Carrier 542E User Manual

installation, operation,

and maintenance instructions

542E

Sizes 024 thru 060

PACKAGED HEAT PUMPS

NOTE TO INSTALLER: Leave these instructions with the

unit after installation.

NOTE: The installation of this unit must conform to the

guidelines presented in these unit Installation Instructions.
Read and become familiar with this publication before start
ing installation.

INTRODUCTION

Models 542D and 542E Packaged Heat Pumps are fully self­contained combinatipn heating/cooling units designed for
outdoor installation. Model 542E may be installed either on
a rooftop or ground-level slab. See Figure 1. Model 542D is
used with an accessory roof-mounting curb (P/N 304851-

302) and incorporates a down-discharge/return-air plenum
as an integral part of the unit. See Figure 2.

These units are factory-charged with R-22 refrigerant.
Installation is simple: connect condensate drain, air ducts,

high- and low-voltage.wiring, and install a field-supplied air
filter (except for model 542D which has factory-supplied air
filters).

All units can be connected into existing duct systems that

are properly sized and designed to handle an airflow of 350 to
450 ffimin per each 12,000 Btuh of rated unit capacity. See

Table I for indoor airflow requirements.

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

A full line of rooftop system accessories is available for field
installation. These accessories include plenums with facto

ry-supplied air filters (plenum not required with Model
542D), roof-mounting curbs, horizontal and downflow
economizers, barometric relief dampers, concentric diffuser
boxes, and flexible duct packages. Filter racks with air
filters are available for rooftop or ground-level installation.

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

IMPORTANT-READ BEFORE INSTALLING

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

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

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

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

place.

5. Styrofoam shipping blocks located between compressor

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

& 542D060

Cancels: 40542DP6-A

À

Figure 1—Model 542E

Figure 2—Model 542D060 Mounted on

Accessory Roof-Mounting Curb

GENERAL

Models 542D and 542E Packaged Heat Pumps have been
designed and tested in accordance with ARI Standards 240­77 and 270-75, and these units are UL-listed.

This publication contains the following sections:

I. Moving and Setting Unit in Place

II. Condensate and Defrost Disposal
HI. Duct Connections
IV. Electrical Connections

V. Preparing Unit for Startup
VI. Startup and Adjustments

VII. Sequence of Operation

VIII. Care and Maintenance

40542DP16-A

6/1/80

A79110

A79111

BDP Company, Division of Carrier Corp.

542E REQUIRED CLEARANCE (Inches)

Top of unit
Duct side of unit

Compressor access door access end...........................12

side

..................................

.........................

.........................................

CONTROL ACCESS DOOR

COMPRESSOR
ACCESS DOOR

48 Blower access door end
12 End opposite blower

30 Bottom of unit above

anticipated snow level.... 6

______

30

OUTDOOR FAN

ELECTRIC HEAT
HIGH-VOLTAGE INLET WITH
MULTIPLE KNOCKOUTS

A79071

542E DIMENSIONS (Inches)

Size

A

B

024 & 030 60-3/16 32-3/16

036

60-3/16 32-3/16 24-13/16

c D E F

24-13/16

042, 048, & 060 68-3/16 40-3/16 30-13/16

L M N

Sizes

024 & 030 18-1/8

036

042, 048, & 060

K

18-1/8

25 1-1/2

1-1/2 15-3/32 12-9/16

15-3/32 12-9/16

1-1/2

20-3/32 15-1/8

21 11-1/2 13-5/16
21 13-3/4 13-5/16
21 16-3/8 17-5/16

P

14-1/2

R

28-9/16
14-1/2 28-9/16 37-1/8 2 7/8
18-1/2 34-9/16

G H J

57
57 4-5/8 6-15/16
65 5-1/8

T

S

37-1/8 2 7/8
44-1/4

2

Figure 3—542E Dimensional Drawing

TABLE l-RATiNGS, PERFORMANCE, & RECOMMENDED FILTER SIZES

MODEL

SIZE
SERIES

Rated Heating Capacity @ 47°F (Btuh)*

Total Power Consumption (Watts)*
COP*

Rated Heating Capacity® 17°F (Btuh)*

Total Power Consumption (Watts)*
COP*

**

024

A A A

030

26,000 30,000

2850 3450 3850

2.7 2.5

13,500 16,000 18,000

2350 2900

1.7 1.6

Rated Cooling Capacity @ 95°F (Btuh)* 25,500 30,000

Total Power Consumption (Watts)*
EER 7.6

Rated Indoor Airflow (Ft^/Min)*

3350 3900

7.7 7.5

850 1050
Rated External Statio Pressure (In. wc)* 0.10 0.15
ARI Sound Rating Humbert 19 19
Recommended Minimum Filter Size (Sq ln.)t

Standard-Type
Cleanable-or High-Capacity-Type 265

408 504

328

* Rated in accordance with ARI Standard 240-77.
t Rated in accordance with ARI Standard 270-75.
f Recommended field-supplied filter sizes shown are based on a velocity of 300 ft/min at the rated indoor airflow.

**Two 20 X 20 X 1 air filters are furnished with Model 542D060.

ttTo achieve the performance ratings indicated, the fresh-air and exhaust openings of the plenum section must be sealed airtight, the

fresh-air damper must be insulated, and the plenum section must be supported by a curb around an opening to the indoor airspace.

542E

036

35,000

042

A A

42,000

4600

2.7 2.7 2.8
21,000

3000

3700

1.8 1.7 1.8

35,000

4650

41,000

5150

8.0

1300

0.15

1535

0.15

19 18 18

624
406

737
479

6-7/8

6-15/16

7-1/2

TJ

V

27-7/8
27-7/8

7/8 35-3/16

048

48,000

060 060

A A

58,000

5100 6300

2.7

25,000 31,000

4150 5300

5420

58,00011

6300tt

2.7t-

31,00011

530011

1.7 1.711

47,000 57,000

6100 7600

57,00011

7600-t

7.7 7.5 7.511

1700 2000 200011

0.20

0.20 0.2011
20 20

816
530

960
624

**
**

-2-

Figure 4—542D060 Dimensional Drawing

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

MODEL

SIZE
SERIES

Unit Volts—Phase (60Hz)
Operating Voltage Range
Total Unit Amps
Max Branch Circuit Fuse Size (Amps)
Unit Ampacity for Wire Sizing
Minimum Wire Size (AWG)*

Maximum Wire Length (Ft)*

J024 J030 J036 1 P036

A

A

208-230-1 208-230-1 208-230-1

197-253 197-253

197-253

16.7 22.7 23.9
30 45

20.2 27.5
10 10

115 85

542E

A

208/230-3 230-1

187-253 207-253 187-253

45 25

14.8

28.7 21.0
50 40

29.2 17.8 34.9
10

12 8 10

80 95 112

B042 1 P042

A

208/230-3

25.2
107

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

MODEL

SIZE
SERIES

Unit Volts—Phase (60Hz)
Operating Voltage Range
Total Unit Amps
Max Branch Circuit Fuse Size (Amps)
Unit Ampacity for Wire Sizing
Minimum Wire Size (AWG)*

Maximum Wire Length (Ft)*

B048 P048

230-1

207-253 187-253

31.9
60

38.9 27.1 13.2 49.8 35.6
8

101 100 181 123

542E

A A A

E048 060 P060

208/230-3 460-3 230-1 208/230-3

414-506 207-253

22.4

10.9

45 20 60
10

14 6

* Use only copper wire for field connections to unit. Wire size is based on 60 or 75°C copper conductor at 86°F (30°C) ambient tempera

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

542E 542D & 542E

187-253 414-506

40.9

30.1 13.7
50 25

8 12

119 229

E060

460-3

15.7

-3-

USE SPREADER BARS TO PROTECT UNIT

Figure 5—542E Suggested Rigging

USE SPREADER BARS TO PROTECT UNIT

A79148

I. MOVING AND SETTING UNIT IN PLACE

CAUTION: Use spreader bars when rigging the unit to be

lifted to protect the top and sides. Model 542E must be

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

When selecting an installation site, locate the unit on the
side opposite the prevailing wind to assure proper operation
of the defrost cycle and to avoid snow drifts that could block
the outdoor coil. Be sure that the unit is installed at least 6

inches above the highest probable snow level to prevent block
age of the outdoor coil and to assure proper drainage of de
frosted ice.

A. Rooftop Installation

CAUTION: When installing the unit on a rooftop, be sure
that the roof will support the additional weight. Refer to the

Product Data Sheet (PDS) for Models 542D and 542E to
obtain total weight and corner weight information.

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

When installing a Model 542E without downflow plenum,
place the unit on a level base that provides proper support.
On flat roofs, be sure that the unit is located at least 4 inches

above the highest expected water level on the roof to prevent
flooding. Consult local codes for additional installation
requirements.

B. Ground-Level Installation

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

C. Clearances

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

Figure 6—542D060 Suggested Rigging

CAUTION: Do not restrict outdoor airflow. An air restric

tion at either the outdoor-air inlet (the entire surface of the
outdoor coil) or the fan discharge can be detrimental to com
pressor life.

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

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

II. CONDENSATE AND DEFROST DISPOSAL
NOTE: Ensure that defrost and condensate water disposal

methods comply with local codes, restrictions, and practices.
Models 542D and 542E dispose of condensate water through

a 3/4-inch MPT plastic drain fitting. To prevent damage dur
ing the shipping and moving of the unit, this fitting and a
plastic drain pipe are shipped inside the unit compressor
compartment (secured with tape). Locate this fitting and
'nsert the nonthreaded end into the plastic drain pipe. See

Figure 8. Insert the plastic pipe over the drain on the drain
pan. The pipe and fitting must lay flat against the base for
proper drainage. The residual curvature in the pipe must be

in a horizontal plane.

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

-4-

LOW-PRESSURE
SERVICE FITTING

ACCUMULATOR

ACCUMULATOR
FUSIBLE
PLUG

DEFROST
THERMOSTAT

METERING
DEVICE

REVERSING VALVE
ASSEMBLY

HIGH-PRESSURE
SERVICE FITTING

CAPACITOR(S)
(COMPRESSOR a

FAN MOTOR)

BLOWER MOTOR
RELAY

BLOWER MOTOR
CAPACITOR

DEFROST

RELAY

DEFROST
TIMER

TRANSFORMER

LOW-VOLTAGE
TERMINAL
BOARD

LOW-VOLTAGE
INLET HOLE

CHASSIS
GROUND
CONNECTION

LOW-PRESSURE SWITCH

INDOOR COIL DRAIN PAN

4 MPT PLASTIC DRAIN FITTING

^(SHIPPED TAPED INSIDE

COMPRESSOR COMPARTMENT)

COMPRESSOR

Figure 8—Partial Side'View With Compressor & Control

Access Panels Removed (Model 542E036, 208V-230V—1)

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

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

Condensate and defrost water can be drained directly onto

the roof in rooftop installations (where permitted) or onto a
gravel apron in ground-level installations. When using a
gravel apron, make sure it slopes away from the unit.

III. DUCT CONNECTIONS

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

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

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

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

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

QUICK-START PTC
THERMISTOR

■HIGH­VOLTAGE
PIGTAIL
LEADS

A79243

CAUTION: When the duct system fastening holes are being

drilled into the side of Model 542E instead of the unit duct
flanges, use extreme care to avoid puncturing the coil or coil
tubes.

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

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

warning on the unit rating plate.

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

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

5. Adequately insulate and weatherproof all ductwork

located outdoors. Insulate ducts passing thru an uncon

ditioned space, and use a vapor barrier in accordance

with the latest issue of SMACNA and NESCA minimum
installation standards for heating and air conditioning
systems. Secure all ducts to the building structure.

6. Flash, weatherproof, and vibration-isolate all openings

in building structure in accordance with local codes and
good building practices.

HIGH-VOLTAGE
PIGTAIL LEADS

BLK

BLK ^

RED

/r

/ r-Tok F1ELD-SUPPL1E(

3-PHASE
UNITS ONLY

-FIELD SPLICE

SWITCH

1

POWER
SUPPLY

A79244

Figure 9—Field High-Voltage Connections

IV. ELECTRICAL CONNECTIONS
WARNING: The unit cabinet must have an uninterruptedj

unbroken, electrical ground to minimize the possibility of
personal injury if an electrical fault should occur. This
ground may consist of electrical wire connected to the unit
ground lug in the control compartment, or conduit approved
for electrical ground when installed in accordance with the
National Electrical Code and local electrical codes. A failure
to follow this warning could result in the installer being lia
ble for the personal injury of others.

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

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

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

3. Ensure that high-voltage power to the unit is within the
operating voltage range indicated on the unit rating

plate. On 3-phase units, ensure that phases are balanced
within 2%. Consult the local power company for correc
tion of improper voltage and/or phase balance.

4. Insulate low-voltage wires for the highest voltage con
tained within the conduit when low-voltage control
wires are run in the same conduit as high-voltage wires.

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

6. Make sure that the service conductors used between the
electrical service panel and the field-supplied electrical
disconnect switch do not have a current capacity less

than the copper wire specified, and do not create a total
voltage drop in excess of 2% of the rated voltage of the
unit.

NOTE: When using aluminum conductor from the electrical

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

A. High-Voltage Connections

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

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

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

panel.

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

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

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

B. Special Procedures for 208-V Operation
WARNING: Make sure that the power supply to the unit is

switched OFF before making any wiring changes.

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

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

NOTE: If a blower motor speed is changed, insulate all

unused motor leads following the same procedures described
for the transformer leads.

C. Low-Voltage Connections

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

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

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

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

Use No. 18 AWG color-coded, insulated (35°C minimum)
wires to make the low-voltage connections between the ther
mostat and the unit. If the thermostat is located more than

100 feet from the unit (as measured along the low-voltage
wires), use No. 16 AWG color-coded, insulated (35°C
minimum) wires.

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

-6-