Trane BCVC, BCXC-SVX01B-EN, BCHC User Manual

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Installation, Operation, and Maintenance

Blower Coil Air Handler

Air Terminal Devices - 400 to 3000 cfm

Models BCHC and BCVC “AO” and later design sequence

April 2008

BCXC-SVX01B-EN

Warnings, Cautions and Notices

Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at

appropriate intervals throughout this manual. Warnings are provide to alert installing contractors to potential hazards that could result in personal injury or death. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that may result in equipment or property-damage-only accidents.

Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

ATTENTION: Warnings, Cautions and Notices appear at appropriate sections throughout this

literature. Read these carefully.

 WARN ING – Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

 CAUTION – Indicates a potentially hazardous situation which, if not avoided, could result in

minor or moderate injury. It could also be used to alert against unsafe practices.

NOTICE – Indicates a situation that could result in equipment or property-damage only accidents.

Important Environmental Concerns!

Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.

Responsible Refrigerant Practices!

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

 WARNING

Refrigerant warning information!

System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage.

Warnings, Cautions and Notices

 WARNING

Hazard of Explosion and Deadly Gases!

Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids. Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.

BCXC-SVX01B-EN 3

Introduction

About This Manual

Use this manual for commercial blower coil models BCHC and BCVC. This is the second version of this manual; this manual supercedes BCXB-SVX01A-EN. It provides specific installation, operation, and maintenance instructions for “AO” and later design sequences.

For previous design sequence information, contact your local Trane representative.

Trademarks

Trane, the Trane logo, Frostat, Integrated Comfort, Rover, Tracer, and Tracer Summit are trademarks of Trane in the United States and other countries. All trademarks referenced in this document are the trademarks of their respective owners.

4 BCXC-SVX01B-EN

Table of Contents

Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Jobsite Storage Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rigging and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Unit Location Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Horizontal Blower Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Vertical Blower Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Angle Filter and Mixing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Bottom or Top Access Filter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Steam Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Coil Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Piping Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Installation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing Wall Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Zone Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Tracer Summit Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Unit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Supply Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical Grounding Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installation Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Heating Coil Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Mixing Box Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Condensate Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Water Coil Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Piping Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Refrigerant Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Field-Installing Evaporator Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

BCXC-SVX01B-EN 5

Steam Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Tracer Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Rover Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Tracer ZN Controller Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 48

Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fan Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Two- and Four-Pipe Changeover Operation . . . . . . . . . . . . . . . . . . . . . . . 55

Electric Heat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Economizer Damper (Tracer ZN520 Only) . . . . . . . . . . . . . . . . . . . . . . . . . 56

Tracer Dehumidification (Tracer ZN520 Only) . . . . . . . . . . . . . . . . . . . . . 57

Data Sharing (Tracer ZN510 or ZN520 Only) . . . . . . . . . . . . . . . . . . . . . . 57

Binary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Binary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Zone Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Coil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Periodic Maintenance Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LED Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Manual Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Translating Multiple Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Resetting Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Common Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6 BCXC-SVX01B-EN

Model Number Description

Following is a complete description of the blower coil model number. Each digit in the model number has a corresponding code that identifies specific unit options.

Digits 1, 2, 3, 4 — Unit Model

BCHC= horizontal blower coil BCVC= vertical blower coil

Digits 5, 6, 7 — Unit Size

012 024 054 018 036 072 090

Digit 8 — Unit Voltage

A = 115/60/1 H = 575/60/3 B = 208/60/1 J = 220/50/1 C = 230/60/1 K = 240/50/1 D = 277/60/1 L = 380/50/3 E = 208/60/3 M = 415/50/3 F = 230/60/3 N = 190/50/3 G = 460/60/3 P = two-speed,

115/60/1

0 = no motor, ctrls, elec ht.

Digit 9 —Insulation Type

1 = 1” matte-faced 2 = 1” foil-faced

Digits 10, 11 — Design Sequence

Digit 12 — Motor, Drive, and Control Box Location

A = same side as coil connections,

horizontal or counterswirl only

B = opposite side from coil

connections, horizontal or counterswirl only

C = same side as coil connections,

pre-swirl only

D = opposite side from coil

connections, pre-swirl only R = right-hand access L = left-hand access

Digit 13 — Drain Pan Type, Coil & Drain Connection Side

0 = none 1 = polymer drain pan & right-hand

connections 2 = polymer drain pan & left-hand

connections 3 = stainless steel drain pan & right-

hand connections 4 = stainless steel drain pan & left-

hand connections

Digit 14 — Unit Coil #1*

Note: All coils are hydronic unless stated

otherwise.

0 = none A = 1-row preheat L = 2-row hydronic high-capacity

preheat F = 4-row hydronic G = 6-row hydronic J = 4-row hydronic, autochangeover K = 6-row hydronic, autochangeover M = 4-row hydronic high-capacity N = 6-row hydronic high-capacity R = 4-row hydronic high-capacity,

autochangeover T = 6-row hydronic high-capacity,

autochangeover 1 = 3-row DX, 3/16” distributor

(0.032) 2 = 4-row DX, 3/16” distributor

(0.032) 3 = 6-row DX, 3/16” distributor

(0.032) 4 = 3-row DX, 3/16” distributor

(0.049) 5 = 4-row DX, 3/16” distributor

(0.049) 6 = 6-row DX, 3/16” distributor

(0.049)

Digit 15 — Unit Coil #2*

Note: All coils are hydronic unless stated

otherwise.

0 = none A = 1-row reheat L = 2-row hydronic high-capacity

reheat F = 4-row hydronic G = 6-row hydronic H = 2-row hydronic, autochangeover J = 4-row hydronic, autochangeover K = 6-row hydronic, autochangeover M = 4-row hydronic high-capacity N = 6-row hydronic high-capacity P = 2-row hydronic high-capacity,

autochangeover R = 4-row hydronic high-capacity,

autochangeover T = 6-row hydronic high-capacity,

autochangeover 1 = 3-row DX, 3/16” distributor

(0.032) 2 = 4-row DX, 3/16” distributor

(0.032) 3 = 6-row DX, 3/16” distributor

(0.032) 4 = 3-row DX, 3/16” distributor

(0.049) 5 = 4-row DX, 3/16” distributor

(0.049) 6 = 6-row DX, 3/16” distributor

(0.049)

Digit 16 — Motor Horsepower

0 = none 4 = 1 hp 1 = 1/3 hp 5 = 1-1/2 hp 2 = 1/2 hp 6 = 2 hp 3 = 3/4 hp 7 = 3 hp

Digit 17 — Motor Drives

0 = none A = 390–552 rpm / 60 Hz B = 478–678 rpm / 60 Hz C = 540–765 rpm / 60 Hz D = 619–878 rpm / 60 Hz E = 727–1029 rpm / 60 Hz F = 879–1245 rpm / 60 Hz G = 1000–1417 rpm / 60 Hz H = 1200–1700 rpm / 60 Hz J = 1313–1859 rpm / 60 Hz K = 1615–2288 rpm / 60 Hz L = 678–877 rpm / 60 Hz M = 765–990 rpm / 60 Hz N = 878–1136 rpm / 60 Hz P = 1029–1332 rpm / 60 Hz R = 1245–1611 rpm / 60 Hz T = 1174–1519 rpm / 50 Hz

Digit 18 — Electric Heat Stages

0 = none 1=1-stage 2 = 2-stage

Digits 19, 20, 21 — Electric Heat

000 = none 100 = 10.0 kW 010 = 1.0 kW 110 015 = 1.5 kW 120 020 = 2.0 kW 130 = 13.0 kW 025 = 2.5 kW 140 = 14.0 kW 030 = 3.0 kW 150 = 15.0 kW 035 = 3.5 kW 160 = 16.0 kW 040 = 4.0 kW 170 = 17.0 kW 045 = 4.5 kW 180 = 18.0 kW 050 = 5.0 kW 190 = 19.0 kW 055 = 5.5 kW 200 = 20.0 kW 060 = 6.0 kW 210 = 21.0 kW 065 = 6.5 kW 220 = 22.0 kW 070 = 7.0 kW 240 = 24.0 kW 075 = 7.5 kW 260 = 26.0 kW 080 = 8.0 kW 280 = 28.0 kW 090 = 9.0 kW 300 = 30.0 kW

= =

11.0 kW

12.0 kW

Digit 22 — Electric Heat Controls

0 = none A = 24 volt magnetic contactors B = 24 volt mercury contactors

Digit 23 — Electric Heat Options

0 = none A = electric heat with heater fuse B = electric heat interlocking non-

C=A & B

fused disconnect

BCXC-SVX01B-EN 7

Model Number Description

Digit 24 — Filters

0 = none A = 1” throwaway B = 2” pleated throwaway

Digit 25 — Accessory Section

0 = none A = mixing box only B = angle filter box C = angle filter/mixing box D = top access filter box E = bottom access filter F = A & D L = C & H G = A & E M = D & H H = steam coil N = E & H J = A & H P = A, D, & H K = B & H R = A, E, & H

Digit 26 — Control Type

0 = no controls (4 x 4 junction box) 1 = control interface 2 = Tracer™ ZN010 3 = Tracer ZN510 4 = Tracer ZN520

Digit 27 — Unit Coil #1 Control Valve

0 = none A = 2-way, 2-position, n.c. B = 2-way, 2-position, n.o. C = 3-way, 2-position, n.c. D = 3-way, 2-position, n.o. E = 2-way modulating F = 3-way modulating G = field-supplied valve, 2-pos., n.c. H = field-supplied valve, 2-pos., n.o. J = field-supplied modulating valve

Digit 28 — Unit Coil #1 Control Valve Cv

0 = none A = 3.3 Cv, 1/2” valve & pipe B = 3.3 Cv, 1/2” valve & 3/4” pipe C = 3.8 Cv, 1/2” valve & 3/4” pipe D = 6.6 Cv, 1” valve & pipe E = 7.4 Cv, 1” modulating valve &

pipe

F = 8.3 Cv, 1-1/4” modulating valve &

pipe G = 3.5 Cv, 1/2” valve & pipe H = 4.4 Cv, 1/2” valve & pipe J = 7.0 Cv, 3-way valve

OR 6.0 Cv, 2-way valve, 1” valve

& pipe K = 8.0 Cv, 1” valve & pipe L = 7.4 Cv, 1” 2-position valve & pipe M = 8.3 Cv, 1-1/4” 2-position valve &

pipe Q = 1.3 Cv, 1/2” valve, 3/4” pipe R = 1.8 Cv, 1/2” valve, 3/4” pipe T = 2.3 Cv, 1/2” valve, 3/4” pipe U = 2.7 Cv, 1/2” valve, 3/4” pipe

Digit 29 — Unit Coil #1 Piping Package

0 = none 1 = basic piping package 2 = deluxe piping package

Digit 30 — Unit Coil #2 Control Val ve

Digit 31 — Unit Coil #2 Control Val ve C v

0 = none A = 3.3 Cv, 1/2” valve & pipe B = 3.3 Cv, 1/2” valve & 3/4” pipe C = 3.8 Cv, 1/2” valve & 3/4” pipe D = 6.6 Cv, 1” valve & pipe E = 7.4 Cv, 1” modulating valve &

pipe

F = 8.3 Cv, 1-1/4” modulating valve &

pipe G = 3.5 Cv, 1/2” valve & pipe H = 4.4 Cv, 1/2” valve & pipe J = 7.0 Cv, 3-way valve

OR 6.0 Cv, 2-way valve, 1” valve

& pipe K = 8.0 Cv, 1” valve & pipe L = 7.4 Cv, 1” 2-position valve & pipe M = 8.3 Cv, 1-1/4” 2-position valve &

pipe Q = 1.3 Cv, 1/2” valve, 3/4” pipe R = 1.8 Cv, 1/2” valve, 3/4” pipe T = 2.3 Cv, 1/2” valve, 3/4” pipe U = 2.7 Cv, 1/2” valve, 3/4” pipe

Digit 32 — Unit Coil #2 Piping Package

0 = none 1 = basic piping package 2 = deluxe piping package

Digit 33 — Remote Heat Options

0 = none 1 = staged electric heat 2 = 2-position hot water, n.c.

Digit 34 — Mixing Box Damper Actuator

Note: The back damper is the control

damper when actuators are ordered. The back damper is n.c. (normally closed) or n.o. (normally open) as selected.

0 = none 1 = 2-position, n.o., ship loose 2 = modulating, n.c. 3 = modulating, n.o. 4 = modulating, ship loose 5 = field-supplied 2-position, n.o. 6 = field-supplied 2-position, n.c. 7 = field-supplied modulating

Digit 35 — Factory Mounted Control Options

0 = none A = fan status C = condensate overflow D = low limit F = A & C K = C & D G = A & D N = A, C, & D

Digit 36 — Control Options 2

0 = none A = outside air sensor, field-mounted B = discharge air sensor C=A & B

Digit 37 — Control Options 3

0 = none A = dehumidification with

communicated value

B = dehumidification with local

humidity sensor

Digit 38 — Zone Sensors

0 = none 1 = off/auto, setpoint knob, on/cancel,

COMM

2 = off/auto/high/low, setpoint knob,

on/cancel, COMM

3 = wall mtd. zone sensor (set point,

occ, COMM)

4 = wall mtd. zone sensor (occ,

COMM) 5 = wall mtd. zone temp sensor A = digital zone sensor (O, A, H, L; SP;

OCC; COMM) B = digital zone sensor (CPS; OCC;

COMM) C = wireless zone sensor (setpoint

only)

Digit 39 — Extra Belt

0 = none 1 = ship loose extra belt

Digit 40 — Extra Filter

0 = none 1 = ship loose extra 1” throwaway

filter 2 = ship loose extra 2” pleated

throwaway

8 BCXC-SVX01B-EN

General Information

Blower Coil General Information

Blower coil units are draw-thru air handlers for cooling load conditions of 400–3000 cfm. Units are available in either horizontal (model BCHC) or vertical (model BCVC) configurations. Horizontal units are typically ceiling suspended via threaded rods. Knockouts are provided in all four corners to pass the rods through the unit. Horizontal units can also be floor mounted. Vertical units are typically floor mounted. They have a side inlet for easy duct connection, and do not require a field fabricated inlet plenum. Vertical units ship in two pieces and can be set up in either a pre-swirl or counter-swirl configuration.

Basic unit components consist of a water coil, condensate drain pan, filter, duct collars, one fan wheel, and motor with drive. See Figure 1. Drive components consist of sheaves, belt, and motor. The coil, drain pan, and motor/drive assembly can easily be field-converted from right hand to left hand configurations or vice versa.

Figure 1. Blower coil air handler unit components (model BCHC, horizontal unit)

Main coil with copper tubes and enhanced

aluminum fins in 2-, 4-, Unit sizes 12, 18, 24, 36, 54, 72, and 90 MBh

Knockouts in all four corners for hanger rods

Galvanized steel cabinet in 14-, 18-, 22-, and 28-inch heights

or 6-row hydronic or 3-,

4-, or 6-row DX

Internal filter frame accommodates 1- or 2-inch filters

Angle filter option and/or

Forward curved fan

Control options include control interface, Tracer™ ZN010, ZN510, or ZN520

1/3 to 3 hp motor with drive selections from 390 to 1611 rpm

Internal 1- or 2-row auxiliary coil in preheat or reheat position

mixing box accommodates 2-inch filters

Main and auxiliary drain connections on same side of unit

Two, four, or six-row main coils are available for either hydronic cooling or heating. Three, four, or six-row direct expansion (DX) coils are also available for cooling. An optional one, two, four, or sixrow heating coil is available factory-installed in either the preheat or reheat position. Also, a onerow preheat steam is available.

All units have an internal flat filter frame for one or two-inch filters. An optional angle filter box (two inch only), mixing box, bottom/top filter access box, or combination angle filter mixing box is available.

In addition, all units are available with either a basic or deluxe piping package option that includes a variety of control valve sizes in two or three-way configurations. The basic package consists of

BCXC-SVX01B-EN 9

General Information

a control valve and stop (ball) valves. The deluxe package consists of a control valve, a stop (ball) valve, a circuit setter, and strainer.

Belt-drive motors range from 1/3 to 3 horsepower in a wide range of voltages. All motors have internal thermal and current overloads, permanently sealed ball bearings, and a resilient cradle mount to reduce noise and vibration transmission.

Variable pitch sheave drive kit options help make it possible to more accurately select design static pressure. For additional flexibility, 115 volt single phase, two speed motors are optional.

Note: Sheaves are factory set in the middle of the range. Field adjustment of sheaves, motor, and

Units may have no controls (4 x 4 junction box) or any of four different control types:

1. control interface

2. Tracer™ ZN010

3. Tracer ZN510

4. Tracer ZN520

All control options are factory-installed and tested.

belt are required to arrive at desired rpm. Refer to the original sales order and Table 35, p. 68 for drive information.

10 BCXC-SVX01B-EN

Pre-Installation

Receiving and Handling

Blower coil units are packaged for easy handling and storage on the job site. Upon delivery, inspect all components for possible shipping damage. See the “Receiving Checklist” section (below) for detailed instructions. Trane recommends leaving units and accessories in their shipping packages/ skids for protection and handling ease until installation.

Shipping Package

Blower coil air handlers ship assembled on skids with protective coverings over the coil and discharge openings.

Ship-Separate Accessories

Field-installed sensors ship separately inside the unit’s main control panel. Piping packages, mixing boxes, ship separately packaged on the same skid as the unit.

Receiving Checklist

Complete the following checklist immediately after receiving unit shipment to detect possible shipping damage.

 Inspect individual cartons before accepting. Check for rattles, bent carton corners, or other visible indications of shipping damage.

 If a unit appears damaged, inspect it immediately before accepting the shipment. Manually rotate the fan wheel to ensure it turns freely. Make specific notations concerning the damage on the freight bill. Do not refuse delivery.

 Inspect the unit for concealed damage before it is stored and as soon as possible after delivery. Report concealed damage to the freight line within the allotted time after delivery. Check with the carrier for their allotted time to submit a claim.

 Do not move damaged material from the receiving location. It is the receiver’s responsibility to provide reasonable evidence that concealed damage did not occur after delivery.

 Do not continue unpacking the shipment if it appears damaged. Retain all internal packing, cartons, and crate. Take photos of damaged material if possible.

 Notify the carrier’s terminal of the damage immediately by phone and mail. Request an immediate joint inspection of the damage by the carrier and consignee.

 Notify your Trane representative of the damage and arrange for repair. Have the carrier inspect the damage before making any repairs to the unit.

 Compare the electrical data on the unit nameplate with the ordering and shipping information to verify the correct unit is received.

Jobsite Storage Recommendations

This unit is intended for indoor use only. To protect the unit from damage due to the elements and prevent it from possibly becoming a contaminant source for IAQ problems, store the unit indoors. If indoor storage is not possible, the Trane Company makes the following provisions for outdoor storage:

1. Place the unit(s) on a dry surface or raised off the ground to assure adequate air circulation beneath unit and to assure that no portion of the unit contacts standing water at any time.

2. Cover the entire unit with a canvas tarp only. Do not use clear, black, or plastic tarps as they may cause excessive moisture condensation and equipment damage.

Note: Wet interior unit insulation can become an amplification site for microbial growth (mold),

which may cause odors and health-related indoor air quality problems. If there is visible evidence of microbial growth (mold) on the interior insulation, remove and replace the insulation prior to operating the system.

BCXC-SVX01B-EN 11

Pre-Installation

Installation Preparation

Before installing the unit, perform the following procedures to ensure proper unit operation.

1. Verify the floor or foundation is level. Shim or repair as necessary. To ensure proper unit

operation, install the unit level (zero tolerance) in both horizontal axes. Failure to level the unit properly can result in condensate management problems, such as standing water inside the unit. Standing water and wet surfaces inside units can result in microbial growth (mold) in the drain pan that may cause unpleasant odors and serious health-related indoor air quality problem.

2. Allow adequate service and code clearances as recommended in the “Service Access” section

(below). Position the unit and skid assembly in its final location. Test lift the unit to determine exact unit balance and stability before hoisting it to the installation location.

Service Access

See Ta b le 1 , below, and Figure 2, p. 13 for recommended service and code clearances.

 WARNING

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.

Table 1. Service requirements, in. (cm)

Unit size Dimension A

12 20 (50.8) 18 25 (63.5) 24 25 (63.5) 36 37 (94.0) 54 37 (94.0) 72 45 (114.3) 90 45 (114.3)

12 BCXC-SVX01B-EN

Pre-Installation

Figure 2. Top view of blower coil unit showing recommended service and code clearances

Rigging and Handling

Before preparing the unit for lifting, estimate the approximate center of gravity for lifting safety. Because of placement of internal components, the unit weight may be unevenly distributed, with more weight in the coil area. Approximate unit weights are given in “Dimensions and Weights,”

p. 15. Also, you may reference the unit weight on the unit nameplate.

Before hoisting the unit into position, use a proper rigging method such as straps, slings, or spreader bars for protection and safety. Always test-lift the unit to determine the exact unit balance and stability before hoisting it to the installation location.

 WARNING

Improper Unit Lift!

Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level. Failure to properly lift unit could result in death or serious injury or possible equipment or property-only damage.

Unit Handling Procedure

1. Position rigging sling under wood skid using spreader bars to avoid unit damage.

2. Use a forklift with caution to prevent unit damage. The fork length must be at least 68 inches

long to safely fork the unit from front or back.

3. The unit center of gravity will fall within the center of gravity block at various locations

depending on unit options.

4. See unit nameplate for unit weight.

Unit Location Recommendations

When selecting and preparing the unit installation location, consider the following recommendations.

BCXC-SVX01B-EN 13

Pre-Installation

1. Consider the unit weight. Reference the unit weight on the unit nameplate or in “Dimensions

and Weights,” p. 15.

2. Allow sufficient space for the recommended clearances, access panel removal, and

maintenance access. Refer to Figure 2, p. 13.

3. The installer must provide threaded suspension rods for ceiling mounted units. All units must

be installed level.

4. Coil piping and condensate drain requirements must be considered.

Allow room for proper ductwork and electrical connections. Support all piping and ductwork independently of unit to prevent excess noise and vibration.

Skid Removal

The unit ships on skids that provide forklift locations from the front or rear. The skid allows easy maneuverability of the unit during storage and transportation. Remove the skids before placing the unit in its permanent location.

Remove the skids using a forklift or jack. Lift one end of the unit off of the skids. Vibration isolators for external isolation are field supplied.

Pre-Installation Checklist

Complete the following checklist before beginning unit installation.

 Verify the unit size and tagging with the unit nameplate.

 Make certain the floor or foundation is level, solid, and sufficient to support the unit and

accessory weights. Refer to “Dimensions and Weights,” p. 15. Level or repair the floor before positioning the unit if necessary.

 Allow minimum recommended clearances for routine maintenance and service. Refer to unit submittals for dimensions.

 Allow one and one half fan diameters above the unit for the discharge ductwork.

14 BCXC-SVX01B-EN

Dimensions and Weights

Horizontal Blower Coil

top view

*NOTE: ON UNITS WITHOUT A BOTTOM FILTER ACCESS SECTION

1.5

front view

Table 2. Horizontal blower coil dimensions (in.) and weights (lb)

Unit size H W L A B C D E FG (RH)G (LH)J (RH)J (LH) K M P Q

12 14.00 24.00 39.75 12.09 18.00 10.56 7.09 0.55 3.00 11.42 13.42 9.42 11.42 4.20 8.46 9.00 5.75 70.40 18 14.00 28.00 39.75 12.09 22.00 10.56 7.09 0.55 3.00 11.42 13.42 9.42 11.42 4.20 10.46 9.00 5.75 76.10 24 18.00 28.00 44.00 16.09 22.00 13.56 12.56 1.30 3.00 11.42 13.42 9.42 11.42 6.20 7.72 9.00 5.75 98.90 36 18.00 40.00 44.00 16.09 34.00 13.56 12.56 1.30 3.00 11.42 13.42 9.42 11.42 6.20 13.72 9.00 5.75 116.10 54 22.00 40.00 49.00 20.09 34.00 13.56 12.56 0.72 3.00 11.42 13.42 9.42 11.42 7.43 13.72 11.00 7.27 138.90 72 22.00 48.00 49.00 20.09 40.00 13.56 12.56 0.72 4.00 11.42 13.42 9.42 11.42 7.43 17.72 11.00 7.27 152.20 90 28.00 48.00 52.00 26.09 40.00 13.56 12.56 1.66 4.00 12.79 14.79 10.79 12.79 8.24 17.72 11.25 11.64 174.80

Basic

weight

unit

BCXC-SVX01B-EN 15

Dimensions and Weights

Vertical Blower Coil

top view

front view

vertical counter swirl

configuration

*NOTE; ON UNITS WITHOUT A TOP FILTER ACCESS SECTION

vertical preswirl

6.00

configuration

Table 3. Vertical blower coil dimensions (in.) and weights (lb)

Unit size H W L A B C D E FG (RH)G (LH)J (RH)J (LH) K M N P Q R

24 63.50 28.00 44.00 16.09 22.00 13.56 12.56 1.30 3.00 11.42 13.42 9.42 11.42 6.20 5.50 18.00 9.00 5.50 28.00 150.30 36 63.50 40.00 44.00 16.09 34.00 13.56 12.56 1.30 3.00 11.42 13.42 9.42 11.42 6.20 5.50 18.00 9.00 5.50 28.00 180.40 54 72.50 40.00 47.00 20.09 34.00 13.56 12.56 0.72 3.00 11.42 13.42 9.42 11.42 4.21 10.43 22.00 11.00 7.27 30.00 206.40 72 72.50 48.00 47.00 20.09 40.00 13.56 12.56 0.72 4.00 11.42 13.42 9.42 11.42 4.18 10.43 22.00 11.00 7.27 30.00 228.20 90 81.50 48.00 50.00 26.09 40.00 13.56 12.56 1.66 4.00 12.79 14.79 10.79 12.79 4.81 15.61 28.00 11.25 11.64 30.00 258.40

16 BCXC-SVX01B-EN

Basic

unit

weight

Angle Filter and Mixing Box

combination angle filter

& mixing box

mixing box

Dimensions and Weights

angle filter box

Table 4. Angle filter and mixing box dimensions (in.) and weights (lb)

Unit size H L W A B Weight

12 14.12 22.00 24.11 7.06 15.56 36.0 16 14.12 22.00 28.11 7.06 19.56 41.0 24 18.12 19.50 28.11 7.06 19.56 43.0 36 18.12 24.50 40.11 7.06 31.56 56.0 54 22.12 23.50 40.11 12.81 31.56 72.0 72 22.00 23.50 48.00 12.81 32.56 72.5 90 27.90 27.56 48.00 12.85 31.56 84.1

BCXC-SVX01B-EN 17

Dimensions and Weights

Bottom or Top Access Filter Box

7.17

.97

AIR FLOW

FILTER

FILTER ACCESS PANEL

right side view

NOTES;

1. DIMENSIONS ARE IN INCHES.

2. ROTATE 180° FOR TOP ACCESS.

3. SECTIONS SHIPS ATTACHED TO THE UNIT.

Table 5. Bottom or top access filter box dimensions (in.) and weights (lb)

Unit size H W A B C D Weight

12 14.00 24.00 9.98 2.01 18.23 2.88 15 18 14.00 28.00 9.98 2.01 21.98 3.01 17 24 18.00 28.00 14.23 1.89 23.23 2.38 18 36 18.00 40.00 14.23 1.89 33.73 3.13 25 54 22.00 40.00 18.23 1.89 33.73 3.13 28 72 22.00 48.00 18.23 1.89 42.73 2.63 32 90 28.00 48.00 23.23 1.89 41.23 3.38 37

AIR FLOW

top view

18 BCXC-SVX01B-EN

Electric Heat

Dimensions and Weights

& 90

top view

front view

& 90

ELECTRIC HEAT MAY NEED FIELD-SUPPLIED EXTERNALLY-WRAPPED INSULATION IF THE UNIT IS INSTALLED IN AN UNCONDITIONED SPACE OR IF SWEATING IS AN ISSUE.

right side view

& 90 ARE HINGED

Table 6. Electric heat dimensions (in.) and weights (lb)

Unit size H W A B C D E Weight

12 14.06 17.88 8.13 6.79 10.50 7.75 0.03 10.0 18 14.06 19.88 10.13 8.79 10.50 7.75 0.03 10.8 24 18.06 21.25 7.63 6.29 13.50 12.63 0.80 11.3 36 18.06 27.25 13.63 12.29 13.50 12.63 0.80 12.8 54 18.06 27.25 13.63 11.67 13.50 12.63 0.22 16.0 72 18.06 27.25 13.63 11.67 13.50 12.63 0.22 17.4 90 18.06 27.25 13.63 11.67 13.50 12.63 1.16 19.2

BCXC-SVX01B-EN 19

Dimensions and Weights

Steam Coil

NOTES:

1. FILTER ACCESS & ACCESS PANEL LOCATED ON BOTH SIDES.

2. WEIGHT INCLUDES CABINET WITH AVERAGE FILTER, BUT DOES NOT INCLUDE CIOL WEIGHT. SEE GENERAL DATA SECTION FOR COIL WEIGHTS.

ACCESS PANEL

HEATING COIL

21.00

0.97

AIRFLOW

0.97

FILTER ACCESS

Table 7. Steam coil box dimensions (in.) and weights (lb)

Coil Connections, NPT

Unit size

12 14.00 24.00 12.06 18.04 2.98 34 1 3/4 18 14.00 28.00 12.06 22.04 2.98 37 1 3/4 24 18.00 28.00 16.06 22.04 2.98 40 1-1/2 1 36 18.00 40.00 16.06 34.04 2.98 48 1-1/2 1 54 22.00 40.00 20.06 34.04 2.98 50 2 1 72 22.00 48.00 20.06 42.04 2.98 56 2 1 90 28.00 48.00 26.06 40.04 3.98 63 2.5 1-1/4

H W A B C Weight Supply Return

20 BCXC-SVX01B-EN

Coil Connections

Dimensions and Weights

Table 8. Hydronic coil connection sizes, OD (in.)

Standard capacity High capacity

Unit size

12 5/8 - - 5/8 7/8 7/8 18 5/8 - - 5/8 7/8 7/8 24 5/8 - - 7/8 1-1/8 1-1/8 36 7/8 - - 7/8 1-1/8 1-1/8 54 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 72 1-1/8 1-3/8 1-3/8 1-1/8 1-1/8 1-1/8 90 1-1/8 1-5/8 1-5/8 1-1/8 1-1/8 1-1/8

Table 9. DX coil connection sizes, OD (in.)

Unit size

12 5/8 5/8 5/8 5/8 18 5/8 5/8 5/8 5/8 24 5/8 5/8 7/8 5/8 36 7/8 5/8 7/8 5/8 54 1-1/8 7/8 1-1/8 7/8 72 1-1/8 7/8 1-1/8 7/8 90 1-3/8 7/8 1-1/8 7/8

1-row 4-row 6-row 2-row 4-row 6-row

3- & 4-row 6-row

Suction Liquid Suction Liquid

Table 10. Steam coil connection sizes, female connection, NPT (in.)

Unit size Supply Return

12 1 3/4 18 1 3/4 24 1-1/2 1 36 1-1/2 1 54 2 1 72 2 1 90 2-1/2 1-1/4

BCXC-SVX01B-EN 21

Dimensions and Weights

Piping Packages

Basic Piping

Two-way, 1/2” and 1” valve basic piping package

Two-way, 1-1/4” valve basic piping package

Three-way, 1/2” and 1” valve basic piping package

22 BCXC-SVX01B-EN

Deluxe Piping

Two-way, 1/2” and 1” valve deluxe piping package

Dimensions and Weights

Two-way 1-1/4” valve deluxe piping package

BCXC-SVX01B-EN 23

Dimensions and Weights

Three-way, 1/2” and 1” valve deluxe piping package

Table 11. Piping package dimensions (in.)

Piping

package

2-way 1/2 5/8 12.025 2.650 12.625 5.650 N/A N/A

3-way 1/2 5/8 12.088 2.097 12.688 4.497 6.351 6.351

Nominal

tube size Actual size A B C D E F

1 1-1/8 13.295 4.260 13.220 9.288 3.020 N/A

3/4 7/8 15.623 1.750 15.313 6.290 6.701 6.701

1 1-1/8 13.370 3.690 13.210 9.060 9.813 9.813

1-1/4 1-3/8 16.885 3.738 16.410 10.023 3.052 10.520

24 BCXC-SVX01B-EN

Installation Controls

Installing Wall Mounted Controls

Wall mounted zone sensors ship taped to the control box. Refer to Figure 3 for zone sensor dimensions.

Position the controller on an inside wall three to five feet above the floor and at least 18 inches from the nearest outside wall. Installing the controller at a lower height may give the advantage of monitoring the temperature closer to the zone, but it also exposes the controller to airflow obstructions. Ensure that air flows freely over the controller.

Before beginning installation, follow the wiring instructions below. Also, refer to the unit wiring schematic for specific wiring details and point connections.

Wiring Instructions

Avoid mounting the controller in an area subject to the following conditions:

• Dead spots, such as behind doors or in corners that do not allow free air circulation.

• Air drafts from stairwells, outside doors, or unsectioned hollow walls.

• Radiant heat from the sun, fireplaces, appliances, etc.

• Airflow from adjacent zones or other units.

• Unheated or uncooled spaces behind the controller, such as outside walls or unoccupied spaces.

• Concealed pipes, air ducts, or chimneys in partition spaces behind the controller.

Zone Sensor Installation

Follow the procedure below to install the zone sensor module (see Figure 3).

Figure 3. Wall-mounted zone sensor dimensions

1. Note the position of the setpoint adjustment knob and gently pry the adjustment knob from the

cover using the blade of a small screwdriver.

2. Insert the screwdriver blade behind the cover at the top of the module and carefully pry the

cover away from the base.

3. To install the zone sensor module without a junction box (directly to the wall):

a. Using the module base as a template, mark the rectangular cutout for the control wiring and

module installation holes. Ensure the base is level.

b. Set the base aside and make the cutout. Then, drill two 3/16” diameter holes approximately

one-inch deep. Insert and fully seat the plastic anchors.

c. Pull the control wires through the cutout and attach the module to the wall using the screws

provided.

4. To install the zone sensor module to a standard junction box:

a. Level and install a 2” x 4” junction box (installer supplied) vertically on the wall.

BCXC-SVX01B-EN 25

Installation Controls

b. Pull the control wires through the cutout. Attach the module to the wall using the screws

provided.

5. Strip the insulation on the interconnection wires back 0.25 inch and connect to TB1. Screw down

the terminal blocks.

6. Replace the zone sensor cover and adjustment knob.

If installing a Tracer™ ZN510 or ZN520 zone sensor, see “Tracer Summit Communication Wiring,”

p. 27 for more information.

Communication Wiring

Units with Tracer ZN510 or ZN520 only

Note: Communication link wiring is a shielded, twisted pair of wire and must comply with

Follow these general guidelines when installing communication wiring on units with either a Tracer™ ZN510 or ZN520 controller:

• Maintain a maximum 5000 ft. aggregate run

• Install all communication wiring in accordance with the NEC and all local codes.

• Solder the conductors and insulate (tape) the joint sufficiently when splicing communication

wire. Do not use wire nuts to make the splice.

• Do not pass communication wiring between buildings because the unit will assume different

ground potentials.

• Do not run power in the same conduit or wire bundle with communication link wiring.

applicable electrical codes.

Service Communication Wiring

Establish service communication using Rover™ service software connected to the Tracer™ ZN controller using a twisted wire pair to one of the following connection points:

• Remote zone sensor module

• Connections on the board

This allows the technician to view and edit the Tracer™ controller configuration and troubleshoot the unit.

Note: Unit control options and field wiring practices may limit the controller’s communication

ability.

Route interconnecting wiring from the Tracer™ controller to provide service communication at the wall-mounted zone sensor module. Install wiring by referencing the unit wiring diagram and

Ta b l e 12 , p . 2 9 for appropriate wire sizes. After wiring is complete, connect the communication

cable (provided with the Rover™ service tool) to the telephone style RJ11 connection on the zone sensor module. Attach the other end of the cable to a computer running Trane Rover software to communicate.

Zone Sensors Without Interconnecting Wiring

Establish service communication to the Tracer™ ZN controller by wiring directly to the board inside the control box. Refer to the unit-wiring diagram for appropriate communication terminals on the board.

Once wiring is complete, Use Trane Rover™ software to communicate to the Tracer™ ZN controller.

Tracer Communications

Tracer™ ZN controllers have Comm5 communication ports. Typically, a communication link is applied between unit controllers and a building automation system. Communication also is possible via Rover™, Trane’s service tool.

26 BCXC-SVX01B-EN

Peer-to-peer communication across controllers is possible even when a building automation system is not present.You do not need to observe polarity for Comm5 communication links.

The controller provides six 0.25-inch quick-connect terminals for the Comm5 communication link connections, as follows:

• Two terminals for communication to the board

• Two terminals for communication from the board to the next unit (daisy chain)

• Two terminals for a connection from the zone sensor back to the controller

Each controller has its own unique address or I.D. number on a Neuron chip. Setting dip switches are not required on the Tracer™ controller.

Tracer Summit Communication Wiring

For Tracer™ ZN-controlled units that will interface with the Trane Tracer Summit® building management system, terminate the communication wiring in the control box at the designated terminals on the board. Reference the unit wiring diagram or submittals.

Ground shields at each Tracer™ ZN controller, taping the opposite end of each shield to prevent any connection between the shield and anther ground. Refer to Trane publication CNT-SVX04A-EN, Tracer ZN.520 Unit Controller - Installation, Operation and Programming Guide, for the communication wiring diagram.

Communication wire must conform to the following specification:

• Shielded twisted pair 18 AWG

• Capacitance 23 (21-25) picofarads (pF) per foot

• Listing/Rating – 300V 150C NEC 725-2 (b) Class 2 Type CL2P

• Trane Part No. 400-20-28 or equivalent, available through Trane BAS Buying Group Accessories

catalog.

Installation Controls

BCXC-SVX01B-EN 27

Installation Electrical

Unit Wiring Diagrams

Specific unit wiring diagrams are provided on the inside of the control panel door. Typical unit wiring diagrams are in “Wiring Diagrams,” p. 81. Use these diagrams for connections or trouble analysis.

 WARNING

Grounding Required!

Follow proper local and state electrical codes for requirements on grounding. Failure to follow code could result in death or serious injury.

Supply Power Wiring

Wiring must conform to NEC and all applicable code requirements.

It is the installer’s responsibility to provide adequately-sized power wires and proper unit grounding.

Bring supply wiring through provided equipment knockouts located at the power connection point on the unit. Equipment submittals should be referred to for the exact electrical access connection point. Connect the power wires to the power connection point provided.

Connection to the installer-provided ground path must be made to the green wire or green grounding screw provided on each unit.

Locate unit wiring diagrams on the inside of the control box cover. Refer to the unit-specific wiring diagrams for wiring, connection point, and fuse installation information. Refer to the unit nameplate for unit-specific electrical information, such as voltage, minimum circuit ampacity (MCA), and maximum fuse size (MFS).

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

NOTICE

Correct phase critical!

Correct phase sequence is critical. If phase sequence of the incoming line voltage is not correct, it could cause motor damage.

Electrical Connections

Units have one of three different connection points, depending on the unit type and options.

1. If the unit has no controls: power and ground are tucked inside of the handy box.

2. If the unit has a control interface or Tracer™ ZN controller: power and ground are inside the

control box. If the unit has a control interface or a Tracer controller, the power wires and ground wire are inside the control box connected to a non fused disconnect switch.

28 BCXC-SVX01B-EN

3. If the unit has a electric heat: power and ground connections are inside the electric heat control

box, connected to a non-fused disconnect switch or terminal block.

Electrical Grounding Restrictions

 WARNING

Hazardous Voltage!

All sensor and input circuits are normally at or near ground (common) potential. When wiring sensors and other input devices to the Tracer™ ZN controller, avoid creating ground loops with grounded conductors external to the unit control circuit. Ground loops can affect the measurement accuracy of the controller.

Note: Unit transformer IT1 provides power to the blower coil unit only and is not intended for field

connections. Field connections to the transformer IT1 may cause immediate or premature unit component failure.

All input/output circuits (except isolated relay contacts and optically-isolated inputs) assume a grounded source, either a ground wire at the supply transformer to control panel chassis, or an installer supplied ground.

Note: Do not connect any sensor or input circuit to an external ground connection.

The installer must provide interconnection wiring to connect wall mounted devices such as a zone sensor module. Refer to the unit wiring schematic for specific wiring details and point-to-point wiring connections. Dashed lines indicate field wiring on the unit wiring schematics. All interconnection wiring must conform to NEC Class 2 wiring requirements and any state and local requirements. Refer to Ta bl e 1 2 for the wire size range and maximum wiring distance for each device.

Table 12. Zone sensor maximum wiring distances, ft (m)

Installation Electrical

Wire size range Max. wiring distance

16–22 AWG 200 (60.96)

Note: Do not bundle or run interconnection wiring in parallel with or in the same conduit with any

high voltage wires (110V or greater). Exposure of interconnection wiring to high voltage wiring, inductive loads, or RF transmitters may cause radio frequency interference (RFI). In addition, improper separation may cause electrical noise problems. Therefore, use shielded wire (Beldon 83559/83562 or equivalent) in applications that require a high degree of noise immunity. Connect the shield to the chassis ground and tape at the other end.

Minimum Circuit Ampacity (MCA) and Maximum Fuse Size (MFS) Calculations for Units with Electric Heat

Use these formulas to calculate the MCA and MFS.

Heater amps = (heater kW x 1000)/heater voltage

Note: Use 120V heater voltage for 115V units. Use 240V heater voltage for 230V units. Use 480V

heater voltage for 460V units. Use 600V heater voltage for 575V units.

MCA = 1.25 x (heater amps + all motor FLAs)

MFS or HACR type circuit breaker = (2.25 x largest motor FLA) + second motor FLA + heater amps (if applicable)

HACR (Heating, Air-Conditioning and Refrigeration) type circuit breakers are required in the branch circuit wiring for all units with electric heat.

BCXC-SVX01B-EN 29

Installation Electrical

See Ta b le 1 3 for electric heat kW and Table 14, p. 31 for motor FLAs.

Select a standard fuse size or HACR type circuit breaker equal to the MCA.

Use the next larger standard size if the MCA does not equal a standard size.

Standard fuse sizes are: 15, 20, 25, 30, 35, 40, 45, 50, 60 amps

Useful Formulas

kW = (cfm x ΔT)/3145 ΔT = (kW x 1000)/voltage

Single phase amps = (kW x 1000)/voltage Three phase amps = (kW x 1000)/(voltage x 1.73) Electric heat MBh = (Heater kW) (3.413)

Table 13. Available electric heat, min–max (kW)

Voltage

115/60/1 1–3 1–3 1–3 1–3 1–3 1–3 1–3 208/60/1 1–4 1–6 1–8 1–8 1–8 1–8 1–8 230/60/1 1–4 1–6 1–8 1–8 1–8 1–8 1–8 277/60/1 1–4 1–6 1–8 1–11 1–11 1–11 1–11 208/60/3 1–4 1–6 1–8 1–11 1–12 1–12 1–12 230/60/3 1–4 1–6 1–8 1–11 1–12 1–12 1–12 460/60/3 1.5–4 1.5–5 1–8 1–11 1–16 1–21 1–30 575/60/3 2–4 2–4 1–8 1–11 1–16 1–21 1–30 220/50/1 1–4 1–6 1–8 1–8 1–8 1–8 1–8 240/50/1 1–4 1–6 1–8 1–8 1–8 1–8 1–8 380/50/3 1–4 1–5 1–8 1–11 1–16 1–20 1–28 415/50/3 1.5–4 1.5–5 1–8 1–11 1–16 1–21 1–30 190/50/3 N/A N/A N/A N/A N/A N/A N/A

Notes:

1. Heaters are available in the fo llowin g K w increments: 1. 0, 1.5, 2.0, 2.5, 3.0, 3. 5, 4.0, 4 .5, 5.0, 5. 5,

2. Magnetic contactors are standard. Mercury contactors are available on horizontal units only.

3. Units with electric heat are available with or without door interlocking disconnect switch.

4. Units with electric heat are available with or without line fuses.

5. Units with electric heat must not be run below the minimum cfm listed in the general data section.

6. Electric heat is balanced staging: 1 stage = 100%, 2 stages = 50%/50%

7. Electric heat is not available on 190/50/3 units.

8. For two-speed units not being controlled by the Tracer™ family of controls, a 0.2-second delay for

Unit size

12 18 24 36

6.0, 6.5, 7.0, 7.5, 8.0, 9.0, 10.0, 11.0, 12.0, 13.0, 14.0, 15.0, 16.0, 17.0, 18.0,19.0, 20.0, 21.0,

22.0, 24.0, 26.0, 28.0, 30.0.

speed switching needs to be incorporated into the control sequence.

72 90

30 BCXC-SVX01B-EN

Installation Electrical

Table 14. Motor electrical data

Voltage Voltage range rpm Rated hp lb FLA LRA

115/60/1

Two-speed

115/60/1

208–230/60/1

277/60/1

208/60/3

230/60/3

460/60/3

575/60/3

Note: For two-speed units not being controlled by the Tracer™ family of controls, a 0.2-second delay for speed switching needs

to be incorporated into the control sequence.

104–126 1750 1/3 18 5.8 22.8

1/2 21 7.2 30.4 3/4 29 12.0 58.4

1.0 29 12.8 58.4

104–126 1750/1160 3/4 40 8.9/6.1 42.0

1.0 41 11.5/8.1 58.2

187–253 1750 1/3 18 3.1 11.4

1/2 21 3.6 15.2 3/4 29 6.0 29.2

1.0 29 6.4 29.2

249–305 1750 1/3 15.5 2.5 12.1

1/2 21.5 3.6 19.3 3/4 25 4.3 25.3

1.0 29 5.6 32.6

187–229 1750 1/2 22 2.3 11.4

3/4 26 2.9 15.9

1.0 28 3.5 20.2

1.5 29 4.8 30.0

2.0 34 6.2 38.5

3.0 49 8.6 55.1

207–253 1750 1/2 22 2.4 12.8

3/4 26 3.0 18.6

1.0 28 3.6 23.0

1.5 29 4.8 33.4

2.0 34 6.2 43.6

3.0 49 8.6 62.0

414–506 1750 1/2 22 1.2 6.4

3/4 26 1.5 9.3

1.0 28 1.8 11.5

1.5 29 2.4 16.7

2.0 34 3.1 21.8

3.0 49 4.3 31.0

518–632 1750 3/4 20.5 1.1 7.5

1.0 22.5 1.4 9.0

1.5 31 1.9 13.3

2.0 36 2.5 17.9

3.0 49 3.3 23.7

BCXC-SVX01B-EN 31

Installation Electrical

Table 14. Motor electrical data (continued)

Voltage Voltage range rpm Rated hp lb FLA LRA

220/50/1

240/50/1

190/50/3

380/50/3

415/50/3

Note: For two-speed units not being controlled by the Tracer™ family of controls, a 0.2-second delay for speed switching needs

198–242 1450 1/3 20.5 3.0 15.6

1/2 25 3.6 20.5 3/4 29 5.2 25.6

1.0 38 9.3 52.2

216–264 1450 1/3 20.5 3.3 17.1

1/2 25 4.0 22.7 3/4 29 5.5 39.1

1.0 38 10.6 57.8 171–209 1450 1/3 22 1.1 5.6 342–418 1/2 26 1.4 7.8

3/4 28 1.7 9.8

1.0 29 2.1 14.6

1.5 34 2.8 18.7

2.0 49 3.6 27.2 374–456 1450 1/3 22 1.2 6.8

1/2 26 1.5 9.4 3/4 28 1.9 11.0

1.0 29 2.5 17.4

1.5 34 3.1 22.6

2.0 49 3.6 32.3

to be incorporated into the control sequence.

32 BCXC-SVX01B-EN

Installation Mechanical

 WARNING

Hazardous Voltage!

Installing the Unit

Follow the procedures below to install the blower coil unit.

Horizontal Units, Model BCHC

Install horizontal units suspended from the ceiling with 3/8” threaded rods that are field provided. There are two knockouts in each corner of the unit for installation of the threaded rods. Ensure the ceiling opening is large enough for unit installation and maintenance requirements.

BCHC Installation Procedure

Materials needed:

• threaded rods, 3/8” (4)

• nuts (8)

• flat washers or steel plates (8)

• vibration isolator hangers or turnbuckles (4)

1. Determine the unit mounting hole dimensions. Prepare the hanger rod isolator assemblies, which are field provided, and install them in the ceiling. Trane recommends using threaded rods to level the unit. Consult the unit nameplate or “Dimensions and Weights,” p. 15 in th is ma nua l for the unit weight. See Figure 4 for proper horizontal unit installation.

Figure 4. How to hang the horizontal unit from the ceiling

2. Remove motor access panels and filter access panels.

3. Punch out the eight knockouts in the top and bottom panels.

BCXC-SVX01B-EN 33

Installation Mechanical

4. Guide the threaded rod through the unit from the top, careful not to damage insulation or wiring. See Figure 5. Insert the threaded rod at an angle to help prevent internal unit damage.

Figure 5. When inserting the threaded rod though the unit knockouts, angle it through the top,

5. Put a nut and large flat washer or steel plate on the bottom of the threaded rod. See Figure 6.

Figure 6. Correct placement of washer or steel plate and nut between threaded rod and unit.

careful not to damage unit coil or insulation.

This helps prevent air leakage.

6. Put a nut and flat washer or steel plate on the top to prevent air leakage.

7. Thread the top of the rod into the isolator or turnbuckle.

8. Hoist the unit to the suspension rods and attach with washers and lock–nuts (see Figure 4, p. 33 for details).

9. Level the unit for proper coil drainage and condensate removal from the drain pan. Refer to

“Condensate Drain Connections,” p. 36.

10. Connect the ductwork to the unit. Refer to “Duct Connections,” p. 37.

Vertical Units, Model BCVC

Install vertical units on the floor. Units are provided with legs that are field-installed to help accommodate a U-trap on the drain connection, if necessary. A field-fabricated inlet plenum is not

34 BCXC-SVX01B-EN

Installation Mechanical

required. The unit is shipped in two pieces, and can be arranged in either a pre-swirl or counterswirl inlet configuration (see Figure 7).

Figure 7. Typical vertical unit installation

Heating Coil Option

Note: The hydronic heating coil option is factory installed in either the reheat or preheat position.

Coils can be rotated for either right or left-hand connections.

If you need to rotate the hydronic heating coil option to change the coil connection side, follow the procedure below.

1. Remove both coil access panels.

2. Remove the coil and rotate to change connection position.

3. Exchange coil patch plates.

4. Knock out drain pipe connections on new coil hand access panel.

5. Plug old drain connections.

Mixing Box Option

Materials provided:

• mounting legs

BCXC-SVX01B-EN 35

Installation Mechanical

• interconnecting linkage, LH or RH attachment

Materials needed:

• grooved and extendible drive rods, 1/2-inch O.D. grooved

• screws

The mixing box option ships separately for field installation. It has two low-leak, opposed blade dampers and all necessary interconnecting linkage components for left or right hand attachment onto 1/2-inch O.D. grooved, extendible drive rods. Also, mounting legs are provided for floor mounting on a vertical unit. Knockouts are provided to suspend the mixing box from the ceiling horizontally.

Mixing Box Installation Procedure

1. Support the mixing box independent of the unit in the horizontal position.

2. Install the mixing box as a sleeve around the duct collar of the filter frame. To attach the mixing box to the filter frame, insert screws through the matching the holes on all sides of the mixing box and filter frame.

3. Install the linkage, following the procedure below.

Linkage Installation Procedure

1. Attach the linkage on either the right or left side of the mixing box following the procedure below.

2. Open the damper blades fully. Locate drive rods on the LH or RH side for linkage attachment. Loosen drive rod set screw, without removing.

3. Remove knockouts on side access panel adjacent to the drive rods.

4. Pierce a hole through the insulation at the knockouts to allow the drive rod to extend freely through side of mixing box. Cut away insulation sufficiently to allow drive rod to turn smoothly.

5. Extend drive rod end at desired position beyond side of unit. Tighten drive rod set screws.

6. Attach linkage and tighten all set screws. Note that neither hand levers are provided. However, mixing box actuators are a factory-provided option that ship inside the mixing box when ordered.

7. Position linkage so both sets of dampers operate freely and so that when one damper is fully open, the other is fully closed.

Condensate Drain Connections

Note: It is the installer’s responsibility to provide adequate condensate piping to prevent potential

water damage to the equipment and/or building.

Size the main drain lines and trap them the same size as the drain connection, which is 3/4” schedule 40 PVC, 1.050” O.D. on blower coils.

If drain pan removal is required, make the main and auxiliary drain connections with compression fittings. Follow the procedure below to remove the drain pan.

1. Remove the opposite side coil access panel.

2. Remove the drain pan clips.

3. Disconnect drain lines.

4. Remove the sheet metal screw.

5. Pull out drain pan through the opposite side.

Note: Prime drain traps to prevent the drain pan overflow.

36 BCXC-SVX01B-EN

Installation Mechanical

Plug or trap the auxiliary connection to prevent air from being drawn in and causing carryover (see

Figure 8).

Figure 8. Recommended drain trap installation for draw-through units

‘

H = 1” of length for each 1” of negative pressure + 1”additional J = 1/2 of H L = H + J + pipe diameter + insulation

All drain lines downstream of the trap must flow continuously downhill. If segments of the line are routed uphill, this can cause the drain line to become pressurized. A pressurized drain line may cause the trap to back up into the drain pan, causing overflow.

Duct Connections

Install all air ducts according to the National Fire Protection Association standards for the “Installation of Air Conditioning and Ventilation Systems other than Residence Type (NFPA 90A) and Residence Type Warm Air Heating and Air Conditioning Systems (NFPA 90B).

Make duct connections to the unit with a flexible material such as heavy canvas to help minimize noise and vibration. If a fire hazard exists, Trane recommends using Flexweave 1000, type FW30 or equivalent canvas. Use three inches for the return duct and three inches for the discharge duct. Keep the material loose to absorb fan vibration.

Run the ductwork straight from the opening for a minimum of 1-1/2 fan diameters. Extend remaining ductwork as far as possible without changing size or direction. Do not make abrupt turns or transitions near the unit due to increased noise and excessive static losses. Avoid sharp turns and use elbows with splitters or turning vanes to minimize static losses.

Poorly constructed turning vanes may cause airflow generated noise. Align the fan outlet properly with the ductwork to decrease duct noise levels and increase fan performance. Check total external static pressures against fan characteristics to be sure the required airflow is available throughout the ductwork.

To achieve maximum acoustical performance, minimize the duct static pressure setpoint.

BCXC-SVX01B-EN 37

Installation Piping

Water Coil Connections

Water coils have sweat connections. Reference coil connection dimensions in “Dimensions and

Wei ght s,” p. 1 5. Proper installation and piping is necessary to ensure satisfactory coil operation and

prevent operational damage. Water inlet and outlet connections extend through the coil section side panel (see Figure 9). Follow standard piping practices when piping to the coil.

Figure 9. Horizontal unit coil connect location

NOTICE

Potential coil-freeze condition!

Make provisions to drain the coil when not in use to prevent coil freeze-up. Failure to follow this procedure could result in equipment/property damage.

Piping Packages

Piping packages ship separate for field installation and have sweat type connections. Interconnecting piping is field provided.

When brazing piping, follow these guidelines to prevent piping component damage.

1. Avoid exposing piping components to high heat when making sweat connections.

2. Protect the closest valve to the connection with a wet rag.

3. Ensure the circuit balancing valve option is in the unseated position.

Refrigerant Coil Piping

The DX cooling coil in a BCHC/BCVC unit is equipped with a single distributor (single-circuited). Exception: size 72 and 90 six-row DX cooling coils are horizontally split and have two distributors (double-circuited) which may be manifolded to a single refrigeration circuit in a condensing unit. Some condensing units have two, independent refrigeration circuits. Do not manifold two,

independent refrigeration circuits into a single-circuited DX (evaporator) coil.

Note: Refer to “Warnings, Cautions and Notices” for information on handling refrigerants.

Units that are UL listed shall not have refrigerant temperatures and pressures exceeding that listed on the unit nameplate.

Follow accepted refrigeration piping practices and safety precautions for typical refrigerant coil piping and components. Specific recommendations are provided with the compressor unit, including instructions for pressure-testing, evacuation, and system charging. Leak test the entire refrigerant system after all piping is complete. Charge the unit according to approximate weight requirements, operating pressures, and superheat/subcooling measurements. Adjust the thermal expansion valve setting, if necessary, for proper superheat.

Liquid Line

Line Sizing. Properly sizing the liquid line is critical to a successful application. If provided, use

the liquid line size recommended by the manufacturer of the compressor unit. The selected tube

38 BCXC-SVX01B-EN

Installation Piping

diameter must be as small as possible, while still providing at least 5°F [2.7°C] of subcooling at the expansion valve throughout the operating envelope.

Routing. Install the liquid line with a slight slope in the direction of flow so that it can be routed

with the suction line. Minimize tube bends and reducers because these items tend to increase pressure drop and reduce subcooling at the expansion valve.

Insulation. The liquid line is generally warmer than the surrounding air, so it does not require

insulation.

Components. Liquid-line refrigerant components necessary for a successful job include an

expansion valve, moisture indicating sight glass, filter drier, manual ball shutoff valves, access port, and possibly a solenoid valve. Position these components as close to the evaporator as possible.

• Thermal expansion valve (TEV)

Select the TEV based on the actual evaporator capacity, considering the full range of loadings. Verify that the valve will successfully operate at the lightest load condition, considering if hot gas bypass is to be used. For improved modulation, choose a TEV with balanced port construction and an external equalizer connection. The valve must be designed to operate against a back pressure of 20 psi higher than actual evaporator pressure. Install the TEV directly on the coil liquid connection (distributor provided).

The remote expansion-valve bulb should be firmly attached to a straight, well-drained, horizontal section of the suction line. The external equalizer line should be inserted downstream of the remote bulb.

• Moisture-indicating sight glass

Install a moisture-indicating sight glass in the liquid line between the expansion valve and filter drier. The sight glass should be sized to match the size of the liquid line.

• Filter drier

Install a properly sized liquid line filter-drier upstream from the expansion valve and as close to the evaporator coil as possible. Select the filter-drier for a maximum pressure drop of 2 psi at the design condition.

Manual, ball-type shutoff valves on either side of the filter drier allows replacement of the core without evacuating the entire refrigerant charge.

• Access port

The access port allows the unit to be charged with liquid refrigerant and is used to determine subcooling. This port is usually a Schraeder valve with a core.

• Solenoid valve

If required by the compressor unit, install the solenoid valve between the filter drier and sight glass.

NOTICE

Valve Dam age !

Disassemble the thermal expansion valve before completing the brazing connections. If necessary, wrap the valve in a cool wet cloth while brazing. Failure to protect the valve from high temperatures could damage internal components.

Suction Line

Line sizing. Properly sizing the suction line is critical for ensuring that the oil returns to the

compressor throughout the system operating envelope. If provided, use the suction line size(s) recommended by the manufacturer of the compressor unit. The selected tube diameter(s) must maintain adequate refrigerant velocities at all operating conditions.

BCXC-SVX01B-EN 39

Installation Piping

Routing. To prevent residual or condensed refrigerant from “free-flowing” toward the

compressor, install the suction line so it slopes slightly—1 inch per 10 feet of run [1 cm per 3 m]— toward the evaporator. Avoid putting refrigerant lines underground. Refrigerant condensation, installation debris inside the line, service access, and abrasion/corrosion can quickly impair system reliability.

Insulation. After operating the system and testing all fittings and joints to verify the system is

leak-free, insulate the suction lines to prevent heat gain and unwanted condensation.

Components. Installing the suction line requires field installation of these components: an

access port and possibly a suction filter. Position them as close to the compressor as possible.

• Access port

The access port is used to determine suction pressure and adjust the TEV. It should be located near the external equalizer line connection. This port is usually a Schraeder valve with a core.

• Suction filter

If required by the compressor unit, a replaceable-core suction filter is installed as close to the compressor unit as possible. Adding manual, ball-type shutoff valves upstream and downstream of the filter simplifies replacement of the filter core.

Field-Installing Evaporator Piping

See Figure 10 and refer to the instructions below to field-install evaporator piping.

1. Pitch the liquid line slightly—1 in./10 ft [1 cm/3 m]—so that the refrigerant drains toward the evaporator.

2. Provide one expansion valve per distributor.

3. Slightly pitch the outlet line from the suction header toward the suction riser — that is, 1 in./10 ft [1 cm/3 m] in the direction of flow. Use the tube diameter that matches the suction-header connection.

4. For the vertical riser, use the tube diameter recommended by the condensing unit manufacturer. Assure the top of the riser is higher than the evaporator coil.

5. Arrange the suction line so the refrigerant vapor leaving the coil flows downward, below the suction-header outlet, before turning upward.

6. Pitch the suction line slightly—1 in./10 ft [1 cm/3 m]—so the refrigerant drains toward the evaporator.

7. Insulate the suction line.

Figure 10. Field-installed evaporation piping example

suction line

Evaporator Coil with

Standard Circuiting

liquid

sight

glass

thermal expansion valve (TXV)

distributor

40 BCXC-SVX01B-EN

valve

line

filter driersolenoid

Steam Piping

Installation Piping

Proper installation, piping and trapping is necessary to insure satisfactory heating coil operation and prevent operational damage under service conditions. These installation recommendations and piping diagram (see Figure 11, p. 42) must be followed to assure satisfactory, trouble-free operation.

General

1. Support all piping independently of coils.

2. Provide swing joints or flexible fittings in all piping connections adjacent to heating coils to absorb expansion and contraction strains.

3. Install coils so air passes through fins in proper direction (stenciled on top of coil channel).

Steam Coils

NOTICE

Coil Condensate!

Condensate must flow freely from the coil at all times to prevent coil damage from water hammer, unequal thermal stresses, freeze-up and/or corrosion. In all steam coil installations, the condensate return connections must be at the low point of the coil. Failure to follow these instructions could result in equipment damage.

1. Install 1/2-inch 15-degree swing check vacuum breaker in unused condensate return tapping as close as possible to coil. Vent vacuum breaker line to atmosphere or connect into return main at discharge side of steam trap. Vacuum relief is particularly important when coil is controlled by modulating steam supply or two-position (on-off) automatic steam supply valve.

2. Proper steam trap selection and installation is necessary for satisfactory coil performance and service life.

a. Select trap based on maximum possible condensate rate and recommended load factors.

b. Locate steam trap discharge at least 12 inches below condensate return tapping. This

provides sufficient hydrostatic head pressure to overcome trap losses and assure complete condensate removal.

c. Float and thermostatic traps are preferred because of gravity drain and continuous

discharge operation.

d. Use float and thermostatic traps with atmospheric pressure gravity condensate return with

automatic controls or where possibility of low pressure supply steam exists.

e. Bucket traps should only be used when supply steam is unmodulated and 25 psig or higher.

f. When installed with series airflow, size traps for each coil using capacity of first coil in airflow

direction.

g. Always trap each coil separately to prevent condensate holdup in one or more coils.

h. Always install strainers as close as possible to inlet side of trap.

3. Use V-port modulating valves to obtain gradual modulating action or slow opening 2-position valves to prevent steam hammer.

Note: Contact the factory for recommendations regarding steam coil valve selections

compatible with Tracer™ ZN controllers.

4. Use normally-open non-modulating control valves if coils are exposed to freezing air.

Note: Contact the factory for recommendations regarding steam coil valve selections

compatible with Tracer™ ZN controllers.

5. Control each coil bank separately when installing coils for series airflow with automatic steam control valves.

BCXC-SVX01B-EN 41

Installation Piping

6. Do not modulate steam or use on-off supply control on systems with overhead or pressurized returns unless condensate is drained by gravity to receiver (vented to atmosphere) and returned to main by condensate pump.

7. At startup with dampers, slowly turn steam on full for at least 10 minutes before opening fresh air intake.

8. Pitch all supply and return steam piping down a minimum of one inch per 10 feet in direction of flow.

9. Do not drain steam mains or take-offs through coils. Drain mains ahead of coils through steam trap to return line.

10. Do not bush or reduce coil return tapping size. Run return pipe full size of steam trap connection except for short nipple screwed directly into coil condensate connection.

11. Overhead returns require 1 psig pressure at steam trap discharge for each 2-foot elevation to assure continuous condensate removal.

Figure 11. Type NS steam coils, horizontal tubes for horizontal airflow

Code of System Components FT = Float and thermostatic steam trap BT = Bucket steam trap GV = Gate valve OV = Automatic two-position (on-off) control valve TV = Automatic three-way control valve VB = Vacuum br eaker , 15 -degree swing check valve CV = Check valve ST = Strainer AV = Automatic or manual air vent

42 BCXC-SVX01B-EN

Controls Interface

Control Options

Blower coil air handlers are available without controls or with one of four different control options:

• Control interface

• Tracer™ ZN010

• Tracer ZN510

• Tracer ZN520

Units without controls have a junction box mounted on the drive side for motor power wire terminations. The controller is easily accessible in the control box for service. Control option descriptions follow below.

Control Interface

The control interface is for use with a field–supplied low voltage thermostat. It includes a control box with a transformer, motor contactor, and disconnect switch. All hot leads to the motor are disconnected at the contactor and disconnect switch to eliminate the risk of shock during service. The end devices are mounted with the wires pulled and terminated inside the two-sided terminal strip. All customer connections other than power are on the outside of the two-sided terminal strip.

Tracer Controllers

The Tracer™ family of controllers—ZN010, ZN510, and ZN520—offer the combined advantages of simple and dependable operation with the latest Trane-designed controller. Standard control features include options normally available on more elaborate control systems. All control options are available factory-configured or can be field-configured using Rover™ service software. For more detailed information, refer to Trane publication CNT-IOP-1, Installation, Operation, and

Programming Guide (for ZN010 or ZN510), or CNT-SVX04A-EN, Installation, Operation, and Programming Guide (for ZN520).

Tr a c e r Z N 010

Tracer™ ZN010 is a stand-alone microprocessor controller.

Tracer ZN510 and ZN520

The Tracer™ ZN510 controller can be used as either a standalone or as part of a Trane Integrated Comfort™ System (ICS).

Figure 12. ZN510 control board Figure 13. ZN520 control board

In the stand-alone configuration, ZN510 or 520 receives operation commands from the zone sensor and/or the auto changeover sensor (on auto changeover units). ZN520 also receives commands from the discharge air sensor. The entering water temperature is read from the auto changeover sensor and determines if the unit is capable of cooling or heating. The zone sensor module is capable of transmitting the following information to the controller:

• Timed override on/cancel request

BCXC-SVX01B-EN 43

Controls Interface

• Zone setpoint

• Current zone temperature

• Fan mode selection (off-auto-high-low)

For optimal system performance, blower coil units can operate as part of an Integrated Comfort™ System (ICS) building automation system controlled by Tracer Summit®. The controller is linked directly to the Summit control panel via a twisted pair communication wire, requiring no additional interface device (i.e., a command unit). The Trane ICS system can monitor or override ZN520 control points. This includes such points as temperature and output positions.

Rover Service Software

This windows-based software package option allows field service personnel to easily monitor, save, download, and configure Tracer™ controllers through a communication link from a portable computer. When connected to the communication link, Rover™ can view any Tracer controller that is on the same communication link.

Table 15. Tracer controller input/output summary

Binary outputs

2-speed fan ••• 2-position hydronic valve • • • 2-position mixing box damper • • 1-stage electric heat • • • Modulating mixed air damper • Modulating hydronic valve • 2-stage electric heat • Reheat (hydronic) • Generic •••

Binary inputs

Condensate overflow detection • • • Low temperature detection • • • Occupancy ••• Generic input •••

Analog inputs

Zone temperature • • • Setpoint • • • Fan mode: auto, high, low ••• Entering water ••• Discharge air ••• Outside air • Generic

Notes:

1. The generic input and output are for use with a Tracer Summit® systems only.

2. Contact the factory for recommendations regarding steam coil valve selections compatible with Tracer™ ZN controllers.

Tracer™ controller

ZN010 ZN510 ZN520

44 BCXC-SVX01B-EN

Controls Interface

Table 16. Tracer controller function summary

Tracer™ Controller

ZN010 ZN510 ZN520

Control functions

Entering water temp. sampling (purge) • • • Timed override • • • Auto changeover ••• Fan cycling • • Warm-up ••• Pre-cool ••• Data sharing (master/slave) • • Random start ••• Dehumidification • Staged capacity (2-stage electric supplementary) • DX cooling •

Other Functions

Manual test • • • Filter maintenance timer • • • Setpoint limits • • •

Table 17. End Device Option Availability

Device

Condensate float switch • • • • Low limit • • • • Filter status • Filter run-time diagnostic • • • • Fan status •• Positive proof fan status switch • • 2-position control valves • • • • Modulating control valves • • 2-position mixing box actuator • • • Modulating mixing box actuator • • 1-stage electric heat • • • • 2-stage electric heat •• Frostat™ protection (DX coils) • •

Notes:

1. The Tracer ZN010, Tracer ZN510, and Tracer ZN520 are factory-provided controls that control the end devices listed in

the table.

2. The control interface option is the wiring tied back to a terminal strip to be controlled by a field-supplied controller.

3. Units with a DX coil are provided with a DX cool relay if unit has the control interface or Tracer controls.

4. Contact the factory for recommendations regarding steam coil valve selections compatible with Tracer™ ZN controllers.

ZN010 Tracer ZN510 Tracer ZN520

Tracer™

Control

interface

BCXC-SVX01B-EN 45

Pre-Start

Pre-Start Checklist

Complete this checklist after installing the unit to verify all recommended installation procedures are complete before unit startup. This does not replace the detailed instructions in the appropriate sections of this manual. Disconnect electrical power before performing this checklist. Always read the entire section carefully to become familiar with the procedures.

 WARNING

Hazardous Voltage!

Receiving

 Inspect unit and components for shipping damage. File damage claims immediately with the delivering carrier.

 Check unit for missing material. Look for ship-with drives, isolators, filters, and sensors that are packaged separately and placed inside the main control panel, fan section, or compressor section (see “Receiving and Handling,” p. 11).

 Check nameplate unit data so that it matches the sales order requirements.

Unit Location

 Remove crating from the unit. Do not remove the shipping skid until the unit is set in its final position.

 Ensure the unit location is adequate for unit dimensions, ductwork, piping, and electrical connections.

 Ensure access and maintenance clearances around the unit are adequate. Allow space at the end of the unit for shaft removal and servicing (see “Service Access,” p. 12).

Unit Mounting

 Place unit in its final location.

 Remove shipping skid bolts and skid.

 If using isolators, properly mount unit according to the isolator placement sheet.

46 BCXC-SVX01B-EN

Pre-Start

Component Overview

 Verify the fan and motor shafts are parallel.

 Verify the fan and motor sheaves are aligned.

 Check the belt tension for proper adjustment. Adjust the belt tension if it is floppy or squeals

continually.

 Ensure the fan rotates freely in the correct direction.

 Tighten locking screws, bearing set screws and sheaves.

 Ensure bearing locking collars do not wobble when rotated and correct torque settings. Refer to

Table 31, p. 64 for recommended torques.

 Verify that a clean air filter is in place.

Ductwork

 If using return ductwork to the unit, secure it with three inches of flexible duct connector.

 Extend discharge duct upward without change in size or direction for at least one and one half

fan diameters.

 Use a 3” flexible duct connection on discharge ductwork.

 Ensure trunk ductwork is complete and secure to prevent leaks.

 Verify that all ductwork conforms to NFPA 90A or 90B and all applicable local codes

Unit Piping

 Verify the condensate drain piping is complete for the unit drain pan. Install and tighten the condensate “P” trap drain plug.

 Make return and supply water connections to the unit and/or piping package.

 Ensure the drain pan and condensate line are not obstructed. Remove any foreign matter that

may have fallen into the drain pan during installation.

 Verify that piping does not leak. Make sure drain lines are open while performing the leak test.

 Treat water to prevent algae, slime, and corrosion.

 Connect refrigerant piping lines.

 Connect steam supply lines and condensate return lines to coil in accordance with steam piping

recommendations.

Electrical

 Check all electrical connections for tightness.

 Verify motor voltage and amps on all phases with the unit nameplate ratings to ensure unit

operates correctly.

Unit Panels

 Ensure all unit access panels are in place and that all screws, nuts, and bolts are tightened to their proper torques.

Note: During the unit break-in period, bearing temperature may be 150–160°F. during normal

operation bearing temperature should range be 90–100°F.

BCXC-SVX01B-EN 47

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Sequence of Operation

Tracer ZN Controller Sequence of Operation

Controller Start-Up

Refer to Trane publication CNT-SVX04A-EN, Installation, Operation, and Programming Guide, to operate the Tracer™ ZN controller with Trane Integrated Comfort™ System (ICS). The factory preprograms the Tracer ZN controller with default values to control the temperature and unit airflow. Use Tracer Summit® building automation system or Rover™ software to change the default values.

Follow the procedure below to operate the Tracer™ ZN controller in a stand-alone operation:

1. Turn power on at the disconnect switch option.

2. Position the fan mode switch to either high, low, or the auto position.

3. Rotate the setpoint dial on the zone sensor module to 55°F for cooling or 85°F for heating.

The appropriate control valve will actuate assuming the following conditions:

1. Room temperature should be greater than 55°F and less than 85°F.

2. For a two-pipe unit with an automatic changeover sensor, the water temperature input is appropriate for the demand placed on the unit. For example, cooling operation is requested and cold water (5° lower than room temperature) flows into the unit.

3. Select the correct temperature setpoint.

Note: Select and enable zone sensor temperature settings to prevent freeze damage to unit.

Power-Up Sequence

When 24 VAC power is initially applied to the Tracer™ ZN controller, the following sequence occurs:

• all outputs are controlled off

• Tracer reads all input values to determine initial values,

• the random start time (0–25 seconds) expires, and

• normal operation begins.

Tracer ZN Modes of Operation

Tracer™ ZN controllers operate the fan in one of the modes listed below as noted:

• occupied

• unoccupied

• occupied standby (Tracer ZN510 or ZN520 only)

• occupied bypass

• Tracer Summit® with supply fan control (Tracer ZN510 or ZN520 only)

Note: The Tracer™ ZN520 controller operates the supply fan continuously when the controller is

in the occupied and occupied standby modes, for either heating or cooling. The controller only cycles the fan off with heating and cooling capacity in the unoccupied mode.

When the communicated occupancy request is unoccupied, the occupancy binary input (if present) does not affect the controller’s occupancy. When the communicated occupancy request is occupied, the controller uses the local occupancy binary input to switch between the occupied and occupied standby modes.

Occupancy Sources

There are four ways to control the Tracer™ ZN controller’s occupancy, as noted below:

1. By pressing the zone sensor’s timed override “on” button

2. Occupancy binary input, either normally open or normally closed, see Ta b le 1 8 for occupancy sensor states

48 BCXC-SVX01B-EN

Start-Up

3. Default operation of the controller (occupied mode)

4. Communicated request, usually provided by the building automation system (BAS) or peer device (available on Tracer™ ZN510 and ZN520 only)

Table 18. Occupancy sensor state

Sensor type Sensor position Unit occupancy mode

Normally open Open Occupied Normally open Closed Unoccupied Normally closed Open Unoccupied Normally closed Closed Occupied

A communicated request will control the controller’s occupancy. Typically, this request comes from the BAS time-of-day scheduling to the controller. However, if a communication request from a BAS or peer controller is lost, the controller reverts to the default operating mode (occupied) after 15 minutes (configurable, specified by the “receive heartbeat time”), if no local hardwired occupancy signal exists.

If the unit is communicating with Tracer Summit® and the supply fan control programming point is configured for Tracer™ (the factory configures as local), then Tracer Summit will control the fan regardless of the fan mode switch position.

For complete information about Tracer Summit® application setup using the Tracer™ ZN controller, see the Tracer Summit product literature. For more information on the setup of another BAS, refer to the product-specific literature from that manufacturer.

Occupied Mode

When the controller is in the occupied mode, the unit attempts to maintain the space temperature at the active occupied heating or cooling setpoint, based on the:

• measured space temperature,

• the discharge air temperature (Tracer™ ZN520 only),

• the active setpoint, and

• the proportional/integral control algorithm.

The modulating control algorithm used when occupied or in occupied standby is described in the following sections. Additional information related to the handling of the controller setpoints can be found in the previous setpoint operation section.

Note: Heating and cooling setpoint high and low limits are always applied to the occupied and

occupied standby setpoints.

Unoccupied Mode

When the controller is in the unoccupied mode, the controller attempts to maintain space temperature at the stored unoccupied heating or cooling setpoint based on the:

• measured space temperature,

• active setpoint, and

• control algorithm, regardless of the presence of a hardwired or communicated setpoint.

Similar to other controller configuration properties, the locally stored unoccupied setpoints can be modified using Rover™ service tool.

During cooling mode, when the space temperature is above the cool setpoint, the primary cooling capacity operates at 100%. If more capacity is needed, the supplementary cooling capacity turns on (or opens to 100%).

During heating mode, when the space temperature is below the heat setpoint, the primary heating capacity turns on. All capacity turns off when the space temperature is between the unoccupied cooling and heating setpoints. Note that primary heating or cooling capacity is defined by the unit type and whether heating or cooling is enabled or disabled. For example, if the economizer is

BCXC-SVX01B-EN 49

Start-Up

enabled (Tracer™ ZN520 only) and possible, it is the primary cooling capacity. If hydronic heating is possible, it will be the primary heating capacity.

Occupied Standby Mode (Tracer ZN510 or ZN520 only)

The controller can be placed into the occupied standby mode when a communicated occupancy request is combined with the local (hardwired) occupancy binary input signal.

During occupied standby mode, the Tracer™ ZN520 controller’s economizer damper position goes to the economizer standby minimum position.

Note: The economizer standby minimum position can be changed using Rover™ service tool.

In the occupied standby mode, the controller uses the occupied standby cooling and heating setpoints. Because the occupied standby setpoints typically cover a wider range than the occupied setpoints, the controller reduces heating/cooling demand for the space. Also, units with Tracer™ ZN520 and the fresh air economizer damper use the economizer standby minimum position to reduce heating and cooling demand.

When no occupancy request is communicated, the occupancy binary input switches the controller’s operating mode between occupied and unoccupied. When no communicated occupancy request exists, the unit cannot switch to occupied standby mode.

Occupied Bypass Mode, Tracer ZN510 or ZN520 Only

The controller can be placed in occupied bypass mode by either communicating an occupancy bypass request to the controller or by using the timed override “on” button on the zone sensor. When the controller is in unoccupied mode, pressing the “on” button will place the controller into occupied bypass mode for the duration of the bypass time (typically 120 minutes).

Tracer Summit With Supply Fan Control, Tracer ZN510 or ZN520 Only

All Tracer™ ZN lockouts (latching diagnostics) are manually reset whenever the fan mode switch is set to the off position or when power is restored to the unit. The last diagnostic to occur is retained until the unit power is disconnected. Refer to Trane publication CNT-SVX04A-EN, Installation, Operation, and Programming Guide, for specific Tracer ZN520 operating procedures.

Cooling Operation

During cooling mode, the Tracer™ ZN controller attempts to maintain the space temperature at the active cooling setpoint. Based on the controller’s occupancy mode, the active cooling setpoint is either the:

• occupied cooling setpoint,

• occupied standby cooling setpoint (Tracer ZN510 or ZN520 only), or

• unoccupied cooling setpoint.

The controller uses the measured space temperature, the active cooling setpoint, and discharge air temperature (Tracer™ ZN520 only) along with the control algorithm to determine the requested cooling capacity of the unit (0–100%). The outputs are controlled based on the unit configuration and the required cooling capacity. To maintain space temperature control, the cooling outputs (modulating or 2-position hydronic valve, or economizer damper) are controlled based on the cooling capacity output.

Note: Economizer dampers and modulating valves are only available on units with the Tracer™

Cooling output is controlled based on the cooling capacity. At 0% capacity, all cooling capacities are off and the damper is at minimum position. Between 0 and 100% capacity, the cooling outputs are controlled according to modulating valve logic (Tracer™ ZN520 only) or cycled with 2-position valves. As the load increases, modulating outputs open further and binary outputs are energized longer. At 100% capacity, the cooling valve or damper is fully open (modulating valves) or on continuously (2-position valves).

ZN520 controller. Two-position dampers are only available on units with Tracer ZN010 and ZN510.

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Note: Unit diagnostics can affect fan operation, causing occupied and occupied standby fan

operation to be defined as abnormal. Refer to “Troubleshooting,” p. 72 for more information about abnormal fan operation.

Economizer Cooling (Tracer ZN520 Only)

The economizer provides cooling whenever the outdoor temperature is below the economizer enable setpoint and there is a need for cooling. The economizer operates to meet the space demand, with other forms of cooling enabling when the economizer cannot meet the demand alone. See economizer air damper operation for additional information.

DX Cooling (Tracer ZN520 only)

The controller does not use both the DX compressor and the economizer at the same time. This prevents problems where the entering air temperature is too low for the evaporator coil to operate as designed, which leads to compressor short cycling due to low discharge air temperatures.

Discharge Air Tempering (Tracer ZN520 Only)

Cascade cooling control initiates a discharge air tempering function if:

• the discharge air temperature falls below the discharge air temperature control low limit,

• all cooling capacity is at minimum, and

• the discharge control loop determines a need to raise the discharge air temperature.

The controller then provides heating capacity to raise the discharge air temperature to its low limit.

The discharge air tempering function enables when cold, fresh air is brought in through the fresh air damper and causes the discharge air to fall below the discharge air temperature control low limit. The controller exits the discharge air tempering function when heat capacity has been at 0% for five minutes.

Heating Operation

During heating mode, the Tracer™ ZN controller attempts to maintain the space temperature at the active heating setpoint. Based on the controller’s occupancy mode, the active heating setpoint can be:

• occupied heating,

• occupied standby heating (Tracer ZN510 or ZN520 only), or

• unoccupied heating.

Note: Unit diagnostics can affect the controller operation, causing unit operation to be defined as

abnormal. Refer to “Troubleshooting,” p. 72 for more information about abnormal unit operation.

Heating output is controlled based on the heating capacity. At 0% capacity, the heating output is off continuously. Between 0 and 100% capacity, the heating output is controlled according to modulating valve logic (ZN520 only) or cycled with 2-position valves. As the load increases, modulating outputs open further and binary outputs are energized longer. At 100% capacity, the modulating valve is fully open (Tracer™ ZN520 only) or on continuously with 2-position valves.

Economizer Damper (Tracer ZN520 Only)

The economizer damper option is never used for as a source for heating, but only for ventilation. Therefore, the damper is at the occupied minimum position in the occupied mode. The damper control is primarily associated with occupied fan operation.

Dehumidification (Tracer ZN520 only)

During dehumidification, the Tracer™ ZN520 controller adjusts the heating setpoint up to the cooling setpoint. This reduces the relative humidity in the space with a minimum of energy usage.

The controller uses the measured space temperature, the active heating setpoint, and discharge air temperature (Tracer™ ZN520 only) along with the control algorithm, to determine the requested

BCXC-SVX01B-EN 51

Start-Up

heating capacity of the unit (0–100%). The outputs are controlled based on the unit configuration and the required heating capacity.

Fan Mode Operation

WARNING Rotating Components!

For multiple fan speed applications, the Tracer™ ZN controller offers additional fan configuration flexibility. See Ta b le 1 9 for fan operation sequences. Separate default fan speeds for heating and cooling modes can be configured using Rover™ service software.

Table 19. Tracer ZN520 fan configuration

Heating Continuous Off

Cooling Continuous Off

Auto fan operation Fan speed default

Low High

The fan runs continuously at selected speeds, high or low. When the fan mode switch is in the auto position or a hardwired fan mode input does not exist, the fan operates at the default configured speed. See Ta bl e 2 0 for Tracer™ ZN520 default fan configuration for heating and cooling modes. During unoccupied mode, the fan cycles between high speed and off with heating and cooling fan modes. If the requested speed is off, the fan always remains off.

Table 20. Fan sequence of operation

Fan speed Tracer™ ZN controller Sequence of operation

Off ZN010, ZN510, ZN520 • fan is off

• control valves and damper option are closed

• low air temperature detection open is still active

Low or high (continuous fan) ZN010, ZN510 • fan operates continuously at selected speed

• 2-position control valve option cycle as needed

• 2-position control valve option opens to an adjustable mechanical stop-position

Low or high (continuous fan) ZN520 • fan operates continuously at selected speed

• modulating control valve option cycles as needed

Auto (cycling) ZN010, ZN510 • fan, 2-position damper cycle, and control valve cycle as needed

• in cooling mode, fan cycles from off to high

• in heating mode, fan cycles from off to low

• when heating/cooling is not required, the fan is off and the 2-position damper option closes

Auto ZN520 • fan cycles between high and me dium, and nev er turns off unle ss the controller is

in unoccupied mode

• modulating or 2-position control open to maintain setpoint

During dehumidification, when the fan is in auto, the fan speed can switch depending on the error. The fan speed increases as the space temperature rises above the active cooling setpoint.

52 BCXC-SVX01B-EN

Start-Up

Additional flexibility built into the controller allows you to enable or disable the local fan switch input. The fan mode request can be hardwired to any of the Tracer™ ZN controllers or communicated to the Tracer ZN510 or ZN520 controller. When both inputs are present, the communicated request has priority over the hardwired input. See Tab l e 19 , p . 5 2 .

Fan Speed Switch

Off. Fan is turned off, two-position damper option spring-returns closed.

High or Low. Fan runs continuously at the selected speed. The two-position damper option

opens to an adjustable mechanical stop-position.

Tracer ZN010 and ZN510

Off. Fan is off; control valves and fresh air damper option close. Low air temperature detection

option is still active.

Auto (Fan Cycling). Fan and fresh air damper cycle with control valve option to maintain

setpoint temperature. If the unit has a 2-speed fan, in cooling mode the fan cycles from off to high and in heating mode it cycles from off to low (factory default that can be field-adjusted using Rover™ service software). When no heating or cooling is required, the fan is off and the fresh air damper option closes. Units with 2-speed fans can also be field-configured using Rover to run at a defined speed when the fan speed switch is in the auto position.

Low or High (Continuous Fan). Fan operates continuously while control valve option cycles to

maintain setpoint temperature. Fresh air damper option is open.

Tracer ZN520

Off. Fan is off; control valve options and fresh air damper options close. The low air temperature

detection option is still active.

Auto. Fan speed control in the auto setting allows the modulating (three-wire floating point)

control valve option and single or two-speed fan to work cooperatively to meet precise capacity requirements, while minimizing fan speed (motor/energy/acoustics) and valve position (pump energy/chilled water reset). As the capacity requirement increases at low fan speed, the water valve opens. When the low fan speed capacity switch point is reached, the fan switches to high speed and the water valve repositions to maintain an equivalent capacity. The reverse sequence takes place with a decrease in required capacity.

Units with 2-speed fans on low or high. The fan will run continuously at the selected speed

and the valve option will cycle to meet setpoint.

Continuous Fan Operation

During occupied and occupied standby modes, the fan normally is on. For multiple speed fan applications, the fan normally operates at the selected or default speed (off, high, or low). When fan mode is auto, the fan operates at the default fan speed.

During unoccupied mode, the fan is off. While unoccupied, the controller will heat or cool to maintain the unoccupied heating and cooling setpoints. In unoccupied mode, the fan runs on high speed only, with heating or cooling. See Table 24, p. 55.

The unit fan is always off during occupied, occupied standby, and unoccupied modes when the unit is off due to a diagnostic or when the unit is in the off mode due to the local zone sensor module, a communicated request, or the default fan speed (off).

If both a zone sensor module and communicated request exist, the communicated request has priority. See Tab l e 2 3, p . 5 5.

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Fan Cycling Operation

Tracer™ ZN520 does not support fan cycling in occupied mode. The fan cycles between high speed and off in the unoccupied mode only. The controller’s cascade control algorithm requires continuous fan operation in the occupied mode.

Fan Off Delay

When a heating output is controlled off, the Tracer™ ZN controller automatically holds the fan on for an additional 30 seconds. This 30-second delay allows the fan to blow off any residual heat from the heating source, such as a steam coil. When the unit is heating, the fan off delay is normally applied to control the fan; otherwise, the fan off delay does not apply.

Fan Start on High Speed

On a transition from off to any other fan speed, the Tracer™ ZN controller automatically starts the fan on high speed and runs the fan at high speed for 0.5 seconds. This provides ample torque required to start all fan motors from the off position.

Fan Operation During Occupied Heating Modes

The ZN520 fan output(s) normally run continuously during the occupied and occupied standby modes, but cycle between high and off speeds with heating/cooling during the unoccupied mode. When in the occupied mode or occupied standby mode and the fan speed is set at the high or low position, the fan runs continuously at the selected speed. Refer to “Troubleshooting,” p. 72 for more information on abnormal fan operation.

Table 21. Fan mode operation, Tracer ZN010 and ZN510

Heating mode Cooling mode

Fan mode

Off Off Off Off Off Low Low Off/high High High Off/high Auto continuous Heat default Off/high Cycling off Off/heat default

Notes:

1. During the transition from off to any fan speed but high, Tracer™ ZN010 and ZN510 automatically start the fan on high

speed and run for one-half of a second before transitioning to the selected speed (if it is other than high). This provides enough torque to start all fan motors from the off position.

2. When the heating output is controlled off, ZN010 and ZN510 automatically control the fan on for an additional 30 seconds. This delay allows the fan to dissipate any residual heat from the heating source, such as electric heat.

(a) Whenever two states are listed for the fan, the first state (off) applies when there is not a call for heating or cooling. The

second state (varies) applies where th ere is a call for heating or cooling. The heat default is factory-configured for low fan speed, and the cool default is high.

Occupied Unoccupied Occupied Unoccupied

(a)

Off/high

(a)

(a) (a) (a)

Low Off/high High Off/high Cool default Off/high Off/cool default

(a)

Off/high

(a) (a) (a) (a)

Table 22. Valid operating range and factor default setpoints, Tracer ZN010 and ZN510

Setpoint/parameter Default setting Valid operating range

Unoccupied cooling setpoint 85°F 40°F–115°F Occupied cooling setpoint 74°F 40°F–115°F Occupied heating setpoint 71°F 40°F–115°F Unoccupied heating setpoint 60°F 40°F–115°F Cooling setpoint high limit 110°F 40°F–115°F Cooling setpoint low limit 40°F 40°F–115°F Heating setpoint high limit 105°F 40°F–115°F Heating setpoint low limit 40°F 40°F–115°F Power up control wait 0 sec 0 sec–240 sec

54 BCXC-SVX01B-EN

Table 23. Local fan switch enabled

Communicated Fan switch (local) Fan operation fan speed input

Off Ignored Off Low Ignored Low High Ignored High Auto Off Off

Low Low High High Auto Auto (configured default, determined by heat/cool mode)

Table 24. Fan operation in heating and cooling modes

Heating Cooling

Fan mode

Off Off Off Off Off Low Low Off/high Low Off/high High High Off/high High Off/high Auto (continuous) Default fan speed Off/high Default fan speed Off/high

Occupied Unoccupied Occupied Unoccupied

Two- and Four-Pipe Changeover Operation

Tracer™ ZN controllers offer accurate and reliable unit changeover using 2-way valves and the controller’s entering water temperature sampling function. Only units using the main hydronic coil for both heating and cooling (2-pipe and 4-pipe changeover units) use the entering water temperature sampling function.

Two-pipe and 4-pipe changeover applications require an entering water temperature sensor to allow the main coil to be used for heating and cooling. This sensor is factory-provided and should be field-installed on the entering water pipe.

The entering water temperature sampling function periodically opens the two-way valve to allow temporary water flow, producing reliable entering water temperature measurement. To ensure accurate unit changeover without sacrificing the benefits of 2-way, 2-position valves, Tracer™ ZN controllers periodically test the entering water temperature on all hydronic main coil changeover units. Hydronic heating/cooling changeover operation requires central plant operation, and the unit controller must use an entering water temperature sensor to verify delivery of the correct water temperature from the central plant.

Start-Up

Entering Water Temperature Sampling Function

The entering water temperature (EWT) must be five degrees above the space temperature for hydronic heating and five degrees below the space temperature for hydronic cooling. When water

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flows normally and frequently through the coil, the controller does not invoke the sampling function because the EWT is satisfactory.

Table 25. Unit mode as related to water temperature

Unit type EWT sensor required? Coil water temperature

2-pipe changeover Yes • Can cool if: space temp - EWT ≥ 5°F

• Can heat if: EWT - space temp ≥ 5°F

4-pipe changeover Yes • Can cool if: space temp - EWT ≥ 5°F

• Can heat if: EWT - space temp ≥ 5°F 2-pipe heating only No Hot water assumed 2-pipe cooling only No Cold water assumed 4-pipe heat/cool No • Cold water assumed in main coil

• Hot water assumed in auxiliary coil

However, when the controller detects an incorrect water temperature based on heating or cooling mode, it invokes the entering water temperature sampling function. For example, when the measured EWT is too cool to heat or too warm to cool. For cooling the EWT needs to be five degrees below the measured space temperature. For heating, the EWT should be five degrees above the measured space temperature.

After the controller invokes the function, the unit opens the main hydronic valve for no more than three minutes before considering the measured EWT. The controller allows an initial stabilization period, equal to 30 seconds plus 1/2 the valve stroke time, to flush the coil. Once the temperature stabilization period expires, the controller compares the EWT against the effective space temperature (either hardwired or communicated) to determine whether the EWT is correct for the desired heating or cooling mode. If the EWT is not usable for the desired mode, the controller continues to compare the EWT against the effective space temperature for a maximum of three minutes.

The controller automatically disables the entering water temperature sampling and closes the main hydronic valve when the measured EWT exceeds the high EWT limit (110°F). When the EWT is warmer than 110°F, the controller assumes the EWT is hot because it is unlikely the coil would drift to a high temperature unless the actual loop temperature was very high.

If the EWT is unusable—too cool to heat or too warm to cool—the controller closes the hydronic valve and waits 60 minutes before initializing another sampling. If the controller determines the EWT is valid for heating or cooling, it resumes normal heating/cooling control and effectively disables entering water temperature sampling until it is required.

Electric Heat Operation

Tracer™ ZN controllers support 1-stage electric heat. Also, Tracer ZN520 supports 2-stage electric heat. Tracer ZN520 cycles the electric heat to control the discharge air temperature. The rate of cycling is dependent upon the load in the space and the temperature of the incoming fresh air from the economizer (if any). Two-pipe changeover units with electric heat use the electric heat only when hot water is not available.

Economizer Damper (Tracer ZN520 Only)

With a valid outdoor air temperature (either hardwired or communicated), Tracer™ ZN520 uses the modulating economizer damper as the highest priority cooling source. Economizer operation is only possible using a modulating damper during the occupied, occupied standby, unoccupied, and occupied bypass modes.

The controller initiates the economizer function if the fresh air temperature is cold enough for use as free cooling capacity. If the fresh air temperature is less than the economizer enable setpoint (absolute dry bulb), the controller modulates the fresh air damper (between the active minimum damper position and 100%) to control the amount of fresh air cooling capacity. When the fresh air

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temperature rises 5°F above the economizer enable point, the controller disables economizing and moves the fresh air damper back to its predetermined minimum position based on the current occupancy mode or communicated minimum damper position.

Table 26. Relationship between outdoor temperature sensors and economizer damper position (Tracer ZN520 only)

Outdoor air temperature

None or invalid Open to occupied minimum

Failed Open to occupied minimum

Present and economizer feasible

Present and economizer not feasible

Modulating fresh air damper occupied or occupied bypass Occupied standby Unoccupied

position

position Economizing: minimum position

to 100% Open to occupied minimum

position

Open to occupied standby minimum position

Open to occupied standby Closed

Economizing: between occupied standby minimum position to 100%

Open to occupied standby minimum position

Tracer Dehumidification (Tracer ZN520 Only)

Dehumidification is possible when mechanical cooling is available, the heating capacity is located in the reheat position, and the space relative humidity setpoint is valid.The controller starts dehumidifying the space when the space humidity exceeds the humidity setpoint. The controller continues to dehumidify until the sensed humidity falls below the setpoint minus the relative humidity offset. The controller uses the cooling and reheat capacities simultaneously to dehumidify the space. While dehumidifying, the discharge air temperature is controlled to maintain the space temperature at the current setpoint.

A typical scenario involves high humidity and high temperature load of the space. The controller sets the cooling capacity to 100% and uses the reheat capacity to warm the discharge air to maintain space temperature control. Dehumidification may be disabled via Tracer™ or configuration.

Note: If the unit is in the unoccupied mode, the dehumidification routine will not operate.

Data Sharing (Tracer ZN510 or ZN520 Only)

Because this controller utilizes LonWorks® technology, the controller can send or receive data (setpoint, heat/cool mode, fan request, space temperature, etc.) to and from other controllers on the communication link, with or without the existence of a building automation system. This applies to applications where multiple unit controllers share a single space temperature sensor (for rooms with multiple units but only one zone sensor) for both standalone (with communication wiring between units) and building automation system applications. For this application you will need to use the Rover™ service tool. For more information on setup, refer to the Trane publication EMTX-IOP-2.

Closed

Open and economizing only when unit operating, closed otherwise

Closed

Binary Inputs

Tracer™ ZN controllers have the following binary inputs, factory-configured for the following functions:

• Binary input 1: low temperature detection (freezestat)

• Binary input 2: condensate overflow

• Binary input 3: occupancy/ generic

• Binary input 4: fan status (Tracer ZN520 only)

Note: The generic binary input can be used with a Tracer Summit®

only.

BIP1: Low Temperature Detection Option

The factory hard wires the low temperature detection sensor to binary input #1 (BIP1) on the Tracer™ ZN controller. The sensor defaults normally closed (N.C.), and will trip off the unit on a low

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Start-Up

temperature diagnostic when detecting low temperature. In addition, Tracer ZN controls unit devices as listed below:

Fan: Off Valves: Open Electric heat: Off Damper: Closed

Note: See the “Diagnostics” section for more information.

BIP2: Condensate Overflow Detection Option

The factory hard wires the condensate overflow sensor to binary input #2 (BIP2) on the Tracer™ ZN controller. The sensor defaults normally closed (N.C.), and will trip off the unit on a condensate overflow diagnostic if condensate reaches the trip point. In addition, Tracer ZN controls unit devices as listed below:

Fan: Off Valves: Closed Electric heat: Off

BIP3: Occupancy Sensor

Binary input #3 (BIP3) on Tracer™ ZN is available for field- wiring an occupancy sensor, such as a binary switch or a timeclock, to detect occupancy. The sensor can be either normally open or normally closed. Reference Tabl e 2 7, p . 5 8.

BIP4: Fan Status (ZN520 Only)

Binary input #4 (BIP4) on Tracer™ ZN is available for sensor, such as a binary switch or a timeclock, to detect occupancy. The sensor defaults normally open but can be configured as either normally open or closed.

Table 27. Binary input configurations

Controller operation

Binary input Description Configuration

(a)

NC Normal Diagnostic NC Normal Diagnostic

NO Normal Diagnostic

BI 1 Low temperature detection BI 2 Condensate overflow BI 3 Occupancy NO Unoccupied Occupied BI 3 Generic binary input NO Normal BI 4 Fan status

Notes:

1. The occupancy binary input is for standalone unit controllers as an occupied/unoccupied input. However, when the

controller receives a communicated occupied/unoccupied request, the communicated request has priority over the hardwired input.

2. If the fan mode input is in the off position or the controller is in the unoc cupied mode with the fan off, the fan status input

will be open. A diagnostic will not be generated when the controller commands the fan off. A diagnostic will only be generated if the fan status input does not close after one minute from energizing a fan output or any time the input is open for one minute. The co ntroll er wait s up to one m inute afte r energiz ing a fan o utput to al low the di fferent ial pressu re to build up across the fan.

(a) During low temperature, condensate overflow, and fan status diagnostics, the Tracer™ ZN520 control disables all normal

unit operation of the fan, valves, and damper.

(b)The table below shows the controller’s response to low temperature detection, condensate overflow, and fan status diag-

nostics.

(c) The generic binary input does not affect unit operation. A building automation system reads this input as a generic binary

input.

(a)

Contact closed Contact open

(b)

(c)

Normal

(c)

BIP

BI 1 Low temperature detection Off Open Off Closed BI 2 Condensate overflow Off Closed Off Closed BI 4 Fan status Off Closed Off Closed

Description

Fan Valve Electric heat Damper

58 BCXC-SVX01B-EN

Start-Up

Analog Inputs

See Ta b le 2 8 for a complete description of analog inputs.

Table 28. Analog inputs

Analog input Terminal Function Range ZN010 ZN510 ZN520

Zone TB3-1 Space temperature input 5° to 122°F (-15° to 50°C) ••• Ground TB3-2 Analog ground N/A ••• Set TB3-3 Se tpoint input 40° to 115°F (4.4° to 46.1°C) ••• Fan TB3-4 Fan switch input 4821 to 4919 W (Off) •••

2297 to 2342 W (Auto) 10593 to 10807 W (Low)

15137 to 16463 W (High) Ground TB3-6 Analog ground N/A ••• Analog Input 1 J3-1 Entering water temperature -40° to 212°F (-40° to 100°C) •••

J3-2 Analog ground N/A

Analog Input 2 J3-3 Discharge air temperature -40° to 212°F (-40° to 100°C) •••

J3-4 Analog ground N/A

Analog Input 3 J3-6 Fresh air temp/generic temp -40° to 212°F (-40° to 100°C) •

Analog ground N/A

Analog Input 4 J3-7 Universal Input 0 – 100% •

Generic 4-20 ma 0 – 100% Humidity 0 – 2000ppm CO

Ground J3-8 Analog ground N/A • Ground J3-9 Analog ground N/A •

Notes:

1. The zone sensor, entering water temperature sensor, discharge air sensor, and the outside air temperature sensor are 10KW thermistors.

2. Zone sensor: Wall mounted sensors include a thermistor soldered to the sensor’s circuit board.

3. Changeover units include an entering water temperature sensor.

Binary Outputs

Binary outputs are configured to support the following:

• Two fan stages (when one or two fan stages are present, J1-2 can be configured as exhaust fan)

• One hydronic cooling stage

• One hydronic heating stage (dehumidification requires this to be in the reheat position)

• One DX cooling stage

• One or two-stage electric heat (dehumidification requires this to be in the reheat position)

• Face and bypass damper

• Modulating fresh air damper (Tracer™ ZN520 only)

• One-stage baseboard heat

BCXC-SVX01B-EN 59

Start-Up

Table 29. Binary output configuration

Binary output pin connection Configuration ZN010 ZN510 ZN520

J1-1 Fan high ••• J1-2 N/A ••• J1-3 Fan low • J1-4 (Key) •

Fan low •• J1-5 Main valve – open, or 2 pos. valve J1-6 Aux. valve/elec. ht. ••

Aux. valve – close J1-7 2-pos. damper •• J1-9 Heat valve – open, or 2 pos. valve, or first stage elec. ht. J1-10 Heat valve – close o r sec. stage elec. ht. J1-11 Fresh air damper – open • J1-12 Fresh air damper – close • TB4-1 Generic / baseboard heat output • TB4-2 24 VAC •

Notes:

1. If no valves are ordered with the unit, the factory default for Tracer™ ZN010 and ZN510 controllers are: main valve

configured as normally closed and aux. valve configured as normally open.

2. If the fresh air damper option is not ordered on the unit, 2-pos. damper is configured as none.

3. Pin J1-2 can be configured for an exhaust fan with the use of Rover™ software. Factory default is none.

(a) Two-pipe hydronic heat/cool changeover units us e terminals J1 -5 and J1-6 to con trol the primary va lve for both heat ing and cooling. Units configured and applied as 2-pipe hydronic heat/cool changeover with electric heat, use terminals J1-5 and J1-6 to control the primary valve (for both cooling and heating), and terminals J1-9 and J1-10 for the electric heat stage. For those 2-pipe changeover units, electric heat will not energize while the hydronic supply is hot (5 or more degrees above the space temperature). In a 4-pipe application, pin J1-5 is for cooling and pin J1-6 for heating.

(a)

•••

•

Zone Sensor

The Tracer™ ZN controller accepts the following zone sensor module inputs:

• Space temperature measurement (10kW thermistor)

• Local setpoint (either internal or external on the zone sensor module)

• Fan mode switch

• Timed override, using “on” and “cancel” buttons (Tracer ZN510 and ZN520 only)

• Communication jack (Tracer ZN510 and ZN520 only)

Table 30. Zone sensor wiring connections

TB1 Description

1Space temperature 2Common 3Setpoint 4Fan mode 5 Communications 6 Communications

Space Temperature Measurement

Zone sensors use a 10kW thermistor to measure the space temperature. Wall-mounted zone sensors include a space temperature thermistor. Unit-mounted zone sensors have a return air sensor mounted in the unit’s return airstream. If both a hardwired and communicated space

60 BCXC-SVX01B-EN

Start-Up

temperature value exists, the controller ignores the hardwired space temperature input and uses the communicated value.

Local Setpoint

The zone sensor may be equipped with a thumbwheel for setpoint adjustment.

Fan Mode Switch

The zone sensor may be equipped with a fan mode switch. The fan mode switch offers selections of off, low, high, or auto.

External Setpoint Adjustment

Zone sensors with an external setpoint adjustment (1kW) provide the Tracer™ ZN controller with a local setpoint (50 to 85°F or 10 to 29.4°C). The external setpoint is exposed on the zone sensor’s front cover.

When the hardwired setpoint adjustment is used to determine the setpoints, all unit setpoints are calculated based on the hardwired setpoint value, the configured setpoints, and the active mode of the controller. The hardwired setpoint is used with the controller’s occupancy mode (occupied, occupied standby, or unoccupied), the heating or cooling mode, the temperature deadband values, and the heating and cooling setpoints (high and low limits) to determine the controller’s active setpoint.

When a building automation system or other controller communicates a setpoint to the controller, the controller ignores the hardwired setpoint input and uses the communicated value. The exception is the unoccupied mode, when the controller always uses the stored default unoccupied setpoints. After the controller completes all setpoint calculations, based on the requested setpoint, the occupancy mode, the heating and cooling mode, and other factors, the calculated setpoint is validated against the following setpoint limits:

• Heating setpoint high limit

• Heating setpoint low limit

• Cooling setpoint high limit

• Cooling setpoint low limit

Note: Only units with ZN510 or ZN520 can receive a communicated setpoint from Tracer™ or

other building automation system. However, Rover™ service software can communicate with all Tracer ZN controllers.

These setpoint limits only apply to the occupied and occupied standby heating and cooling setpoints. These setpoint limits do not apply to the unoccupied heating and cooling setpoints stored in the controller’s configuration.

When the controller is in unoccupied mode, it always uses the stored unoccupied heating and cooling setpoints.The unit can also be configured to enable or disable the local (hardwired) setpoint. This parameter provides additional flexibility to allow you to apply communicated, hardwired, or default setpoints without making physical changes to the unit.

Similar to hardwired setpoints, the effective setpoint value for a communicated setpoint is determined based on the stored default setpoints (which determines the occupied and occupied standby temperature deadbands) and the controller’s occupancy mode.

Fan Switch

The zone sensor fan switch provides the controller with an occupied (and occupied standby) fan request signal (Off, Low, High, Auto). If the fan control request is communicated to the controller, the controller ignores the hardwired fan switch input and uses the communicated value. The zone sensor fan switch input can be enabled or disabled through configuration using the Rover™ service tool. If the zone sensor switch is disabled, the controller resorts to its stored configuration default fan speeds for heating and cooling, unless the controller receives a communicated fan input.

BCXC-SVX01B-EN 61

Start-Up

When the fan switch is in the off position, the controller does not control any unit capacity. The unit remains powered and all outputs drive to the closed position. Upon a loss of signal on the fan speed input, the controller reports a diagnostic and reverts to using the default fan speed.

On/Cancel Buttons

Momentarily pressing the on button during unoccupied mode places the controller in occupied bypass mode for 120 minutes. You can adjust the number of minutes in the unit controller configuration using Rover™ service tool. The controller remains in occupied bypass mode until the override time expires or until you press the Cancel button.

Communication Jack

Use the RJ-11 communication as the connection point from Rover™ service tool to the communication link—when the communication jack is wired to the communication link at the controller. By accessing the communication jack via Rover, you gain access to any controller on the link.

Figure 14. Resistance temperature curve for the zone sensor, entering water temperature sensor,

and discharge air sensor

62 BCXC-SVX01B-EN

Maintenance

Maintenance Procedures

Perform the following maintenance procedures to ensure proper unit operation.

Air Filters

Always install filters with directional arrows pointing toward the fan.

Fan Bearings

Fan bearings are permanently sealed and lubricated and do not require additional lubrication.

Fan Motors

Inspect fan motors periodically for excessive vibration or temperature. Operating conditions will vary the frequency of inspection and lubrication. Motor lubrication instructions are on the motor tag or nameplate. If for some reason these instructions are not available, contact the motor manufacturer. Some motor manufacturers may not provide oil tubes on motors with permanently sealed bearings.

 WARNING

Hazardous Voltage!

Before lubricating the motor:

1. Turn the motor off and disconnect power to the unit to ensure the motor doesn’t accidentally start.

2. Use a No. 10 SAE, non-detergent automotive type oil. Do not over-oil.

Sheave Alignment

To prevent interference of the fan frame with the belt, make sure that the belt edge closes to the motor has the proper clearance from the fan frame as shown in Figure 15, p. 64.

Align the fan and motor sheaves by using a straight–edge or taut string, as shown in Figure 16,

p. 64. The straight-edge must be long enough to span the distance between the sheave outside

edges.

When the sheaves are aligned, the straight–edge will touch both sheaves at points A through D, as shown in Figure 16. For uneven width sheaves, place a string in the center groove of both

BCXC-SVX01B-EN 63

Maintenance

sheaves and pull tight. Adjust sheaves and tighten the sheave set screws to the correct torques recommended in Ta b le 3 1 .

Figure 15. Clearance recommendation to

Figure 16. Correct sheave alignment

prevent fan frame and belt interface

Table 31. Recommended torques for tightening sheaves and bearing thrust collar

Torque (in.-lb) Ft-lb N-m

Sheave setscrew 144 12 16.3 Bearing thrust collar 66 5. 5 7.5 Fan wheel screw 144 12 16.3

Fan Assembly Set Screws

Check and adjust fan wheel, bearing, and sheave set screws whenever a component is removed or an adjustment is made. Refer to Tab l e 3 1 for recommendations.

Fan Belt Tension

Proper belt tension is necessary to endure maximum bearing and drive component life and is based on fan brake horsepower requirements. Replace belt when frayed or worn.

Fan belt tension should only be tight enough so the belt does not slip and maintains adequate airflow.

Note: Check fan belt tension at least twice during the first days of new belt operation since there

is a rapid decrease in tension until belts are run-in.

Be careful not to over-tension fan belt. Excessive tension will reduce fan and motor bearing life, accelerate belt wear and possibly cause shaft failure. Clean the sheaves and belt with a dry cloth. Keep oil and grease away from the belt because they may cause belt deterioration and slippage. Trane does not recommend belt dressing.

64 BCXC-SVX01B-EN

Maintenance

NOTICE

Belt tension!

Do not over-tension belts. Excessive belt tension will reduce fan and motor bearing life, accelerate belt wear, and could result in shaft failure.

Table 32. BCHC/BCVC fan, filter, and mixing box general data

Unit size 12 18 24 36 54 72 90

Nominal cfm 400 600 800 1200 1800 2400 3000

Air flow

Minimum cfm 250 375 500 750 1125 1500 1875 Maximum cfm 500 675 1000 1600 2400 3000 4000

Fan data

Fan wheel, in. (dia. x width) 9.5 x 4.5 9.5 x 4.5 9.5 x 9.5 9.5 x 9.5 12.6 x 9.5 12.6 x 9.5 12.6 x 9.5 Maximum rpm 2300 2300 1800 1800 1500 1500 1500 Motor hp 0.33–1.0 0.33–1.0 0.33–1.0 0.33–1.5 0.33–2.0 0.33–3.0 0.33–3.0

Unit flat filter

Qty. - size, in. 1 - 12 x 24 1 - 12 x 24 1 - 16 x 25 2 - 16 x 20 2 - 20 x 20 1 - 20 x 20 3 - 16 x 25

1 - 20 x 25 Area, sq. ft 2.000 2.000 2.778 4.444 5.556 6.250 8.333 Velocity, ft/min. 200 300 288 270 324 384 360

Angle filter

Qty. - size, in. 2 - 12 x 24 2 - 12 x 24 2 - 12 x 24 2 - 20 x 20 4 - 16 x 20 4 - 16 x 20 4 - 20 x 20 Area, sq. ft 4.000 4.000 4.000 5.556 8.889 8.889 11.111 Velocity, ft/min. 100 150 200 216 203 270 270

Bottom / top access filter box

Qty. - size, in. 1 - 12 x 20 1 - 12 x 24 1 - 16 x 25 1 - 16 x 20 1 - 16 x 20 1 - 20 x 25 2 - 16 x 25

1 - 16 x 16 1 - 20 x 20 1 - 20 x 20 1 - 14 x 25 Area, sq. ft 1.700 2.000 2.800 4.000 5.000 6.300 8.000 Velocity, ft/min. 240 300 288 300 360 384 375

Mixing box

Damper opening width, in. 15.5 19.5 19.5 31.5 31.5 31.5 31.5 Damper opening height, in. 7 7 7 7 12.75 12.75 12.75 Area, sq. ft 0.753 0.948 0.948 1.531 2.789 2.789 2.789 Velocity, ft/min. 531 633 844 784 645 861 1076

Note: Minimum air flow limits apply to units wi th hot w ater or el ectric he at only. There is no min imum airf low limit on coolin g

on units. Maximum airflow limits are to help prevent moisture carryover.

Table 33. BCBH/BCVC valve package waterflow limits

Tube size (in.) gpm

1/2 8.6 3/4 19.3 1 34.3 1-1/4 53.5

BCXC-SVX01B-EN 65

Maintenance

Table 34. BCHC/BCVC coil general data

Unit size 12 18 24 36 54 72 90

Nominal cfm 400 600 800 1200 1800 2400 3000

Hydronic & DX coil data

Area - ft2 0.89 1.11 1.67 2.67 4.00 5.00 6.67 Width - in. Length - in.

(a),(b)

(c)

Velocity - ft/min. 450 540 480 450 450 480 450

Hydronic coil data

•High-capacity

Area - ft Width - in. Length - in.

(a),(d)

(c)

Velocity - ft/min. 450 540 480 450 463 494 480

1-row coil

Minimum gpm Maximum gpm

(e)

(f)

Dry coil weight - lb 4.4 5.2 6.6 9.3 17.6 20.4 25.8 Wet coil weight - lb 5.1 6.0 7.8 11.0 22.4 26.0 32.9 Internal volume - in

2-row coil

•High-capacity

Minimum gpm Maximum gpm

(e)

(f)

Dry coil weight - lb 5.9 7.0 9.9 14.1 27.2 32.1 39.4 Wet coil weight - lb (kg) 7.2 8.4 12.3 17.6 36.1 42.5 52.6 Internal volume - in

4-row coil

• Standard capacity

Minimum gpm Maximum gpm Dry coil weight - lb Wet coil weight - lb Internal volume - in

(e)

(f)

(g)

(g) 3 (g)

•High-capacity

Minimum gpm Maximum gpm

(e)

(f)

Dry coil weight - lb 10.5 12.4 17.7 25.5 47.0 56.3 73.1 Wet coil weight - lb 13.1 15.5 22.5 32.5 62.7 74.9 97.9 Internal volume - in

8 8 1212181824 16 20 20 32 32 40 40

0.89 1.11 1.67 2.67 3.89 4.86 6.25 8 8 12 12 17.5 17.5 22.5 16 20 20 32 32 40 40

1.0 1.0 1.0 1.0 6.1 6.1 7.9

5.2 5.2 5.2 5.2 32.6 32.6 42.0

19.4 22.2 33.2 47.1 132.9 155.1 196.6

1.0 1.0 2.0 2.0 6.1 6.1 7.9

5.2 5.2 10.4 10.4 32.6 32.6 42.0

36.0 38.8 66.5 96.9 246.5 288.0 365.5

N/A N/A N/A N/A 8.8 8.8 11.7 N/A N/A N/A N/A 47.0 47.0 62.6 N/A N/A N/A N/A 37.2 44.5 58.5 N/A N/A N/A N/A 48.3 57.7 77.0 N/A N/A N/A N/A 307.4 365.5 512.3

2.0 2.0 2.9 2.9 6.1 6.1 7.9

10.4 10.4 15.7 15.7 32.6 32.6 42.0

72.0 85.8 132.9 193.8 433.0 516.7 688.3

66 BCXC-SVX01B-EN

Maintenance

Table 34. BCHC/BCVC coil general data (continued)

Unit size 12 18 24 36 54 72 90

Nominal cfm 400 600 800 1200 1800 2400 3000

6-row coil

• Standard capacity

Minimum gpm Maximum gpm Dry coil weight - lb Wet coil weight - lb Internal volume - in

(e)

(f)

(g)

(g) 3 (g)

•High-capacity

Minimum gpm Maximum gpm

(e)

(f)

Dry coil weight - lb 14.6 17.4 24.7 36.1 65.4 78.6 101.5 Wet coil weight - lb 18.2 21.8 31.5 46.1 87.8 105.6 137.0 Internal volume - in

• Steam coil data

Area - ft Width - in. Length - in.

(a)

(c)

Velocity - ft/min. 26 25 18 17 17 16 16

1-row coil

Minimum steam press - psig 2.0 2.0 2.0 2.0 2.0 2.0 2.0 Maximum steam press - psig 15.0 15.0 15.0 15.0 15.0 15.0 15.0 Dry coil weight - lb 16.7 18.7 32.5 41.1 57.4 64.8 84.9 Wet coil weight - lb 18.2 20.4 36.0 45.8 64.5 73.2 96.1 Internal volume - in

(a) Coil width = Length in the direction of a coil header, typically vertical. (b)“Hydronic and DX coil data” width dimensions apply only to DX coils (all unit sizes), 1-row standard ca-

pacity hydronic coils (unit sizes 012 through 036), and 4- and 6-row standard capacity hydronic coils (54

through 90). (c) Coil length = Length of coil in direction of the coil tubes, typically horizontal and perpendicular to airflow. (d)“High-capacity hydronic coil data” width dimensions apply only to 1-row standard capacity hydronic coils

(unit sizes 054 through 090) and 2-, 4-, and 6-row high capacity hydronic coils (all unit sizes). (e) The minimum waterflow at 1.5 fps tubeside velocity is to ensure the coil self-vents properly. There is no

minimum waterflow limit for coils that do not require self venting. (f) Maximum gpm limits are to prevent erosion and noise problems. (g)DX coil height and width dimensions are same as comparable hydronic coils. Four- and six-row DX coil dry

weight dimensions are same as comparable 4- and 6-row hydronic coils. A 3-row DX coil dry weight is 25%

less than a comparable 4-row hydronic coil. Internal volumes are approximately 6% less than comparable

hydronic coils.

N/A N/A N/A N/A 8.8 8.8 11.7 N/A N/A N/A N/A 47.0 47.0 62.6 N/A N/A N/A N/A 52.4 63.1 82.7 N/A N/A N/A N/A 68.1 82.0 108.7 N/A N/A N/A N/A 434.8 523.4 720.0

2.0 2.0 2.9 2.9 6.1 6.1 7.9

10.4 10.4 15.7 15.7 32.6 32.6 42.0

99.7 121.8 188.3 276.9 620.4 745.9 983.1

0.71 0.88 1.75 2.75 4.13 5.13 6.83 6 6 1212181824 17 21 21 33 33 41 41

335514149

41.7 47.7 95.3 130.8 196.1 231.6 308.7

BCXC-SVX01B-EN 67

Maintenance

Table 35. Drive data

Unit

Motor sheave Fan sheave Belt

Motor

size

12, 18 186–1119 1/3 to 1-1/2 1VL40x5/8 X10090082090 AK74x3/4 X10070173270 A41 X10200254160 619–878 513–727 D

24, 36 186–1119 1/3 to 1-1/2 1VL40x5/8 X10090082090 AK114x3/4 X10070173A30 A53 X10200254280 390–552 323–457 A

54, 72 186–1119 1/3 to 1-1/2 1VL40x5/8 X10090082090 AK114x3/4 X10070173A30 A53 X10200254280 390–552 323–457 A

watts HP Browning Trane Browning Trane Browning Trane

AK64x3/4 X10070173030 A39 X10200254140 727–109 602–853 E AK54x3/4 X10070172C40 A37 X10200254120 879–1245 728–1031 F AK46x3/4 X10070172A20 A36 X10200254110 1000–1417 829–1174 G AK39x3/4 X10070172700 A35 X10200254100 1200–1700 994–1409 H AK34x3/4 X10070172640 A34 X10200254090 1313–1859 1088–1541 J AK28x3/4 X10070172440 A34 X10200254090 1615–2288 1338–1896 K

AK94x3/4 X10070173630 A48 X10200254230 478–678 396–562 B AK84x3/4 X10070173450 A46 X10200254210 540–765 447–634 C AK74x3/4 X10070173270 A45 X10200254200 619–878 513–727 D AK64x3/4 X10070173030 A43 X10200254180 727–1029 602–853 E AK54x3/4 X10070172C40 A41 X10200254160 879–1245 728–1031 F AK46x3/4 X10070172A20 A39 X10200254140 1000–1417 829–1174 G AK39x3/4 X10070172700 A38 X10200254130 1200–1700 994–1409 H AK34x3/4 X10070172640 A37 X10200254120 1313–1859 1088–1541 J

(a)

1492–2238 2 and 3

90 186–1119 1/3 to 1 1/2 1VL40x5/8 X10090082090 AK114x3/4 X10070173A30 A59 X10200254340 390–552 323–457 A

1492–2238 2 and 3

(a) 2 hp 60 Hz motors have 5/8” bore sheaves. 2 hp 50 Hz motors have 7/8” bore sheaves. All 3 hp motors have 7/8” bore sheaves with the exception of

575V, which has the 5/8” bore.

1VM50x5/8 X10090082170 AK94x3/4 X10070173630 A48 X10200254230 678–877 562–727 L

(a)

1VM50x7/8 X10090082190 AK84x3/4 X10070173450 A46 X10200254210 765–990 634–820 M

(a)

1VM50x5/8 X10090082170 AK94x3/4 X10070173630 A51 X10200254260 678–877 562–727 L

(a)

1VM50x7/8 X10090082190 AK84x3/4 X10070173450 A49 X10200254240 765–990 634–820 M

(a)

1VM50 X 5/8 X10090082170 AK94x3/4 X10070173630 A56 X10200254310 6 78–877 562–727 L

(a)

1VM50 X 7/8 X10090082190 AK84x3/4 X10070173450 A56 X10200254310 7 65–990 634–820 M

AK28x3/4 X10070172440 A36 X10200254110 1615–2288 1338–1896 K

AK74x3/4 X10070173270 A45 X10200254200 878–1136 727–941 N AK64x3/4 X10070173030 A43 X10200254180 1029–1332 853–1104 P AK54x3/4 X10070172C40 A41 X10200254160 1245–1611 1031–1335 R AK46x3/4 X10070172A20 A40 X10200254150 1174–1519 T

AK94x3/4 X10070173630 A50 X10200254250 478–678 396–562 B AK84x3/4 X10070173450 A48 X10200254230 540–765 447–634 C AK74x3/4 X10070173270 A46 X10200254210 619–878 513–727 D AK64x3/4 X10070173030 A45 X10200254200 727–1029 602–853 E AK54x3/4 X10070172C40 A43 X10200254180 879–1245 728–1031 F AK46x3/4 X10070172A20 A41 X10200254160 1000–1417 829–1174 G AK39x3/4 X10070172700 A40 X10200254150 1200–1700 994–1409 H AK34x3/4 X10070172640 A40 X10200254150 1313–1859 1088–1541 J

AK74x3/4 X10070173270 A48 X10200254230 878–1136 727–941 N AK64x3/4 X10070173030 A46 X10200254210 1029–1332 853–1104 P AK54x3/4 X10070172C40 A45 X10200254200 1245–1611 1031–1335 R AK46x3/4 X10070172A20 A43 X10200254180 1174–1519 T

AK94x3/4 X10070173630 A56 X10200254310 478–678 396–562 B AK84x3/4 X10070173450 A53 X10200254280 540–765 447–634 C AK74x3/4 X10070173270 A53 X10200254280 619–878 513–727 D AK64x3/4 X10070173030 A50 X10200254250 727–1029 602–853 E AK54x3/4 X10070172C40 A49 X10200254240 879–1245 728–1031 F AK46x3/4 X10070172A20 A48 X10200254230 1000–1417 829–1174 G AK39x3/4 X10070172700 A46 X10200254210 1200–1700 994–1409 H AK34x3/4 X10070172640 A46 X10200254210 1313–1859 1088–1541 J

AK74x3/4 X10070173270 A53 X10200254280 878–1136 727–941 N AK64x3/4 X10070173030 A53 X10200254280 1029–1332 853–1104 P AK54x3/4 X10070172C40 A50 X10200254250 1245–1611 1031–1335 R AK46x3/4 X10070172A20 A49 X10200254240 1174–1519 T

Fan rpm range

Motor speed

1750

(60 Hz)

1450

(50 Hz)

Drive letter

68 BCXC-SVX01B-EN

Coil Maintenance

Maintenance

Keep coils clean to maintain maximum performance. For operation at its highest efficiency, clean the coil often during periods of high demand or when dirty conditions prevail. Clean the coil a minimum of once per year to prevent dirt buildup in the coil fins, where it may not be visible.

Remove large debris from the coils and straighten fins before cleaning. Remove filters before cleaning. Rinse coils thoroughly after cleaning. Clean the coil fins using one of these methods:

• steam with detergent

• hot water spray and detergent

• commercially available chemical coil cleaner

NOTICE

Potential unit damage from coil cleaners!

Do not use acidic chemical coil cleaners. Also, do not use alkaline chemical coil cleaners with a pH value greater then 8.5 (after mixing) without using an aluminum corrosion inhibitor in the cleaning solution. Using these types of cleaners could result in equipment damage.

Inspecting and Cleaning Coils

Coils become externally fouled as a result of normal operation. Dirt on the coil surface reduces its ability to transfer heat and can cause comfort problems, increased airflow resistance and thus increased operating energy costs. If the coil surface dirt becomes wet, which commonly occurs with cooling coils, microbial growth (mold) may result, causing unpleasant odors and serious health-related indoor air quality problems.

Inspect coils at least every six months or more frequently as dictated by operating experience. Cleaning frequently is dependent upon system operating hours, filter maintenance, and efficiency and dirt load. Follow is the suggested method below:

Steam, Hot Water, and Cooling Coil Cleaning Procedure

1. Don the appropriate personal protective equipment (PPE).

2. Gain access to both sides of the coil section.

3. Use a soft brush to remove loose debris from both sides of the coil.

4. Use a steam cleaning machine, starting from the top of the coil and working downward. Clean the leaving air side of the coil first, then the entering air side.

Use a block-off to prevent steam from blowing through the coil and into a dry section of the unit.

5. Repeat Step 4 as necessary. Confirm that the drain line is open following completion of the cleaning process.

6. Allow the unit to dry thoroughly before putting the system back into service.

7. Straighten any coil fins that may be damaged with a fin rake.

8. Replace all panels and parts and restore electrical power to the unit.

9. Ensure that contaminated material does not contact other areas of the unit or building. Properly dispose of all contaminated materials and cleaning solutions.

 WARNING

Hazardous chemicals!

Coil cleaning agents can be either acidic or highly alkaline. Handle chemical carefully. Proper handling should include goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety refer to the cleaning agent manufacturer’s Materials Safety Data Sheet and follow all recommended safe handling practices. Failure to follow all safety instructions could result in death or serious injury.

BCXC-SVX01B-EN 69

Maintenance

Winterizing the Coil

Make provisions to drain coils that are not in use, especially when subjected to freezing temperatures.

To drain the coil, first blow out the coil with compressed air. Next, fill and drain the tubes with fullstrength ethylene glycol several times. Then drain the coil as completely as possible.

NOTICE

Potential coil-freeze condition!

Make provisions to drain the coil when not in use to prevent coil freeze-up. Failure to follow this procedure could result in equipment damage.

Periodic Maintenance Checklists

Monthly Checklist

The following check list provides the recommended maintenance schedule to keep the unit running efficiently.

 WARNING

Hazardous Voltage!

 WARNING

Rotating parts!

Secure drive sheaves to ensure motor cannot freewheel. Failure to follow this procedure could result in death, personal injury or equipment damage.

1. Inspect unit air filters. Clean or replace if airflow is blocked or if filters are dirty.

2. Check the condition and tension of fan belts. Adjust tension if belts are floppy or squeal continually. Replace worn or fraying belts in matched sets.

Note: Check and adjust belt tension at least twice daily the first days of new belt operation. Belt

tension will rapidly decrease until the belts are run in.

3. Re-lubricate motor bearings, if motor is fitted with oil tubes and operating conditions include moist or dirty air, continuous duty and/or high temperatures.

Semi-Annual Maintenance

1. Verify the fan motor is properly lubricated. Follow lubrication recommendations on the motor tag or nameplate. Contact the motor manufacturer for more information.

2. With power disconnected, manually rotate the fan wheel to check for obstructions in the housing or interference with fan blades. Remove any obstructions and debris.

3. Check the fan assembly sheave alignment. Tighten set screws to their proper torques.

4. Check fan belt tension. Adjust if belt is slipping. Replace if belt is worn or frayed.

5. Inspect the coils for dirt build-up. Clean fins if airflow is clogged.

Annual Maintenance

Check and tighten all set screws, bolts, locking collars and sheaves.

1. Inspect, clean, and tighten all electrical connections and wiring.

70 BCXC-SVX01B-EN

Maintenance

2. Visually inspect the entire unit casing for chips or corrosion. Remove rust or corrosion and repaint surfaces.

3. Clean fan wheels and fan shaft. Remove any rust from the fan shaft with an emery cloth and recoat with L.P.S. 3 or equivalent.

4. Inspect the drainpan for sludge or other foreign material. Clear the drain openings and drain line to ensure adequate flow.

5. Rotate the fan wheel and check for obstructions in the fan housing. The wheel should not rub on the fan housing or cutoff. Adjust to center if necessary and tighten the wheel set screws per the torque recommendations in Table 31, p. 64.

6. Examine flex connector for cracks or leaks.

7. Repair or replace any damaged duct material.

BCXC-SVX01B-EN 71

Diagnostics

Troubleshooting

LED Activity

Red Service LED

The red LED normally indicates if the unit controller is operating properly or not. Refer to Ta bl e 36 .

Table 36. Red service LED activity‘

LED activity Description

Off continuously after power is applied to the controller. Normal operation On continuously, even when power is first applied to the

controller. LED flashes about once every second. Uninstall (normal controller mode). Use Rover™ service

Black Service push button. Use the Service button to install the Tracer™ ZN520

Green Status LED

The green LED normally indicates whether the controller is powered on (24 VAC supplied). Refer to Ta bl e 37 .

Table 37. Green status LED activity

Green LED activity Description

On continuously Power on (normal operation). Blinks (one blink)

Blinks (two blinks)

LED blinks (1/4 second on, 1/4 second, off for 10 seconds) Wink mode.

LED off

(a)The Wink feature allows you to identify a controller. By se nd in g a req ue st fr om R ov er™ s er vic e too l, you can r equ es t t he

Someone is pressing the Service button or the controller has failed.

tool to restore normal unit operation.

controller in a communication network.

The controller is in manual output test mode. No diagnostics present.

The controller is in manual output test mode. One or more diagnostics are present.

(a)

Power is off. Controller failure. Test button is pressed.

controller to wink (blink on and off as a notification that the controller received the signal). The green LED blinks (1/4 second on, 1/4 second off for 10 seconds) during Wink mode.

Yellow Comm LED

The yellow comm LED blinks at the rate the controller receives communication. The yellow LED does not blink when the controller is transmitting communication data. Refer to Ta bl e 3 8 .

Table 38. Yellow comm LED activity

LED activity Description

Off continuously The controller is not detecting any communication.

LED blinks or flickers The controller detects communication.

LED on continuously Abnormal condition or extremely high traffic on the link.

Note: If the service push button is held down for more than 15 seconds, the Tracer™ ZN controller

will uninstall itself from the ICS communication network and shut down all unit operation. This mode is indicated by the red Service LED flashing once every second. See the Red

72 BCXC-SVX01B-EN

(Normal for standalone applications.)

(Normal for communicating applications, including data sharing.)

High traffic on the link.

Manual Output Test

The purpose of the manual output test sequence is to verify output and end device operation. Use the manual output test to:

• Verify output wiring and operation without using Rover™, service tool.

• Force the water valve to open and balance the hydronic system.

Note: The manual output test is not an automatic cycle. You must press the Test button to proceed

The controller observes all diagnostics that occur during the test sequence. Although an automatic diagnostic reset sequence exists as part of the controller’s normal operation, the automatic diagnostic reset feature is not active during the test sequence.

If left in an individual test step, the controller remains in test mode for 60 minutes and then exits to normal operation.

Many service calls are due to unit diagnostics. The test sequence resets unit diagnostics and attempts to restore normal unit operation prior to testing the outputs. If the diagnostics remain after a reset, the STATUS LED indicates the diagnostic condition is still present (two blinks).

Manual Output Test Procedure

Follow the procedure below to test the Tracer™ ZN010, ZN510, or ZN520 controller.

1. Press and hold the Test button for at least two seconds (not exceeding five seconds), and then

2. The test sequence will turn off all outputs and then attempt to clear all diagnostics.

3. Press the Test button several more times (no more than once per second) to advance through

The outputs are not subject to minimum times during the test sequence. However, the test sequence only permits one step per second which limits minimum output time.

The green LED is turned off when the Test button is pressed. To begin the manual output test mode, press and hold the Test button (turning off the green LED) for at least two seconds. The green LED will begin to blink, indicating the controller is in test mode.

Diagnostics

Service LED section. Use Rover™ service tool to restore the unit to normal operation. Refer to the Rover product literature for more information.

through each step.

release, to start the test mode.

the test sequence.

BCXC-SVX01B-EN 73

Diagnostics

Table 39. Tracer ZN010 and ZN510 test sequence for 1-heat/1-cool configurations

Steps

1. Off Off Off Off Closed

2. Fan high High Off Off Closed

3. Exhaust fan

4. Fan Low Off Off Closed

5. Cool High On Off Closed

6. Heat High Off On Closed

7. Two-position damper

8. Exit

Note: The 2-position damper energizes during this step if the controller is configured for a 2-position damper.

(a) At the beginning of step 2, the controller attempts to clear all diagnostics. (b)Tracer™ ZN010 and ZN510 have a binary output default as “none” on J1-X from the factory. If the unit has a 2-speed fan,

step 3 will energize the low f an speed. If the unit has a single speed fan, step 3 will continue to ener gize the high fan speed . This binary output can be reconfigured as an exhaust fan, with the use of Rover™ software.

(c) After the fresh air damper step, the test sequence performs the exit step.This initiates a reset and attempts to return the

controller to normal operation.

(d)For all 1-heat/1-cool applications including 2-pipe changeover, th e cool ing and heat t est stag e ene rgize. This oc curs e ven

though during normal 2-pipe changeover operation binary output controls the unit valve for both cooling and heating.

Table 40. Tracer ZN520 test sequence

Fan Cool output

(a)

Heat output Damper

J1-1, J1-3 J1- J1- J1-

(b)

(c)

High Off Off Open

(d)

Off Off Closed

Fan

Step

(a)

1. Off

2. Fan high

(c)

4. Fan low Off Off Low Off Off Off Off Off Off Off

5. Main open High Off Off On Off Off Off O ff Off Off

6. Main close, EH1 on High Off Off Off On On Off Off Off Off

7. Aux. open High

8. Aux. close, damper open High Off Off Off Off Off

9. Damper close High Off Off Off Off Off Off Off On Off

10. Generic/baseboard heat energized High Off Off Off Off Off Off Off Off On

11. Exit

(a)Upon entering manual output test mode, the controller turns off all fan and electric heat outputs and drives. (b)At the beginning of step 2, the controller attempts to clear all diagnostics. (c) The low fan speed output energizes at step 3. If the unit is configured for a 1 speed fan, the fan remains on high speed at step 3. (d)If the unit is configured for a 1- or 2-speed fan, and BOP2 is configured for an exhaust fan, the exhaust fan output energizes on step 7. The exhaust

(e) After step 10, the test sequence performs an exit. This initiates a reset and attempts to return the controller to normal operation.

(b)

(e)

fan output is shared with medium speed.

J1-1 J1-2 J1-3 J1-5 J1-6 J1-9 J1-10 J1-11 J1-12 TB4-1

Off Off Off Off On

High Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off

Exh

EH1 on

Exit

valve

(d)

Off Off Off On Off Off Off Off

Main

Electric heat or

aux. valve

EH: off

Fresh air damper Generic/baseboard heat

Off aux: on Off On Off

On Off Off

EH1 offOnEH2 on

Diagnostics

Translating Multiple Diagnostics

The controller senses and records each diagnostic independently of other diagnostics. It is possible to have multiple diagnostics present simultaneously. The diagnostics are reported in the order they occur.

Possible diagnostics include:

74 BCXC-SVX01B-EN

• Low temperature detection

• Condensate overflow

• Low air flow - fan status

• Discharge air temp limit

• Space temperature failure

• Entering water temp failure

• Discharge air temp failure

• Outdoor air temp failure

• Local setpoint failure

• Local fan mode failure

•CO2 sensor failure

• Generic AIP failure

• Humidity input failure

• Defrosting compressor lockout

• Maintenance required

• Invalid Unit Configuration

• Generic temperature failure

• Discharge air low limit

Resetting Diagnostics

There are seven ways to reset unit diagnostics:

1. Automatically by the controller

2. By initiating a manual output test at the controller

3. By cycling power to the controller

4. By using a building automation system (Tracer™ ZN510 or ZN520 only)

5. By using the Rover™ service tool

6. By using any other communicating device able to access the controller’s diagnostic reset input (Tracer ZN510 or ZN520 only)

7. By cycling the fan switch from off to any speed setting (Tracer ZN520 only)

Diagnostics

Automatic Reset by the Controller

The controller includes an automatic diagnostic reset function which attempts to automatically restore the unit when a low temperature diagnostic occurs.

Note: The controller implements the automatic diagnostic reset function only once every 24

hours. For the controller to increment the 24 hour timer, you must maintain power to the controller. Cycling power resets all timers and counters.

After the controller detects the first low temperature diagnostic, the unit waits 30 minutes before invoking the automatic diagnostic reset function. The automatic diagnostic reset function clears the special diagnostic and attempts to restore the controller to normal operation. The controller resumes normal operation until another diagnostic occurs.

Note: The automatic diagnostic reset function does not operate during the manual output test

sequence.

If a special diagnostic occurs within 24 hours after an automatic diagnostic reset, the controller must be manually reset. Other possible methods of resetting diagnostics are described in the sections that follow.

Non-latching diagnostics automatically reset when the input is present and valid.

BCXC-SVX01B-EN 75

Diagnostics

Manual Output Test

You can use the Test button on the controller either during installation to verify proper end device operation or during troubleshooting. When you press the Test button, the controller exercises all outputs in a predefined sequence. The first and last outputs of the sequence reset the controller diagnostics. See p. 73 for more information about the manual output test.

Cycling Power

When someone turns off the controller’s 24 VAC power, then re-applies power, the unit cycles through a power up sequence. By default, the controller attempts to reset all diagnostics at power up. Diagnostics present at power-up and those that occur after power-up are handled according to the defined unit diagnostics sequences (see Table 41, p. 77 and Table 42, p. 77).

Building Automation System (Tracer ZN510 or ZN520 Only)

Some building automation systems can reset diagnostics in the Tracer™ ZN510 or ZN520 controller. For more complete information, refer to the product literature for the building automation system.

Rover Service Tool

Rover™ service tool can reset diagnostics in the Tracer™ ZN520 controller. For more complete information, refer to the Rover Installation, Operation, and Programming manual.

Diagnostic Reset (Tracer ZN510 or ZN520 Only)

Any device that can communicate the network variable nviRequest (enumeration “clear_alarm”) can reset diagnostics in the Tracer™ ZN510 or ZN520 controller. The controller also attempts to reset diagnostics whenever power is cycled.

Cycling the Fan Switch (Tracer ZN520 Only)

If the user cycles the fan speed switch from off to any speed, the controller resets all diagnostics. Diagnostics may recur immediately if the problem still exists.

The green LED normally indicates whether or not the controller is powered on (24 VAC).

Trane’s Service Tool, Rover

Rover™, Trane’s service tool, can reset diagnostics present in the controller. For complete information about Rover, refer to Trane publication EMTX-IOP-2 Rover Installation, Operation and Programming Guide.

Alarm Reset

Any device that can communicate alarm reset information can reset diagnostics present in the controller.

76 BCXC-SVX01B-EN

Diagnostics

Table 41. Tracer ZN010 and ZN510 controller diagnostics

Diagnostic Latching Fan Valves Electric heat Damper

Auxiliary temperature failure No Enabled No action No action No action Condensate overflow detection Yes Off Closed Off Closed Entering water temperature No Enabled Enabled Enabled Enabled Fan mode failure No Enabled Enabled Enabled Enabled Invalid unit configuration failure Yes Disabled Disabled Disabled Disabled Low temperature detection Yes Off Open Off Closed Maintenance required Yes Enabled No action No action No action Setpoint No Enabled No action No action No action Zone temperature failure No Off Closed Off Closed

Notes:

1. Priority Level: Diagnostics are listed in order from highest to lowest priority. The controller senses and records each

diagnostic independently of other diagnostics. It is possible to have multiple diagnostics present simultaneously. The diagnostics affect unit operation according to priority level.

2. Latching: A latching diagnostic requires a manual reset of the controller; while a non-latching diagnostic automatically resets when the input is present and valid.

3. Enabled: End device is allowed to run if there is a call for it to run.

4. Disabled: End device is not allowed to run even if there is a call for it to run.

5. No Action: The diagnostic has no affect on the end device.

Table 42. Tracer ZN520 diagnostics

Diagnostic Fan Other outputs

Condensate overflow Off Valves closed, fresh air damper closed, electric heat off, baseboard heat off Low temperature detection Off Valves open, fresh air damper closed, electric heat off, baseboard heat off Low air flow - fan failure Off Valves closed, fresh air damper closed, electric heat off, baseboard heat off Space temperature failure Off Valves closed, fresh air damper closed, electric heat off, baseboard heat off Entering water temperature failure On Valves enabled Discharge air temperature low limit Off Valves open, fresh air damper closed, electric heat off, baseboard heat off Discharge air temperature failure Off Valves closed, fresh air damper closed, electric heat off, baseboard heat off Fresh air temperature failure On Valves enabled, fresh air damper minimum position

enabled Relative humidity failure On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled Generic 4-20ma failure On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled

input failure On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled

Maintenance required On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled Local fan mode failure On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled Local setpoint failure On Valves enabled, fresh air damper enabled, electric heat enabled, baseboard heat enabled Invalid unit configuration Off Valves disabled, fresh air damper disabled, electric heat disabled, baseboard heat disabled Normal - power up On Valves enabled, fresh air damper enabled, electric heat enabled

(a) The generic binary output (TB4-1, TB4-2) state is unaffected by all unit diagnostics. (b)When the entering water temperature is required but not present, the Tracer™ ZN520 controller generates a diagnostic to indicate the sensor loss

condition. The controller automatically cle ars the diag n ostic o nc e a val id ente rin g wat er t emperat ure valu e is p res en t (no n-latching diagnostic). When the entering water temperat ure sensor fails, the controller prohi bits all hydronic cooling operation, but allows the delivery o f heat when heating is required. In the Cool mode, all cooling is locked-out, but normal fan and outdoor air damper operation is permitted.

(c) When the outdoor air temperature sensor has failed or is not present, the Tracer ZN520 controller generates a diagnostic to indicate the sensor loss

condition. The controller automatically clears the diagnostic once a valid outdoor air temperature value is present (non-latching diagnostic). When the outdoor air temperature sensor fails or is not present, the controller prohibits economizer operation.

(a)

(b)

, fresh air damper enabled

(b)

, electric heat enabled

(c)

, electric heat enabled, baseboard heat

(b)

, baseboard heat off

BCXC-SVX01B-EN 77

Diagnostics

Common Diagnostics

Table 43. Fan outputs do not energize

Probably cause Explanation

Random start observed After power-up, the controller always observes a random start that varies between 0 and 30 seconds. The controller

Power-up control wait When power-up control wait is enabled (non-zero time), the controller remains off until one of two conditions occurs:

Cycling fan operation When the fan mode switch is in the auto position, the unit fan cycles off when there is no call for heating or cooling.

Unoccupied operation The fan cycles with capacity when the unit is in unoccupied mode. This occurs even if the unit is in continuous fan

Fan mode off When using the local fan mode switch to determine the fan operation, the off position controls the unit fan to off. Requested mode: off It is possible to communicate the operating mode (such as off, heat, and cool) to the controller. When “off” is

Diagnostic present A specific list of diagnostics affects fan operation. For more information, see Table 41, p. 77 and Table 42, p. 77. No power to the

controller

Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

Manual output test The controller includes a manual output test sequence to verify binary output operation and the as sociated wiring.

Unit wiring The wiring between the controller outputs and the fan relays and contact s must be present and correct for n ormal fan

remains off until the random start time expires.

1. The controller exits power-up control wait once it receives communicated information.

2. The controller exits power-up control wait once the power-up control wait time expires.

The heating/cooling sources cycle on or o ff periodically with the unit fan to match the capacit y according to pulse width modulation (PWM) logic.

operation. While unoccupied, the fan cycles on or off with heating/cooling to provide varying amounts of heating or cooling to the space. to match the capacity diagnostics according to pulse-width-modulation (PWM) logic.

communicated to the controller, the unit controls the fan to off . The un it is not capable of heating or cooling when the controller is in this mode.

If the controller does not have powe r , the unit fan does not operate. For the T r acer™ ZN controller to operate normally, it must have an input voltage of 24 V AC. When the green LED is off continuously , the controller does not have sufficient power or has failed.

configuration does not match the actual end devices, the valves may not work correctly.

However , based on the current step in the test sequence, the unit fan may not be powered on. Refer to “Manual Output

Test ,” p. 73.

operation. Refer to the specific unit wiring diagrams on the unit.

Table 44. Valves stay closed

Probable cause Explanation

Normal operation The controller opens and closes the valves to meet the unit capacity requirements. Requested mode: off It is possible to communicate the operating mode (such as off, heat, and cool) to the controller. When off is

Valve override The controller can communicate a valve override request.This request affects the valve operation. Manual output test The controller includes a manual output test sequence to verify analo g and binary output operation and the associated

Diagnostic present A specific list of diagnostics affects valve operation. For more information, see Table 41, p. 77 and Table 42, p. 77. Sampling logic The controller includes entering water temper ature sampling logic that automatically invokes during 2-pipe or 4-pipe

Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

No power to the controller

Unit wiring The wiring between the co ntroller outputs and the valve(s) must be present and correct for normal valve operation.

communicated to the controller, the unit controls the fan to off. The unit is n ot capable of heating o r cooling when the controller is in this mode.

wiring. However, based on the current step in the test sequence, the valves may not be open. Refer to the “Manual

Output Test,” p. 73.

changeover. It determines when the entering wate r temperature is either too cool or too hot for the desired heating or cooling mode. Refer to “Entering Water Temperature Sampling Function,” p. 55.

configuration does not match the actual end device, the valves may not work correctly. If the controller does not have power, the unit fan does not operate. For the T racer™ ZN010, 510 controller to operate

normally , it must have an input voltage of 24 VAC. When the green LED is off continuously , the controller does not ha ve sufficient power or has failed.

Refer to the unit wiring diagrams on the unit.

78 BCXC-SVX01B-EN

Diagnostics

Table 45. Valves stay open

Probable cause Explanation

Normal operation The controller opens and closes the valves to meet the unit capacity requirements. Valve override The controller can communicate a valve override request to affect the valve operation. Manual output test The controller includes a manual output test sequence that verifies analog and binary output operation and the

Diagnostic present A specific list of diagnostics affects valve operation. For more information, see Table 41, p. 77 and Table 42, p. 77. Sampling logic The controller includes entering water temperature sampling logic that automatically invokes during 2-pipe or 4-pipe

Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

Unit wiring The wiring between the controller outputs and the valve(s) must be present and correct for normal valve operation.

Table 46. Electric heat not operating

Probable cause Explanation

Normal operation The controller cycles electric heat on and off to meet the unit capacity requirements. Requested mode: off It is possible to communicate the operating mode (such as off, heat, cool) to the controller. When off is communicated

Communicated disable Numerous communicated requests may disable electric heat, including an auxiliary heat enable input and the heat/

Manual output test The controller includes a manual output test sequence that verifies analog and binary output oper ation and associated

Diagnostic present A specific list of diagnostics affects electric heat operation. For more information, see Table 41, p. 77 and Table 42,

Unit configuration The controller must be properly configured based on the actual installed end devices and ap plic ation. When the unit

No power to the controller

Unit wiring The wiring between the controller outputs and the electric heat contacts must be present and correct for normal electric

associated wiring. However, based on the current step in the test sequence, the valves may be open. Refer to the

“Manual Output Test,” p. 73.

changeover to determine if the entering water temperature is correct for t he unit operat ing mode. R efer to “Entering

Water Temperature Sampling Function,” p. 55.

configuration does not match the actual end device, the valves may not work correctly.

Refer to the unit wiring diagrams on the unit.

to the controller, the units shuts off the electric heat.

cool mode input. Depending on the state of the communicated request, the unit may disable electric heat.

output wiring. However, based on the current step in the test sequence, the electric heat may not be on. Refer to the

“Manual Output Test,” p. 73.

p. 77.

configuration does not match the actual end device, the electric heat may not work properly. If the controller does not have power , the un it fan does not operate. For the Tracer™ ZN010, 510 controller to operate

normally, it must have an input voltage of 24 VAC. When the gr een LED is off continuously , the controller does not have sufficient power or has failed.

heat operation. Refer to the unit wiring diagrams on the unit.

Table 47. Fresh air damper stays closed

Probable cause Explanation

Warm-up and cool-down The controller includes both a warmup and cool down sequence to keep the fresh ai r damper closed during the tr ansition

Requested mode: off It is possible to communicate the operating mode (such as off , heat, cool) to the controller. When off is communicated

Manual output test The controller includes a manual output test sequence that verifies analog and binary output o peration and associated

Diagnostic present A specific list of diagnostics effects fresh air damper operation. For more information, see Table 41, p. 77 and Table 42,

Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

No power to the controller

Unit wiring The wiring between the controller outputs and the fresh air damper must be present and correct for normal damper

BCXC-SVX01B-EN 79

from unoccupied to occupied. This is an attempt to bring the space under control as quickly as possible.

to the controller, the unit closes the fresh air damper.

output wiring. However, based on the current step in the test sequence, the fresh air damper ma y not be open. Refer to the “Manual Output Test,” p. 73.

p. 77.

configuration does not match the actual end device, the damper may not work correctly. If the controller does not have power , the unit fan does not oper ate. For the T r acer™ ZN010, 510 controller to operate

normally , it must have an input voltage of 24 V AC. When the green LED is off continuously , the controller does not hav e sufficient power or has failed.

operation. Refer to the unit wiring diagrams on the unit.

Diagnostics

Table 48. Fresh air damper stays open

Probable cause Explanation

Normal operation The controller opens and closes the fresh air damper based on the controller’s occupancy mode and fan status. Normally,

Manual output test The controller includes a manual output test sequence that verifies analog and binary output o peration and associated

Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

Unit wiring The wiring between the controller outputs and the fresh air damper must be present and correct for normal damper

Table 49. Valves stay closed

Probable cause Explanation

Requested mode off You can communicate a desir ed operating mode (such as off , heat, and cool) to the controller . When off is co mmunicated

Power-up control wait When power up control wait is enabled (non-zero time), the controller remains off until one of two conditions occ urs:

Manual output test The controller includes a manual output test seq uence you can use to verify output operation and associated output

Fan mode off When a local fan mode switch (provided on the Trane zone sensor) determines the fan operation, the off position

Sampling logic The controller includes entering water temperature sampling logic which is automatically invoked during 2-pipe and

Diagnostic present A specific list of diagnostic affects valve operation. For more information, see Table 41, p. 77 and Table 42, p. 77. Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

Unit wiring The wiring between the controller outputs and the valve(s) must be present and correct for normal valve operation. Random start observed After power up, the controller always observes a random start from 0 to 25 sec onds. The co ntroller remains off until

the fresh air damper is open during occupied mode when the fan is running and closed during unoccupied mode.

wiring. However , based on the current step in the test sequence, the fresh air damper may be open. Refer to the “Manual

Output Test,” p. 73.

configuration does not match the actual end device, the damper may not work correctly.

operation. Refer to the unit wiring diagrams on the unit.

to the controller, the unit controls the fan off. There is no heating or cooling (valves are closed).

The controller exits power up control wait once it receives communicated information. The controller exits power up control wait once the power up control wait time expires.

wiring. However, based on the current step in the test sequence, the valve(s) may not be open. Refer to the “Manual

Output Test,” p. 73.

controls the unit off and valves to close.

4-pipe changeover when the entering water temperature is either too cool or too hot for the desired heating or cooling. Refer to “Entering Water Temperature Sampling Function,” p. 55.

configuration does not match the actual end devices, the valves may not work correctly. Example: A 2-pipe heat/cool changeover unit will not cool if the entering water temperature is too warm for cooling or if the entering water sensor is not present. The unit will not heat if the entering water temperature is too cool for heating.

the random start time expires.

Table 50. DX or electric outputs do not energize

Probable cause Explanation

Unit wiring The wiring between the controller outputs and the end devices must be present and correct for normal operation. Unit configuration The controller must be properly configured based on the actual installed end devices and application. When the unit

Diagnostic present A specific list of diagnostic affects valve operation. For more information, see Table 41, p. 77 and Table 42, p. 77. Manual output test The controller includes a manual output test seq uence you can use to verify output operation and associated output

Freeze avoidance When the fan is off with no demand for capacity (0%) and the outdoor air temperature is below is below the freeze

Normal operation The controller energizes the outputs only as needed to meet the unit capacity requirements.

80 BCXC-SVX01B-EN

configuration does not match the actual end devices, the unit may not work correctly.

wiring. However, based on the current step in the test sequence, the valve(s) may not be open. Refer to the “Manual

Output Test,” p. 73.

avoidance setpoint, the controller disabl es compressors and electric heat outputs. This includes uno ccupied mode when there is no call for capacity or any other time the fan is off.

Wiring Diagrams

Two-Pipe BCXC with Tracer ZN510

• 208 volt/3 phase

• 2-position damper

• single stage electric heat

• 2-position valve

• condensate overflow

• wall-mounted zone sensor

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

BCXC-SVX01B-EN 81

Wiring Diagrams

Four-Pipe BCXC with Tracer ZN510

• 208 volt/3 phase

• 2-position valves

• 2-position damper

• condensate overflow

• low limit protection

• wall-mounted zone sensor

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

82 BCXC-SVX01B-EN

Four-Pipe BCXC with Tracer ZN510

• 115 volt/1 phase

• 2-position valves

• 2-position damper

• 2-speed motor

• condensate overflow

Wiring Diagrams

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

BCXC-SVX01B-EN 83

Wiring Diagrams

Two-Pipe BCXC with Tracer ZN520

• 460 volt/3 phase

• 2-position valve

• economizer damper

• 2-stage electric heat

• fan status switch

• condensate overflow

• wall-mounted zone sensor

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

84 BCXC-SVX01B-EN

Four-Pipe BCXC with Tracer ZN520

• 460 volt/3 phase

• 2-position valves

• condensate overflow

• fan status switch

Wiring Diagrams

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

BCXC-SVX01B-EN 85

Wiring Diagrams

Four-Pipe BCXC with Tracer ZN520

• 460 volt/3 phase

• economizer damper

• condensate overflow

• fan status switch

• wall-mounted zone sensor

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

86 BCXC-SVX01B-EN

Four-Pipe BCXC with Tracer ZN520

• 460 volt/3 phase

• 3-wire floating point valves

• economizer damper

• condensate overflow

• fan status switch

• wall-mounted zone sensor

Wiring Diagrams

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

BCXC-SVX01B-EN 87

Wiring Diagrams

Four-Pipe BCXC with Control Interface

• • 208 volt/3 phase

• • 3-wire floating point valves

• • 2-position damper

• • low limit protection

• • condensate overflow

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

88 BCXC-SVX01B-EN

Four-Pipe BCXC with Control Interface

• 115 volt/1 phase

• 2-position damper

• 2-speed motor

• condensate overflow

• low limit protection

Wiring Diagrams

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

BCXC-SVX01B-EN 89

Wiring Diagrams

5 ON/OFF

CLG

DX COOLING

38A

G,J

DX RELAY

1K3

2S8

EVAP DEFROST FROSTAT

1K3-23

19B

GENERIC BOP

TB4-1 BOP

TB4-2 24V

GENERIC

CONTROL BOX

ELECTRIC HEAT

STAGE 1

BRN

ORG

COMMON

9 STAGE 1

15C(ORG)

BLK

WHT

BLK,BLK

WHT,

4A(WHT)

1K1

2B1

PUR

STAGE 2

10 STAGE 2

16C(PUR)

ELECTRIC HEAT CONTROL BOX

2S7

ELECTRIC HT LOCKOUT SWITCH

7RT1

DISCHARGE AIR TEMP SENSOR

SPLICE

J3-3

J3-4

AI-2 DAT

COMM HI(+)

COMM LOW(-)

CSP33

FAN SWITCH

COM22

ZONE11

ZONE TB3-1

GND TB3-2

SET TB3-3

FAN TB3-4

TB2-6

COMM

TB2-5

E(WHT)

B(BLK)

MIXING BOX DAMPER ACTUATOR

4U4

CCW

TR1

CCW

TR1

12 CLOSE

OAD

11 OPEN

13A(BRN)

12A(PNK)

2 EXHAUST

7RT3

OUTSIDE AIR TEMP SENSOR

J3-5

AI-3-OAT

J3-6

SPLICE

2S2

CONDENSATE OVERFLOW SWITCH3232

J2-4

J2-3

BI-2

CONDENSATE

23A(PUR)

24A(PUR)

GREEN PLUG

FAN STATUS SWITCH

2S5

J2-7

J2-8

26A(YEL)

25A(YEL)

BI-4

FAN-STAT

BRN

277/60/1

D(WHT)

B(BLK)

TRANE CO.

BY THE FIELD. SOLID LINES INDICATE WIRING BY

DEVICE OUTLINES INDICATE COMPONENTS PROVIDED

BY OTHERS. DASHED LINE ENCLOSURES AND/OR DASHED

DASHED LINES INDICATE RECOMMENDED FIELD WIRING

UNLESS OTHERWISE NOTED, ALL SWITCHES ARE SHOWN

OFF, AND AFTER A NORMAL SHUTDOWN HAS OCCURED.

50% RELATIVE HUMIDITY, WITH ALL UTILITIES TURNED

AT 25° C (77° F), AT ATMOSPHERIC PRESSURE, AT

NOTES:

1 2 3 4 5 6

MAIN CONTROL PANEL SUPPLY FAN AND COIL SECTION

MIXING BOX SECTION EXTERNAL PIPING

AREA

DEVICE PREFIX LOCATION CODE

1K1

SUPPLY FAN CONTACTOR

ALL FIELD WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NEC), STATE AND LOCAL REQUIREMENTS.

FIELD INSTALLED DEVICE

NUMBER

LINE

LEGEND

DESCRIPTION

DESIGNATION

DEVICE

CONTROL POWER TRANSFORMER

1T1

CONTROL TERMINAL BLOCK

1TB1-L1,-L2

ZN CONTROLLER

1U1

SUPPLY FAN MOTOR

2B1

FUSED DISCONNECT SWITCH

7S6

ZONE SENSOR MODULE

7U6

PLUG CONNECTOR

JACK CONNECTOR

LOCATION

GRN

YEL

BLU

7K5

EXHAUST FAN CONTROL RELAY

OR HIGH VOLTAGE POWER WIRES.

NOT INSTALL WIRES IN CONDUIT THAT CONTAINS WIRES 24VAC

SHIELD MUST BE GROUNDED AT UCM END(END CHASSIS) AND TAPED AT THE OTHER END. IF INSTALLED IN CONDUIT, DO

PAIR SHIELDED CABLE AND NO MORE THAN 1000 FT LG.

WIRING TO ZONE SENSOR MUST BE 16-22 AWG, CU TWISTED

75VA

BLK

W(BLK)

1CB1

TRANSFORMER CIRCUIT BREAKER1616

OR FIELD RECONFIGURED AS GENERIC

J2-6

J2-5

OCC/UNOCC

TB1-1 24V

1 HIGH SPEED

TB2-4

COMM

TB2-1

TB2-3

TB2-2

COMM OUT

INSULATE SHIELDS

COMM IN

TRACER

LO(-)

HI(+)

SPLICE AND

LO(-)

GND TB1-2

POWER

1U1

BI-3

17A(BLK)

COMMUNICATION WIRE MUST BE TRANE PART NO. 400-20-28, OR WINDY CITY OR CONNECT AIR

AGGREGATE RUN.

"LEVEL 4" CABLE. MAXIMUM OF 4500 FOOT

FOR ADDITIONAL INFORMATION REFER TO EMTX-EB-68.

CAUTION! DO NOT RUN POWER IN THE SAME CONDUIT OR WIRE BUNDLE WITH COMMUNICATION LINK.

7U6

2 EXHAUST

14A(YEL)

(BLK)

1K1-10,12

DESIGNATE THE LOCATION OF CONTACTS BY LINE NUMBER.

NUMBERS ALONG THE RIGHT SIDE OF THE SCHEMATIC

FIELD SUPPLIED CONTROL RELAYS, POWERED BY THIS UNIT, MUST BE PILOT DUTY RATED, 24VAC COIL, 6VA MAX.

1TB1-L2

1S1

7S6

1T1

24V

7S6

2S7

2B1

COM

LOW

2B1

COM

LOW

2B1

1K1

1K2

7K5

1K2

1TB1-L11010

1TB1-L1

1TB1-L2

1K1

1K2

1K1

1K2

1P1-3

2RT1

2P12-1

2J12-1

2P12-2

2J12-2

2J13-1

2P13-1

2S2

2P13-2

2J13-2

2S3

2S5

1K1

2J9-4

4P9-4

2J9-3

4P9-3

1P1-11

1P1-12

4P9-2

2J9-2

4P9-1

2J9-1

5P3-2

2J3-2

1P2-2

1J2-2

1J2-1

1P2-1

2J3-1

5P3-1

1P1-5

1P1-6

1J2-1

1P2-1

1P1-5

1J5-1

1P5-1

1P1-9

1P1-10

1P5-3

1J5-3

5P6-3

2J6-3

1P1-9

1J5-1

1P5-1

1P1-9

1J5-1

1P5-1

5RT2

5P10-1

2J10-1

5P10-2

2J10-2

1J2-1

1P2-1

1P1-6

1P1-5

1J2-1

1P2-1

1P1-5

1J5-1

1P5-1

1P1-10

1P1-9

1J5-1

1P5-1

1P1-9

1P1-11

1P1-12

7RT3

7RT1

1CB1

1P1-2

1P1-1

1P1-9

1P1-10

1J8-3

1P8-3

1J8-4

1P8-4

1P8-1

1J8-1

1P8-2

1J8-2

5P3-2

2J3-2

1P2-2

1J2-2

1P2-3

1J2-3

5P3-3

2J3-3

2J3-1

5P3-1

1J2-1

1P2-1

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J6-1

5P6-1

5P6-3

2J6-3

5P6-2

2J6-2

1P5-3

1J5-3

1P5-2

1J5-2

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J3-1

5P3-1

1P2-3

1J2-3

5P3-3

2J3-3

5P3-2

2J3-2

1P2-2

1J2-2

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J3-1

5P3-1

1P2-2

1J2-2

5P3-2

2J3-2

2J3-1

5P3-1

5P3-3

2J3-3

1P2-3

1J2-3

5P3-2

2J3-2

1P2-2

1J2-2

2J6-1

5P6-1

1P5-3

1J5-3

1P5-2

1J5-2

5P6-3

2J6-3

5P6-2

2J6-2

1P11-1

1J11-1

1P11-2

1J11-2

1P1-11

1P1-12

1J8-3

1P8-3

1J8-4

1P8-4

1P8-2

1J8-2

1P8-1

1J8-1

1J8-3

1P8-3

1J8-4

1P8-4

1P8-2

1J8-2

1P8-1

1J8-1

5P4-2

5J4-2

5P7-2

5J7-2

5J4-1

5P4-1

5J7-1

5P7-1

5P4-3

5J4-3

5J4-1

5P4-1

5P4-2

5J4-2

5J4-1

5P4-1

5P4-2

5J4-2

5P4-3

5J4-3

5J4-1

5P4-1

5P4-2

5J4-2

5J4-1

5P4-1

5P4-2

5J4-2

5P4-3

5J4-3

5J7-1

5P7-1

5P7-3

5J7-3

5P7-2

5J7-2

5P7-2

5J7-2

5P7-3

5J7-3

5J7-1

5P7-1

5J7-1

5P7-1

5P7-2

5J7-2

5J7-1

5P7-1

5P7-3

5J7-3

5P7-2

5J7-2

1P1-5

2S8

1K3

1P2-2

1J2-2

1J2-1

1P2-1

BCXC with DX Coil and Tracer ZN520

NOTES:

UNLESS OTHERWISE NOTED, ALL SWITCHES ARE SHOWN AT 25° C (77° F), AT ATMOSPHERIC PRESSURE, AT 50% RELATIVE HUMIDITY, WITH ALL UTILITIES TURNED

OFF, AND AFTER A NORMAL SHUTDOWN HAS OCCURED.

DASHED LINES INDICATE RECOMMENDED FIELD WIRING BY OTHERS. DASHED LINE ENCLOSURES AND/OR DASHED

DEVICE OUTLINES INDICATE COMPONENTS PROVIDED BY THE FIELD. SOLID LINES INDICATE WIRING BY TRANE CO.

ALL FIELD WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NEC), STATE AND LOCAL

REQUIREMENTS.

NUMBERS ALONG THE RIGHT SIDE OF THE SCHEMATIC DESIGNATE THE LOCATION OF CONTACTS BY LINE NUMBER.

FIELD SUPPLIED CONTROL RELAYS, POWERED BY THIS UNIT, MUST BE PILOT DUTY RATED, 24VAC COIL, 6VA MAX.

WIRING TO ZONE SENSOR MUST BE 16-22 AWG, CU TWISTED PAIR SHIELDED CABLE AND NO MORE THAN 1000 FT LG.

SHIELD MUST BE GROUNDED AT UCM END(END CHASSIS) AND TAPED AT THE OTHER END. IF INSTALLED IN CONDUIT, DO NOT INSTALL WIRES IN CONDUIT THAT CONTAINS WIRES 24VAC

OR HIGH VOLTAGE POWER WIRES.

COMMUNICATION WIRE MUST BE TRANE PART NO.

400-20-28, OR WINDY CITY OR CONNECT AIR "LEVEL 4" CABLE. MAXIMUM OF 4500 FOOT AGGREGATE RUN.

CAUTION! DO NOT RUN POWER IN THE SAME CONDUIT OR WIRE BUNDLE WITH COMMUNICATION LINK. FOR ADDITIONAL INFORMATION REFER TO EMTX-EB-68.

88888888888

1TB1-L1

B(BLK)

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

90 BCXC-SVX01B-EN

(BLK)

2S7

• 277 volt/1 phase

• economizer damper

• condensate overflow

• wall-mounted zone sensor

1CB1

1K3

5P4-1

5P7-1

STAGE 1

STAGE 2

5J4-3

5J7-3

224

TR1

5P4-3

5P7-3

TR1

TRTRCW

5J4-1

5P3-3

2J3-3

5J7-1

5P6-3

2J6-3

4P9-3

2J9-3

4P9-4

2J9-4

1J2-1

1J5-1

E(WHT)

1J8-3

1J8-4

W(BLK)

(BLK)

1P2-1

888

1P2-1

1P5-1

BRN

88888

888

1TB1-L2

1K1

7K5

1K2

5P3-1

DX COOLING

2J3-1

1P2-3

1J2-3

5P6-1

COMMON

2J6-1

ELECTRIC HEAT

1P5-3

CONTROL BOX

1J5-3

1P8-3

1P8-4

4U4

CCW

BLU

G,J

113

ORG

PUR

CCW

1K3

5P4-2

5P4-3

5P7-2

5P7-3

277/60/1

ELECTRIC HEAT

CONTROL BOX

1S1

WHT

BRN

5J4-2

38A

5J4-3

5J7-2

5J7-3

2J9-1

4P9-1

2J9-2

4P9-2

5RT2

5P10-1

5P10-2

SPLICE

7S6

BLK

WHT,

BRN

BLK,BLK

BLK

24V

75VA

17A(BLK)

14A(YEL)

5P3-2

1P2-2

2J3-2

5P3-3

1P2-3

1P2-2

2S8

19B

2J3-3

5P6-2

1P5-2

2J6-2

5P6-3

1P5-3

2J6-3

1J8-1

1P8-1

1J8-2

1P8-2

GENERIC BOP

1P11-1

2J10-1

1P11-2

2J10-2

2RT1

7RT1

SPLICE

2P12-1

2P12-2

7RT3

SPLICE

DEVICE PREFIX LOCATION CODE

AREA

1 2 3 4 5 6 7

1K1

4A(WHT)

1K2

1K1

1T1

YEL

TB1-1 24V

1 HIGH SPEED

1P1-1

2 EXHAUST

1P1-2

1P1-3

1J2-2

1J2-3

15C(ORG)

1J5-2

16C(PUR)

1J5-3

1J2-2

12A(PNK)

13A(BRN)

1J11-1

1J11-2

2J12-1

2J12-2

1P1-5

1P1-6

1P1-5

1P1-9

1P1-10

1P1-11

1P1-12

5 ON/OFF

9 STAGE 1

10 STAGE 2

11 OPEN

12 CLOSE

TB4-1 BOP

GENERIC

TB4-2 24V

J3-3

AI-2 DAT

J3-4

J3-5

AI-3-OAT

J3-6

LOCATION MAIN CONTROL PANEL SUPPLY FAN AND COIL SECTION

MIXING BOX SECTION EXTERNAL PIPING

ELECTRIC HEAT CONTROL BOX

FIELD INSTALLED DEVICE

2B1

COM

LOW

1U1

POWER

GRN

GND TB1-2

ZONE TB3-1

GND TB3-2

SET TB3-3

FAN TB3-4

CLG

OAD

COMM

BI-2

CONDENSATE

BI-3

BI-4

FAN -STAT

TB2-6

TB2-5

TB2-4

TB2-3

TB2-2

TB2-1

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

DEVICE

DESIGNATION

1CB1

TRANSFORMER CIRCUIT BREAKER

1K1

SUPPLY FAN CONTACTOR

DX RELAY

1K3

CONTROL POWER TRANSFORMER

1T1

1TB1-L1,-L2

CONTROL TERMINAL BLOCK

ZN CONTROLLER

1U1

SUPPLY FAN MOTOR

2B1

2S2

1TB1-L2

D(WHT)

CONDENSATE OVERFLOW SWITCH

FAN STATUS SWITCH

2S5

2S7

ELECTRIC HT LOCKOUT SWITCH

2S8

EVAP DEFROST FROSTAT

MIXING BOX DAMPER ACTUATOR

4U4

7K5

EXHAUST FAN CONTROL RELAY

7RT1

DISCHARGE AIR TEMP SENSOR

7RT3

OUTSIDE AIR TEMP SENSOR

FUSED DISCONNECT SWITCH

7S6

ZONE SENSOR MODULE

7U6

PLUG CONNECTOR

JACK CONNECTOR

B(BLK)

ZONE

COM

CSP

FAN SWITCH

COMM LOW(-)

LO(-)

HI(+)

SPLICE AND INSULATE SHIELDS

LO(-)

HI(+)

2P13-1

COMM HI(+)

TRACER COMM OUT

TRACER COMM IN

2S3

2S2

OCC/UNOCC

2S5

23A(PUR)

24A(PUR)

25A(YEL)

26A(YEL)

2J13-1

7U6

GREEN PLUG

LEGEND

DESCRIPTION

2P13-2

OR FIELD RECONFIGURED AS GENERIC

1K1-10,12

1K3-23

2J13-2

LINE

NUMBER

BCXC with DX Coil, Hydronic Heating, and Tracer ZN520

5 ON/OFF

CLG

DX COOLING

38A

G,J

DX RELAY

1K3

2S8

EVAP DEFROST FROSTAT

1K3-23

19B

CCW

7U4

TR1

12A(PNK)

13A(BRN)

12 CLOSE

11 OPEN

OAD

7U4

MIXING BOX DAMPER ACTUATOR2727

E(WHT)

B(BLK)

SPLICE

GENERIC BOP

TB4-1 BOP

TB4-2 24V

GENERIC

MANUAL DISCONNECT SWITCH

1S1

EQUIPMENT

GROUND

GRN

SPLICE

BLK

SPLICE

7B3

HEATING COIL VALVE MOTOR

(7VA MAX)

9 ON/OFF

HTG

BLUE CONNECTORS USED FOR COOLING CIRCUIT, RED CONNECTORS USED FOR HEATING CIRCUIT. BLUE WIRES USED FOR COOLING CIRCUIT, RED WIRES USED FOR HEATING CIRCUIT.

15A

COMM HI(+)

COMM LOW(-)

CSP33

FAN SWITCH

COM22

ZONE11

ZONE TB3-1

GND TB3-2

SET TB3-3

FAN TB3-4

TB2-6

COMM

TB2-5

BLK/RED

460/60/3

A,BLK

BLK

SPLICE

BLK

DISCHARGE AIR TEMP SENSOR

2RT1

J3-3

AI-2 DAT

J3-4

34A(BRN)

35A(BRN)

7RT3

OUTSIDE AIR TEMP SENSOR

J3-5

AI-3-OAT

J3-6

SPLICE

2S2

CONDENSATE OVERFLOW SWITCH3232

J2-4

J2-3

BI-2

CONDENSATE

23A(PUR)

24A(PUR)

GREEN PLUG

FREEZE-STAT

2S3

BI-1

J2-1

J2-2

FRZ-STAT

21A(GRA)

22A(GRA)

D(WHT)

B(BLK)

TRANE CO.

BY THE FIELD. SOLID LINES INDICATE WIRING BY

DEVICE OUTLINES INDICATE COMPONENTS PROVIDED

BY OTHERS. DASHED LINE ENCLOSURES AND/OR DASHED

DASHED LINES INDICATE RECOMMENDED FIELD WIRING

UNLESS OTHERWISE NOTED, ALL SWITCHES ARE SHOWN

OFF, AND AFTER A NORMAL SHUTDOWN HAS OCCURED.

50% RELATIVE HUMIDITY, WITH ALL UTILITIES TURNED

AT 25˚˚

C (77˚˚

F), AT ATMOSPHERIC PRESSURE, AT

NOTES:

1 2 3 4 5 6

MAIN CONTROL PANEL SUPPLY FAN AND COIL SECTION

MIXING BOX SECTION EXTERNAL PIPING

AREA

DEVICE PREFIX LOCATION CODE

1K1

SUPPLY FAN CONTACTOR

ALL FIELD WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NEC), STATE AND LOCAL REQUIREMENTS.

FIELD INSTALLED DEVICE

NUMBER

LINE

LEGEND

DESCRIPTION

DESIGNATION

DEVICE

CONTROL POWER TRANSFORMER

1T1

CONTROL TERMINAL BLOCK

1TB1-L1,-L2

ZN CONTROLLER

1U1

SUPPLY FAN MOTOR

2B1

FUSED DISCONNECT SWITCH

7S6

ZONE SENSOR MODULE

7U6

PLUG CONNECTOR

JACK CONNECTOR

LOCATION

GRN

YEL

BLU

7K5

EXHAUST FAN CONTROL RELAY

OR HIGH VOLTAGE POWER WIRES.

NOT INSTALL WIRES IN CONDUIT THAT CONTAINS WIRES 24VAC

SHIELD MUST BE GROUNDED AT UCM END(END CHASSIS) AND TAPED AT THE OTHER END. IF INSTALLED IN CONDUIT, DO

PAIR SHIELDED CABLE AND NO MORE THAN 1000 FT LG.

WIRING TO ZONE SENSOR MUST BE 16-22 AWG, CU TWISTED

75VA

BLK

W(BLK)

1CB1

TRANSFORMER CIRCUIT BREAKER1616

OR FIELD RECONFIGURED AS GENERIC

J2-6

J2-5

OCC/UNOCC

TB1-1 24V

1 HIGH SPEED

TB2-4

COMM

TB2-1

TB2-3

TB2-2

COMM OUT

INSULATE SHIELDS

COMM IN

TRACER

LO(-)

HI(+)

SPLICE AND

LO(-)

GND TB1-2

POWER

1U1

BI-3

17A(BLK)

COMMUNICATION WIRE MUST BE TRANE PART NO. 400-20-28, OR WINDY CITY OR CONNECT AIR

AGGREGATE RUN.

"LEVEL 4" CABLE. MAXIMUM OF 4500 FOOT

FOR ADDITIONAL INFORMATION REFER TO EMTX-EB-68.

CAUTION! DO NOT RUN POWER IN THE SAME CONDUIT OR WIRE BUNDLE WITH COMMUNICATION LINK.

7U6

2 EXHAUST

14A(YEL)

(BLK)

1K1-10,12

DESIGNATE THE LOCATION OF CONTACTS BY LINE NUMBER.

NUMBERS ALONG THE RIGHT SIDE OF THE SCHEMATIC

FIELD SUPPLIED CONTROL RELAYS, POWERED BY THIS UNIT, MUST BE PILOT DUTY RATED, 24VAC COIL, 6VA MAX.

1TB1-L2

1S1

7S6

1T1

24V

7S6

2S7

2B1

COM

LOW

2B1

COM

LOW

2B1

1K1

1K2

7K5

1K2

1TB1-L11010

1TB1-L1

1TB1-L2

1K1

1K2

1K1

1K2

1P1-3

2RT1

2P12-1

2J12-1

2P12-2

2J12-2

2J13-1

2P13-1

2S2

2P13-2

2J13-2

2S3

2S5

1K1

2J9-4

4P9-4

2J9-3

4P9-3

1P1-11

1P1-12

4P9-2

2J9-2

4P9-1

2J9-1

5P3-2

2J3-2

1P2-2

1J2-2

1J2-1

1P2-1

2J3-1

5P3-1

1P1-5

1P1-6

1J2-1

1P2-1

1P1-5

1J5-1

1P5-1

1P1-9

1P1-10

1P5-3

1J5-3

5P6-3

2J6-3

1P1-9

1J5-1

1P5-1

1P1-9

1J5-1

1P5-1

5RT2

5P10-1

2J10-1

5P10-2

2J10-2

1J2-1

1P2-1

1P1-6

1P1-5

1J2-1

1P2-1

1P1-5

1J5-1

1P5-1

1P1-10

1P1-9

1J5-1

1P5-1

1P1-9

1P1-11

1P1-12

7RT3

7RT1

1CB1

1P1-2

1P1-1

1P1-9

1P1-10

1J8-3

1P8-3

1J8-4

1P8-4

1P8-1

1J8-1

1P8-2

1J8-2

5P3-2

2J3-2

1P2-2

1J2-2

1P2-3

1J2-3

5P3-3

2J3-3

2J3-1

5P3-1

1J2-1

1P2-1

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J6-1

5P6-1

5P6-3

2J6-3

5P6-2

2J6-2

1P5-3

1J5-3

1P5-2

1J5-2

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J3-1

5P3-1

1P2-3

1J2-3

5P3-3

2J3-3

5P3-2

2J3-2

1P2-2

1J2-2

2J6-1

5P6-1

5P6-2

2J6-2

1P5-2

1J5-2

2J3-1

5P3-1

1P2-2

1J2-2

5P3-2

2J3-2

2J3-1

5P3-1

5P3-3

2J3-3

1P2-3

1J2-3

5P3-2

2J3-2

1P2-2

1J2-2

2J6-1

5P6-1

1P5-3

1J5-3

1P5-2

1J5-2

5P6-3

2J6-3

5P6-2

2J6-2

1P11-1

1J11-1

1P11-2

1J11-2

1P1-11

1P1-12

1J8-3

1P8-3

1J8-4

1P8-4

1P8-2

1J8-2

1P8-1

1J8-1

1J8-3

1P8-3

1J8-4

1P8-4

1P8-2

1J8-2

1P8-1

1J8-1

5P4-2

5J4-2

5P7-2

5J7-2

5J4-1

5P4-1

5J7-1

5P7-1

5P4-3

5J4-3

5J4-1

5P4-1

5P4-2

5J4-2

5J4-1

5P4-1

5P4-2

5J4-2

5P4-3

5J4-3

5J4-1

5P4-1

5P4-2

5J4-2

5J4-1

5P4-1

5P4-2

5J4-2

5P4-3

5J4-3

5J7-1

5P7-1

5P7-3

5J7-3

5P7-2

5J7-2

5P7-2

5J7-2

5P7-3

5J7-3

5J7-1

5P7-1

5J7-1

5P7-1

5P7-2

5J7-2

5J7-1

5P7-1

5P7-3

5J7-3

5P7-2

5J7-2

1P1-5

2S8

1K3

1P2-2

1J2-2

1J2-1

1P2-1

NOTES:

UNLESS OTHERWISE NOTED, ALL SWITCHES ARE SHOWN AT 25 50% RELATIVE HUMIDITY, WITH ALL UTILITIES TURNED

OFF, AND AFTER A NORMAL SHUTDOWN HAS OCCURED.

DASHED LINES INDICATE RECOMMENDED FIELD WIRING BY OTHERS. DASHED LINE ENCLOSURES AND/OR DASHED

DEVICE OUTLINES INDICATE COMPONENTS PROVIDED BY THE FIELD. SOLID LINES INDICATE WIRING BY TRANE CO.

ALL FIELD WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NEC), STATE AND LOCAL

REQUIREMENTS.

BCXC-SVX01B-EN 91

NUMBERS ALONG THE RIGHT SIDE OF THE SCHEMATIC DESIGNATE THE LOCATION OF CONTACTS BY LINE NUMBER.

FIELD SUPPLIED CONTROL RELAYS, POWERED BY THIS UNIT, MUST BE PILOT DUTY RATED, 24VAC COIL, 6VA MAX.

WIRING TO ZONE SENSOR MUST BE 16-22 AWG, CU TWISTED PAIR SHIELDED CABLE AND NO MORE THAN 1000 FT LG.

SHIELD MUST BE GROUNDED AT UCM END(END CHASSIS) AND TAPED AT THE OTHER END. IF INSTALLED IN CONDUIT, DO NOT INSTALL WIRES IN CONDUIT THAT CONTAINS WIRES 24VAC

OR HIGH VOLTAGE POWER WIRES.

COMMUNICATION WIRE MUST BE TRANE PART NO.

400-20-28, OR WINDY CITY OR CONNECT AIR "LEVEL 4" CABLE. MAXIMUM OF 4500 FOOT AGGREGATE RUN.

CAUTION! DO NOT RUN POWER IN THE SAME CONDUIT OR WIRE BUNDLE WITH COMMUNICATION LINK. FOR ADDITIONAL INFORMATION REFER TO EMTX-EB-68.

88888888888

BLUE CONNECTORS USED FOR COOLING CIRCUIT, RED CONNECTORS USED FOR HEATING CIRCUIT. BLUE WIRES USED FOR COOLING CIRCUIT, RED

WIRES USED FOR HEATING CIRCUIT.

1TB1-L1

B(BLK)

 WARNING

Hazardous Voltage!

NOTICE

Use copper conductors only!

Unit terminals are not designed to accept other conductor types. Failure to use copper conductors could cause equipment damage.

C (77

F), AT ATMOSPHERIC PRESSURE, AT

W(BLK)

1TB1-L2

(BLK)

2S7

1J2-1

1J5-1

E(WHT)

1J8-3

1J8-4

(BLK)

1P2-1

888

1P2-1

1P5-1

88888

888

• 460 volt/3 phase

• economizer damper

• condensate overflow

• wall-mounted zone sensor

SPLICE

GRN

1S1

EQUIPMENT

GROUND

5J4-3

5J7-3

1K3

224

5P4-3

5P7-3

7B3

TR1

G,J

(7VA MAX)

7U4

CCW

BLU

5P4-2

1K3

5P4-3

113

5P7-2

5P7-3

5J4-2

5J4-3

5J7-2

5J7-3

38A

4P9-1

4P9-2

1P8-3

1P8-4

1K1

7K5

1K2

5P3-1

DX COOLING

2J3-1

1P2-3

1J2-3

5P6-1

2J6-1

1P5-3

1J5-3

4P9-3

2J9-3

4P9-4

2J9-4

1CB1

5P4-1

5J4-1

5P3-3

2J3-3

5P7-1

5J7-1

5P6-3

2J6-3

SPLICE

BLK

15A

SPLICE

5RT2

5P10-2

SPLICE

460/60/3

BLK/RED

5P3-2

5P3-3

2S8

5P6-2

5P6-3

2J9-1

2J9-2

5P10-1

7S6

SPLICE

BLK

BLK/RED

A,BLK

BLK

1T1

24V

75VA

17A(BLK)

14A(YEL)

1P2-2

1J2-2

2J3-2

1P2-3

1P2-2

19B

1J2-3

2J3-3

2J6-2

2J6-3

1P8-1

1P8-2

GENERIC BOP

2J10-1

2J10-2

2RT1

7RT1

7RT3

1J8-1

1J8-2

1P11-2

2P12-1

2P12-2

SPLICE

1P5-2

1P5-3

1P11-1

1J5-2

1J5-3

1J2-2

12A(PNK)

13A(BRN)

1P1-10

1P1-11

1P1-12

1J11-1

1J11-2

34A(BRN)

2J12-1

35A(BRN)

2J12-2

DEVICE PREFIX LOCATION CODE

AREA

1K1

1K2

1K1

YEL

TB1-1 24V

1 HIGH SPEED

1P1-1

2 EXHAUST

1P1-2

1P1-3

1P1-5

5 ON/OFF

1P1-6

1P1-5

9 ON/OFF

1P1-9

11 OPEN

12 CLOSE

TB4-1 BOP

GENERIC

TB4-2 24V

J3-3

AI-2 DAT

J3-4

J3-5

AI-3-OAT

J3-6

LOCATION

MAIN CONTROL PANEL

1 2

SUPPLY FAN AND COIL SECTION

MIXING BOX SECTION

EXTERNAL PIPING

5 6 7

FIELD INSTALLED DEVICE

2B1

COM

LOW

GRN

1U1

GND TB1-2

POWER

ZONE TB3-1

GND TB3-2

SET TB3-3

FAN TB3-4

CLG

COMM

HTG

COMM

OAD

COMM

FRZ-STAT

CONDENSATE

1TB1-L2

D(WHT)

TB2-6

TB2-5

TB2-4

TB2-3

TB2-2

TB2-1

21A(GRA)

J2-1

BI-1

22A(GRA)

J2-2

23A(PUR)

J2-3

24A(PUR)

J2-4

J2-5

J2-6

2J13-1

BI-2

BI-3

DEVICE

DESIGNATION

1CB1

TRANSFORMER CIRCUIT BREAKER

1K1

SUPPLY FAN CONTACTOR

DX RELAY

1K3

MANUAL DISCONNECT SWITCH

1S1

CONTROL POWER TRANSFORMER

1T1

1TB1-L1,-L2

CONTROL TERMINAL BLOCK

ZN CONTROLLER

1U1

SUPPLY FAN MOTOR

2B1

DISCHARGE AIR TEMP SENSOR

2RT1

2S2

CONDENSATE OVERFLOW SWITCH

FREEZE-STAT

2S3

2S8

EVAP DEFROST FROSTAT

7B3

HEATING COIL VALVE MOTOR

7K5

EXHAUST FAN CONTROL RELAY

7RT3

OUTSIDE AIR TEMP SENSOR

FUSED DISCONNECT SWITCH

7S6

7U4

MIXING BOX DAMPER ACTUATOR

ZONE SENSOR MODULE

7U6

PLUG CONNECTOR

JACK CONNECTOR

B(BLK)

ZONE

COM

CSP

FAN SWITCH

COMM LOW(-)

COMM HI(+)

LO(-)

TRACER COMM OUT

HI(+)

SPLICE AND INSULATE SHIELDS

LO(-)

TRACER COMM IN

HI(+)

2S3

2S2

2P13-1

OCC/UNOCC

2S5

Wiring Diagrams

LEGEND

DESCRIPTION

7U6

2P13-2

GREEN PLUG

1K1-10,12

1K3-23

2J13-2

OR FIELD RECONFIGURED AS GENERIC

LINE

NUMBER

www.trane.com

For more information, contact your local Trane office or e-mail us at comfort@trane.com

Literature Order Number BCXC-SVX01B-EN

Date April 2008

Supersedes BCXC-SVX01A-EN September 2002

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

Trane BCVC, BCXC-SVX01B-EN, BCHC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Model Number Description

General Information

Pre-Installation

Receiving and Handling

Jobsite Storage Recommendations

Installation Preparation

Service Access

Rigging and Handling

Unit Location Recommendations

Skid Removal

Pre-Installation Checklist

Dimensions and Weights

Horizontal Blower Coil

Vertical Blower Coil

Angle Filter and Mixing Box

Bottom or Top Access Filter Box

Electric Heat

Steam Coil

Coil Connections

Piping Packages

Installation Controls

Installing Wall Mounted Controls

Zone Sensor Installation

Communication Wiring

Tracer Summit Communication Wiring

Installation Electrical

Unit Wiring Diagrams

Supply Power Wiring

Electrical Connections

Electrical Grounding Restrictions

Installation Mechanical

Installing the Unit

Heating Coil Option

Mixing Box Option

Condensate Drain Connections

Duct Connections

Installation Piping

Water Coil Connections

Piping Packages

Refrigerant Coil Piping

Field-Installing Evaporator Piping

Steam Piping

Controls Interface

Control Options

Tracer Controllers

Rover Service Software

Pre-Start

Start-Up

Sequence of Operation

Tracer ZN Controller Sequence of Operation

Cooling Operation

Fan Mode Operation

Two- and Four-Pipe Changeover Operation

Electric Heat Operation

Economizer Damper (Tracer ZN520 Only)

Tracer Dehumidification (Tracer ZN520 Only)

Data Sharing (Tracer ZN510 or ZN520 Only)

Binary Inputs

Analog Inputs

Binary Outputs

Zone Sensor

Maintenance

Maintenance Procedures

Coil Maintenance

Periodic Maintenance Checklists

Diagnostics

Troubleshooting

LED Activity

Manual Output Test

Diagnostics

Translating Multiple Diagnostics

Resetting Diagnostics

Common Diagnostics

Wiring Diagrams