Trane BAYEVAC04BK1B Installer's Manual

Page 1
INSTALLER'S
s
s
WARNING
s
s
WARNING
CAUTION
ss
WARNING
GUIDE
ALL phases of this installation must comply with NATION-
18-GJ09D1-10A-EN
Models:
BAYEVAC04BK1B BAYEVAC04LG1B BAYEVAC05BK1B BAYEVAC05LG1B BAYEVAC08BK1B BAYEVAC08LG1B
IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work.
BAYEVAC10BK1B BAYEVAC10LG1B BAYEVBC15BK1B BAYEVBC20BK1B BAYEVAC10LG3B BAYEVBC15LG3B
Supplementary Electric Heaters
for Air Handler Installations
Section 1. Safety Information
SAFETY HAZARD! This information is intended
for use by individuals possessing adequate back­grounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it as­sume any liability in connection with its use.
HAZARDOUS VOLTAGE! Disconnect all electric
power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
LIVE ELECTRICAL COMPONENTS! During
installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electri­cal safety precautions when exposed to live electrical components could result in death or serious injury.
SAFETY HAZARD! Sharp Edge Hazard. Be care-
ful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. Personal
Table of Contents
Section 1. Safety Information ....................................................................................................................................... 1
Section 2. General Information .................................................................................................................................... 2
Section 3. Heater Assembly Labeled .......................................................................................................................... 2
Section 4. Heater Selection .......................................................................................................................................... 3
Section 5. Adjust Heater ............................................................................................................................................... 5
Section 6. Install Heater ............................................................................................................................................... 7
Section 7. Tables ......................................................................................................................................................... 12
Section 8. Sequence of Operation ............................................................................................................................. 14
injury may result.
Page 2
INSTALLER'S GUIDE
Section 2. General Information
This electric heater accessory is designed to provide power directly to the air handler from the accessory heater's power supply, eliminating the need for addi­tional circuits. The power and control wiring each use a single wire harness to connect the heater and the air handler.
1. Check the unit heater label to confirm that the selected heater is approved for use with the air handler in the in­stalled configuration. For some heaters, a corresponding secondary nameplate label is included. Place the label within the heater data table on the air handler nameplate.
2. Check the components received for damage. Report any defects or shortages to the transportation company im­mediately.
3. Be sure the power supply matches the listing shown on the heater nameplate.
Section 3. Heater Assembly Labeled
Retainer Tab and Screw
- In document pack
Filler Plate
Electric Heat Control Platform
Electric Heat Control ­Communicating
Base Plate
Edge Guard
- In document pack
Heater Rack
Cyclic Thermal Limit Switch
Heater Element Terminations
Nameplate
Width Adjustment Brackets
Heater Baffle
Non-Cyclic Thermal Limit Switch
Retainer Tab and Screw
- In document pack
Filler Plate
Seal Plate (Breaker models only)
- In document pack
Page 2
Ground Lug (LG heater has terminal lug)
Breaker Bracket (LG heater terminal bracket differs)
Circuit Breaker (Breaker models only)
Wiring diagram not shown
Parts may vary by model. Items shown are for illustrative purposes only.
Page 3
INSTALLER'S GUIDE
Section 4. Heater Selection
Determine which heater best fits your application needs. In addition to electrical considerations, you must know your cabinet size and the range of heaters which fit that cabinet.
4.1 Air Handler Model Number Matrix
Step 1 - Measure your cabinet and use the Air Handler
Model Number Matrix to determine your cabinet size.
Air Handler Model Number Matrix
Digit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Example
Brand
Product Type Air Handler
Convertibility Multi-poise 4-way
Product Tier Multi-speed
Major Design Modifications
No Descriptor Air Handler / Coil
Size (Footprint)
Cooling Size:
Air Handler
Electric Heat Input
Airflow Type &
Capability
Power Supply 208-230/1/60
System Control
Type
Letter
Sequence
17.5 x 21.5
21.0 x 21.5
23.5 x 21.5
AH Coil - 1,000
BTU's (18, 24, 30,
36, 42, 48, 60)
Electric Heat - kW
(05, 08, 10, 15,
20, 25)
H - Hi Effy, Multi-
speed, 1-5 - nom.
Tonnage (cfm/ton)
Standard
- 24 VAC
T A M 7 A 0 B 3 0 H 2 1 S A A
T
A
M
7
A
0
A
B
C
0-9 0-9
0-9 0-9
H 1-5
1
S
Minor Design Modifications
Unit Parts
Identifier
Letter
Sequence
Letter
Sequence
The cabinet size in this example is B.
Record Your Cabinet Size = _________
A
A
This matrix is provided as an example only.
Page 3
Page 4
INSTALLER'S GUIDE
Step 2 - Use the Heater Model Number Matrix to de­termine which heaters will fit in your cabinet and to determine if you will have to modify the heater to fit the cabinet.
Electric Heat Model Number
Digit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Example
Brand Both Brands B
Product Type Accessory A Y
Heat Type Electric Heater E
Product Tier Air Handler Tier
Size
(Footprint)
Electric Heat Input Electric Heat - kW (04,
Connection Breaker B K
Power Supply 208-230/1/60 1
(7 and 8)
Minimum Cabinet
Width (A,B,C)
Maximum Cabinet
Width (A,B,C)
05, 08, 10, 15, 20, 25)
Lugs L G
B A Y E V A C 1 5 B K 1 A A A
V
A
C
0-9 0-9
200/1/50 A
208-230/3/60 3
Major Design Modifications Letter Sequence A
Minor Design Modifications Letter Sequence A
Unit Parts Identifier Letter Sequence A
The heater in this example will fit into cabinets A, B, & C. From Step 1 we know that the heater needs to be sized to fit in a B cabinet.
See Section 5 for instructions for modifying your heater to fit various cabinet sizes.
Record Your Heater Size = _________
This matrix is provided as an example only.
Page 4
Page 5
Section 5. Adjust Heater
STEP 1 - Position Width Adjustment Brackets.
Two Width Adjustment Brackets are located at the back of the heater assembly. The heater comes sized for the smallest cabinet it will fit in. For this example our heater fits cabinets A, B, and C. It came sized for an A cabinet and we are sizing it for a B cabinet.
1. Loosen the screws that hold the Width Adjustment Brackets to the back of the heater.
2. Reposition each Width Adjustment Bracket until the correct holes line up with the loosened screws as il­lustrated in this step.
3. Tighten screws to hold Width Adjustment Bracket securely in place.
INSTALLER'S GUIDE
Width Adjustment Brackets
(two per unit)
Cabinet A
The heater comes from the factory sized for cabinet A. No modifications to the Width Adjustment Brackets are required.
Cabinet B
Prepare the heater for cabinet B by modifying the Width Adjustment Brackets to align with the holes labeled B.
Cabinet C
Prepare the heater for cabinet C by modifying the Width Adjustment Brackets to align with the holes labeled C.
STEP 2 - Adjust Filler Plates.
14.5
18.5
20.5
Cabinet A
NOTE: No Filler Plates are required for the A cabinet.
Cabinet B or C
1. Loosen the Filler Plate screws on each side of Base Plate (four total).
2. Slide in the correct Filler Plate on each side. Filler Plates are marked for the cabinet size they match with, for example, the Filler Plate for cabinet B is marked "B-CAB".
3. Tighten the Filler Plate screws loosened previously and add a screw (provided) to the bottom of each plate to hold Filler Plates in place.
Filler Plate Screws
-three per side Filler Plate
Retainer Tab & Screw
Page 5
Page 6
INSTALLER'S GUIDE
CAUTION
STEP3 - Attach Retainer Tabs and Edge Guard
Note: For A cabinet widths, only the right side retainer tab must be installed.
1. Add the Retainer tabs using the screws provided (both tabs and screws are located in the documentation packet).
Leave the screws slightly loose so that the tab can slide
to the left or right as needed. The tab will be used later to engage in a slot within the air handler cabinet.
Note: If no filler plates are needed, the retainer tabs must be attached to the heater coil flange. Leave the screws slightly loose so they can be slid to the left or right as needed.
2. The edge guard is located in the document pack. Cut the edge guard to the length needed for the heater width, including the filler plates.
3. Install the edge guard on the front of the heater flange as shown.
STEP 4 - (Optional) Rotate Circuit Breaker Assembly.
Note: For LG (lug) heater models the terminal block bracket does not rotate.
The need to reorient the Circuit Breaker Assembly depends upon the orientation of your application and which of the high voltage electrical conduit entry points you use for high voltage wiring.
Important: For air handler units installed in the horizontal right position, the circuit breakers on the heater must be rotated in order to comply with National Electric Code (NEC Section 240.81). The NEC requires that circuit breakers operated verti­cally must be oriented so that the "on" position of the breaker is upward.
B and C Cabinet
Factory
Connections
Circuit
Breaker
Rounded end
inserts into cabinet
A Cabinet
Screw
Field
Connections
ON
SAFETY HAZARD! Sharp Edge Hazard. Be care-
ful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. Personal injury may result.
1. Unscrew the Breaker Bracket from the Base Plate using a magnetic 1/4" hex driver with an extension. The extension allows for easier access to the screws which are located at the back of the bracket.
2. Rotate the bracket with circuit breaker(s) 180 °.
3. Use the screws removed in action 2 (above) to secure the bracket to the Base Plate.
Page 6
Screw
Circuit Breaker Assembly
Breaker Bracket
Page 7
Section 6. Install Heater
STEP 1 - Remove Heater Compartment Panel.
STEP 2 - Disconnect & Dispose of Pigtail Harness.
1. Cut the wire tie that is holding the pigtail harness.
2. Unplug and dispose of pigtail harness.
INSTALLER'S GUIDE
Heater
Compartment
Panel
Breaker
Cover
Important: If using a BAYSUPFLGA, B, or C Supply Duct Flange Kit, install the kit before inserting the heater.
STEP 3 - Insert heater assembly into heater compart­ment.
1. Move factory wiring out of the way and into the grooves provided in cabinet.
2. Slide heater into heater compartment of air handler.
Wire Tie
Pigtail
Harness
Page 7
Page 8
INSTALLER'S GUIDE
STEP - 4 Lock Retainer tabs.
Note: Retainer tabs are used to secure the heater inside of the heater compartment.
1. Slide retainer tab into recess in air handler cabinet.
2. Tighten screws to hold tab securely.
3. Repeat actions to secure the other tab.
Note: For A cabinet widths, only the right side retainer tab must be installed.
STEP 5 - Route High Voltage wiring to unit.
Select a conduit entry point. Drill a hole for the desired conduit size on units without a plug. A locating target is identified on these units.
Note: Some models may have a pre-molded conduit connection with plug. If a connection hole is already present, remove the plug from the entry point and use as is.
Retainer
Tab
Filler Plate
(B and C only)
Conduit Entry Points
1. Select the entry point you will use to bring in your high voltage wiring.
2. Remove plug from the entry point.
STEP 6 - Route conduit, if used, and wiring to the entry point and connect.
Note: The conduit nut is factory supplied and found in the
air handler document pack.
1. Use one hand to secure the factory supplied conduit nut from the inside of heater compartment.
2. Connect field supplied 3/4" or 1-1/2" conduit to conduit nut.
Note: Reducing bushings may be required for your application.
Page 8
Page 9
INSTALLER'S GUIDE
STEP 8 - Connect high voltage wiring
1. Connect the wiring to the lugs on the breaker models or to the terminal block on the lug models as illustrated.
2. Connect the ground wire to the ground lug.
3. Connect the 3-pin plug on the heater to the 3-pin plug in the air handler case.
Note: Minimum terminal screw torque is 45 in-lbs.
Factory
wiring
BLK
RED
Factory
wiring
BLK
RED
Factory
wiring
BLK
Breaker Model
GREEN
Ground
RED
Field wiringFactory wiring
Factory
wiring
Field
wiring
Field
wiring
Field
wiring
Ground
GREEN
3-Phase Model
STEP 9 - Install the seal plate. Breaker models only.
1. Place the seal plate over the breaker so the tab on the right side is in place.
2. Snap on the left side of the seal plate that has the slot by the tab.
Field
wiring
Snap in
place over
breaker second
LG (lug) Model
Field
wiring
Ground
GREEN
Place over
breaker first
Page 9
Page 10
INSTALLER'S GUIDE
STEP 10 - Connect low voltage wiring.
1. Connect the low voltage harness to Electric Heat Con­trol as shown.
Low Voltage
Harness
STEP 11 - Place Wiring Diagram.
1. Attach the wiring diagram, included in the documenta­tion packet, to the back of the heater compartment panel.
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Page 10
Page 11
Note: Breaker models only.
STEP 12 - Remove breaker cover.
1. Remove 5/16 hex screw on back of breaker cover.
2. Remove and discard the two piece breaker cover from the heater compartment panel.
STEP 13 - Replace Heater compartment panel on air handler.
INSTALLER'S GUIDE
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T
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L
L O
R O F W
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RE
D W Y
HI L
TE YELLO
R
D
I
SC
G
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D
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3
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B
H1
H3
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OR
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PR
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T E
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TOTA D
4
C .80/20
I R C U
3 . 6/1
9 . 60/40
7. 3
7 .20/
B
H
L
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B
-
K
N
H
B
TC
4
O
K B
K B
BK
H 2
BK
B
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E
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T2
BK
H3
H
BL
T
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TR
3
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T
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4
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5
T1
H4
T
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6
T2
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T3
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4
SW
T
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7
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6
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8
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ATER RA
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CIRCU
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. 60/
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T
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STEP 14 - On the unit nameplate, check off the heater that is being installed or apply the new secondary nameplate label within the heater data table on the air handler nameplate as shown.
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INSTALLER'S GUIDE
1
1
1
1
1
1
1
1
1
Section 7. Tables
Minimum Heating Airflow Settings
BAYEVAC04BK1
MODEL NO.
TAM8C0A24V21 638/713 638/900 675 1
TAM8C0B30V21 723/808 723/1020 765/1020 680/808 765/1063 850/1105 -- --
TAM8C0C36V31 876/979 876/1236 927/1236 824/979 927/1288 1030/1339 1236/1442 --
TAM8C0C42V31 978/1093 978/1380 1035/1380 920/1093 1035/1438 1150/1495 1380/1610 --
TAM8C0C48V41 1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750 1625/1813 TAM8C0C60V51 1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750 1625 1
MODEL NO.
TAM7A0A24H21 638/713 638/900 675 1
TAM7A0B30H21 723/808 723/1020 765/1020 680/808 765/1063 850/1105 -- --
TAM7A0C36H31 876/979 876/1236 927/1236 824/979 927/1288 1030/1339 1236/1442 --
TAM7A0C42H31 978/1093 978/1380 1035/1380 920/1093 1035/1438 1150/1495 1380/1610 --
TAM7A0C48H41 1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750 1625/1813 TAM7B0C60H51 1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750 1625 1
MODEL NO.
TAMGA0A24H21
TAMGA0C36H31
TAMGA0C48H41
TAMGA0C60H51
BAYEVAC04LG1 BAYEVAC05BK1 BAYEVAC05LG1
BAYEVAC04BK1 BAYEVAC04LG1 BAYEVAC05BK1 BAYEVAC05LG1
BAYEVAC04BK1
BAYEVAC04LG1
BAYEVAC05BK1
BAYEVAC05LG1
638/713 638/900
876/979 876/1236 927/1236 824/979 927/1288 1030/1339 1236/1442 --
1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750 1625/1813
1063/1188 1063/1500 1125/1500 1000/1188 1125/1563 1250/1625 1500/1750
BAYEVAC08BK1 BAYEVAC08LG1
1
BAYEVAC08BK1 BAYEVAC08LG1
1
BAYEVAC08BK1 BAYEVAC08LG1
1
Heater not qualified for 208V when installed in horizontal left position without Heat Pump
Heater not qualified for 208V when installed in horizontal left position without Heat Pump
Heater not qualified for 208V when installed in horizontal left position without Heat Pump
MINIMUM HEATER AIRFLOW CFM - HEATER MATRIX
BAYEVAC10BK1 BAYEVAC10LG1
/900 600/713 -- -- -- --
SEE AIR HANDLER NAMEPLATE FOR APPROVED COMBINATIONS
MINIMUM HEATER AIRFLOW CFM - HEATER MATRIX
BAYEVAC10BK1 BAYEVAC10LG1 BAYEVAC10LG3 BAYEVCB15LG3 BAYEVBC15BK1 BAYEVBC20BK1 BAYEVCC25BK1
/900 600/713 -- -- -- --
SEE AIR HANDLER NAMEPLATE FOR APPROVED COMBINATIONS
MINIMUM HEATER AIRFLOW CFM - HEATER MATRIX
BAYEVAC10BK1 BAYEVAC10LG1
675 1
/900
SEE AIR HANDLER NAMEPLATE FOR APPROVED COMBINATIONS
BAYEVAC10LG3 BAYEVCB15LG3 BAYEVBC15BK1 BAYEVBC20BK1 BAYEVCC25BK1
WITHOUT HEAT PUMP / WITH HP
WITHOUT HEAT PUMP / WITH HP
BAYEVAC10LG3 BAYEVCB15LG3
600/713 -- -- -- --
WITHOUT HEAT PUMP / WITH HP
BAYEVBC15BK1
BAYEVBC20BK1 BAYEVCC25BK1
1625 1
/1813
/1813
/1813
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INSTALLER'S GUIDE
Important: The BAYEV* electric heat accessory may include up to a combination of three 60 amp circuit breakers to provide an electrical disconnect for service personnel that is intended to help protect internal electrical components in the event of a short circuit or ground fault. As designed, the circuit breakers supplied in the BAYEV* accessory DO NOT provide overcurrent protection of the branch circuit. Therefore, the branch circuit(s) shall be sized and protected according to the unit nameplate.
Heater Data
Table 3.1 BAYEV -- HEATER DATA
240 VOLT 208 VOLT
Heater Model No.
BAYEVAC04BK1 1 3.84 13100 16.0 2.88 9800 13.8
BAYEVAC04LG1 1 3.84 13100 16.0 2.88 9800 13.8
BAYEVAC05BK1 1 4.80 16400 20 3.60 12300 17.3
BAYEVAC05LG1 1 4.80 16400 20 3.60 12300 17.3
BAYEVAC08BK1 1 7.68 26200 32 5.76 19700 27.7
BAYEVAC08LG1 1 7.68 26200 32 5.76 19700 27.7
BAYEVAC10BK1 1 9.60 32800 40 7.20 24600 34.6
BAYEVAC10LG1 1 9.60 32800 40 7.20 24600 34.6
BAYEVBC15BK1 2 14.40 49200 40/20 10.80 36900 34.6/17.3
BAYEVBC20BK1 2 19.20 65600 40/40 14.40 49200 34.6/34.6
BAYEVAC10LG3 1-3 PH 9.60 32800 23.1 7.20 24600 20.0
BAYEVBC15LG3 1-3 PH 14.40 49200 34.6 10.80 36900 30.0
BAYEVCC25BK1 3 24.00 82000 40/40/20 18.00 61500 34.6/34.6/17.3
Number of
Circuits
Capacity
kW BTUH kW BTUH
Heater Amps
per Circuit
Capacity
Heater Amps
per Circuit
Control Board Jumper Settings
When the heater comes from the factory, all dip switches will be in the ON (park) position. The control is already configured for the heater size that is required, so no adjustments are necessary.
NOTE: If the dip switches are changed to another kw rat­ing, the original "Park" programming is not lost;, however the dip switches must be placed in the ON (park) position or the correct kw of the heater model for normal opera­tion.
Heater Wattage Selection Table
Heater Wattage S1 SW1 S1 SW2 S1 SW3 S1 SW4 S1 SW5
PARK ON ON ON ON ON
4 KW ON ON ON OFF OFF
5 KW OFF ON ON ON ON
8 KW ON OFF ON ON ON
10 KW ON ON OFF ON ON
15 KW ON ON ON OFF ON
20 KW ON ON ON ON OFF
25 KW OFF ON ON ON OFF
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INSTALLER'S GUIDE
Section 8. Heater Operation
8.1 TAM7 Heater Operation
Electric Heat
1. R-W contacts close on the comfort control sending 24VAC to W1 of the AFC.
2. R-G contacts close on the comfort control sending 24VAC to G of the AFC.
3. The AFC communicates to the EHC that 1st stage elec­tric heat is being called upon.
4. The EHC determines the number of elements that are used for 1st stage and sends a message to the AFC for that correct cfm. (The EHC determines the amount of heat per stage by either factory programming or by the kw jumper position)
5. The AFC micro-processor sends a command to the serial communicating blower motor to run and close the blower interlock relay on the EHC. The blower motor will now run at the W1 electric heat cfm.
6. On subsequent calls for W2 and/or W3, the EHC will communicate to the AFC the required airflow request and energize the additional relays.
NOTE: The EHC has “lead-lag” logic built in that energizes
the electric heat relays based upon cycle counts.
For example: BAYEV**15 – The first time W1 only is ener-
gized; the K1 relay would close and energize the “A” heater. The second time W1 only is energized; the K2 relay would close and energize the “B” heater. The third time W1 only is energized; the K3 relay would close and energize the “C” heater.
8.3 TAMG Heater Operation
Electric Heat
1. R-W contacts close on the comfort control sending 24VAC to W1 of the AFC.
2. R-G contacts close on the comfort control sending 24VAC to G of the AFC.
3. The AFC communicates to the EHC that 1st stage elec­tric heat is being called upon.
4. The EHC determines the number of elements that are used for 1st stage and sends a message to the AFC for that correct cfm. (The EHC determines the amount of heat per stage by either factory programming or by the kw jumper position)
5. The AFC micro-processor sends a command to the serial communicating blower motor to run and close the blower interlock relay on the EHC. The blower motor will now run at the W1 electric heat cfm.
6. On subsequent calls for W2 and/or W3, the EHC will communicate to the AFC the required airflow request and energize the additional relays.
NOTE: The EHC has “lead-lag” logic built in that energizes
the electric heat relays based upon cycle counts.
For example: BAYEV**15 – The first time W1 only is ener-
gized; the K1 relay would close and energize the “A” heater. The second time W1 only is energized; the K2 relay would close and energize the “B” heater. The third time W1 only is energized; the K3 relay would close and energize the “C” heater.
8.2 TAM8 Heater Operation
Electric Heat
1. When a request for electric heat is received, the AFC
communicates to the EHC how much demand for auxil­iary heat is being requested
2. The EHC determines the number of elements that will be used for this request and sends a message to the AFC for proper airflow. (The EHC determines the amount of heat available per stage by either factory programming or by the kW jumper position)
3. The AFC sends a command to the serial communicating blower motor to run proper airflow and close the blower interlock relay on the EHC.
4. As demand from the thermostat increases, the EHC will communicate to the AFC the required airflow when ener­gizing additional relays.
NOTE: The EHC has “lead-lag or rotating” logic built in that
energizes the electric heat relays based upon cycle counts. To verify operation of all heating elements, switch thermostat to Emergency Heat and raise the setpoint of the thermostat at least 5 degrees above the actual room temperature.
Page 14
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INSTALLER'S GUIDE
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About Trane and American Standard Heating and Air Conditioning
Trane and American Standard create comfortable, energy efficient indoor environments for residential applications. For more information, please visit www.trane.com or www.americanstandardair.com
The manufacturer has a policy of continuous data improvement and it reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
18-GJ09D1-10A-EN 29 Apr 2020 Supersedes 18-GJ09D1-10 (August 2014)
© 2020
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