Bryant DURAPAC PLUS SERIES 542J Installation, Start-Up And Service Instructions Manual Download Page 37 | Manualshive

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SERVICE TRAINING

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discussed in this manual, including:

• Unit Familiarization

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• 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

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Summary of Contents for DURAPAC PLUS SERIES 542J

Page 1: ...ter 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 di...

Page 2: ...hipped disassembled 2 Insulated panels 1 thick neoprene coated 1 1 2 lb density 3 Dimensions in are in millimeters 4 Direction of airflow 5 Roof curb 16 ga VA03 56 stl 6 A 90 degree elbow must be installed on the supply ductwork below the unit discharge for units equipped with electric heaters 7 To prevent the hazard of stagnant water build up in the drain pan of the indoor section unit can only b...

Page 3: ...cient 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 23 14 3 4 6 3 1 2 FULLY INSULATED SUPPLY PLENUM 1 INSULATION 1 1 2 DENSITY STICK PINNED GLUED 2 X 1 4 SUPPORT TYP STITCH WELDED 12 WIDE STANDING SEAM PANELS NOTE CRRFCURB013A00 is a fully factory preassembled horizontal adapter an...

Page 4: ... Orifice Rows 3 3 Fins in 15 15 Total Face Area sq ft 17 5 17 5 INDOOR FAN Centrifugal Adjustable Pitch Belt Drive Quantity Size in 2 10 x 10 2 12 x 12 Nominal Cfm 5000 6000 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 6 0 11 4 Belt Quantity Type Length in 1 BX 42 1 BX 46...

Page 5: ...ntrol 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 Al...

Page 6: ...ntrol 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 Al...

Page 7: ...to determine the percentage of voltage imbalance Percentage of Voltage Imbalance EXAMPLE Supply voltage is 460 3 60 AB 452 v BC 464 v AC 455 v 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 imbalance This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If...

Page 8: ...d 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 remove the handle and shaft from shipping location 2 Loosen the Allen bolt located on the disconnect switch The bolt is located on the square hole and is used to hold the shaft in place The shaft cannot be ins...

Page 9: ...8 8 70 70 100 100 69 69 406 406 39 45 14 19 119 126 125 150 69 69 72 82 26 34 159 173 175 175 100 112 117 135 42 56 216 205 225 225 152 173 460 414 508 19 9 114 3 0 8 3 7 4 8 32 50 31 189 18 15 54 60 31 39 32 81 90 50 66 55 98 110 82 2 3 6 0 34 50 34 195 18 15 57 70 34 39 32 83 90 53 66 55 100 110 84 180 208 230 187 253 28 2 160 28 2 160 3 1 7 5 15 8 15 8 84 84 110 110 89 89 499 485 72 82 26 34 17...

Page 10: ...anel 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 outdoor 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 s...

Page 11: ...l EconoMi erIV See Fig 20 and 21 for EconoMi erIV component locations NOTE These instructions are for installing the optional EconoMi erIV only Refer to the accessory EconoMi erIV or EconoMi er2 installation instructions when field installing an EconoMi erIV or EconoMi er2 accessory To complete installation of the optional EconoMi erIV per form the following procedure 1 Remove the EconoMi erIV hoo...

Page 12: ...f 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 Fig 20 EconoMi erIV Component Locations End View ECONOMI ERIV OUTDOOR AIR TEMPERATURE SENSOR INSTALLED OPERATION POSITION SCREWS SCREWS FRAME TOP LOW TEMPERATURE COMPRESSOR LOCKOUT SWITCH Fig 2...

Page 13: ...erIV will adjust the outdoor air dampers to mini mum position If the outdoor air temperature is below the set point the position of the outdoor air dampers will be con trolled to provide free cooling using outdoor air When in this mode the LED next to the free cooling set point potentiome ter will be on The changeover temperature set point is con trolled by the free cooling set point potentiometer...

Page 14: ... fully clockwise to the D setting NOTE Remove 620 ohm resistor if differential enthalpy sen sor 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 space or return air duct Mount the accessory IAQ sensor according to manufacturer specifications The IAQ sensor should be wired to the AQ and AQ1 te...

Page 15: ...16 60 16 65 18 65 18 70 21 70 21 75 24 75 24 80 27 80 27 85 29 90 32 95 35 100 38 APPROXIMATE DRY BULB TEMPERATURE F C A A B B C C D D R E L A T I V E H U M I D I T Y HIGH LIMIT CURVE TR1 24 Vac COM TR 24 Vac HOT 1 2 3 4 5 EF EF1 _ P1 T1 P T N EXH 2V 10V EXH Set Set 2V 10V 2V 10V DCV DCV Free Cool B C A D SO SR SR SO AQ1 AQ DCV Min Pos Open Max N1 Fig 27 EconoMi erIV Controller 0 1000 2000 3000 40...

Page 16: ...vement from full open to full closed or vice versa takes 21 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 Occup...

Page 17: ...ess Mode to exit and resume normal operation The custom settings of the CO2 sensor can be changed any time after the sensor is energized Follow the steps below to change the non standard settings 1 Press Clear and Mode buttons Hold at least 5 sec onds 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...

Page 18: ...er circuit one on the suction line and one on the dis charge line Be sure all valves are open V CRANKCASE HEATERS Heaters are energized as long as there is power to unit 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 ...

Page 19: ...138 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 1246 2423 2 76 5500 950 1675 1 91 1041 1918 2 19 1124 2165 2 47 1201 2409 2 75 1272 2655 3 02 5750 985 1901 2 17 1072 2147 2 4...

Page 20: ...0 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 3...

Page 21: ...ilure Unit warranty will not be affected ACCESSORY FIOP UNIT SIZE 542J UNIT VOLTAGE kW AIRFLOW Cfm 3750 4000 4500 5000 5600 6000 6250 7200 7500 Electric Heaters 150 208 230 3 60 14 34 42 56 0 05 0 06 0 05 0 06 0 06 0 07 0 07 0 08 0 08 0 10 0 09 0 12 0 09 0 13 460 3 60 15 32 55 0 05 0 06 0 05 0 06 0 06 0 07 0 07 0 08 0 08 0 10 0 09 0 12 0 09 0 13 180 208 230 3 60 26 34 42 56 0 08 0 10 0 09 0 12 0 0...

Page 22: ... opens and closes the power exhaust fan will be ener gized and deenergized If field installed accessory CO2 sensors are connected to the EconoMi erIV control a demand controlled ventilation strategy will begin to operate As the CO2 level in the zone increases above the CO2 set point the minimum position of the damper will be increased proportionally As the CO2 level decreases because of the increa...

Page 23: ...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 ...

Page 24: ...ws 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 chann...

Page 25: ...rigerant system is exposed to atmosphere X PROTECTIVE DEVICES A Compressor Protection Overcurrent Each compressor has one manual reset calibrated trip mag netic circuit breaker Do not bypass connections or increase the size of the circuit breaker to correct trouble Determine the cause of the trouble and correct it before resetting the breaker Overtemperature Each compressor has internal protector ...

Page 26: ...d with external and internal hinged access doors to facilitate service Four external hinged access doors are provided All external doors are provided with 2 large 1 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 ...

Page 27: ... 27 Fig 40 Typical Wiring Diagram 542J150 208 230 3 60 V Shown ...

Page 28: ... 28 Fig 41 Typical Component Arrangement 542J150 208 230 3 60 V Shown ...

Page 29: ...ode OAT Outdoor Air Temperature Sensor OCCUP Occupancy Sensor LEGEND NOTES 1 Compressor and or fan motor s thermally protected three phase motors protected against primary single phasing conditions 2 If any of the original wire furnished must be replaced it must be replaced with Type 90 C or its equivalent 3 TRAN1 is wired for 230 v operation If unit is 208 v disconnect the black wires from the OR...

Page 30: ...an contacts 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 SO and Connect 1 2 kilo ohm 4074EJM checkout resistor across terminals SO and 8 Put 620 ohm resistor across terminals SR and 9 Set minimum position DCV set point and exhau...

Page 31: ...ooting 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 potentiometer to previ ous setting 4 Set minimum position DCV set point and exhaust potentiometers to previous settings 5 Remove 620 ohm resistor from terminals SR and 6 Remove 1 2 kilo ohm checkout resistor from terminals SO a...

Page 32: ...ils CHECK VALVE COOLING A B C D E F Closed Open Closed Open Closed Open Fig 43 Heat Pump Heating Cycle Fig 42 Heat Pump Cooling Cycle LEGEND NOTE Circuitry shown is for single system 542J180 units have 2 individual and independent refrigeration systems that each operate in an identical manner Refrigerant Flow Direction Check Valve Flow Direction X Fixed Orifice See Table 15 for check valve operati...

Page 33: ... 33 Fig 44 Troubleshooting Chart Heating Cycle ODT Outdoor Temperature ...

Page 34: ... 34 Fig 45 Troubleshooting Chart Cooling Cycle ...

Page 35: ...n DCV or fully open supply air signal INPUTS OUTPUTS Demand Control Ventilation DCV Enthalpy Y1 Y2 Compressor N Terminal Outdoor Return Stage 1 Stage 2 Occupied Unoccupied Damper Below set DCV LED Off High Free Cooling LED Off Low On On On On Minimum position Closed On Off On Off Off Off Off Off Low Free Cooling LED On High On On On Off Modulating between min position and full open Modulating betw...

Page 36: ...ubrication 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 control 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 inlet screens Cleaning 23 Outdoor air temperature s...

Page 37: ...d 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 CATALO...

Page 38: ...Copyright 2006 Bryant Heating Cooling Systems Printed in U S A CATALOG NO 5354 203 ...

Page 39: ......

Page 40: ...NS AND TERMINALS ARE TIGHT CHECK THAT AIR INLET FILTERS ARE CLEAN AND IN PLACE VERIFY THAT UNIT IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND VERIFY SET SCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR AL LEAST 24 HOURS II START UP ELECTRICAL TEMPERATURES PRESSURES COOLING MODE VER...

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