Bryant DURAPAC PLUS SERIES 542J - Manual

Cancels: II 542J-150-3 II 542J-150-4
3/15/06
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
HEAT PUMP UNITS
542J
Dura Pac Plus Series
Sizes 150,180
12 and 15 Tons
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 compo-
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance func-
tions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguisher available for all brazing operations.
INSTALLATION
IMPORTANT: Units have high ambient operating limits. If
limits are exceeded, the unit will automatically lock the com-
pressor out of operation. Manual reset will be required to
restart the compressor.
I. STEP 1 — PROVIDE UNIT SUPPORT
A. Roof Curb
Assemble and install accessory roof curb in accordance 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. Ductwork can be secured to roof
curb before unit is set in place. Horizontal adapter installa-
tion is shown in Fig. 2.
IMPORTANT: The gasketing of the unit to the roof curb is crit-
ical for watertight seal. Install gasket supplied with the roof
curb as shown in Fig. 1. Improperly 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 ±
1 /
16
in. per lin-
ear ft in any direction. Refer to Accessory Roof Curb Installa-
tion Instructions for additional 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, sup-
port 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 sling or cable damage.
Rollers may be used to move unit across a roof. Level by using
unit frame as a reference; leveling tolerance is ±
1 /
16
in. per
linear ft in any direction. See Fig. 1 for additional leveling tol-
erance 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 instructions 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 building structure. Use flexible duct con-
nectors between unit and ducts as required. Insulate and
weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applica-
ble codes.
Ducts passing through an unconditioned space must be insu-
lated and covered with a vapor barrier.
The 542J units with electric heat require a 1-in. clearance for
the first 24 in. of ductwork.
WARNING: Before performing service or mainte-
nance operations on unit, turn off main power switch to
unit. Electrical shock could cause personal injury.