°C)

AT 50% RH

73 (23) 70 (21) 67 (19) 63 (17)

(2)

LPY

40 (4)

(29)90(32)95(35)

Y A

—

(16)

(13)

(10)

(7)

(21)

(18)

(27)

(24)

RELA

100

105

(38)

110

(41)

(43)

)

(

IDITY

IVE HUM

AQ1

SO+

SR+

(2)

(4)

(7)

(10)

(13)

(16)

(18)

(21)

(24)

(27)

(29)90(32)95(35)

100 (38)

105 (41)

110 (43)

HIGH LIMIT CURVE

APPROXIMATE DRY BULB TEMPERATURE— °F (°C)

Fig. 26 — Enthalpy Changeover Settings

CO SENSOR MAX RANGE SETTING

EXH

2V 10V

EXH

Open

2V 10V

DCV

2V 10V

Free Cool

Min Pos

DCV

Max

DCV

Set

TR1

24 Vac

Vac

COM

HOT

EF1

6000

5000

4000

3000

2000

1000

RANGE CONFIGURATION (ppm)

Fig. 28 — CO2 Sensor Maximum Range Setting

800 ppm 900 ppm 1000 ppm 1100 ppm

2345678

DAMPER VOLTAGE FOR MAX VENTILATION RATE

Fig. 27 — EconoMi$erIV Controller

—15—

Page 16

Minimum Position Control There is a minimum damper p osition potent iometer on the

EconoMi$erIV controller. See Fig. 23. The minimum damper position maintains the minimum airflow into the building during the occupied period.

When using demand ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compound) ventilation requirements. The maximum demand ventilation position is used for fully occupied ventilation.

When demand ventilation control is not being used, the minimum position potentiometer should be used to set the occupied ventilation position. The maximum demand ventilation position should be turned fully clockwise.

Adjust the minimum position potentiometer to allow the minimum amount of outdoor air, as required by local codes, to enter the building. Make minimum position adjustments with at least 10° F temperature difference between the outdoor and return-air temperatures.

To determine the minimum position setting, perform the following proced ur e :

1. Calculate the appropriate mixed-air temperature using the following formula:

= Outdoor-Air Temperature

)+ (TR xRA ) = T

100 100

OA = Percent of Outdoor Air T

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

As an example, if local codes require 10% outdoor air during occupied conditions, outdoor-air temperature is 60 F, and return-air temperature is 75 F.

(60 x .10) + (75 x .90) = 73.5 F

2. Disconnect the supply-air sensor from terminals T and T1.

3. Ensure that the f actory-installed jumper is i n place across terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired accor din g to Fig. 22 and that t he mi nimu m position potentiometer is turned fully clockwise.

4. Connect 24 vac across terminals TR and TR1.

5. Carefully adjust the minimum position potent iomet er until the measured mixed-air temperature matches the calculated va lue.

6. Reconnect the supply-air sensor to terminals T and T1.

Remote control of the EconoMi$erIV damper is desirable when requiring additional temporary ventilation. If a field-supplied remote potentiometer (Honeywell part number S963B1128) is wired to the Ec onoMi $erIV con tr oller, the minimum position of the damper can be controlled from a remote location.

To control the minimum damper position remotely, remove the factory-insta lled jumper on the P and P1 terminals on the EconoMi$erIV controller. Wire the field-supplied potentiometer to the P and P1 terminal s on the EconoMi $erIV controller. See Fig. 27.

Damper Movement Damper movement from full open to full closed (or vice

versa) takes 2

/2 minutes. Thermostats The EconoMi$erIV control works with conventional thermo-

stats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1 (heat stage 1), W2 (heat stage 2), and G (fan). The EconoMi$erIV control does not support space temperature sensors. Connections are made at the thermostat terminal connection board located in the main control box.

Occupancy Control The factory defaul t configuration for EconoMi$er IV control

is occupied mode. This is implemented by the RED jumper at TB2-9 to TB2-10. When unoccupied mode is desired, remove the RED jumper and install a field-supplied timeclock function between TB2-9 and TB2-10. When the timeclock contacts are open, the unit control will be in unoccupied mode; when the contacts ar e closed, the u nit control w ill be in occupied mode.

Demand Controlled V enti lation (DCV) When using the EconoMi$erIV for demand controlled venti-

lation, there are some equipment selection criteria which should be considered. When selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditio ns. The maximum damper position must be calculated to provide the desired fresh air.

Typically the maximum ventilation rate will be ab out 5 to 10% more than the typical cfm required per person, using normal outside air design criteria.

A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipment that cannot exceed the requ ired ventilation rate at design con dition s. Exceeding th e requ ired ventilation rate means the equipment can co ndition air a t a maximum ventilation rate that is gre ater than the requ ired ventilation rate for maximum occupancy. A proportionalanticipatory strategy will cause the fresh air supplied to increase as the room CO

level increases even though the

CO2 set point has not been reached. By the time the CO level reaches the set point, the damper will be at maximum ventilation and should maintain the set point.

In order to have the CO

sensor control the economizer damper

in this manner, first determine the damper voltage output for minimum or ba se ventilatio n. Base ventila tion is the ven tilation required to remove contaminants during unoccu pied periods. The following equation may be used to determine the percent of outside-air entering the building for a given damper position. For best results there should be at least a 10 degree difference in outside and return-air temperatures.

(TO x

)+ (TR x

100 100

= Outdoor-Air Temperature

) = T

OA = Percent of Outdoor Air T

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

—16—

Page 17

Once base ventilation has been determined, set the minimum damper position potentiometer to the correct position.

The same equation can be used to determine the occupied or maximum ventilation rate to the building. For example, an output of 3.6 volts t o the ac tuat o r pro vide s a ba se ve ntil at io n rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or bas e plu s 15 cfm pe r pers on). Use Fig. 28 to determine the maximum setting of the CO

sensor.

For example, a 1100 ppm set point relates to a 15 cfm per person design. Use the 1100 ppm curve on Fig. 28 to find the point when the CO

sensor output will be 6.7 volts. Line up

the point on the graph with the left side of the chart to determine that the range configuration for the CO

sensor sho uld

be 1800 ppm. T he EconoMi$erIV control ler will output the

6.7 volts fro m the CO

sensor to the actuator when the CO

concentration in the spac e is a t 1100 ppm . The D CV set point may be left at 2 volts since the CO

sensor voltage wi ll be

ignored by the Econo Mi$erIV controller until it rises above the 3.6 volt setting of the minimum position potentiometer.

Once the fully occupied damper position has been determined, set the maximu m da mpe r de ma nd con t ro l ve nt il atio n potentiometer to this position. Do not set to the maximum position as this can result in over-ventilation to the space and potential high-humidity levels.

Sensor Configuration

The CO2 sensor has preset standard voltage settings that can be selected anytime afte r the sensor is powere d up. See Table 8.

Use setting 1 or 2 f or Bryant equipment. See Table 8.

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

3. Use the Up/Down button to select the preset number. See Table 8.

4. Press Enter to lock in the selection.

5. Press Mode to exit and resume normal operation.

The custom settings of the CO

sensor can be changed any-

time after the s ensor is energiz ed. Follow the s teps belo w to change the non-standard settings:

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

3. Use the Up/Down button to toggle to the NONSTD menu and press Enter.

4. Use the Up/Down button to toggle through each of

the nine variables, starting with Altitude, until the desired setting is reached.

5. Press Mode to move through the variables.

6. Press Enter to lock in the selection, then press Mode to continue to the next variable.

Dehumidification of Fresh Air with DCV Control Information from ASHRAE indicates that the largest humid-

ity load on any zone is the fresh air introduced. For some applications, a field-supplied energy recovery unit can be added to reduce the moisture content of the fresh air being brought into the building when the enthalpy is high. In most cases, the normal heating and cooling processes are more than adequate to remove the humidity loads for most commercial applications.

If normal roof top heating and cooling operation is not adequate for the outdoor humidity level, an energy recovery unit and/or a dehumidification option should be considered.

Table 8 — CO

SETTING EQUIPMENT OUTPUT

Interface with Standard

2 Proportional Any

Building Control System

3 Exponential Any

4 5 Proportional 20

Economizer

6 Exponential 15 7 Exponential 20 8 Health & Safety Proportional —

Parking/Air Intakes/

Loading Docks

LEGEND

ppm — Parts Per Million

Proportional Any

Proportional 15

Proportional —

Sensor Standard Settings

VENTILATION

RATE

(cfm/Person)

ANALOG

OUTPUT

0-10V

4-20 mA

2-10V

7-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

CONTROL RANGE

(ppm)

0-2000 1000 50 0-2000 1000 50 0-2000 1100 50 0-1100 1100 50 0- 900 900 50 0-1100 1100 50 0- 900 900 50 0-9999 5000 500 0-2000 700 50

OPTIONAL

RELAY SETPOINT

(ppm)

RELAY

HYSTERESIS

(ppm)

—17—

Page 18

XI. STEP 11 — DEFROST CYCLE

The defrost timer is factory set at 30 minutes. The timer may be field-adjusted to 50 or 90 minutes by moving the wire from the 30 minute contact to the 50 to 90 minute contact. At the end of the time period, the defro st cycle will begin. See Fig. 29.

START-UP

Use the following information and complete Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up.

I. UNIT PREPARATION

Check that unit has been installed in accordance with these installation instructions and all applicable codes.

II. COMPRESSOR MOUNTING

Loosen compressor holddown bolts until sideways movement of the washer under each holddown bolt head can be obtained. Do not loosen completely, as bolts are self -locking and will maintain adjustment.

III. INTERNAL WIRING

Check all electrical co nnec t ions i n uni t contr ol boxe s; tig h ten as required.

IV. REFRIGERANT SERVICE PORTS AND VALVES

Each 542J unit has 2 Schrader-type service ports per circuit; one on the suction line and one on the liquid line. Be sure that caps on the ports are tight. The units also have 2 service valves per circuit; one on the suction line and one on the discharge line. Be sure all valves are open.

V. CRANKCASE HEATERS

Heaters are energized as long as there is power to un it. IMPORTANT: Unit power must be on for 24 hours prior to

start-up. Otherwise, damage to compressor may result.

VI. INDOOR FAN

Fan belt and pulleys are factory installed. Remove tape from the fan pulley and adjust pulleys on 542J150 units as required. See Service section on page 23 for inst ructions on adjusting indoor fan performance. See Table 9 for air quantity limits. See Tables 10 and 11 for fan performance data.

DEFROST BOARD

DFT

OF1

OF2

DEFROST CYCLE TIME

ADJUSTMENT WIRE

LOGIC

CTD

TEST

Fig. 29 — Defrost Board Timer Wiring

Be sure that fa ns r otate in the proper di re c t ion . Se e Table 12 for static pressure drops for accessories and options. See Fig. 30 and 31 for fan performance using horizontal adapter and power exhaust. See Table 14 for fan rpm pulley settings. See Table 16 for indoor-fan moto r performance. To alter fan performance, see Indo or-F an, 542 J150 Un its and In door -Fan, 542J180 Units sections, pages 23 and 24.

Table 9 — Air Quantity Limits

UNIT 542J

150 3750 6250 180 4500* 7500

*Minimum cfm is 5600 when electric heater is used.

MINIMUM AIRFLOW

(Cfm)

MAXIMUM AIRF LOW

(Cfm)

—18—

Page 19

Table 10 — Fan Performance Data, 542J150 Units

AIRFLOW

(Cfm)

3750 724 481 0.55 838 685 0.78 937 889 1.01 1028 1097 1.25 1111 1309 1.49 4000 754 613 0.70 865 824 0.94 962 1034 1.18 1050 1247 1.42 1131 1463 1.67 4250 786 757 0.86 893 975 1.11 987 1191 1.36 1073 1408 1.60 1152 1629 1.86 4500 818 914 1.04 922 1138 1.30 1013 1360 1.55 1097 1583 1.80 1174 1808 2.06 4750 850 1084 1.23 951 1313 1.50 1040 1541 1.76 1122 1770 2.02 1197 2000 2.28 5000 883 1267 1.44 980 1501 1.71 1068 1736 1.98 1147 1969 2.24 1221 2204 2.51 5250 917 1464 1.67 1011 1703 1.94 1096 1943 2.21 1174 2183 2.49 1 246 2423 2.76 5500 950 1675 1.91 1041 1918 2.19 1124 2165 2.47 1201 2409 2.75 1 272 2655 3.02 5750 985 1901 2.17 1072 2147 2.45 1153 2400 2.73 1228 2650 3.02 1 298 2901 3.31 6000 1020 2142 2.44 1103 2391 2.72 1183 2649 3.02 1256 2905 3.31 1324 3160 3.60 6250 1055 2398 2.73 1135 2650 3.02 1213 2912 3.32 1284 3175 3.62 1352 3435 3.91

AIRFLOW

(Cfm)

3750 1190 1526 1.74 1265 1746 1.99 1337 1972 2.25 1405 2199 2.51 1471 2431 2.77 4000 1208 1684 1.92 1281 1908 2.17 1351 2136 2.43 1418 2368 2.70 1483 2603 2.97 4250 1227 1853 2.11 1299 2082 2.37 1367 2313 2.64 1433 2548 2.90 1496 2787 3.18 4500 1247 2036 2.32 1317 2268 2.58 1384 2503 2.85 1448 2742 3.12 1510 2983 3.40 4750 1269 2232 2.54 1337 2468 2.81 1403 2707 3.08 1465 2948 3.36 1526 3194 3.64 5000 1291 2441 2.78 1358 2680 3.05 1422 2923 3.33 1484 3168 3.61 1544 3418 3.89 5250 1315 2664 3.03 1380 2907 3.31 1443 3154 3.59 1503 3403 3.88 1562 3655 4.16 5500 1339 2900 3.30 1403 3148 3.59 1464 3398 3.87 1524 3651 4.16 —— — 5750 1364 3151 3.59 1426 3403 3.88 1486 3657 4.17 6000 1389 3416 3.89 1450 3672 4.18 6250 1415 3695 4.21

LEGEND Bhp — Brake Horsepower Input to Fan

FIOP — Factory-Installed Option Watts — In p u t Watts to M o t o r

NOTES:

1. Boldface indicates field-supplied drive required.

2. indicates field-supplied motor and drive required.

3. Factory-shipped motor drive range is 862 to 1132 rpm. Other rpms may require a field-supplied drive.

4. Maximum continuous bhp is 4.25 maximum continuous watts are

3775. Do not adjust motor rpm such that motor maximum bhp and/ or watts is exceeded at the maximum operating cfm.

Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp

Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bh p Rpm Watts Bhp Rpm Watts Bhp

0.2 0.4 0.6 0.8 1.0

1.2 1.4 1.6 1.8 2.0

1476 3957 4.51 1534 4219 4.81 — — — — — —

EXTERNAL STATIC PRESSURE (in. wg)

EXTERNAL ST ATIC PRESSURE (in. wg)

1510 3930 4.48 — — — — — —

5. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

6. Interpolation is per miss ible. Do not extrapolate.

7. Fan performance is based on wet coils, clean filters, and casing losses. See Table 12 for accessory/FIOP static pressure information.

8. Extensive motor and drive testing on these units ensures tha t the full horsepower and watts range of the motor can be utilized with confidence. Using fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

1545 3914 4.46 — — —

—19—

Page 20

Table 11 — Fan Performance Data, 542J180 Units

AIRFLOW

(Cfm)

4500 584 717 0.8 695 952 1.1 798 1205 1.3 893 1483 1.7 984 1786 2.0 4800 609 839 0.9 717 1085 1.2 815 1346 1.5 907 1630 1.8 994 1938 2.2 5100 634 971 1.1 738 1229 1.4 833 1500 1.7 921 1791 2.0 1006 2104 2.4 5400 660 1118 1.3 760 1389 1.6 852 1669 1.9 937 1968 2.2 1019 2286 2.6 5700 687 1284 1.4 783 1566 1.8 873 1858 2.1 956 2165 2.4 1034 2490 2.8 6000 712 1458 1.6 805 1752 2.0 892 2055 2.3 973 2371 2.7 1049 2703 3.0 6300 736 1644 1.8 826 1952 2.2 911 2265 2.5 990 2591 2.9 1064 2930 3.3 6600 763 1856 2.1 851 2176 2.4 933 2502 2.8 1010 2837 3. 2 1082 3186 3.6 6900 788 2078 2.3 873 2410 2.7 954 2747 3.1 1029 3093 3. 5 1099 3451 3.9 7200 813 2316 2.6 896 2662 3.0 975 3011 3.4 1048 3367 3. 8 1117 3734 4.2 7500 841 2584 2.9 921 2943 3.3 998 3304 3.7 1070 3672 4. 1 1137 4049 4.5

AIRFLOW

(Cfm)

4500 1070 2113 2.4 1151 2458 2.8 1229 2819 3.2 1302 3194 3.6 1371 3578 4.0 4800 1078 2269 2.5 1157 2620 2.9 1233 2990 3.3 1306 3374 3.8 1375 3769 4.2 5100 1086 2439 2.7 1164 2795 3.1 1238 3170 3.5 1310 3560 4.0 1378 3965 4.4 5400 1097 2626 2.9 1172 2986 3.3 1245 3366 3.8 1315 3763 4.2 1382 4174 4.7 5700 1110 2835 3.2 1183 3200 3.6 1253 3584 4.0 1322 3986 4.5 1388 4404 4.9 6000 1122 3053 3.4 1193 3422 3.8 1262 3810 4.3 1329 4216 4.7 1393 4638 5.2 6300 1135 3286 3.7 1204 3660 4.1 1271 4052 4.5 1336 4461 5.0 1399 4887 5.5 6600 1151 3549 4.0 1218 3928 4.4 1283 4325 4.8 1347 4739 5.3 1409 5169 5.8 6900 1167 3821 4.3 1232 4207 4.7 1295 4608 5.2 1357 5026 5.6 7200 1183 4113 4.6 1246 4505 5.0 1308 4912 5.5 7500 1202 4437 5.0 1264 4837 5.4

LEGEND Bhp — Brake Horsepower Input to Fan

FIOP — Factory-Installed Option Watts — In p u t Watts to M o t o r

NOTES:

1. Boldface indicates field-supplied drive required.

2. indicates field-supplied motor and drive required.

3. Factory-shipped motor drive range is 799 to 1010 rpm. Other rpms may require a field-supplied drive.

4. Maximum continuous bhp is 5.90 maximum continuous watts are

5180. Do not adjust motor rpm such that motor maximum bhp and/ or watts is exceeded at the maximum operating cfm.

Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp

Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bh p Rpm Watts Bhp Rpm Watts Bhp

0.2 0.4 0.6 0.8 1.0

1.2 1.4 1.6 1.8 2.0

EXTERNAL STATIC PRESSURE (in. wg)

EXTERNAL ST ATIC PRESSURE (in. wg)

1324 5251 5.9 1383 5679 6.4 1440 6122 6.9

5. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

6. Interpolation is per miss ible. Do not extrapolate.

7. Fan performance is based on wet coils, clean filters, and casing losses. See Table 12 for accessory/FIOP static pressure information.

1368 5335 6.0 1437 5773 6.5

1417 5460 6.1

—20—

Page 21

Table 12 — Accessory/FIOP Static Pressure (in. wg)

ACCESSORY/FIOP

Electric Heaters

UNIT SIZE

542J

150

180

UNIT VOLTAGE kW

208/230-3-60

460-3-60

208/230-3-60

460-3-60

14,34 42,56

15,32550.05 26,34

42,56

32 55

3750 4000 4500 5000 5600 6000 6250 7200 7500

0.05

0.06

0.05

0.06

0.07

0.06

0.07

0.06

0.06 ****

****

AIRFLOW (Cfm)

0.07

0.08

0.10

0.07

0.08

0.10

0.08

0.10

0.08

0.10

0.09

0.12

0.09

0.12

0.09

0.12

0.09

0.12

0.09

0.13

0.09

0.13

0.09

0.13

0.09

0.13

†† ††

0.11

0.16

0.11

0.15

EconoMi$erIV All All — 0.030.030.040.050.060.070.070.090.10

Glycol Coil All All — 0.160.180.220.260.310.350.370.440.46

LEGEND

FIOP — Factory-Installed Option

*Do not operate unit with electric heat at this cfm. Operation at this cfm

is below electric heat required minimum cfm.

†Do not operate unit at this cfm. Operation at this cfm is above unit

maximum cfm limit.

NOTES:

1. Heaters are rated at 208 v, 240 v and 480 v.

2. The factory asse mbled horizontal adapter substantially improves fan performance. See Fig. 30.

3. The static pressure must be added to external static pressure. The sum and the indoor-air section entering-air cfm should then be used in conjunction with the Fan Performance table to deter mine blower rpm, bhp, and watts.

Table 13 — Fan Rpm at Motor Pulley Settings* (Factory-Supplied Drives)

UNIT 542J

150 † † 1132 1105 1078 1051 1024 997 970 943 916 889 862 180 † † 1010 989 968 947 926 905 883 862 841 820 799

*Approximate fan rpm shown.

†Due to belt and pulley size, pulley cannot be set to this number of turns

open.

MOTOR PULLEY TURNS OPEN

NOTE: To run units at speeds not listed, field-supplied drives are

required.

551/

0.12

0.17

0.12

0.17

Table 14 — Indoor-Fan Motor Performance

UNIT 542J

UNIT

VOLTAGE

ACCEPTABLE CONTINUOUS

BHP*

MAXIMUM

150

180

208/230

460 4.9 85.8

208/230

460 7.9 87.5

4.25 3775

5.90 5180

LEGEND *Extensive motor and electrical testing on these units ensures that the

Bhp — Brake Horsepower

MAXIMUM

ACCEPTABLE

OPERATING

MAXIMUM

AMP DRAW

MOTOR

EFFICIENCY

WATTS

10.5 85.8

15.8 87.5

full horsepower range of the motors can be utilized with confidence. Using fan motors up to the horsepower ratings shown in this table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

NOTE: The CRRFCURB013A00 horizontal supply and return adapter accessory improves 542J fan performance by increasing external static pressure by amount shown above.

Fig. 30 — Horizontal Supply/Return Fan Performance

with CRRFCURB013A00 Horizontal Supply Adapter

Fig. 31 — Fan Performance Using Accessory

Power Exha ust

—21—

Page 22

VII. OUTDOOR FANS AND MOTORS

Fans and motors are factory set. Refer to Outdoor-Fan Adjustment section on page 24 as required.

VIII. RETURN-AIR FILTERS

Check that correc t filters are instal led in filter tracks. See Table 1. Do not operate unit without return-air filters.

IX. OUTDOOR-AIR INLET SCREENS

Outdoor-air inlet screens mu st be in place before op erating unit.

X. OPERA TING SEQUENCE A. Cooling, Units Without Economizer

When thermostat calls for cooling, terminals G and Y1 are energized. The indoor-fan contactor (IFC), reversing valve solenoids (RVS1 and RVS2 [RVS2 on size 180 only]) and compressor contactor are energized and indoor-fan motor, compressor, and outdoor fan starts. The outdoor-fan motor runs continuously while unit is cooling.

B. Heating, Units Without Economizer

Upon a request for heating from the space thermostat, terminal W1 will be ener gized with 24 v. The IFC, outdoor-fan contactor (OFC), C1, and C2 (size 180 only) will be energized. The indoor fan, outdoor fans, and compressor no. 1, and compressor no. 2 are energized and RVS1 and RVS2 (size 180 only) are deenergized and switch position.

If the space temperature continues to fall while W1 is energized, W2 will be energized with 24 v, and the heater contactor(s) (HC) will b e energized, which will energize the electric heater(s).

When the space thermo stat is satisfied, W2 will be deenergized first, and the electric heater(s) will be deenergized.

Upon a further rise in space temperature, W1 will be deenergized.

C. Cooling, Units With EconoMi$erIV

When free cooling is not avail able, the compressors will be controlled by the zone thermostat. When free cooling is available, the outdoor-air damper is modulated by the EconoMi$erIV c on tr o l to p rov id e a 50 to 5 5 F supply-air temperature into the zone. As the supply-air temperature fluctuates above 55 o r below 50 F, the dampers will be modu lated (open or close) to bring the supply-air temperature back within set point limits.

For EconoMi$erIV operation, there must be a thermostat call for the fan (G). This will move the damper to its minimum position during the occupied mode.

Above 50 F supply-air temperature, the dampers will modulate from 100% o pen to the minimum open po sition. From 50 F to 45 F supply-air temperature, the dampers will maintain at the minimum open position. Below 45 F the dampers will be completely shut. As the supply-air temperature rises, the dampers will com e ba ck ope n to the m inim u m ope n po si tion once the supply-air temperature rises to 48 F.

If optional power exhaust is installed, as the outdoor-air damper opens and c loses, the power exhaust fan will be e nergized and deenergized.

If field-installed accessory CO

sensors are connecte d to the

EconoMi$erIV control, a demand controlled ventilation strategy will begin to operate. As the CO increases abov e the CO

set point, the minimum position of

level in the zone

the damper will be increased proportionally. As the CO2 level decreases because of the increase in fresh air, the outdoor-air

damper will be propo rtionally closed. Damper position will follow the higher demand condition from DCV mode or free cooling mode.

Damper movement from full closed to full open (or vice versa) will take between 1

/2 and 21/2 minutes.

If free cooling can be used as determined from the appropriate changeover command (switch, dr y bulb, enthalpy curve, differential dry bulb, or differential enthalpy), a call for cooling (Y1 closes at the thermostat) will cause the control to modulate the dampers open to maintain the supply a ir temperature set point at 50 to 55 F.

As the supply-air temperature drops below the set point range of 50 to 55 F, the control will modulate the outdoor-air dampers closed to maintain the proper supply-air temperature.

D. Heating, Units With EconoMi$erIV

When the room thermostat calls for heat, the heating controls are energized as described in the Heating, Units Without Economizer section. When the indoor fan is energized, the economizer damper moves to the minimum position. When the indoor fan is off, the economizer damper is fully closed.

E. Defrost

When the tempera ture of the outdoo r coil drops bel ow 28 F as sensed by the defros t thermostat (DFT2) and the defr ost timer is at the end of a timed period (adjustable at 30, 50, or 90 minutes), reversing valve solenoids (RVS1 and RVS2) are energized and the OFC is deenergized. This switches the position of the reversing valves and shuts off the outdoor fan. The electric heaters (if installed) will be energized.

The unit continues to defrost until the coil temperature as measured by DFT2 (see Fi g. 32 ) reach es 65 F, or the duration of defrost cycle completes a 10-minute period.

During the Defrost mode, if circuit 1 defrosts first, RVS1 will oscillate between Heating and Cooling modes until the Defrost mode is complete.

At the end of the defrost cycle, the electric heaters (if installed) will be deenergized; the reversing valves switch and the outdoor-fan motor will be energized. The unit will now operate in the Heating mode.

If the space thermostat is satisfied during a defrost cycle, the unit will continue in the Defrost mode until the time or temperature constraints are satisfied.

DEFROST THERMOSTAT

NOTE: Defrost thermostat is located at the bottom tee of circuit no. 1 and the top tee of circuit no. 2.

Fig. 32 — Defrost Thermostat Location

—22—

Page 23

SERVICE

WARNING: Before performing service or mainte-

nance operations on unit, turn off main power switch to unit. Turn off accessory heater power switch if applicab le. Electrical shock could cause personal injury.

I. CLEANING

Inspect unit i nterior at beginni ng of each heating and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior.

A. Indoor Coil

Clean as required with a commercial coil cleaner.

B. Outdoor Coil

Clean outdoor coil annually and as required by location and outdoor-air conditions. Inspect coil monthly — clean as required.

C. Condensate Drain

Check and clean each year at start of cooling season.

D. Filters

Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer to Table 1 for type and size.

E. Outdoor-Air Inlet Screens

Clean screens with steam or hot water and a mild detergent. Do not use throwaway filters in place of screens.

II. LUBRICATION A. Compressors

Each compressor is charged with the correct amount of oil at the factory. Observe the level in the sight glass immediately after shutdown while the oil is still warm. If the oil level is observed when the oil is cold, the level observed may be a mixture of oil and refrigerant which is not a true indication of the oil level. If oil level observed is not between the low limit and high limit levels as indicated in Fig. 33, add oil until it is in the correct range.

B. Fan Shaft Bearings

For size 150 units, bearings are permanently lubricated. No field lubrication is required. For size 180 units, the bearings are of the pillow block type and have grease fittings. The bearing opposite the motor end has an extended tube line so it can be lubricated from the motor side. Lubricate the bearings twice annually.

Typical lubricants are given below:

MANUFACTURER LUBRICANT

Texaco Regal AFB-2*

Mobil Mobilplex EP No. 1

Sunoco Prestige 42

Texaco Multifak 2

*Preferred lubricant because it contains rust and oxidation inhibitors.

C. Outdoor and Indoor-Fan Motor Bearings

The outdoor and indoor-fan motors have permanently sealed bearings, so no field lubrication is necessary.

III. INDOOR FAN, 542J150 UNITS A. Performance Adjustment

Fan motor pulleys on the 542J150 units are factory set for speed shown in Table 1.

To change fan speeds :

1. Shut off unit power supply.

2. Loosen belt by loosening fan motor mounting plate nuts.

3. Loosen movable-pulley flange setscrew (see Fig. 34).

4. Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed. Increasing fa n speed i ncreases load on mo tor. Do not exceed maximum speed specifie d in Table 1.

5. Set movable flange at nearest keyway of pulley hub and tighten setscrew.

To align fan and motor pulleys:

1. Loosen fan pulley setscrews.

2. Slide fan pulley along fan shaft.

3. Make angular alignment by loosening motor from mounting plate.

B. Service and Replacement (see Fig. 35) NOTE: To remove belts only, follow Steps 1-7.

1. Remove filter and supply-air section panels.

2. Remove unit top panel.

3. Remove coil guard.

4. Loosen screws A and B on both sides of motor mount assembly.

5. Loosen screw C.

6. Rotate motor mount assembly (with motor attached) as far as possible away from indoor coil.

7. Remove belt.

8. Rotate motor mount assembly back past original position toward indoor coil.

9. Remove motor mounting nuts D and E (both sides).

10. Lift motor up through top of unit.

11. Reverse Steps 1-10 to install new motor.

12. Check and adjust belt tension as necessary.

Fig. 33 — Compressor Sight Glass Oil Level

Fig. 34 — Indoor-Fan Pulley Alignment and Adjustment

—23—

Page 24

Fig. 35 — 542J150 Indoor-Fan Motor Section

IV. INDOOR FAN, 542J180 UNITS A. Performance Adjustment

Fan motor pulleys are factory set for speed shown in Table 1.

To change fan speeds :

1. Shut off unit power supply.

2. Loosen nuts on th e 2 carriage bolts in the mo unting base. Install jacking bolt and plate under motor base (bolt and plate are shipped in installer’s packet). Using bolt and plate, raise motor to top of slide and remove belt. Secure motor in this position by tightening the nuts on the carriage bolts.

3. Loosen movable-pulley flange setscrew (See Fig. 34).

4. Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed. Increasing fan speed incr eases lo ad on motor. Do not exceed maximum speed specified in Table 1. See Table 9 for air quantity limits.

5. Set movable flange at nearest keyway of pulley hub and tighten setscrew. (See Table 1 for speed change for each full turn of pulley flange.)

6. Replace and tighten belts. See Belt Tension Adjustment section below.

To align fan and motor pulleys:

1. Loosen fan pulley setscrews.

2. Slide fan pulley along fan shaft.

3. Make angular alignment by loosening motor from mounting plate.

B. Service and Replacement (see Fig. 36)

The 542J180 units use a fan motor mounting system that features a slide-out motor mounting plat e. To replace or service the motor, slide out the bracket.

1. Remove the indoor-fan access panel and the heating control access panel.

2. Remove the center post (located between the indoor fan and heating control access panels) and all screws securing it.

3. Loosen nuts on the two carriage bolts in the motor mounting base.

4. Using jacking bolt under motor base, raise motor to top of slide and remove belt. Secure motor in this position by tightening the nuts on the carriage bolts.

5. Remove the belt drive.

6. Remove jacking bolt and tapped jacking bolt plate.

7. Remove the 2 screws that secure the motor mounting plate to the motor support channel.

8. Remove the 3 screws from the end of the motor support channel that interfere with the motor slide path.

9. Slide out the motor and motor mounting plate.

10. Disconnect wiring connections and remove the 4 mounting bolts.

11. Remov e the motor.

12. To install the new motor, reverse Steps 1-11.

13. Check and adjust belt tension as necessary.

V. BELT TENSION ADJUSTMENT

To adjust belt tension:

1. Loosen fan motor bolts.

2. a. Size 150 units: Move motor mounting plate up or down for proper

belt tension (

/2 in. deflection w ith one finger).

b. Size 180 units:

Turn motor jacking bolt to move motor mounting plate up or down for proper belt tension (3/8 in. deflection at midspan with one finger [9 lb force]).

3. Tighten nuts.

4. Adjust bolts and nut on mounting plate to secure

motor in fixed position.

VI. OUTDOOR-FAN ADJUSTMENT (Fig. 37)

1. Turn off unit power supply.

2. Remove access panel(s) closest to the fan to be

adjusted.

3. Loosen fan hub setscrews.

4. Adjust the fan height on the shaft using a straight-

edge placed across the fan orifice.

5. Tighten setscrews and replace panel(s).

6. Turn on unit power.

VII. POWER FAILURE

Dampers have a spring return. In event of power failure, dampers will return to fully closed position until power is restored. Do not manually operate damper motor.

—24—

Page 25

NOTE: A 31/2-in. bolt and threaded plate are included in the installer’s packet. They can be added to the motor support channel below the motor mounting plate to aid in raising the motor.

Fig. 36 — 542J180 Indoor-Fan Motor Section

NOTE: Dimensions are in inches.

Fig. 37 — Outdoor Fan Adjustment

VIII. REFRIGERANT CHARGE

Amount of refrigerant charge is listed on unit nameplate and in Table 1.

Unit panels must be in place when unit is operating during charging procedure.

A. No Charge

Use standard evacuating techniques. After evacuating system, weigh in the specified amount of re frigerant (refer to Table 1).

B. Low Charge, Cooling

Using appropriate cooling charging chart (see Fig. 38 and

39), add refrigerant until conditions of the chart are met. Note that charging charts are different from those normally used. Charts are based on ch arging units to correct superheat for various operating co nditions. An accurate pressure gage and temperature sensin g device are required. Connec t temperature sensing device to service port on suction line and insulate it so that outdoor ambient temperature does not affect reading. Indoor-air cfm must be within normal operating range of unit.

C. To Use Cooling Charging Chart

Take outdoor ambient temperature and read the suction pressure gage. Refer to appropriate chart to determ ine correct suction temperature. If suction temperature is high, add refrigerant. If suction tem perature is low, careful ly recover some of the charge. Recheck suction pressure as charge is adjusted.

Example (Fig. 39)

Outdoor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 5 F

Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 psig

Suction Temperature Should be . . . . . . . . . . . . . . . . . . . .60 F

(Suction Temperature may vary ± 5 F.)

D. Low Charge, Heating

If outdoor ambient temperature is above 40 F, operate unit on cooling and refer to Low Charge, Cooli ng se ction ab ove. If outdoor ambient is below 40 F, evacuate sys tem and weigh in specified amount of refrigerant. (Refer to Table 1.)

IX. FILTER DRIER

Replace whenever refrigerant system is exposed to atmosphere.

X. PROTECTIVE DEVICES A. Compressor Protection

Overcurrent Each compressor has one manu al reset, calibrated trip, mag-

netic circuit bre aker. Do not bypass c onnections or incr ease the size of the circuit break er to correct trouble. Determine the cause of the trouble and c orrect it before resetting the breaker.

Overtemperature Each compressor has internal protector to protect it against

excessively high discharge gas temperature. Crankcase Heater Each compres sor ha s 125-wa tt cran kcase heat ers to preven t

absorption of liq uid r efri ge rant by oi l in the cr ank case when the compressor is idle. Since power for the crankcase heaters is drawn from the unit incoming power, main unit power must be on for the heaters to be energized.

IMPORTANT: After a prolonged shutdown or service job, energize the crankcase heaters for 24 hours before starting the compressors.

Compressor Lockout If any of the saf eties (high-pressure or low-pressure, freeze

protection thermostat, compressor internal thermostat) trip, or if there is loss of power to the compressor s, the CLO (compressor lockout) will lock the compressor s off. To reset, manually move the thermostat setting.

B. Indoor-Fan Motor Protection

A manual reset, calibrated trip, magnetic circuit breaker protects against ov ercurrent. Do not bypass connections or increase the size of the breaker to correct trouble. Determine the cause and correct it before r esetting the breaker.

C. Outdoor-Fan Motor Protection

Each outdoor-fan motor is internally protected against overtemperature.

—25—

Page 26

Fig. 38 — Cooling Charging Chart, 542J150 Units

D. High and Low-Pressure Switches

If either switch trips, or if the compressor overtemperature switch activates, that refrigerant circuit will be automatically locked out by the CLO. To reset, manually move the thermostat setting.

E. Freeze Protection Thermostat (FPT)

An FPT is located on the indoor coil. It detects frost build-up and turns off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergized by resetting the CLO from the thermostat.

XI. RELIEF DEVICES

All units have relief devices to protect against damage from excessive pressu res (i.e., fire). These devices protect the high and low side.

XII. CONTROL CIRCUIT, 24-V

This control circuit is protected against overcurrent by a

3.2-amp circuit breaker. Breaker can be reset. If it trips, determine cause of trouble before resetting. Typical wiring is shown in Fi g. 40 and 41.

XIII. OPTIONAL HINGED ACCESS DOORS

When the option al se rvic e pac ka ge is ord ered or i f the hin ged access doors option is ordered, the unit will be provided with external and internal hi nged access doors to facilitate service.

Four external hinged access doors are provided. All external doors are provid ed with 2 l arge

/4 turn latches with folding bail-type handles. (Compressor access doors have one latch.) A single door is provided for filter and drive access. One door is provided for control box access. The control box access door is interlocked with the non-fused disconnect which must be in the OFF position to open the door. Two doors are provided for access to the compressor compartment.

Two internal access doors are provided inside the filter/drive access door. The filter access d oo r (on t he left) is secured by 2

small

/4 turn latches with folding bail-type handles. This door must be opened prior to opening the drive access door. The drive access door is shipped with 2 sheet metal screws holding the door closed. Upon initial opening of the door, these screws may be removed and discarded. The door is then held shut by the filter access door, which closes over it.

XIV. REPLACEMENT PARTS

A complete list of repl acement parts may be obtained from any Bryant distributor upon request.

Fig. 39 — Cooling Charging Chart, 542J180 Units

—26—

Page 27

Fig. 40 — Typical Wiring Diagram (542J150, 208/230-3-60 V Shown)

—27—

Page 28

Fig. 41 — Typical Component Arrangement (542J150, 208/230-3-60 V Shown)

—28—

Page 29

LEGEND AND NOTES FOR FIG. 40 AND 41

LEGEND

AHA — Adjustable, Heat Anticipator BRK W/AT — Breaks with Amp Turns C—Contactor, Compressor CAP — Capacitor CB — Circuit Breaker CC — Cooling Compensator CH — Crankcase Heater CLO — Compressor Lockout COMP — Compressor Motor CTD — Compressor Time Delay DB — Defrost Board DFT — Defrost Thermostat DM — Damper Motor DR — Defrost Relay DU — Dummy Terminal EQUIP — Equipment FL — Fuse Link FPT — Freeze Protection Thermostat FU — Fuse GND — Ground HC — Heater Contactor HPS — High-Pressure Switch HR — Heat Relay HTR — Heater IAQ — Indoor Air Quality Sensor IFC — Indoor-Fan Contactor IFCB — Indoor-Fan Circuit Breaker IFM — Indoor-Fan Motor IP — Internal Protector L—Light LALS — Low Temperature Compressor

LPS — Low-Pressure Switch LS — Limit Switch NEC — National Electric Code OAT — Outdoor Air Temperature Sensor OCCUP — Occupancy Sensor

Lockout Switch

OFC — Outdoor Fan Contactor OFM — Outdoor Fan Motor OP — Overcurrent Protector PL — Plug Assembly QT — Quadruple Terminal RVR — Reversing Valve Relay RVS — Rev ersing Valve Solenoid TB — Terminal Block TC — Ther m osta t Cooling TH — Ther m osta t Heating TRAN — Transformer

Terminal (Marked) Terminal (Unmarked) Terminal Block Splice

Factory Wiring Field Wiring Option/Accessory Wiring To indicate common potential only;

not to represent wiring. Economizer Motor

Remote POT Field Accessory OAT Sensor Disch Air Sensor RAT Accessory Sensor

Low Ambient Lockout Switch

NOTES:

1. Compressor and/or fan motor(s) thermally protected three-phase motors protected against primar y single phasing conditions.

2. If any of the original wire furnished must be replaced, it must be replaced with T y pe 90° C or its equiv alent.

3. TRAN1 is wired for 230-v operation. If unit is 208-v, disconnect the black wires from the ORN TRAN wire and reconnect to the RED TRAN wire, apply wirenuts to wires.

4. CB1,2 must trip amps are equal to or less than 156% FLA, IFCB 140%.

5. The CLO locks out the com pressor to p revent short cycling on com pressor overload and safety devices; before replacing CLO, check these devices.

6. Jumpers are omitted when unit is equipped with economizer.

7. Number(s) indicates the line location of used contacts. A bracket over (2) numbers signifies a single pole, double throw contact. An underlined number signifies a norm ally closed contact. Plain (no line) number signifies a normally open contact.

8. Remove jumper between RC & RN.

9. 620 Ohm, 1 watt, 5% resistor should be removed only when using differential enthalpy or dry bulb.

10. If a separate field-supplied 24-v transformer is used for the IAQ sensor power supply, it cannot have the secondary of the transformer grounded.

11. OAT sensor is shipped inside unit and must be relocated in the field for proper operation.

12. For field-installed remote minimum position POT, remove black wire jumper between P and P1 and set control minimum position POT to the minimum position.

—29—

Page 30

TROUBLESHOOTING

I. UNIT TROUBLESHOOTING

Refer to Table 15 and Fig. 42-45, for assistance when troubleshooting the 542J units.

A. Cooling Cycle

1. Hot gas from compressor flows through the 4-way valve and is directed to the outdoor-coil header. At the header it is condensed and subcooled through converging circuits (7-2-1). Refrigerant leaves the outdoor-coil by way of the check valve to the liquid line.

2. The refrigerant then flows through the filter drier and feeds the indoor coil by way of fixed orifice tubes on each circuit.

3. Each circuit evaporates the refrigerant, and the circuits are combined in the indoor-coil header with some of the circuits flowin g through the check valve.

4. The refrigerant then flows through the 4-way valve, accumulator and back to the compressor.

B. Heating Cycle

1. Hot gas from the compressor flows through the 4-way valve and is directed to the indoor-coil header. At the header it is condensed and directed through subcooling circuits and out the indoor-coil check valve to the liquid line.

2. The refrigerant then flows through a strainer and feeds the outdoor-coil by way of fixed orific e tubes on each circuit.

3. Each circuit evaporates the refrigerant, and the circuits are combined in the outdoor-coil header with some of the circuits flowin g through the check valve.

4. The refrigerant then flows through the 4-way valve, accumulator and back to the compressor.

II. ECONOMI$ERIV TROUBLSHOOTING

See Table 16 for EconoMi$erIV logic. A functional view of the Econ oMi$erIV is shown in Fig. 46.

Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$erIV simulator program is available from Bryant to help with EconoMi$erIV training and troubleshooting.

A. EconoMi$erIV Preparation

This procedure is used to prepare the EconoMi$erIV for troubleshooting. No troubleshooting or testing is done by performing the following procedure.

NOTE: This procedure requires a 9-v battery, 1.2 kilo-ohm resistor, and a 5.6 kilo-ohm resistor which are not supplied with the EconoM i$ er IV.

IMPORTANT: Be sure to record the positions of all potentiometers before star ting troubleshooting.

1. Disconnect power at TR and TR1. All LEDs should be off. Exhaust fan contac ts should be open.

2. Disconnect device at P and P1.

3. Jumper P to P1.

4. Disconnect wires at T and T1. Place 5.6 kilo-ohm resistor across T and T1.

5. Jumper TR to 1.

6. Jumper TR to N.

7. If connected, remove sensor from terminals S

and +.

Connect 1.2 kilo-ohm 4074EJM checkout resistor across terminals S

8. Put 620-ohm resistor across terminals S

and +.

9. Set minimum position, DCV set point, and exhaust potentiometers fully CCW (counterclockwise).

10. Set DCV maximum position potentiometer fully CW (clockwise).

11. Set enthalpy potentiometer to D.

12. Apply power (24 vac) to terminals TR and TR1.

B. Differential Enthalpy

To check differential enthalpy:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Place 620-ohm resistor across S

3. Place 1.2 kilo-ohm resistor across S

and +.

and +. The Free

Cool LED should be lit.

4. Remove 620-ohm resistor across S

and +. The Free

Cool LED should tu rn off.

5. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

C. Single Enthlapy

To check si ngle enthalpy:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Set the enthalpy potentiometer to A (fully CCW). The Free Cool LED should be lit.

3. Set the enthalpy potentiometer to D (fully CW). The Free Cool LED should turn off.

4. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

D. DCV (Demand Controlled Ventilation) and Power Exhaust

To check DCV and Power Exhaust:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Ensure terminals AQ and AQ1 are open. The LE D for both DCV and Exhaust should be off. The actuator should be fully closed.

3. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The LED for both DCV and Exhaust should turn on. The a ctua tor s hou ld dri ve to be tween 90 and 95% open.

4. Turn the Exhaust potentiometer CW until the Exhaust LED turns off. The LED should turn off when the potentiometer is approximately 90%. The actuator should remain in position.

5. Turn the DCV set point potentiometer CW until the DCV LED turns off. The DCV LED should turn off when the potentiometer is approximately 9 v. The actuator should drive fully closed.

6. Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds afte r the Exhaust LED turns on.

7. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

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Page 31

E. DCV Minimum and Maximum Position

To check the DCV minimum and maximum position:

1. Make sure EconoM i$erIV prepara tion procedu re has been performed.

2. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). Th e DCV LED should turn on. The actuator should drive to between 90 and 95% open.

3. Turn the DCV Maximum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.

4. Turn the DCV Maximum Position potentiometer to fully CCW. The actuator should drive fully closed.

5. Turn the Minimum Position potentiometer to midpoint. The actu ator should drive to bet ween 20 and 80% open.

6. Turn the Minimum Position Potentiometer fully CW. The actuator should drive fully open.

7. Remove the jumper from TR and N. The actuator should drive fully closed.

8. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

F. Supply-Air Input

To check supply-air input:

1. Make sure EconoM i$erIV prepara tion procedu re has been performed.

2. Set the Enthalpy potentiometer to A. The Free Cool LED turns on. The actuator should drive to between 20 and 80% open.

3. Remove the 5.6 kilo-ohm resistor and jumper T to T1. The actuator should drive fully open.

4. Remove the jumper across T and T1. The actuator should drive fully closed.

5. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

G. EconoMi$erIV Troubleshooting Completion

This procedure is used to return the Eco no Mi$ er IV to op eration. No trouble shooting or testing is done by performing the following procedure.

1. Disconnect power at TR and TR1.

2. Set enthalpy potentiometer to previous setting.

3. Set DCV maximum position potentiomete r to previous setting.

4. Set minimum position, DCV set point, and exhaust potentiometers to previous settings.

5. Remove 620-ohm resistor from terminals S

and +.

6. Remove 1.2 kilo-ohm checkout resistor from terminals S

and +. If used, reconnect sensor from terminals S

and +.

7. Remove jumper from TR to N.

8. Remove jumper from TR to 1.

9. Remove 5.6 kilo-ohm resistor from T and T1. Reconnect wires at T and T1.

10. Remov e jumper from P to P1. Reconn ect device at P and P1.

11. Apply power (24 vac) to terminals TR and TR1.

CHECK VALVE

IDENTIFICATION

(See Fig. 42 and 43)

LOCATION

Outdoor coil; Header

Outdoor coil; Liquid line feeding fixed orifice

Outdoor coil; Liquid line leaving coil

Indoor coil; Liquid line feeding fixed orifice

Indoor coil; Liquid line leaving coil

Indoor coil; Header

Table 15 — Check Valve Functions

COOLING

CYCLE

Closed Open

Open Closed Normal

Closed Open

Open Closed Normal

Closed Open

Open Closed Normal

HEATING

CYCLE

Lose circuiting in outdoor coil. Acts like low charge.

Restricted liquid line

Bypasses coil and floods compressor

COOLING CYCLE

CHECK VALVE STUCK

Open Closed Open Closed

Normal Normal

Lose some capacity

Normal Normal Restricted

indoor fixed orifice

Normal Normal Bottom circuits

of indoor coil inactive

Restricted outdoor fixed orifice

Lose some capacity Normal

Lose indoor coil circuiting — symptom of low charge

HEATING CYCLE

CHECK VALVE STUCK

Bottom 3 circuits restricted

Normal

Flooding outdoor coil and compressor

Restricted liquid line

Normal

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LEGEND

→ — Refrigerant Flow Direction ∆ — Check Valve Flow Direction

X—Fixed Orifice

NOTE: Circuitry shown is for single system; 542J180 units have

2 individual and independent refrigeration systems that each operate in an identical manner.

Fig. 42 — Heat Pump Cooling Cycle

CHECK VALVE* COOLING

A B C D E F

*See Table 15 for check valve operation

details.

Closed Open Closed Open Closed Open

LEGEND

→ — Refrigerant Flow Direction ∆ — Check Valve Flow Direction

X—Fixed Orifice

NOTE: Circuitr y shown is for single system; 542J180 units have

2 individual and independent refrigeration systems that each operate in an identical manner.

Fig. 43 — Heat Pump Heating Cycle

—32—

CHECK VALVE* COOLING

A B C D E F

*See Table 15 for check valve operation

details.

Open Closed Open Closed Open Closed

Page 33

Fig. 44 — Troubleshooting Chart, Heating Cycle

ODT — Outdoor Temperature

—33—

Page 34

Fig. 45 — Troubleshooting Chart, Cooling Cycle

—34—

Page 35

Table 16 — EconoMi$erIV Input/Output Logic

INPUTS OUTPUTS

Demand Control

Ventil ation (DCV)

Below set (DCV LED Off)

Above set (DCV LED On)

*For single enthalpy control, the module compares outdoor enthalpy

to the ABCD set point.

†Power at N terminal determines Occupied/Unoccupied setting:

24 vac (Occupied), no power (Unoccupied).

**Modulation is based on the supply air sensor signal.

††Modulation is based on the DCV signal.

High (Free Cooling LED Off)

Low (Free Cooling LED On)

High (Free Cooling LED Off)

Low (Free Cooling LED On)

Enthalpy*

Outdoor Return

Low On On On On Minimum position Closed

High On On On Off Modulating** (between min.

Low On On On On M odulating†† (between min.

High On On On Off Modulating*** Modulating†††

Y1 Y2

On Off On Off Off Off Off Off

On Off Off Off Off Off Off Off Minimum position Closed

On Off On Off Off Off Off Off

On Off Off Off Off Off Off Off

Compressor N Terminal†

Stage1Stage

position and full-open)

position and DCV maximum)

***Modulation is based on the greater of DCV and supply air sensor

signals, between minimum position and either maximum position (DCV) or fully open (supply air signal).

†††Modulation is based on the greater of DCV and supply air sensor

signals, between closed and either maximum position (DCV) or fully open (supply air signal).

Occupied Unoccupied

Damper

Modulating** (between closed and full-open)

Modulating†† (between closed and DCV maximum)

Fig. 46 — EconoMi$erIV Functional View

—35—

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Air quantity limits

Changeover set points 14 Charging chart, refr igera nt 26 Clearance 5, 6 CO2 sensor Configuration 17 Settings 15, 17 Compressor Lockout 13, 25 Lubrication 23 Mounting 18 Concentric duct 7 Condensate drain Cleaning 23 Location 3, 8 Control circuit Wiring 8, 9 Convenience outlet 8 Crankcase heater 18, 25 Defrost thermostat 22 Demand control ventilation 16, 17 Dimensions 2, 3, 5, 6 Ductwork 1, 3, 7 EconoMi$erIV 11-17 Control mode 13 Controller wiring 12 Damper movement 16 Demand ventilation control 16 Dry bulb changeover 13 Troubleshooting 30, 31, 35 Usage 13 Wiring 12 Electrical connections 7 Electrical data 9 Enthalpy changeover set points 15 Filter Cleaning 23 Size 4 Filter drier 25 Freeze protection thermostat 26 Heat anticipator settings 9 High-pressure switch 4 Hinged access doors 26 Horizontal adapter roof curb 3, 21 Indoor air quality sensor 14 Indoor coil 4 Cleaning 23 Indoor fan motor Lubrication 23 Motor data 21 Performance 19, 20 Pulley adjustment 23 Pulley setting 4, 21 Speed 4 Low-pressure switch 4 Manual outdoor air damper 10 Motormaster I cont ro l 11 Mounting Compressor 18 Unit 1 Non-fused disconnect 8, 9 Operating limits 18 Operating sequence 22 Cooling 22 Defrost 22 EconoMi$erIV 22 Heating 22 Outdoor air hood 10 Outdoor air i nlet s cre ens Cleaning 23 Outdoor air temperature sensor 13 Outdoor coil 4 Cleaning 23 Outdoor fan 4 Adjustment 24, 25 Physical data 4 Power exhaust 21

INDEX

Power supply 7 Wiring 8 Pressure, drop Economizer 21 Electric heat 21 Glycol heat 21 Pressure switches High pressure 4 Low pressure 4 Refrigerant Charge 25 Type 4 Refrigerant service ports 18 Replacement parts 26 Return air filter 4, 22 Return air temperature sen sor 14 Rigging unit 1, 3 Roof curb Assembly 1 Dimensions 2, 3 Leveling tolerances 2 W eight 4 Safety considerations 1 Service 23-29 Start-up 18-22 Start-up checklist CL-1 Supply-air temperature sensor 13 Thermostat 9, 16 Troubleshooting 30-35 W eight Economizer 4-6 Maximum 3 Unit 4-6 Wind baffle 11 Wiring EconoMi$erIV 12 Power connections 8 Thermostat 9 Unit 27, 28

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Page 37

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiari zat ion • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training which includes “hands-on” experience with the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

—37—

Page 38

Page 39

Page 40

START-UP CHECKLIST

(Remove and Store in Job File)

MODEL NO.: __________________________________ SERIAL NO.: _____________________________________ DATE: ________________________________________ TECHNICIAN: ____________________________________

I. PRE-START-UP



VERIFY THA T ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT



VERIFY PROPER ADJUSTMENT OF INDOOR FAN MOTOR ADJUSTMENT BOLT (150 UNITS) AND ADJUSTMENT BOL T AND PLATE (180 UNITS)



LOOSEN ALL SHIPPING HOLDDOWN BOLTS PER INSTRUCTIONS



OPEN ALL SERVICE VAL VES (SUCTION, DISCHARGE, AND LIQUID)



VERIFY INSTALLATION OF OUTDOOR-AIR HOOD



VERIFY THA T CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS



VERIFY THA T ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT



CHECK THAT AIR INLET FIL TERS ARE CLEAN AND IN PLACE



VERIFY THA T UNIT IS LEVEL



CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SET SCREW IS TIGHT



VERIFY THA T FAN SHEAVES ARE ALIGNED AND BEL TS ARE PROPERLY TENSIONED



VERIFY THA T CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR AL LEAST 24 HOURS

II. START-UP

ELECTRICAL

CUT ALONG DOTTED LINE

SUPPLY VOL TAGE L1-L2 L2-L3 L3-L1 COMPRESSOR AMPS — COMPRESSOR NO. 1 L1 L2 L3

INDOOR-F AN AMPS — COMPRESSOR NO. 2 (180 ONL Y ) L1 L2 L3 SUPPL Y FAN AMPS EXHAUST FAN AMPS ELECTRIC HEAT AMPS L1 L2 L3

TEMPERATURES

OUTDOOR-AIR TEMPERATURE F DB (Dry-Bulb) RETURN-AIR TEMPERATURE F DB F WB (Wet-Bulb) COOLING SUPPLY AIR F HEAT PUMP SUPPLY AIR F ELECTRIC HEAT SUPPL Y AIR F

PRESSURES (COOLING MODE)

REFRIGERANT SUCTION CIRCUIT NO. 1 PSIG CIRCUIT NO. 2 (180 ONL Y) PSIG REFRIGERANT DISCHARGE CIRCUIT NO. 1 PSIG CIRCUIT NO. 2 (180 ONLY ) PSIG



VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 26

GENERAL



ECONOMI$ERIV MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS

CUT ALONG DOTTED LINE

Bryant DURAPAC PLUS SERIES 542J Installation, Start-up And Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual