Manual IOM 12 a 20 TR

InstallationOperationMaintenance

Packaged Electric/Electric

TC-IOM-718-AB60D24

April 2003

TC*150D***B*, TCD151C***B*, TCH151C***C*, TC*155B***H*,TC*175C***E*, TC*180B***H*, TC*181C***C*, TC*200B***J*,TC*210C***E*, TC*211C***C*, TC*240B***J*, TC*241C***C*,TC*300B***H*, TC*301C***C*

©American Standard Inc. 2003

Contents

General InformationLiterature Change History ................ 5Overview of Manual ......................... 5Hazard Identification ........................ 5Model Number Description .............. 6Unit Nameplate ................................ 6Compressor Nameplate ................... 6Unit Description ................................ 6Economizer Control Actuator ........... 6ReliaTel™ Control ............................ 6ReliaTel™ Trane Communication

Interface .................................... 7RLCI - ReliaTel™ LonTalk Communica-

tion Interface (Optional) ............ 7RTOM – ReliaTel™ Options Module

(Optional) .................................. 7System Input Devices & Functions .. 7Supply Fan Failure Input (Optional) . 7Clogged Filter Switch (Optional) ...... 7Compressor Disable (CPR1/2) ......... 7Low Pressure Control ....................... 8High Pressure Control (Optional) ..... 8Power Exhaust Control (Optional) .... 8Lead/Lag Control (Dual Circuit Only) 8(BAYSENS006B) .............................. 8(BAYSENS008B) .............................. 8(BAYSENS010B) .............................. 8BAYSENS019B ................................ 8(BAYSENS013B) .............................. 8(BAYSENS014B) .............................. 8(BAYSENS016A) .............................. 9(BAYSENS017B) .............................. 9BAYSENS025A Remote sensor for

BAYSTAT036A, 037A. ............... 9High Temperature Sensor

(BAYFRST001A) ....................... 9Evaporator Frost Control .................. 9Smoke Detector Sensor (Optional) .. 9Unit Inspection ............................... 10Precautionary Measures ................ 10Storage........................................... 10

Unit DimensionsInstallation Clearances ................... 11Unit/Curb Dimensions .................... 12Unit/Curb Dimensions .................... 13Horizontal Duct Dimensions ........... 14

Unit Weight / RiggingRigging and Center-of-Gravity Data15

InstallationFoundation ..................................... 16Ductwork ........................................ 16General Unit Requirements ............ 17Factory Installed Economizer ......... 17Electric Heat Requirements ........... 17Condensate Drain Configuration .... 17Condensate Trap Installation .......... 17Filter Installation ............................. 17Main Unit Power ............................. 18Standard Wiring ............................. 18Optional TBUE Wiring .................... 19Field Installed Control Wiring ......... 19Control Power Transformer ............. 19Controls using 24 VAC ................... 1924V AC Conductors with Reliatel ... 19Controls using DC Analog Input/Outputs ................................ 20DC Conductors .............................. 20Reliatel Conventional ThermostatField Wiring Diagrams .................... 20Reliatel Refrigeration Module ......... 20Smoke Detector ............................. 21Customer Low Voltage Wiring- ....... 21Space Temperature Averaging ....... 23Temperature vs. Resistance ........... 23Voltage Imbalance .......................... 24Electrical Phasing .......................... 24Crankcase Heaters (Optional) ........ 25

Pre - StartTest Modes ..................................... 26Verifying Proper Air Flow ................ 27

Start UpEconomizer Start-Up ...................... 28Compressor Start-Up ..................... 28Scroll Compressors ........................ 28Heating Start-Up ............................ 29

Final System Set UpFinal System Setup ........................ 30

MaintenanceFan Belt Adjustment ....................... 31Filters ............................................. 32Return Air Smoke DetectorMaintenance .................................. 32Cooling Season .............................. 32

Heating Season ............................. 32Final Process ................................. 33Sample Maintenance Log .............. 34

Trouble ShootingReliaTel Control .............................. 35System StatusCheckout Procedure ...................... 35System Failure ............................... 36Cooling Failure ............................... 36Service Failure ............................... 36Simultaneous Heat and CoolFailure ............................................ 36Cool Failure .................................... 36Resetting Cooling and HeatingLockouts ......................................... 36(ZTS) Service Indicator .................. 37Fan Failure Switch .......................... 37(ZTS) Test ....................................... 37(ZTEMP) ........................................ 37Cooling Set Point (CSP)and Heating Set Point (HSP) ......... 37Testingserial communication voltage ......... 38ReliaTel Refrigeration Module(RTRM) Default Chart .................... 38Unit Economizer Control(ECA) Troubleshooting ................... 38ReliaTel Control .............................. 38

3

Model Number Description

Digit 8 - Electrical Characteristics

3 = 208-230/60/34 = 460/60/3D = 400/50/3T = 380/60/3W = 575/60/3

Packaged Cooling with Electric Heat Unit Typical Model Nomenclature

Digits 1, 2 - Product Type

TC = Packaged Cooling, ElectricHeatTF = With Factory InstalledOptions

Digits 4, 5, 6 - Nominal Gross CoolingCapacity (MBh)

150 = 12½ Tons Standard Efficiency151 = 12½ Tons High Efficiency180 = 15 Tons Standard Efficiency181 = 15 Tons High Efficiency210 = 17½ Tons Standard Efficiency211 = 17½ Tons High Efficiency240 = 20 Tons Standard Efficiency241 = 20 Tons High Efficiency300 = 25 Tons Standard Efficiency301 = 25 Tons High Efficiency

Digit 7- Major Development Sequence

Digit 11- Minor Design Sequence

T C D 1 5 0 C 3 0 0 A A

1 2 3 4 5 6 7 8 9 10 11 12

Digit 3 - Airflow Configuration

D = DownflowH = Horizontal Digit 9, 10 - Factory-Installed Options

00 = No Factory-installed Options0A = Factory-installed Economizer0B = Oversized Motor0C = Downflow Economizer / Oversized Motor0F = Trane Communications Interface(TCI)0G = Downflow Economizer / TCI0H = Thermal Expansion Valve0L = Factory-installed Economizer / Thermal Expansion Valve0J = Oversized Motor / Thermal Expansion Valve0K = Downflow Economizer / Oversized Motor / Thermal Expansion Valve

Digit 12- Service Digit

4

General Information

Literature Change History

TC-IOM-7 (April 2003)Reliatel Control System implemented

Overview of Manual

Note: One copy of this documentships inside the control panel of eachunit and is customer property. It mustbe retained by the unit’s maintenancepersonnel.

This booklet describes proper installa-tion, operation, and maintenance proce-dures for air cooled systems. By care-fully reviewing the information within thismanual and following the instructions,the risk of improper operation and/orcomponent damage will be minimized.

It is important that periodic maintenancebe performed to help assure trouble freeoperation. A maintenance schedule isprovided at the end of this manual.Should equipment failure occur, contacta qualified service organization withqualified, experienced HVAC techniciansto properly diagnose and repair thisequipment.

Hazard IdentificationWarnings and Cautions appear atappropriate sections throughout this

manual. Read these carefully.

WARNING – Indicates apotentially hazardous situationwhich, if not avoided, could result indeath or serious injury.

CAUTION – Indicates apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury. It may alsobe used to alert against unsafepractices.

CAUTION – Indicates a situationthat may result in equipment orproperty-damage-only accidents.

Model Number Description

All products are identified by a multiple-character model number that preciselyidentifies a particular type of unit. Anexplanation of the alphanumeric identifi-cation code is provided below. Its usewill enable the owner/operator, install-ing contractors, and service engineersto define the operation, specific compo-nents, and other options for any specificunit.

5

General Information

Direct-drive, vertical discharge con-denser fans are provided with built-inthermal overload protection.

The ReliaTel™ Control Module is a mi-croelectronic control system that is re-ferred to as “Refrigeration Module”(RTRM). The acronym RTRM is usedextensively throughout this documentwhen referring to the control systemnetwork.

This module through Proportional/Inte-gral control algorithms perform specificunit functions that governs unit opera-tion in response to; zone temperature,supply air temperature, and/or humidityconditions depending on the applica-tion. The stages of capacity control forthese units are achieved by starting andstopping the compressors.

The RTRM is mounted in the controlpanel and is factory wired to the re-spective internal components. TheRTRM receives and interprets informa-tion from other unit modules, sensors,remote panels, and customer binarycontacts to satisfy the applicable re-quest for cooling.

Economizer Control ActuatorReliaTel™ ControlThe ECA monitors the mixed air tem-perature, return air temperature, mini-mum position setpoint (local or remote),power exhaust setpoint, CO2 setpoint,CO2, and ambient dry bulb/enthalpysensor or comparative humidity (returnair humidity against ambient humidity)sensors, if selected, to control dampersto an accuracy of +/- 5% of stroke. Theactuator is spring returned to the closedposition any time that power is lost tothe unit. It is capable of delivering up to25 inch pounds of torque and is pow-ered by 24 VAC.

When ordering replacement parts or re-questing service, be sure to refer to thespecific model number and serial num-ber printed on the unit nameplate.

WARNINGContains Refrigerant!

System contains oil and refrigerantunder high pressure. Recoverrefrigerant to relieve pressure beforeopening the system. See unit name-plate for refrigerant type. Do not usenon-approved refrigerants, refriger-ant substitutes, or refrigerant addi-tives.Failure to follow proper proceduresor the use of non-approved refriger-ants, refrigerant substitutes, or re-frigerant additives could result indeath or serious injury or equipmentdamage.

Unit Nameplate

A Mylar unit nameplate is located onthe unit’s corner support next to thecontrol box. It includes the unit modelnumber, serial number, electrical char-acteristics, refrigerant charge, as wellas other pertinent unit data.

Compressor Nameplate

The nameplate for the compressors arelocated on the side of the compressor.

Unit Description

Before shipment, each unit is leaktested, dehydrated, charged with refrig-erant and compressor oil, and runtested for proper control operation.

The condenser coils are aluminum fin,mechanically bonded to copper tubing.

6

General Information

RTCI -- ReliaTel™ TraneCommunication Interface(Optional)This module is used when the applica-tion calls for an ICSTM building manage-ment type control system. It allows thecontrol and monitoring of the systemthrough an ICS panel. The module canbe ordered from the factory or orderedas a kit to be field installed. Follow theinstallation instruction that ships witheach kit when field installation is neces-sary.

RLCI - ReliaTel™ LonTalkCommunication Interface(Optional)This module is used when the applica-tion calls for an ICSTM building manage-ment type control system that isLonTalk. It allows the control and moni-toring of the system through an ICSpanel. The module can be ordered fromthe factory or ordered as a kit to be fieldinstalled. Follow the installation instruc-tion that ships with each kit when fieldinstallation is necessary.

RTOM – ReliaTel™ OptionsModule (Optional)The RTOM monitors the supply fanproving, clogged filter, supply air tem-perature, exhaust fan setpoint, supplyair tempering, Frostat™ and smoke de-tector. Refer to system input devicesand functions for operation.

Clogged Filter Switch (Optional)The unit mounted clogged filter switchmonitors the pressure differentialacross the return air filters. It ismounted in the filter section and is con-nected to the RTOM. A diagnostic SER-VICE signal is sent to the remote panelif the pressure differential across the fil-ters is at least 0.5" w.c. The contactswill automatically open when the pres-sure differential across the filters de-creases to approximately 0.4" w.c. Theclogged filter output is energized whenthe supply fan is operating and theclogged filter switch has been closedfor at least 2 minutes. The system willcontinue to operate regardless of thestatus of the filter switch.

Compressor Disable (CPR1/2)This input incorporates the low pres-sure control (LPC) of each refrigerationcircuit and can be activated by openinga field supplied contact installed on theLTB.

If this circuit is open before the com-pressor is started, the compressor willnot be allowed to operate. Anytime thiscircuit is opened for 1 continuous sec-ond during compressor operation, thecompressor for that circuit is immedi-ately turned “Off”. The compressor willnot be allowed to restart for a minimumof 3 minutes should the contacts close.

If four consecutive open conditions oc-cur during the first three minutes of op-eration, the compressor for that circuitwill be locked out, a diagnostic commu-nicated to the remote panel (if in-stalled), and a manual reset will be re-quired to restart the compressor.

System Input Devices &Functions

The RTRM must have a zone sensor orthermostat input in order to operate theunit. The flexibility of having severalmode capabilities depends upon thetype of zone sensor or thermostat se-lected to interface with the RTRM.

The descriptions of the following basicInput Devices used within the RTRMnetwork are to acquaint the operatorwith their function as they interface withthe various modules. Refer to the unit’selectrical schematic for the specificmodule connections.

The following controls are availablefrom the factory for field installation.

Supply Fan Failure Input (Optional)The Fan Failure Switch can be con-nected to sense indoor fan operation:

FFS (Fan Failure Switch) If air flowthrough the unit is not proven by the dif-ferential pressure switch connected tothe RTOM (factory set point 0.07 “ w.c.)within 40 seconds nominally, the RTRMwill shut off all mechanical operations,lock the system out, send a diagnosticto ICS, and the SERVICE output willflash. The system will remain locked outuntil a reset is initiated either manuallyor through ICS.

7

General Information

Low Pressure Control

ReliaTel ControlWhen the LPC is opened for 1 continu-ous second, the compressor for that cir-cuit is turned off immediately. The com-pressor will not be allowed to restart fora minimum of 3 minutes.

If four consecutive open conditions oc-cur during the first three minutes of op-eration, the compressor will be lockedout, a diagnostic communicated toICSTM if applicable, and a manual resetwill be required to restart the compres-sor.

High Pressure Control (Optional)ReliaTel ControlThe high pressure controls are wired inseries between the compressor outputson the RTRM and the compressorcontactor coils. If the high pressurecontrol switch opens, the RTRM sensesa lack of current while calling for coolingand locks the compressor out.

On dual circuit units, if the high pres-sure control opens, the compressor onthe affected circuit is locked out. Amanual reset for the affected circuit isrequired.

Power Exhaust Control (Optional)The power exhaust fan is started when-ever the position of the economizerdampers meets or exceed the powerexhaust setpoint when the indoor fan ison.

The setpoint panel is located in the re-turn air section and is factory set at25%.

Lead/Lag Control (Dual Circuit Only)Lead/Lag is a selectable input locatedon the RTRM. The RTRM is configuredfrom the factory with the Lead/Lagcontrol disabled. To activate the Lead/Lag function, simply cut the wireconnected to J3-8 at the RTRM. When itis activated, each time the designatedlead compressor is shut off due to theload being satisfied, the lead compres-sor or refrigeration circuit switches.When the RTRM is powered up, i.e.after a power failure, the control willdefault to the number one circuitcompressor.

Zone Sensor Module (ZSM)(BAYSENS006B)This electronic sensor features threesystem switch settings (Heat, Cool,and Off) and two fan settings (On andAuto). It is a manual changeover controlwith single setpoint. (Cooling SetpointOnly)

Zone Sensor Module (ZSM)(BAYSENS008B)This electronic sensor features foursystem switch settings (Heat, Cool,Auto, and Off) and two fan settings (Onand Auto). It is a manual or autochangeover control with dual setpointcapability. It can be used with a remotezone temperature sensorBAYSENS017B.

Zone Sensor (BAYSENS010B)This electronic sensor features foursystem switch settings (Heat, Cool,Auto, and Off) and two fan settings (Onand Auto) with four system statusLED’s. It is a manual or autochangeover control with dual setpointcapability. It can be used with a remotezone temperature sensorBAYSENS017B.

Programmable Zone Sensor -BAYSENS019BThis 7 day programmable sensor fea-tures 2, 3 or 4 periods for Occupied orUnoccupied programming per day. If thepower is interrupted, the program is re-tained in permanent memory. If poweris off for an extended period of time,only the clock and day may have to bereset.

The Zone Sensor allows selection of 2,3 or 4 system modes (Heat, Cool, Auto,and Off), two fan modes (On and Auto).It has dual temperature selection withprogrammable start time capability.

The occupied cooling set point rangesbetween 45 and 98 degrees Fahrenheit.The heating set point ranges between43 and 96 degrees Fahrenheit.

A liquid crystal display (LCD) displayszone temperature, temperature setpoints, day of the week, time, and op-erational mode symbols.

The Option Menu is used to enable ordisable applicable functions, i.e.; Morn-ing Warm-up, Economizer minimum po-sition override during unoccupied sta-tus, Fahrenheit or Centigrade, Supplyair tempering, Remote zone tempera-ture sensor, 12/24 hour time display,Smart fan, and Computed recovery.

Remote Zone Sensor(BAYSENS013B)This electronic sensor features remotezone sensing and timed override withoverride cancellation. It is used with aTrane Integrated ComfortTM

buildingmanagement system.

Remote Zone Sensor(BAYSENS014B)This electronic sensor features singlesetpoint capability and timed overridewith override cancellation. It is usedwith a Trane Integrated ComfortTM build-ing management system.

8

Remote Zone Sensor(BAYSENS016A)This bullet type temperature sensor canbe used for; outside air (ambient) sens-ing, return air temperature sensing,supply air temperature sensing, remotetemperature sensing (uncovered. Wiringprocedures vary according to the par-ticular application and equipment in-volved. Refer to the unit’s wiring dia-grams for proper connections.

Remote Zone Sensor(BAYSENS017B)This electronic sensor can be used withBAYSENS006B, 008B, 010B, 019B Re-mote Panels. When this sensor is wiredto a BAYSENS019B Remote Panel, wir-ing must be 18 AWG Shielded TwistedPair (Belden 8760 or equivalent). Referto the specific Remote Panel for wiringdetails.

BAYSTAT036ASingle Stage - 1 Heat/1 Cool

BAYSTAT037AMulti Stage - 2 Heat/2 Cool - Can beUsed for Economizer Operation

BAYSENS025A Remote sensor forBAYSTAT036A, 037A.

High Temperature Sensor(BAYFRST001A)This sensor connects to the RTRMEmergency Stop Input on the LTB andprovides high limit “shutdown” of theunit. The sensor is used to detect hightemperatures due to fire in the air con-ditioning or ventilation ducts. The sen-sor is designed to mount directly to thesheet metal duct. Each kit contains twosensors. The return air duct sensor(X1310004001) is set to open at 135°F.The supply air duct sensor(X1310004002) is set to open at 240°F.The control can be reset after the tem-perature has been lowered approxi-mately 25°F below the cutout setpoint.

Evaporator Frost ControlThis input incorporates the Frostat™control (FOS) mounted in the indoorcoil and can be activated by closing afield supplied contact installed in paral-lel with the FOS.

If this circuit is open before the com-pressor is started, the compressor willnot be allowed to operate. Anytime thiscircuit is opened for 5 continuous sec-onds during compressor operation, thecompressor for that circuit is immedi-ately turned “Off”. The compressor willnot be allowed to restart for a minimumof 3 minutes should the FOS close.

Smoke Detector Sensor (Optional)This sensor is only applicable on unitsequipped with a RTOM. It provides highlimit “shutdown” of the unit and requiresa manual reset. The sensor is used todetect smoke due to fire in the air con-ditioning or ventilation ducts.

Important: The supply and return airsmoke detectors are designed toshut off the unit if smoke is sensed inthe supply air stream or return airstream. This function is performed bysampling the airflow entering the unitat the return air opening. Follow theinstructions provided below toassure that the airflow through theunit is sufficient for adequatesampling. Failure to follow theseinstructions will prevent the smokedetectors from performing it's designfunction.

Important: Airflow through the unit isaffected by the amount of dirt anddebris accumulated on the indoorcoil and filters. To insure that airflowthrough the unit is adequate forproper sampling by the return airsmoke detector, complete adherenceto the maintenance procedures,including recommended intervalsbetween filter changes, and coilcleaning is required.

Important: Periodic checks andmaintenance procedures must beperformed on the smoke detector toinsure that it will function properly.For detailed instructions concerningthese checks and procedures, refer tothe appropriate section(s) of thesmoke detector Installation andMaintenance Instructions providedwith the literature package for thisunit.

In order for the supply air smoke detec-tor or return air smoke detector to prop-erly sense smoke in the supply airstream or return air stream, the air ve-locity entering the smoke detector unitmust be between 500 and 4000 feet perminute. Equipment covered in thismanual will develop an airflow velocitythat falls within these limits over the en-tire airflow range specified in the evapo-rator fan performance tables.

There are certain models, however, ifoperated at low airflow, will not developan airflow velocity that falls within therequired 500 to 4000 feet per minuterange. For these models, the design air-flow shall be greater than or equalto theminimum CFM specifedin the table pro-vided below. Failure to follow these in-structions will prevent the smoke detec-tor from performing it’s design function.

Unit Model Minimum Allowable Airflow Number with

Return Air Smoke Detector

TCD181 5300 CFM

General Information

9

Unit Inspection

As soon as the unit arrives at the jobsite:

[ ] Verify that the nameplate datamatches the data on the sales orderand bill of lading (including electricaldata).

[ ] Verify that the power supply complieswith the unit nameplate specifica-tions.

[ ] Visually inspect the exterior of theunit, including the roof, for signs ofshipping damage.

[ ] Visually inspect the internal compo-nents for shipping damage as soonas possible after delivery and beforeit is stored. Do not walk on the sheetmetal base pans.

[ ] If concealed damage is discovered,notify the carrier’s terminal of dam-age immediately by phone and bymail. Concealed damage must be re-ported within 15 days.

Request an immediate joint inspec-tion of the damage by the carrier andthe consignee. Do not remove dam-aged material from the receiving lo-cation. Take photos of the damage, ifpossible. The owner must providereasonable evidence that the dam-age did not occur after delivery.

[ ] Notify the appropriate sales repre-sentative before installing or repair-ing a damaged unit.

WARNINGFiberglass WoolProduct contains fiberglass wool.Disturbing the insulation in thisproduct during installation, mainte-nance or repair will expose you toairborne particles of glass wool fi-bers and ceramic fibers known to thestate of California to cause cancerthrough inhalation. Glass wool fibersmay also cause respiratory, skin oreye irritation.

Precautionary Measures

· Avoid breathing fiberglass dust.

· Use a NIOSH approved dust/mistrespirator.

· Avoid contact with the skin oreyes. Wear long-sleeved, loose-fit-ting clothing, gloves, and eye pro-tection.

· Wash clothes separately fromother clothing: rinse washer thor-oughly.

· Operations such as sawing, blow-ing, tear-out, and spray-ing may generate fiber concentra-tions requiring additionalrespiratory protection. Usethe appropriate NIOSH approvedrespiration in these situa-tions.

First Aid Measures

Eye Contact - Flush eyes with water toremove dust. If symptoms persist,seek medical attention.

Skin Contact - Wash affected areasgently with soap and warm waterafter handling.

Storage

Take precautions to prevent condensatefrom forming inside the unit’s electricalcompartments and motors if:

a. the unit is stored before it is installed;or,

b. the unit is set on the roof curb, andtemporary heat is provided in thebuilding. Isolate all side panel ser-vice entrances and base pan open-ings (e.g., conduit holes, S/A and R/A openings, and flue openings) fromthe ambient air until the unit is readyfor start-up.

Note: Do not use the unit’s heater fortemporary heat without firstcompleting the start-up proceduredetailed under “Starting the Unit”.

The manufacturer will not assume anyresponsibility for equipment damage re-sulting from condensate accumulationon the unit’s electrical and/or mechani-cal components.

Unit ClearancesFigure 1 illustrates the minimum operat-ing and service clearances for either asingle or multiple unit installation. Theseclearances are the minimum distancesnecessary to assure adequate service-ability, cataloged unit capacity, andpeak operating efficiency.

Providing less than the recommendedclearances may result in condenser coilstarvation, “short-circuiting” of exhaustand economizer airflows, or recircula-tion of hot condenser air.

General Information

10

Unit Dimensions

Figure 1Typical Installation Clearances for Single & Multiple Unit Applications

11

Unit / Curb Dimensions

Figure 2Unit Dimensional Data12 1/2 Ton, 15 Ton, 171/2 Ton

Roof Curb Dimensional Data12 1/2 Ton, 15 Ton, 171/2 Ton

12

Figure 3Unit Dimensional Data20 Ton, 25 Ton

Roofcurb Dimensional Data20 Ton, 25 Ton

Unit / Curb Dimensions

13

Horizontal Duct Dimensions

Figure 4Horizontal Duct Dimensional Data12 1/2 Ton, 15 Ton, 17 1/2 Ton

Figure 5Horizontal Duct Dimensional Data20 Ton, 25 Ton

14

Unit Weight / Rigging

Table 1Typical Unit Weights & Point Loading Data

Unit Net Corner Wts. (lbs)Models Weight A B C D

TC*150D 1319 446 339 230 303TC*151C 1408 474 349 248 337TC*155B 1371 482 350 227 312TC*180B 1498 547 358 234 359TC*181C 1838 627 461 317 431TC*175C 1452 500 378 247 327TC*210C 1654 565 425 285 378TC*211C 1921 643 495 341 442TC*200B 1850 654 487 303 406TC*240B 1913 679 482 312 440TC*241C 2011 692 523 343 453TC*250B 1906 661 507 320 418TC*300B 1906 661 507 320 418TC*301C 2016 695 524 343 454* Downflow or HorizontalNote: Corner weights are given for information only.Unit is to be supported continuously by a curb or equivalent frame support.

Figure 6Rigging and Center-of-Gravity Data

WARNINGHeavy Objects!

Do not use cables (chains or slings) except as shown.Each of the cables (chains or slings) used to lift the unitmust be capable of supporting the entire weight of theunit. Lifting cables (chains or slings) may not be of thesame length. Adjust as necessary for even unit lift. Otherlifting arrangements may cause equipment or property-only damage. Failure to properly lift unit may result indeath or serious injury. See details below.

WARNINGImproper Unit Lift!

Test lift unit approximately 24 inches to verify propercenter of gravity lift point. To avoid dropping of unit, re-position lifting point if unit is not level. Failure to prop-erly lift unit could result in death or serious injury or pos-sible equipment or property-only damage.

RiggingRefer to Figure 6 and Table 1 for typical unit operating weightsriffing before proceeding.

1. Remove the shipping crate from around the unit. Do not re-move the crating from the top of the unit.

2. Rig the unit as shown in Figure 6. Attach adequatestrength lifting slings to all four lifting brackets in the unitbase rail. Do not use cables, chains, or slings except asshown.

3. Install a lifting bar, as shown in Figure 6, to protect the unitand to facilitate a uniform lift. The minimum distance be-tween the lifting hook and the top of the unit should be 7feet.

4. Test-lift the unit to ensure it is properly rigged and bal-anced, make any necessary rigging adjustments.

5. Lift the unit and position it into place.

6. Downflow units; align the base rail of the unit with the curbrail while lowering the unit onto the curb. Make sure thatthe gasket on the curb is not damaged while positioningthe unit.

15

Installation

Foundation

Horizontal UnitsIf the unit is installed at ground level, el-evate it above the snow line. Provideconcrete footings at each support loca-tion with a “full perimeter” support struc-ture or a slab foundation for support.Refer to Table 1 for the unit’s operatingand point loading weights when con-structing a footing foundation.

If anchoring is required, anchor the unitto the slab using hold down bolts or iso-lators. Isolators should be installed tominimize the transmission of vibrationsinto the building.

For rooftop applications, ensure theroof is strong enough to support thecombined unit and support structuralweight. Refer to Table 1 for the unit op-erating weights. If anchoring is re-quired, anchor the unit to the roof withhold-down bolts or isolators.

Check with a roofing contractor forproper waterproofing procedures.

Ductwork

Elbows with turning vanes or splittersare recommended to minimize air noisedue to turbulence and to reduce staticpressure.

When attaching the ductwork to theunit, provide a water- tight flexible con-nector at the unit to prevent operatingsounds from transmitting through theductwork.

All outdoor ductwork between the unitand the structure should be weatherproofed after installation is completed.

Note: For sound consideration, cutonly the holes in the roof deck for theductwork penetrations. Do not cutout the entire roof deck within thecurb perimeter.

If a Curb Accessory Kit is not used:

a. The ductwork can be attacheddirectly to the factory-providedflanges around the unit’s supplyand return air openings. Be sureto use flexible duct connectionsat the unit.

b. For “built-up” curbs supplied byothers, gaskets must be installedaround the curb perimeter flangeand the supply and return airopening flanges.

16

Installation

General Unit Requirements

The checklist listed below is a summaryof the steps required to successfully in-stall a commercial unit. This checklist isintended to acquaint the installing per-sonnel with what is required in the in-stallation process. It does not replacethe detailed instructions called out inthe applicable sections of this manual.

[ ] Check the unit for shipping damageand material shortage; file a freightclaim and notify appropriate salesrepresentative.

[ ] Verify correct model, options andvoltage from nameplate.

[ ] Verify that the installation location ofthe unit will provide the requiredclearance for proper operation.

[ ] Assemble and install the roof curb (ifapplicable). Refer to the latest editionof the curb installers guide that shipswith each curb kit.

[ ] Fabricate and install ductwork; se-cure ductwork to curb.

[ ] Rigging the unit.

[ ] Set the unit onto the curb; check forlevelness.

[ ] Ensure unit-to-curb seal is tight andwithout buckles or cracks.

[ ] Install and connect a condensatedrain line to the evaporator drainconnection.

Factory Installed Economizer

[ ] Ensure the economizer has beenpulled out into the operating position.Refer to the economizer installersguide for proper position and setup.

[ ] Install all access panels.

Main Electrical Power Requirements

[ ] Verify that the power supply complieswith the unit nameplate specifica-tions.

[ ] Inspect all control panel components;tighten any loose connections.

[ ] Connect properly sized and pro-tected power supply wiring to a field-supplied/installed disconnect switchand to the main power terminal block(HTB1) in the unit control panel.

[ ] Install proper grounding wires to anearth ground.

Note: All field-installed wiring mustcomply with NEC and applicable localcodes.

Electric Heat Requirements

[ ] Verify that the power supply complieswith the electric heater specificationson the unit and heater nameplate.

[ ] Inspect the heater junction box andcontrol panel; tighten any loose con-nections.

[ ] Check electric heat circuits for conti-nuity.

Low Voltage Wiring (AC & DC) Require-ments

[ ] Install the zone thermostat, with orwithout switching subbase.

[ ] Connect properly sized control wiringto the proper termination points be-tween the zone thermostat and theunit control panel.

Condensate Drain Configuration

An evaporator condensate drain con-nection is provided on each unit. Referto Figures 2, 3, 4 or 5 for the appropri-ate drain location.

A condensate trap must be installed atthe unit due to the drain connection be-ing on the “negative pressure” side ofthe fan. Install the P-Trap using theguidelines in Figure 7.

A condensate drain line must be con-nected to the P-Trap. Pitch the drainlines at least 1/2 inch for every 10 feetof horizontal run to assure proper con-densate flow. Do not allow the horizon-tal run to sag causing a possibledouble-trap condition which could resultin condensate backup due to “air lock”.

Figure 7Condensate Trap Installation

Filter Installation

Each unit ships with 2 inch filters in-stalled. The quantity of filters is deter-mined by unit size. Access to the filtersis obtained by removing the indoor fanaccess panel.

Refer to the unit Service Facts(shipped with each unit) for filter re-quirements.

Note: Do not operate the unit withoutfilters.

17

Installation

Field Installed Power WiringAn overall dimensional layout for thestandard field installed wiring entranceinto the unit is illustrated in Figures2,and 3. To insure that the unit’s supplypower wiring is properly sized and in-stalled, follow the guidelines outlinedbelow.

Note: All field installed wiring mustconform to NEC guidelines as well asState and Local codes.

Verify that the power supply available iscompatible with the unit’s nameplateratings. The available supply powermust be within 10% of the rated voltagestamped on the nameplate. Use onlycopper conductors to connect thepower supply to the unit.

CAUTIONUse Copper ConductorsOnly!

Unit terminals are not designed toaccept other types of conductors.Failure to use copper conductorsmay result in equipment damage.

Failure to do so may cause damage tothe equipment.

Note: If the unit is not equipped withan optional factory installednonfused disconnect switch or circuitbreaker, a field supplied disconnectswitch must be installed at or nearthe unit in accordance with theNational Electrical Code (NEC latestedition).

Main Unit PowerStandard Wiring

The electrical service must be protectedfrom over current and short circuit condi-tions in accordance with NEC require-ments. Protection devices must be sizedaccording to the electrical data on thenameplate.

1. If the unit is not equipped with an op-tional factory installed nonfused dis-connect switch or circuit breaker, afield supplied disconnect switch mustbe installed at or near the unit in ac-cordance with the National ElectricalCode (NEC latest edition).

2. Location of the applicable electricalservice entrance is illustrated in Fig-ures 2 or 3. Complete the unit’spower wiring connections onto ei-ther; the main terminal block HTB1inside the unit control panel, the fac-tory mounted nonfused disconnectswitch (UCD) or circuit breaker(UCB), or the electric heat terminalblock. Refer to the customer connec-tion diagram that shipped with theunit for specific termination points.

3. Provide proper grounding for the unitin accordance with local and nationalcodes.

18

Installation

Main Unit PowerOptional TBUE Wiring(Through the Base Electrical Option)

1. Location of the applicable electrical service is illustratedbelow. Refer to the customer connection diagram that isshipped with the unit for specific termination points. Thetermination points, depending on the customer option se-lected would be a factory mounted nonfused disconnectswitch (UDC) or circuit breaker (UCB).

2. Provide proper grounding for the unit in accordance with lo-cal and national codes.

Field Installed Control Wiring

An overall layout of the various control options available withthe required number of conductors for each control device isillustrated in Figure 8.

Note: All field wiring must conform to NEC guidelines aswell as state and local codes.

Control Power Transformer

The 24 volt control power transformers are to be used onlywith the accessories called out in this manual. Transformersrated greater than 50 VA are equipped with internal circuitbreakers. If a circuit breaker trips, turn “Off” all power to theunit before attempting to reset it.

WARNINGHazardous Voltage!

Disconnect all electric power, including remote discon-nects before servicing. Follow proper lockout/tagout pro-cedures to ensure the power can not be inadvertently en-ergized. Failure to disconnect power before servicingcould result in death or serious injury.

Failure to disconnect power before servicing can cause se-vere personal injury or death.

The transformer is located in the control panel. The circuitbreaker is located on the left side of the transformer and canbe reset by pressing in on the black reset button.

Controls using 24 VAC

Before installing any connecting wiring, refer to Figure 2 or 3for the electrical access locations provided on the unit andTable 2 for AC conductor sizing guidelines, and;

a. Use copper conductors unless otherwise specified.

b. Ensure that the AC control wiring between the controls andthe unit’s termination point does not exceed three (3)ohms/conductor for the length of the run.

Note: Resistance in excess of 3 ohms per conductor maycause component failure due to insufficient AC voltagesupply.

c. Be sure to check all loads and conductors for grounds,shorts, and mis-wiring.

d. Do not run the AC low voltage wiring in the same conduitwith the high voltage power wiring.

e. Route low voltage wiring per illustrations on page 19.

Table 2 - Electromechanical Thermostat24V AC Conductors with Reliatel

Distance from Unit Recommendedto Control Wire Size

000 - 460 feet 18 gauge

000 - 140 m .75 mm2

461 - 732 feet 16 gauge

19

Installation

Controls using DC Analog Input/Outputs(Standard Low Voltage Multiconductor Wire)

Before installing any connecting wiring between the unit andcomponents utilizing a DC analog input\output signal, refer toFigure 2 or 3 for the electrical access locations provided onthe unit.

a. Table 3 lists the conductor sizing guidelines that must befollowed when interconnecting the DC binary output de-vices and the system components utilizing a DC analoginput\output signal to the unit.

Note: Resistance in excess of 2.5 ohms per conductor cancause deviations in the accuracy of the controls.

b. Ensure that the wiring between controls and the unit’s ter-mination point does not exceed two and a half (2.5) ohms/conductor for the length of the run.

c. Do not run the electrical wires transporting DC signals in oraround conduit housing high voltage wires.

DC ConductorsTable 3 Sensor Module wiring

Distance from RecommendedUnit to Control Wire Size

0 - 150 feet 22 gauge0 - 45.7 m .33 mm2

151 - 240 feet 20 gauge46 - 73.1 m .50 mm2

241 -385 feet 18 gauge

Reliatel Conventional Thermostat Field WiringDiagrams

20

Installation

Smoke DetectorCustomer Low Voltage Wiring-

When interlocking System Sensorsmoke detectors together, all of the de-tectors must be powered from the samepower supply. If multiple smoke detec-tors are required, all detectors must bedisconnected from the HVAC unit powersupply and connected together from an-other single source supply.

Note: Do not interconnect smokedetectors together that have separatepower supplies. Do not exceed tensmoke detectors on one powersupply.

Note: Multiple System Sensor smokedetectors are connected togetherusing terminals 1 and 12 on eachdetector.

If you have supply and return smokedetectors in all HVAC units, you canconnect a maximum of 5 HVAC units(10 detectors) up to one power supply.See the following field wiring examplebelow.

If you have more than 5 HVAC units,you can connect all the supplies to-gether on one power supply (up to 10HVAC units), and all the returns to-gether (up to 10 HVAC units) on an-other power supply. See the followingfield wiring example below.

21

Installation

Figure 8Typical Field Wiring Diagrams for Optional Controls (ReliaTel™ only)

22

Installation

Space Temperature Averaging

Space temperature averaging is accomplished by wiring a number of remote sensors in a series/parallel circuit.

Using the BAYSENS016* or BAYSENS017*, at least four sensors are required to accomplish space temperature averag-ing. Example #1 illustrates two series circuits with two sensors in each circiut wired in parallel. The square of any numberof remote sensors required. Example #2 illustrates three sensors squared in a series/parallel circuit. Using BAYSENS032*,two sensors are required to accomplish space temperature averaging. Example #3 illustrates the circuit required for thissenor. Table 4 lists the temperature versus resistance coefficient for all sensing.

Table 4Temperature vs. Resistance

Degrees F°

Degrees C°

Nominal Resistance

-20° -28.9° 170.1 K - Ohms-15° -26.1° 143.5 K - Ohms-10° -23.3° 121.4 K - Ohms -5° -20.6° 103.0 K - Ohms 0° -17.8° 87.56 K - Ohms 5° -15.0° 74.65 K - Ohms

10° -12.2° 63.80 K - Ohms 15° -9.4° 54.66 K - Ohms20° -6.7° 46.94 K - Ohms25° -3.8° 40.40 K - Ohms30° -1.1° 34.85 K - Ohms35° 1.7° 30.18 K - Ohms40° 4.4° 26.22 K - Ohms45° 7.2° 22.85 K - Ohms50° 10.0° 19.96 K - Ohms55° 12.8° 17.47 K - Ohms60° 15.6° 15.33 K - Ohms65° 18.3° 13.49 K - Ohms70° 21.1° 11.89 K - Ohms75° 23.9° 10.50 K - Ohms80° 26.7° 9.297 K - Ohms85° 29.4° 8.247 K - Ohms90° 32.2° 7.330 K - Ohms95° 35.0° 6.528 K - Ohms

100° 37.8° 5.824 K - Ohms

Temperature

23

Installation

Use the checklist provided below inconjunction with the “General Unit Re-quirements” checklist to ensure that theunit is properly installed and ready foroperation.


Disconnect all electric power, includ-ing remote disconnects before ser-vicing. Follow proper lockout/tagoutprocedures to ensure the power cannot be inadvertently energized. Fail-ure to disconnect power before ser-vicing could result in death or seri-ous injury.

Failure to disconnect power before ser-vicing can cause severe personal injuryor death.

[ ] Check all electrical connections fortightness and “point of termination”accuracy.

[ ] Verify that the condenser airflow willbe unobstructed.

[ ] Verify that the condenser fan and in-door blower turn freely without rub-bing and are properly tightened onthe shafts.

[ ] Check the supply fan belts for propertension and the fan bearings for suf-ficient lubrication. If the belts requireadjustment, or if the bearings needlubricating, refer to the maintenancesection of this manual for instruc-tions.

[ ] Verify that a condensate trap is in-stalled and the piping is properlysized and pitched.

[ ] Verify that the correct size and num-ber of filters are in place.

[ ] Inspect the interior of the unit fortools and debris and install all panelsin preparation for starting the unit.

Voltage Imbalance

Three phase electrical power to the unitmust meet stringent requirements forthe unit to operate properly. Measureeach leg (phase-to-phase) of the powersupply. Each reading must fall within theutilization range stamped on the unitnameplate. If any of the readings do notfall within the proper tolerances, notifythe power company to correct this situ-ation before operating the unit.

Excessive three phase voltage imbal-ance between phases will cause mo-tors to overheat and eventually fail. Themaximum allowable voltage imbalanceis 2%. Measure and record the voltagebetween phases 1, 2, and 3 and calcu-late the amount of imbalance as fol-lows:

% Voltage Imbalance =

100 X AV - VD where;AV

AV (Average Voltage) =

Volt 1 + Volt 2 + Volt 3 3

V1, V2, V3 = Line Voltage ReadingsVD = Line Voltage reading that devi-ates the farthest from the averagevoltage.

Example: If the voltage readings ofthe supply power measured 221, 230,and 227, the average volts would be:

221 + 230 + 227 = 226 Avg. 3

VD (reading farthest from average) = 221

The percentage of Imbalance equals:

100 X 226 - 221 = 2.2%226

The 2.2% imbalance in this example ex-ceeds the maximum allowable imbal-ance of 2.0%. This much imbalance be-tween phases can equal as much as a20% current imbalance with a resultingincrease in motor winding temperaturesthat will decrease motor life. If the volt-age imbalance is over 2%, notify theproper agencies to correct the voltageproblem before operating this equip-ment.

Electrical Phasing(Three Phase Motors)

The compressor motor(s) and the sup-ply fan motor are internally connectedfor the proper rotation when the incom-ing power supply is phased as A, B, C.

Proper electrical supply phasing can bequickly determined and corrected be-fore starting the unit by using an instru-ment such as an Associated ResearchModel 45 Phase Sequence Indicatorand following the steps below:

[ ] Turn the field supplied disconnectswitch that provides power to themain power terminal block or to the“Line” side of the optional factorymounted disconnect switch to the“Off” position.

[ ] Connect the phase sequence indica-tor leads to the terminal block or tothe “Line” side of the optional factorymounted disconnect switch as fol-lows;

Black (phase A) to L1Red (phase B) to L2Yellow (phase C) to L3

[ ] Close the field supplied main powerdisconnect switch or circuit protectorswitch that provides the supplypower to the unit.

24

Installation

WARNINGLive Electrical Components!

During installation, testing, servicingand troubleshooting of this product,it may be necessary to work with liveelectrical components. Have a quali-fied licensed electrician or other in-dividual who has been properlytrained in handling live electricalcomponents perform these tasks.Failure to follow all electrical safetyprecautions when exposed to liveelectrical components could result indeath or serious injury.

To prevent injury or death from electro-cution, it is the responsibility of thetechnician to recognize this hazard anduse extreme care when performing ser-vice procedures with the electricalpower energized.

[ ] Observe the ABC and CBA phase in-dicator lights on the face of the se-quencer. The ABC indicator light willglow if the phase is ABC. If the CBAindicator light glows, open the dis-connect switch or circuit protectionswitch and reverse any two powerwires.

[ ] Restore the main electrical powerand recheck the phasing. If the phas-ing is correct, open the disconnectswitch or circuit protection switchand remove the phase sequence in-dicator.

Compressor Crankcase Heaters(Optional)

Each compressor can be equipped witha crankcase heater. The proper opera-tion of the crankcase heater is impor-tant to maintain an elevated compres-sor oil temperature during the “Off”cycle to reduce oil foaming during com-pressor starts. Oil foaming occurs whenrefrigerant condenses in the compres-sor and mixes with the oil. In lower am-bient conditions, refrigerant migration tothe compressor could increase.

When the compressor starts, the sud-den reduction in crankcase pressurecauses the liquid refrigerant to boil rap-idly causing the oil to foam. This condi-tion could damage compressor bear-ings due to reduced lubrication andcould cause compressor mechanicalfailures.

Before starting the unit in the “Cooling”mode, set the system switch to the “Off”position and turn the main power dis-connect to the “On” position and allowthe crankcase heater to operate a mini-mum of 8 hours.

Before closing the main power discon-nect switch, insure that the “System”selection switch is in the “Off” positionand the “Fan” selection switch is in the“Auto” position.

Close the main power disconnectswitch and the unit mounted disconnectswitch, if applicable.

WARNINGLive Electrical Components!

During installation, testing, servicingand troubleshooting of this product,it may be necessary to work with liveelectrical components. Have a quali-fied licensed electrician or other in-dividual who has been properlytrained in handling live electricalcomponents perform these tasks.Failure to follow all electrical safetyprecautions when exposed to liveelectrical components could result indeath or serious injury.

To prevent injury or death from electro-cution, it is the responsibility of thetechnician to recognize this hazard anduse extreme care when performing ser-vice procedures with the electricalpower energized.

ReliaTel ControlsUpon power initialization, the RTRMperforms self-diagnostic checks to in-sure that all internal controls are func-tional. It also checks the configurationparameters against the componentsconnected to the system. The LiteportLED located on the RTRM module isturned “On” within one second ofpower-up if internal operation is okay.

Use one of the following “Test” proce-dure to bypass some time delays and tostart the unit at the control panel. Eachstep of unit operation can be activatedindividually by temporarily shortingacross the “Test” terminals for two tothree seconds. The Liteport LED lo-cated on the RTRM module will blinkwhen the test mode has been initiated.The unit can be left in any “Test” stepfor up to one hour before it will auto-matically terminate, or it can be termi-nated by opening the main power dis-connect switch. Once the test mode hasbeen terminated, the Liteport LED willglow continuously and the unit will re-vert to the “System” control.

25

Pre - Start

Test Modes

There are three methods in which the“Test” mode can be cycled at LTB-Test1 and LTB-Test 2.

1. Step Test Mode - This method ini-tiates the different components of theunit, one at a time, by temporarilyshorting across the two test termi-nals for two to three seconds.

For the initial start-up of the unit, thismethod allows the technician to cycle acomponent “On” and have up to onehour to complete the check.

2. Resistance Test Mode - This methodcan be used for start-up providing adecade box for variable resistanceoutputs is available. This method ini-tiates the different components of theunit, one at a time, when a specificresistance value is placed across thetwo test terminals. The unit will re-main in the specific test mode for ap-proximately one hour even thoughthe resistance is left on the test ter-minals.

3. Auto Test Mode - This method is notrecommended for start-up due to theshort timing between individual com-ponent steps. This method initiatesthe different components of the unit,one at a time, when a jumper is in-stalled across the test terminals. Theunit will start the first test step andchange to the next step every 30seconds. At the end of the testmode, control of the unit will auto-matically revert to the applied "Sys-tem" control method.

For unit test steps, test modes, andstep resistance values to cycle the vari-ous components, refer to Table 5.

Table 5Service Test Guide for Component Operation

TEST MODE Fan Econ Comp Comp Heat Heat OhmsSTEP (Note 2) 1 2 1 2

MinimumFan On Position Off Off Off Off

1 Setpoint 2.2K0%

MinimumVentilation On Selectable Off Off Off Off

2 EconomizerTest Open On Open Off Off Off Off 3.3K

3 Cool Minimum (Note 1)Stage 1 On Position On Off Off Off 4.7K

4 Cool Minimum (Note 1) (Note 1)(Note 3) Stage 2 On Position On On Off Off 6.8K

5(Note 3)

6 Heat(Note 3) Stage 1 On Minimum Off Off On Off 10K

7 Heat(Note 3) Stage 2 On Minimum Off Off On On 15K

Notes:1 - The condenser fans will operate any time a compressor is "On" providing the outdoor air temperatures are within the operating values.

Reheat On Minimum On On Off Off 33K

26

Verifying Proper Air Flow(Units with Belt Drive Indoor Fan)

Much of the systems performance andreliability is closely associated with, anddependent upon having the proper air-flow supplied both to the space that isbeing conditioned and across theevaporator coil.

The indoor fan speed is changed byopening or closing the adjustable motorsheave.

Before starting the SERVICE TEST, setthe minimum position setpoint for theeconomizer to 0 percent using thesetpoint potentiometer located on theEconomizer Control (ECA), if appli-cable.

ReliaTel ControlUsing the Service Test Guide in Table 5,momentarily jump across the Test 1 &Test 2 terminals on LTB1 one time tostart the Minimum Ventilation Test.

Once the supply fan has started, checkfor proper rotation. The direction of rota-tion is indicated by an arrow on the fanhousing.

With the fan operating properly, deter-mine the total system airflow (CFM) by;

1. Measuring the actual RPM,

2. Measure the amperage at the supplyfan contactor and compare it with thefull load amp (FLA) rating stampedon the motor nameplate.

a. Calculate the theoretical BHP

Actual Motor Amps X Motor HPMotor Nameplate Amps

b. Using the fan performance tablesin the unit Service Facts, plot the

actual RPM (step 1) and theBHP (step 2a) to obtain theoperating CFM.

3. If the required CFM is too low, (ex-ternal static pressure is high caus-ing motor HP output to be belowtable value),

a. Relieve supply and/or returnduct static.

b. Change indoor fan speed andrepeat steps 1 and 2.

1. To Increase Fan RPM; Loosen thepulley adjustment set screw andturn sheave clockwise.

2. To Decrease Fan RPM; Loosen thepulley adjustment set screw andturn sheave counterclockwise.

3. If the required CFM is too high, (ex-ternal static pressure is low causingmotor HP output to be above tablevalue), change indoor fan speedand repeat steps 1 and 2.

4. To stop the SERVICE TEST, turn themain power disconnect switch to the“Off” position or proceed to the nextcomponent start-up procedure. Re-move electro mechanical test modeconnections (if applicable).

Return Air Smoke DetectorThe return air smoke detector is de-signed to shut off the unit if smoke issensed in the return air stream. Sam-pling the airflow entering the unit atthe return air opening performs thisfunction.

In order for the smoke detector toproperly sense smoke in the return airstream, the air velocity entering theunit must be between 500 and 4000feet per minute. Equipment covered inthis manual will develop an airflow ve-locity that falls within these limits overthe entire airflow range specified in theevaporator fan performance tables.

There are certain models however, ifoperated at low airflow, will not developan airflow velocity that falls within therequired 500 to 4000 feet per minuterange. For these models, the design air-flow shall be greater than or equal tothe minimum CFM specified in the tableprovided below. Failure to follow theseinstructions will prevent the smoke de-tector from performing its design func-tion.

Pre - Start

27

Start Up

Economizer Start-UpReliaTel ControlUsing the Service Test Guide in Table 5,momentarily jump across the Test 1 &Test 2 terminals on LTB1 one time tostart the Minimum Ventilation Test.

1. Set the minimum position setpoint forthe economizer to the required per-centage of minimum ventilation usingthe setpoint potentiometer locatedon the Economizer Control (ECA).

The economizer will drive to its mini-mum position setpoint, exhaust fans(if applicable) may start at random,and the supply fan will start when theSERVICE TEST is initiated.

WARNINGRotating Components!

During installation, testing, servicingand troubleshooting of this productit may be necessary to measure thespeed of rotating components. Havea qualified or licensed service indi-vidual who has been properly trainedin handling exposed rotating compo-nents, perform these tasks. Failure tofollow all safety precautions whenexposed to rotating componentscould result in death or serious in-jury.

The Exhaust Fan will start anytime theeconomizer damper position is equal toor greater than the exhaust fansetpoint.

2. Verify that the dampers stroked to theminimum position.

3. Momentarily jump across the Test 1& Test 2 terminals on LTB one addi-tional time if continuing from previ-ous component start-up or until thedesired start-up component Test isstarted.

4. Verify that the dampers stroked to thefull open position.


Compressor Start-Up

1. Attach a set of service gauges ontothe suction and discharge gaugeports for each circuit. Refer to the re-frigerant circuit illustration in the Ser-vice Facts.

Using the Service Test Guide in Table 5,continue the SERVICE TEST start-upprocedure for each compressor circuit.

Momentarily jump across the Test 1 &Test 2 terminals on LTB1 one additionaltime if continuing from previous compo-nent start-up or until the desired start-up component Test is started.

Scroll Compressorsa. Once each compressor has started,

verify that the rotation is correct. If ascroll compressor is rotating back-wards, it will not pump and a loudrattling sound can be observed.

b. If the electrical phasing is correct, be-fore condemning a compressor, in-terchange any two leads (at the com-pressor Terminal block) to check theinternal phasing. Refer to the follow-ing illustration for the compressorterminal/phase identification. If thecompressor runs backward for an ex-tended period (15 to 30 minutes), themotor winding can overheat andcause the motor winding thermostatto open.

c. Check the compressor oil levels. Theoil level in each compressor sightglass should be 1/2 to 3/4 full whenthey are “Off”.

The scroll compressor uses TraneOIL-42 without substitution. Theappropriate oil charge for a 9 and 10Ton scroll compressor is 8 pints. Fora 14 and 15 Ton scroll compressor,use 14 pints.

2. After the compressor and condenserfan have started and operated for ap-proximately 30 minutes, observe theoperating pressures. Compare theoperating pressures to the operatingpressure curve in the Service Facts.

3. Check system superheat. Follow theinstruction listed on the superheatcharging curve in the Service Facts.

Superheat should be within ±5 F of thesuperheat chart value.

4. Repeat steps 1 through 4 for each re-frigerant circuit.


28

Heating Start-Up

1. Clamp an amp meter around one of1st stage heater power wires at theheater contactor.

2. ReliaTel ControlUsing the Service Test Guide in Table 5,continue the SERVICE TEST start-upprocedure for each compressor circuit.Momentarily jump across the Test 1 &Test 2 terminals on LTB one additionaltime if continuing from previous compo-nent start-up or until the desired start-up component Test is started.

3. Verify that the heater stage is operat-ing properly.

4. Clamp an amp meter around one of2nd stage heater power wires at theheater contactor (if applicable).

5. ReliaTel Control Using the Service Test Guide in Table

5, continue the SERVICE TESTstart-up procedure for each com-pressor circuit. Momentarily jumpacross the Test 1 & Test 2 terminalson LTB one additional time if continu-ing from previous component start-up or until the desired start-up com-ponent Test is started.

6. Verify that the heater stage is operat-ing properly


Start Up

29

Final System Set Up

Final System SetupAfter completing all of the pre-start andstart-up procedures outlined in the pre-vious sections (i.e., operating the unit ineach of its Modes through all availablestages of cooling & heating), performthese final checks before leaving theunit:

[ ] Program the Night Setback (NSB)panel (if applicable) for proper unoc-cupied operation. Refer to the pro-gramming instructions for the spe-cific panel.

[ ] Verify that the Remote panel “Sys-tem” selection switch, “Fan” selectionswitch, and “Zone Temperature” set-tings for automatic operation are cor-rect.

[ ] Inspect the unit for misplaced tools,hardware, and debris.

[ ] Verify that all exterior panels includ-ing the control panel doors and con-denser grilles are secured in place.

[ ] Close the main disconnect switch orcircuit protector switch that providesthe supply power to the unit’s termi-nal block or the unit mounted discon-nect switch.

30

Maintenance

WARNINGRotating Components!

During installation, testing, servicing and troubleshoot-ing of this product it may be necessary to measure thespeed of rotating components. Have a qualified or li-censed service individual who has been properly trainedin handling exposed rotating components, perform thesetasks. Failure to follow all safety precautions when ex-posed to rotating components could result in death orserious injury.

Make sure all personnel are standing clear of the unit beforeproceeding. The system components will start when thepower is applied.

Fan Belt Adjustment - Belt Drive Units

The fan belts must be inspected periodically to assure properunit operation.

Replacement is necessary if the belts appear frayed or worn.Units with dual belts require a matched set of belts to ensureequal belt length.

When removing or installing the new belts, do not stretchthem over the sheaves. Loosen the belts using the belt ten-sion adjustment bolts on the motor mounting base.

Once the new belts are installed, using a Browning or Gatestension gauge (or equivalent) illustrated in Figure 7; adjustthe belt tension as follows;

1. To determine the appropriate belt deflection;

a. Measure the center-to-center shaft distance (ininches) between the fan and motor sheaves.

b. Divide the distance measured in Step 1a by 64; theresulting value represents the amount of belt deflectionthat corresponds to the proper belt tension.

2. Set the large O-ring on the belt tension gauge at the de-flection value determined in Step 1b.

3. Set the small O-ring at zero on the force scale of the gaugeplunger.

4. Place the large end of the gauge at the center of the beltspan; then depress the gauge plunger until the large O-ring is even with the top of the next belt or even with astraightedge placed across the fan and motor sheaves.Refer to Figure 7.

5. Remove the belt tension gauge. The small O-ring now indi-cates a number other than zero on the plunger’s force

scale. This number represents the force (in pounds) re-quired to give the needed deflection.

6. Compare the “force” scale reading (Step 5) with the appro-priate “force” value listed in Table 6. If the “force” reading isoutside the range, readjust the belt tension.

Note: Actual belt deflection “force” must not exceed themaximum “force” value shown inTable 6.

7. Recheck the belt tension at least twice during the first 2 to3 days of operation. Belt tension may decrease until thenew belts are “run in”.

Figure 9Belt Tension Gauge

Table 6Belt Tension Measurement and Deflection Ranges

Deflection Force (Lbs.)Belts Super Steel CableCross Small P.D Gripbelts Gripnotch Gripbelts

Section RangeMin. Max. Min. Max. Min. Max

3.0 - 3.6 3 4 1/2 3 7/8 5 1/2 3 1/4 4A 3.8 - 4.8 3 1/2 5 4 1/2 6 1/4 3 3/4 4 3/4

5.0 - 7.0 4 5 1/2 5 6 7/8 4 1/4 5 1/43.4 - 4.2 4 5 1/2 5 3/4 8 4 1/2 5 1/2

B 4.4 - 5.6 5 1/8 7 1/8 6 1/2 9 1/8 5 3/4 7 1/45.8 - 8.8 6 3/8 8 3/4 7 3/8 10 1/8 7 8 3/4

31

Maintenance

Monthly Maintenance

Before completing the following checks,turn the unit OFF and lock the mainpower disconnect switch open.


Disconnect all electric power, includ-ing remote disconnects before ser-vicing. Follow proper lockout/tagoutprocedures to ensure the power cannot be inadvertently energized. Fail-ure to disconnect power before ser-vicing could result in death or seri-ous injury.

Failure to disconnect power before ser-vicing can cause severe personal injuryor death.

Filters

[ ] Inspect the return air filters. Clean orreplace them if necessary. Refer tothe unit Service Facts for filter infor-mation.

Return Air Smoke DetectorMaintenance

Airflow through the unit is affected bythe amount of dirt and debris accumu-lated on the indoor coil and filters. To in-sure that airflow through the unit is ad-equate for proper sampling by the re-turn air smoke detector, complete ad-herence to the maintenance proce-dures, including recommended intervalsbetween filter changes, and coil clean-ing is required.

Periodic checks and maintenance pro-cedures must be performed on thesmoke detector to insure that it willfunction properly. For detailed instruc-tions concerning these checks and pro-cedures, refer to the appropriatesection(s) of the smoke detector Instal-lation and Maintenance Instructionsprovided with the literature package forthis unit.

Cooling Season

[ ] Check the unit’s drain pans and con-densate piping to ensure that thereare no blockages.

[ ] Inspect the evaporator and con-denser coils for dirt, bent fins, etc. Ifthe coils appear dirty, clean them ac-cording to the instructions describedin “Coil Cleaning” later in this sec-tion.

[ ] Manually rotate the condenser fan(s)to ensure free movement and checkmotor bearings for wear. Verify thatall of the fan mounting hardware istight.

[ ] Inspect the F/A-R/A damper hingesand pins to ensure that all movingparts are securely mounted. Keepthe blades clean as necessary.

[ ] Verify that all damper linkages movefreely; lubricate with white grease, ifnecessary.

[ ] Check supply fan motor bearings; re-pair or replace the motor as neces-sary.

[ ] Check the fan shaft bearings forwear. Replace the bearings as nec-essary.

[ ] Check the supply fan belt. If the beltis frayed or worn, replace it. Refer tothe “Fan Belt Adjustment” section forbelt replacement and adjustments.

[ ] Verify that all wire terminal connec-tions are tight.

[ ] Remove any corrosion present onthe exterior surfaces of the unit andrepaint these areas.

[ ] Generally inspect the unit for unusualconditions (e.g., loose access pan-els, leaking piping connections, etc.)

[ ] Make sure that all retaining screwsare reinstalled in the unit accesspanels once these checks are com-plete.

[ ] With the unit running, check andrecord the: ambient temperature;compressor suction and dischargepressures (each circuit); superheat(each circuit);

Record this data on an “operator’smaintenance log” like the one shown inTable 7. If the operating pressures indi-cate a refrigerant shortage, measurethe system superheat. For guidelines,refer to the “Compressor Start-Up” sec-tion.

Note: Do Not release refrigerant tothe atmosphere! If adding orremoving refrigerant is required, theservice technician must comply withall federal, state and local laws.

Heating Season

[ ] Inspect the unit’s air filters. If neces-sary, clean or replace them.

[ ] Check supply fan motor bearings; re-pair or replace the motor as neces-sary.

[ ] Inspect both the main unit controlpanel and heat section control boxfor loose electrical components andterminal connections, as well asdamaged wire insulation. Make anynecessary repairs.

[ ] Verify that the electric heat systemoperates properly.

Coil Cleaning

Regular coil maintenance, including an-nual cleaning, enhances the unit’s oper-ating efficiency by minimizing: compres-sor head pressure and amperage draw;evaporator water carryover; fan brakehorsepower, due to increase staticpressure losses; airflow reduction.

At least once each year, or more oftenif the unit is located in a “dirty” environ-ment, clean the evaporator and con-denser coils using the instructions out-lined below. Be sure to follow these in-structions as closely as possible toavoid damaging the coils.

32

Maintenance

To clean refrigerant coils, use a softbrush and a sprayer (either a gardenpump-up type or a high-pressuresprayer). A high-quality detergent isalso required; suggested brands in-clude “SPREX A.C.”, “OAKITE 161”,“OAKITE 166” and “COILOX”. If the de-tergent selected is strongly alkaline (phvalue exceeds 8.5), add an inhibitor.

1. Remove enough panels from the unitto gain access to the coil. Removethe access panel from the roof lo-cated next to the rear condenser fan.

2. Protect all electrical devices such asmotors and controllers from any overspray.

3. Straighten any bent coil fins with a fincomb.

4. Mix the detergent with water accord-ing to the manufacturer’s instruc-tions. If desired, heat the solution to150 F maximum to improve itscleansing capability.

WARNINGHazardous Pressures!

Coils contain refrigerant under pres-sure. When cleaning coils, maintaincoil cleaning solution temperatureunder 150°F to avoid excessive pres-sure in the coil. Failure to followthese safety precautions could resultin coil bursting, which could result indeath or serious injury.

Do not heat the detergent-and-watersolution above 150o F. Hot liquidssprayed on the exterior of the coil willraise the coil’s internal pressure andmay cause it to burst. Failure to followproper procedures can result in per-sonal illness or injury or severe equip-ment damage.

5. Pour the cleaning solution into thesprayer. If a high-pressure sprayer isused:

a. do not allow sprayer pressure toexceed 600 psi.

b. the minimum nozzle spray angleis 15 degrees.

c. maintain a minimum clearance of6" between the sprayer nozzleand the coil.

d. spray the solution perpendicular(at 90 degrees) to the coil face.

6. Spray the leaving-airflow side of thecoil first; then spray the opposite sideof the coil. Allow the cleaning solu-tion to stand on the coil for five min-utes.

7. Rinse both sides of the coil with cool,clean water.

8. Inspect both sides of the coil; if it stillappears to be dirty, repeat Steps 6and 7.

9. Reinstall all of the components andpanels removed in Step 1 and anyprotective covers installed in step 2.

10. Restore the unit to it’s operationalstatus and check system operation.

Final Process

For future reference, you may find ithelpful to record the unit data re-quested below in the blanks provided.(1) Complete Unit Model Number:

(2) Unit Serial Number:

(3) Wiring Diagram Numbers (from unit control pane

— schematic(s)

— connection(s)

33

Maintenance

Table 7Sample Maintenance Log

Refrigerant Circuit #1 Refrigerant Circuit #2 Current

Ambient Compr. Suct. Disch. Liquid Super- Sub- Compr. Suct. Disch. Liquid Super- Sub-Temp. Oil Press. Press. Press. heat cool. Oil Press. Press. Press. heat cool.

Date F/C Level Psig/kPa Psig/kPa Psig/kPa F/C F/C Level Psig/kPa Psig/kPa Psig/kPa F/C F/C

- ok - ok- low - low










Note: Check and record the data requested above each month during the cooling season with the unit running.

34

Trouble Shooting

ReliaTel ControlThe RTRM has the ability to provide theservice personnel with some unit diag-nostics and system status information.

Before turning the main power discon-nect switch “Off”, follow the steps belowto check the ReliaTel RefrigerationModule (RTRM). All diagnostics & sys-tem status information stored in theRTRM will be lost when the main poweris turned “Off”.

WARNINGHazardousService Procedures!

The maintenance and troubleshoot-ing procedures recommended in thissection of the manual could result inexposure to electrical, mechanical orother potential safety hazards. Al-ways refer to the safety warningsprovided throughout this manualconcerning these procedures. Whenpossible, disconnect all electricalpower including remote disconnectsbefore servicing. Follow proper lock-out/tagout procedures to ensure thepower can not be inadvertently ener-gized. When necessary to work withlive electrical components, have aqualified licensed electrician orother individual who has beentrained in handling live electricalcomponents perform these tasks.Failure to follow all of the recom-mended safety warnings provided,could result in death or serious in-jury.

To prevent injury or death from electro-cution, it is the responsibility of thetechnician to recognize this hazard anduse extreme care when performingservice procedures with the electricalpower energized.

1. Verify that the Liteport LED on theRTRM is burning continuously. If theLED is lit, go to Step 3.

2. If the LED is not lit, verify that 24 VACis presence between J1-1 and J1-2.If 24 VAC is present, proceed to Step3. If 24 VAC is not present, check theunit main power supply, check trans-former (TNS1). Proceed to Step 3 ifnecessary.

3. Utilizing “Method 1” or “Method 2” inthe “System Status Checkout Proce-dure, check the following:

System statusHeating statusCooling status

If a System failure is indicated, pro-ceed to Step 4. If no failures are indi-cated, proceed to Step 5.

4. If a System failure is indicated, re-check Steps 1 and 2. If the LED isnot lit in Step 1, and 24 VAC ispresent in Step 2, the RTRM hasfailed. Replace the RTRM.

5. If no failures are indicated, use oneof the TEST mode procedures de-scribed in the “Unit Start-Up” sectionto start the unit. This procedure willallow you to check all of the RTRMoutputs, and all of the external con-trols (relays, contactors, etc.) that theRTRM outputs energize, for each re-spective mode. Proceed to Step 6.

6. Step the system through all of theavailable modes, and verify opera-tion of all outputs, controls, andmodes. If a problem in operation isnoted in any mode, you may leavethe system in that mode for up toone hour while troubleshooting. Re-fer to the sequence of operations foreach mode, to assist in verifyingproper operation. Make the neces-sary repairs and proceed to Steps 7and 8.

7. If no abnormal operating conditionsappear in the test mode, exit the testmode by turning the power “Off” atthe main power disconnect switch.

8. Refer to the individual componenttest procedures if other microelec-tronic components are suspect.

System Status Checkout Procedure

“System Status” is checked by usingone of the following two methods:

Method 1

If the Zone Sensor Module (ZSM) isequipped with a remote panel with LEDstatus indication, you can check the unitwithin the space. If the ZSM does nothave LED’s, use Method 2.BAYSENS010B, BAYSENS011B,BAYSENS019B, BAYSENS020B,BAYSENS021A & BAYSENS023A allhave the remote panel indication fea-ture. The LED descriptions are listedbelow.

LED 1 (System)“On” during normal operation.“Off” if a system failure occurs or theLED fails.“Flashing” indicates test mode.

LED 2 (Heat)“On” when the heat cycle is operating.“Off” when the heat cycle terminates orthe LED fails.“Flashing” indicates a heating failure.

LED 3 (Cool)“On” when the cooling cycle is operat-ing.“Off” when the cooling cycle terminatesor the LED fails.“Flashing” indicates a cooling failure.

LED 4 (Service)“On” indicates a clogged filter.“Off” during normal operation.“Flashing” indicates an evaporator fanfailure

35

Below is the complete listing of failureindication causes.

System FailureCheck the voltage between terminals 6and 9 on J6, it should read approxi-mately 32 VDC. If no voltage is present,a System failure has occurred. Refer toStep 4 in the previous section for therecommended troubleshooting proce-dure.

Cooling Failure1. Cooling and heating set point (slide

pot) on the zone sensor has failed.Refer to the “Zone Sensor Test Pro-cedure” section.

2. Zone temperature thermistor ZTEMPon ZTS failed. Refer to the “ZoneSensor Test Procedure” section.

3. CC1 or CC2 24 VAC control circuithas opened, check CC1 & CC2 coils,and any of the controls below thatapply to the unit (HPC1, HPC2).

4. LPC1 has opened during the 3minute minimum “on time” during 4consecutive compressor starts,check LPC1 or LPC2 by testing volt-age between the J1-8 & J3-2 termi-nals on the RTRM and ground. If 24VAC is present, the LPC’s has nottripped. If no voltage is present,LPC’s has tripped.

Service Failure1. If the supply fan proving switch has

closed, the unit will not operate(when connected to RTOM), checkthe fan motor, belts, and provingswitch.

2. Clogged filter switch has closed,check the filters.

Simultaneous Heat and Cool Failure1. Emergency Stop is activated.

Method 2

The second method for determiningsystem status is done by checking volt-age readings at the RTRM (J6). Thesystem indication descriptions and theapproximate voltages are listed below.

System FailureMeasure the voltage between terminalsJ6-9 & J6-6.Normal Operation = approximately 32VDCSystem Failure = less than 1 VDC, ap-proximately 0.75 VDCTest Mode = voltage alternates between32 VDC & 0.75 VDC

Heat FailureMeasure the voltage between terminalsJ6-7 & J6-6.Heat Operating = approximately 32VDCHeat Off = less than 1 VDC, approxi-mately 0.75 VDCHeating Failure = voltage alternates be-tween 32 VDC & 0.75 VDC

Cool FailureMeasure the voltage between terminalsJ6-8 & J6-6.Cool Operating = approximately 32VDCCool Off = less than 1 VDC, approxi-mately 0.75 VDCCooling Failure = voltage alternates be-tween 32 VDC & 0.75 VDC

Service FailureMeasure the voltage between terminalsJ6-10 & J6-6.Clogged Filter = Approximately 32 VDC.Normal = Less than 1 VDC, approxi-mately 0.75 VDC

Fan Failure = voltage alternates be-tween 32 VDC & 0.75 VDC.

To use LED’s for quick status informa-tion at the unit, purchase aBAYSENS010B ZSM and connect wireswith alligator clamps to terminals 6through 10. Connect each respectiveterminal wire (6 through 10) from the

Zone Sensor to the unit J6 terminals 6through 10.

Note: If the system is equipped with aprogrammable zone sensor,(BAYSENS019A, BAYSENS020A orBAYSENS023A), the LED indicatorswill not function while theBAYSENS010A is connected.

Resetting Cooling and HeatingLockouts

Cooling Failures and Heating Lockoutsare reset in an identical manner.Method 1 explains resetting the systemfrom the space; Method 2 explains re-setting the system at the unit.

Note: Before resetting CoolingFailures and Heating Lockouts checkthe Failure Status Diagnostics by themethods previously explained.Diagnostics will be lost when thepower to the unit is disconnected.

Method 1

To reset the system from the space,turn the “Mode” selection switch at thezone sensor to the “Off” position. Afterapproximately 30 seconds, turn the“Mode” selection switch to the desiredmode, i.e. Heat, Cool or Auto.

Method 2

To reset the system at the unit, cyclethe unit power by turning the disconnectswitch “Off” and then “On”.

Lockouts can be cleared through thebuilding management system. Refer tothe building management system in-structions for more information.

Trouble Shooting

36

Test 4LED Indicator Test, (SYS ON, HEAT,COOL & SERVICE)

Method 1

Testing the LED using a meter with di-ode test function. Test both forward andreverse bias. Forward bias should mea-sure a voltage drop of 1.5 to 2.5 volts,depending on your meter. Reverse biaswill show an Over Load, or open circuitindication if LED is functional.

Method 2

Testing the LED with an analog Ohm-meter. Connect Ohmmeter across LEDin one direction, then reverse the leadsfor the opposite direction. The LEDshould have at least 100 times more re-sistance in reverse direction, as com-pared with the forward direction. If highresistance in both directions, LED isopen. If low in both directions, LED isshorted.

Method 3

To test LED’s with ZSM connected tounit, test voltages at LED terminals onZSM. A measurement of 32 VDC,across an unlit LED, means the LEDhas failed.

Note: Measurements should be madefrom LED common (ZSM terminal 6 torespective LED terminal). Refer to theZone Sensor Module (ZSM) TerminalIdentification table at the beginningof this section.

Zone Temperature Sensor (ZTS)Service Indicator

The ZSM SERVICE LED is a genericindicator, that will signal the closing of aNormally Open switch at any time, pro-viding the Indoor Motor (IDM) is operat-ing. This indicator is usually used to in-dicate a clogged filter, or an air side fanfailure.

The RTRM will ignore the closing of thisNormally Open switch for 2 (±1) min-utes. This helps prevent nuisance SER-VICE LED indications. The exception isthe LED will flash 40 seconds after thefan is turned “On” if the Fan ProvingSwitch is not made.

Clogged Filter SwitchThis LED will remain lit the entire timethat the Normally Open switch isclosed. The LED will be turned off im-mediately after resetting the switch (tothe Normally Open position), or anytime that the IDM is turned “Off”.

If the switch remains closed, and theIDM is turned “On”, the SERVICE LEDwill be turned “On” again after the 2(±1) minute ignore delay.

This LED being turned “On”, will haveno other affect on unit operation. It is anindicator only.

Fan Failure SwitchWhen the “Fan Failure” switch is wiredto the RTOM, the LED will remain flash-ing the entire time the fan provingswitch is closed, indicating a fan failure,and it will shut the unit operationsdown.

Zone Temperature Sensor (ZTS) Test

Note: These procedures are not forprogrammable or digital models andare conducted with the Zone SensorModule electrically removed from thesystem.

Test 1Zone Temperature Thermistor(ZTEMP)

This component is tested by measuringthe resistance between terminals 1 and2 on the Zone Temperature Sensor. Be-low are some typical indoor tempera-tures, and corresponding resistive val-ues.

Nominal ZTEMP Nominal CSP or Resistance SP Resistance

50 F° 10.0 C 19.9 K-Ohms 889 Ohms 55 F 12.8 C 17.47 K-Ohms 812 Ohms60 F 15.6 C 15.3 K-Ohms 695 Ohms65 F 18.3 C 13.49 K-Ohms 597 Ohms 70 F 21.1 C 11.9 K-Ohms 500 Ohms 75 F 23.9 C 10.50 K-Ohms 403 Ohms80 F 26.7 C 9.3 K-Ohms 305 Ohms 85 F 29.4 C 8.25 K-Ohms 208 Ohms90 F 32.2 C 7.3 K-Ohms 110 Ohms

Zone Temperature

Test 2Cooling Set Point (CSP) and HeatingSet Point (HSP)The resistance of these potentiometersare measured between the followingZSM terminals. Refer to the chart abovefor approximate resistances at the givensetpoints.

Cool SP = Terminals 2 and 3Range = 100 to 900 Ohms approximate

Heat SP = Terminals 2 and 5Range = 100 to 900 Ohms approximate

Test 3System Mode and Fan Selection

The combined resistance of the Modeselection switch and the Fan selectionswitch can be measured between termi-nals 2 and 4 on the Zone Sensor. Thepossible switch combinations are listedon the following page with their corre-sponding resistance values.

Trouble Shooting

37

Trouble Shooting

Programmable & Digital Zone SensorTest

Testing serial communicationvoltage1. Verify 24 VAC is present between ter-

minals J6-14 & J6-11.

2. Disconnect wires from J6-11 and J6-12. Measure the voltage between J6-11 and J6-12, should be about 32VDC.

3. Reconnect wires to terminals J6-11and J6-12. Measure voltage againbetween J6-11 and J6-12, voltageshould flash high and low every 0.5seconds. The voltage on the low endwill measure about 19 VDC, whilethe voltage on the high end will mea-sure from approximately 24 to 38VDC.

4. Verify all modes of operation, by run-ning the unit through all of the stepsin the “Test Modes” section dis-cussed in “Unit Start-Up”.

5. After verifying proper unit operation,exit the test mode. Turn the fan on

Unit Operation without a Zone Sen-sor

This procedure is for temporary opera-tion only. The economizer and con-denser fan cycling functions are dis-abled.

1. Open and Lock the unit disconnectswitch.

2. Remove the Outside Air Sensor(OAS) from the condenser section ofunit.

3. Use two (2) wire nuts, to individuallycap the wires.

4. Locate the RTRM (J6). Connect two(2) wires to terminals J6-1 and 2.

5. Connect the sensor (OAS) using twowire nuts to the two (2) field suppliedwires that were connected to termi-nals 1 and 2 on J6.

Unit Economizer Control (ECA)TroubleshootingReliaTel Control

Verify Economizer Status by Econo-mizer Actuator (ECA) LED indicator:

OFF: No Power or FailureON: Normal, OK to EconomizeSlow Flash: Normal, Not OK to Economize

Fast Flash - 1/2 Second On / 2 Seconds Off: Error Code: Communications Failure

Pulse Flash: 2 Seconds On / 1/2 Second Off:Error Code:

1 Flash: Actuator Fault2 Flashes: CO2 Sensor3 Flashes: RA Humidity Sensor4 Flashes RA Temp Sensor5 Flashes: OA Quality Sensor6 Flashes: OA Humidity Sensor7 Flashes: OA Temp Sensor8 Flashes: MA Temp Sensor9 Flashes: RAM Fault10 Flashes: ROM Fault11 Flashes: EEPROM Fault

Test 3System Mode and Fan Selection

Resistance Zone Sensor Local Unit Local Fan Valves Unit/Fan(Ohms) Mode Mode Mode2.32K Off/ Auto Off Auto4.87K Cool/Auto Cool Auto7.68K Auto/Auto Auto Auto10.77K Off/On Off On13.32K Cool/On Cool On16.13K Auto/On Auto On19.48K Heat/Auto Heat Auto27.93K Heat/On Heat On35.0K Emergency Heat/Auto Emergency Heat Auto43.45K Emergency Heat/On Emergency Heat OnOut of Range (Short) INVALID/Short Invalid (CV), Auto (VAV) InvalidOut of Range (Open) INVALID/Open Invalid (CV), Off (VAV) Invalid

continuously at the ZSM, by pressingthe button with the fan symbol. If thefan comes on and runs continuously,the ZSM is good. If you are not ableto turn the fan on, the ZSM is defec-tive.

ReliaTel Refrigeration Module(RTRM) Default Chart

If the RTCI loses input from the buildingmanagement system, the RTRM willcontrol in the default mode after ap-proximately 15 minutes. If the RTRMloses the Heating and Cooling setpointinput, the RTRM will control in the de-fault mode instantaneously. The tem-perature sensing thermistor in the ZoneSensor Module is the only componentrequired for the “Default Mode” to oper-ate.

38

Central Air ConditionerTCY, TCX, TCC, TCD, TCH, TCK,TCM, TCP, THC and TSC (Parts Only)Models Less Than 20 Tons for Commercial Use*This warranty is extended by American Standard Inc., to the original purchaserand to any succeeding owner of the real property to which the Air Conditioneris originally affixed, and applies to products purchased and retained for usewithin the U.S.A. and Canada. There is no warranty against corrosion, erosionordeterioration.

If any part of your Air Conditioner fails because of a manufacturing defect withinone year from the date of the original purchase, Warrantor will furnish withoutcharge the required replacement part.

In addition, if the sealed motor-compressor fails because of a manufacturingdefect within the second through fifth year from the date of original purchase,Warrantor will furnish without charge the required replacement compressor.Warrantor’s obligations and liabilities under this warranty are limited tofurnishing F.O.B. Warrantor factory or warehouse replacement parts forWarrantor’s products covered under this warranty. Warrantor shall not beobligated to pay for the cost of lost refrigerant. No liability shall attach toWarrantor until products have been paid for and then liability shall be limitedsolely to the purchase price of the equipment under warranty shown to bedefective.THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE INLIEU OF ALL OTHER WARRANTIES AND LIABILITIES, WHETHERIN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, INLAW OR IN FACT, INCLUDING BUT NOT SPECIFICALLY LIMITEDTO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR PARTICULAR USE, AND IN NO EVENT SHALL WARRANTORBE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIALDAMAGES.Some states do not allow limitations on how long an implied warranty lasts or donot allow the exclusion or limitation of incidental or consequential damages, sothe above limitation or exclusion may not apply to you. This warranty gives youspecific legal rights, and you may also have other rights which vary from state tostate.American Standard Inc.2701 Wilma Rudolph Blvd.Clarksville, TN 37040-1008Attention: Manager,Product ServiceGW-602-4800* This warranty is for commercial usage of said equipment and not applicablewhen the equipment is used for a residential application. Commercial use is anyapplication where the end purchaser uses the product for other than personal,family or household purposes.

Warranty

39

�Standard Equipment WarrantyTerms and Conditions

Commercial Equipment Warranty and LiabilityModels Larger that 20 Tons for Commercial Use*

The Company warrants for a period of 12 months from initial start-up or 18months from date of shipment, whichever is less, that the Company prod-ucts covered by this order (1) are free from defects in material and work-manship and (2) have the capacities and ratings set forth in the Company’scatalogs and bulletins, provided that no warranty is made against corrosion,erosion or deterioration.The Company’s obligations and liabilities under thiswarranty are limited to furnishing f.o.b. factory or warehouse at Companydesignated shipping point, freight allowed to Buyer’s city (or port of exportfor shipment outside the conterminous United States) replacement equip-ment (or at the option of the Company parts therefore) for all Companyproducts not conforming to this warranty and which have been returned tothe manufacturer. The Company shall not be obligated to pay for the cost oflost refrigerant. No liability whatever shall attach to the Company until saidproducts have been paid for and then said liability shall be limited to thepurchase price of the equipment shown to be defective.

The Company makes certain further warranty protection available on anoptional extra-cost basis. Any further warranty must be in writing, signed byan officer of the Company.

The warranty and liability set forth herein are in lieu of all other warrantiesand liabilities, whether in contract or in negligence, express or implied, in lawor in fact, including implied warranties of merchantability and fitness forparticular use. In no event shall the Company be liable for any incidental orconsequential damages.

American Standard Inc.2701 Wilma Rudolph Blvd.Clarksville, TN 37040-1008Attention: Manager,Product Service

Warranty

An American Standard CompanySince the manufacturer has a policy of continuous product improvement, it reserves the right to change design andspecifications without notice.

Literature Order Number

File Number

Supersedes

Stocking Location

TC-IOM-7SV-UN-RT-TC-IOM-7 12/02

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