Trane TSC060ED, TSC120ED Installation, Operation And Maintenance Manual

Page 1

Installation, Operation, and Maintenance

Packaged Rooftop Air Conditioners Precedent™- Electric/Electric

5 – 10 Tons – 50 Hz

Model Numbers

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or alter ed equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

September 2012 RT-SVX37B-EN

TSC060ED - TSC120ED

SAFETY WARNING

Page 2

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 death or personal injury . Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that could 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.

Read this manual thoroughly before operating or servicing this unit.

ATTENTION: Warnings, Cautions and Notices appear at

appropriate sections throughout this literature. Read these carefully:

WARNING

CAUTIONs

NOTICE:

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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.

Indicates a situation that could result in equipment or property-damage only

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 af fect 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. T rane 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

Proper Field Wiring and Grounding Required!

All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, y ou MUST f ollow r equir ements for field wiring installation and grounding as described in NEC and your local/state electrical codes. Failure to follow code could result in death or serious injury.

WARNING

Personal Protective Equipment (PPE) Required!

Installing/servicing this unit could result in exposure to electrical, mechanical and chemical hazards.

• Before installing/servi cin g th is un it, technicians MUST put on all P ersonal Protective Equipmen t (PPE) recommended for the work being undertaken. AL W A YS r efer to appr opriate MSDS sheets and OSHA guidelines for proper PPE.

• When working with or ar ound hazar dous chemi cals, ALWAYS refer to the appropriate MSDS sheets and OSHA guidelines for information on allowable personal exposure levels, proper respiratory protection and handling recommendations.

• If there is a risk of arc or flash, te chnicians MUST put on all Personal Protective Equipment (PPE) in accordance with NFPA 70E or other country-specific requirements for arc flash protection, PRIOR to servicing the unit.

Failure to f ollow recommendations could result in death or serious injury.

Revision Summary

RT-SVX37B-EN (10 September 2012)

• MERV 8 filter with filter removal tool

• Stainless steel drain pan, condensate overflow switch

• Updated Model Number Description, Maintenance, Troubleshooting

Page 3

Table of Contents

Warnings, Cautions and Notices . . . . . . . . . . 2

Model Number Descriptions . . . . . . . . . . . . . . 4

General Information . . . . . . . . . . . . . . . . . . . . . 6

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 11

Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Unit Requirements . . . . . . . . . . . . 20

Horizontal Discharge  Conversion (5 Ton Unit)

Horizontal Discharge Conversion (6 Through 10 Ton Units)

Field Installed Power Wiring . . . . . . . . . . . 22

Main Unit Power . . . . . . . . . . . . . . . . . . . . . 23

Space Temperature Averaging . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . . . . 20

. . . . . . . . . . . . . . . 20

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Voltage Imbalance . . . . . . . . . . . . . . . . . . . . 28

Electrical Phasing (Three Phase Motors) . 28

Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Verifying Proper Air Flow . . . . . . . . . . . . . . 31

Economizer Start-Up . . . . . . . . . . . . . . . . . . 31

Compressor Start-Up . . . . . . . . . . . . . . . . . 32

Final System Setup . . . . . . . . . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fan Belt Adjustment - Belt Drive Units . . . 33

Monthly Maintenance . . . . . . . . . . . . . . . . . 33

Annual Maintenance . . . . . . . . . . . . . . . . . . 35

Final Process . . . . . . . . . . . . . . . . . . . . . . . . . 36

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . 37

ReliaTel™ Control . . . . . . . . . . . . . . . . . . . . 37

System Status Checkout Procedure . . . . . 37

Zone Temperature Sensor (ZTS) Service Indicator

Zone Temperature Sensor (ZTS) Test . . . 39 Unit Economizer Control (ECA) Troubleshoot-

ing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . 41

RT-SVX37B-EN 3

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Model Number Descriptions

TSC 060 E D R L A ** 123 456 7 8 9 10 11 1213

Digit 1 - Unit Type

T DX Cooling

Digit 2 - Efficiency

S Standard Efficiency HHigh Efficiency

Digit 3 - Airflow

C Convertible

Digit 4,5,6 - Nominal Gross Cooling Capacity (MBh)

036 3 Ton 048 4 Ton 060 5 Ton 072 6 Ton 090 7½ Ton, Single Compressor 092 7½ Ton, Dual Compressor 102 8½ Ton 120 10 Ton

Digit 7 - Major Design Sequence

E R-410A Refrigerant F Microchannel Type Condenser

Coils

Digit 8 - Voltage Selection

D 380-415/50/3

Digit 9 - Unit Controls

E Electromechanical R ReliaTel™ Microprocessor

Digit 10 - Heating Capacity

0=No Electric Heat F=14 kW (1 phase) A=5 kW (1 phase)1G=18 kW (1&3 phase) B=6 kW (3 phase) J=23 kW (3 phase) C=9 kW (3 phase) K= 27 kW (3 phase) D=10 kW (1 phase) E=12 kW (3 phase) P = 54 kW (3 phase)

N = 36 kW (3 phase)

Digit 11 - Minor Design Sequence

A First Sequence B Second Sequence

Digit 12,13 - Service Sequence

** Factory Assigned

Digit 14 - Fresh Air Selection

0No Fresh Air A Manual Outside Air Damper 0-50% B Motorized Outside Air Damper

0-50%

C Economizer, Dry Bulb 0-100%

without Barometric Relief

D Economizer, Dry Bulb 0-100%

with Barometric Relief

E Economizer, Reference Enthalpy

0-100% without Barometric Relief

F Economizer, Reference Enthalpy

0-100% with Barometric Relief

G Economizer, Comparative

Enthalpy 0-100% without Barometric Relief

3,7

H Economizer, Comparative

Enthalpy 0-100% with Barometric

3,7

Relief

Digit 15 - Supply Fa n/Drive Type/ Motor

0 Standard Drive 1 Oversized Motor 2 Optional Belt Drive Motor 6 Single Zone Variable Air Volume 7 Multi-Speed Indoor Fan

Digit 16 - Hinged Service Access/Filters

0 Standard Panels/Standard Filters A Hinged Access Panels/Standard

Filters B Standard Panels/2” MERV 8 Filters C Hinged Access Panels/2” MERV 8

Filters D Standard Panels/2” MERV 13 Filters E Hinged Access Panels/2” MERV 13

Filters

Digit 17 - Condenser Coil Protection

0 Standard Coil 1 Standard Coil with Hail Guard 2 Black Epoxy Pre-Coated Condenser

Coil 3 Black Epoxy Pre-Coated

Condenser Coil with Hail Guard 4 CompleteCoat™ Condenser Coil 5 CompleteCoat™ Condenser Coil

with Hail Guard

Digit 18 - Through the Base Provisions

0 No Through-the-Base Provisions A Through-the-Base Electric

Digit 19 - Disconnect/Circuit Breaker (three-phase only)

0 No Disconnect/No Circuit Breaker 1 Unit Mounted Non-Fused

Disconnect 2 Unit Mounted Circuit Breaker

Digit 20 - Convenience Outlet

0 No Convenience Outlet

A Unpowered Convenience Outlet B Powered Convenience Outlet

(three-phase only)

3,7

Digit 21 - Communications

Sensor

DCV

Options

0 No Communications Interface 1 Trane Communications Interface 2 LonTalk® Communications Interface 3 Novar 2024 Controls 4 Novar 3051 Controls without Zone

5 Novar 3051Controls Interface with

6 BACnet™ Communications Interface

Digit 22 - Refrigeration System Option

0 Standard Refrigeration System B Dehumidification Option

21,22

Digit 23 - Refrigeration Controls

Note: Applicable to Digit 7 = E, F

0 No Refrigeration Control 1Frostat 2 Crankcase Heater 3Frostat

11,28

and Crankcase Heater

Digit 24 - Smoke Detector

0 No Smoke Detector A Return Air Smoke Detector B Supply Air Smoke Detector C Supply and Return Air Smoke

Detectors

12,13

D Plenum Smoke Detector

12,13

Digit 25 - System Monitoring Controls

0 No Monitoring Control 1 Clogged Filter Switch 2 Fan Failure Switch 3 Discharge Air Sensing Tube 4 Clogged Filter Switch and Fan

Failure Switch

5 Clogged Filter Switch and Discharge

Air Sensing Tube

6 Fan Failure Switch and Discharge Air

Sensing Tube

7 Clogged Filter Switch, Fan Failure 

Switch and Discharge Air Sensing Tube

8 Novar Return Air Sensor

(NOVAR 2024)

9 Novar Zone Temp Sensor

(NOVAR 3051)

15,29

18,29

A Condensate Drain Pan Overflow

Switch

B Clogged Filter Switch

Condensate Drain Pan Overflow

Switch

C Fan Failure Switch

Drain Pan Overflow Switch

D Discharge Air Sensing

Condensate Drain Pan Overflow Switch

and

and Condensate

and

4 RT-SVX37B-EN

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Model Number Descriptions

E Clogged Filter Switch

F Clogged Filter Switch

G Fan Failure Switch, Discharge Air

H Clogged Filter Switch

Switch Overflow Switch

Air Sensing Tube Drain Pan Overflow Switch

Sensing Tube Drain Pan Overflow Switch

Switch and Condensate Drain Pan Overflow Switch

and Condensate Drain Pan

, Discharge Air Sensing

, Fan Failure

, Discharge

and Condensate

, Fan Failure

Digit 26 - System Monitoring Controls

0 No Monitoring Controls A Demand Control Ventilation

30,31

(CO

)

Digit 27 - Unit Hardware Enhancements

0 No Enhancements 1 Stainless Steel Drain Pan

Model Number Notes

1. Available on 3-5 ton models.

2. Standard on 4-5 Ton E3,4,W and  6-10 Ton Heat Pumps and all High Efficiency models.

3. Not available with electromechanical controls.

4. Manual outside air damper will ship factory supplied within the unit, but must be field installed.

5. High pressure control is standard on all units.

6. On 3-5 ton, multispeed direct drive is standard on single phase and 15 SEER. On 6-10 ton, multispeed direct drive is standard on all 10 ton and 7.5-8.5 ton high efficiency. Belt drive is standard on all other units.

Digit 15 = 0

Standard Efficiency 1 Phase = High Efficiency Multispeed Direct Drive Motor 3 Phase (3-8½ Ton) = Belt Drive 3 Phase (10 T on) = Ultra High Efficiency Direct Drive Plenum Fan High Efficiency 1 Phase = High Efficiency Multispeed Direct Drive Motor 3 Phase (3-5 ton) = High Efficiency Multispeed Direct Drive Motor 3 Phase (3-5 ton w/Dehumidification) = Belt Drive Motor 3 Phase (7½-10 ton) = Ultra High Efficiency Direct Drive Plenum Fan

7. Economizer with Barometric Relief is for downflow configured units only. Order Economizer without Barometric Relief for

horizontal configuration. Barometric Relief for horizontal configured units must be ordered as field installed accessory.

8. Through the base electric required when ordering disconnect/circuit breaker options.

9. Requires use of Disconnect or Circuit Breaker.

Not Available

Standard Efficiency 10 Ton w/575V High Efficiency 3-5 ton w/Standard Indoor Motor w/460V

10. Standard metering devices are TXVs.

1 1 . Frostat cannot be field installed in

electro-mechanical units.

12. The return air smoke detector may not fit up or work properly on the Precedent units when used in conjunction with 3rd party accessories such as bolt on heat wheels, economizers and power exhaust. Do not order the return air smoke detectors when using this type of accessory.

13. Return Air Smoke Detector cannot be ordered with Novar Controls.

14. These options are standard when ordering Novar Controls.

15. This option is used when ordering Novar Controls.

16. Not available with high temperature duct sensor accessory.

17. Digit 15 = 2

Standard Efficiency 1 Phase = Not Available 3 Phase = Not Available High Efficiency 1 Phase = Not Available 3 Phase (3-5 ton) = May be Ordered 3 Phase (3-5 ton w/Dehumidification) = Not Available 3 Phase (6-10 ton) = Not Available

18. Novar Sensor utilized with  Digit 21 = (4) Novar 3051 Controls without Zone Sensor.

19. Available for 10 ton standard efficiency models only .

20. Available for 3, 4, 5, 6, 7½, 8½ ton standard/high efficiency models only.

21. Requires selection of 2” Pleated Filters (option B or C) for Digit 16.

22. Not availabl e on 6 ton units and all single phase or standard efficiency.

23. Standard on TSC 6, 7½ (single and dual systems), 8½, 10 ton standard efficiency mo de ls and THC 4, 5, 6, 7½ ton high efficiency models (except for dehumidification models).

24. Epoxy coil and epoxy with hailguard options are not available for units with microchannel condenser coil.

25. Single Zone VA V is only available on 7.5-10 ton high efficiency and 10 ton standard efficiency products with ReliaT el™ controls.

26. Multi-speed indoor fan available only on 7.5 & 8.5 ton high efficiency, and 10 ton products with ReliaTel™ controls.

27. Motorized Outside Air Damper is not available on Multi-Speed or SZVAV (Single Zone Variable Air Volume) products.

28. Frostat standard on Multi-Speed and SZVA V (Single Zone V ariable Air Volume)

products.

29. Novar is not available with SZVA V products.

30. Demand Control Ventilation no t available with electromechanical controls.

31. Demand Control Ventilation Option includes wiring only. The

sensor is a field-installed only

option.

RT-SVX37B-EN 5

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General Information

Unit Inspection

As soon as the unit arrives at the job site

• V erify that the nameplate data matches the data on the sales order and bill of lading (includin g electrical data).

• Verify that the power supply complies with the unit nameplate specifications.

• Visually inspect the exterior of the unit, including the roof, for signs of shipping damage.

If the job site inspection of the unit reveals damage or material shortages, file a claim with the carrier immediately. Specify the type and extent of the damage on the “bill of lading” before signing.

• Visually inspect the internal components for shippi ng damage as soon as possible after delivery and before it is stored. Do not walk on the sheet metal base pans.

• If concealed damage is discovered, notify th e carrier’s terminal of damage immediately by phone and by mail. Concealed damage must be reported within 15 days.

• Request an immediate joint inspection of the damage by the carrier and the consignee. Do not remove damaged material from the receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery.

• Notify the appropriate sales representative before installing or repairing a damaged unit.

When ordering replacement parts or requesting service, be sure to refer to the specific model number and serial number printed on the unit nameplate.

Overview of Manual

Note: One copy of this document ships inside the control

panel of each uni t and is customer property . It must be retained by the unit’s maintenance personnel.

This booklet describes proper installation, operation, and maintenance procedures for air cooled systems. By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized.

It is important that periodic maintenance be performed to help assure trouble free operation. A maintenance schedule is pro vi ded at the en d of thi s manual. Shou ld equipment failure occur, contact a qualified service organization with qualified, experienced HV AC technicians to properly diagnose and repair this equipment.

Unit Nameplate

A Mylar unit nameplate is located on the unit’s corner support next to the filter access panel. It includes the unit model number, serial number, electrical characteristics, refrigerant charge, as well as other pertinent unit data.

Compressor Nameplate

The nameplate for the compressors are located on the side of the compressor.

Storage

Take precautions to prevent condensate from forming inside the unit’s electrical compartments and motors if:

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

2. the unit is set on the roof curb, and temporary heat is provided in the building. Isolate all sid e panel service entrances and base pan openings (e.g., conduit holes, S/A and R/A openings, and flue openings) from the ambient air until the unit is ready for start-up.

Note: Do not use the unit’s heater for temporary heat

without first completing the start-up procedure detailed under “Starting the Unit”.

The manufacturer will not assume any responsibility for equipment damage resulting from condensate accumulation on the unit’s electrical and/or mechanical components.

Model Number Description

All products are identified by a multiple-character model number that precisely id entifies a particular type of unit. Its use will enable the owner/operator , installing contractors, and service engineers to define the operation, specific components, and other options for any specific unit.

Unit Description

Before shipment, each unit is leak tested , dehydrated, charged with re fr igerant and compressor oil, and run tested for proper control operation.

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

Direct-drive, vertical discharge condenser fans are provided with built-in thermal overload protection.

The ReliaT el™ Control Modu le is a microelectronic control system that is referred to as “Refrigeration Module” (RTRM). The acronym RTRM is used extensively throughout this document when referring to the control system network.

These modules through Proportional/Integral control algorithms perform specific unit functions that governs unit operation in response to; zone temperature, supp ly air temperature, and/or humidity conditions depending on the application. The stages of capacity control for these units are achieved by starting and stopping the compressors.

The RTRM is mounted in the control panel and is factory wired to the respective internal components. The RTRM receives and interprets information from other unit

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General Information

modules, sensors, remote panels, and customer binary contacts to satisfy the applicable request for cooling.

Economizer Control Actuator (Optional)

ReliaTel™ Control

The ECA monitors the mixed air temperature, return air temperature, minimum position setpoint (local or remote), power exhaust setpoint, CO ambient dry bulb/enthalpy sensor or comparative humidity (return air humidity against ambient humidity) sensors, if selected, to control dampers to an accuracy of +/- 5% of stroke. The actuator is spring returned to the closed position any time that power is lost to the unit. It is capable of delivering up to 25 inch pounds of torque and is powered by 24 VAC.

setpoint, CO2, and

RTCI - ReliaTel™ Trane Communication Interface (Optional)

This module is used when the application calls for an ICSTM building management type control system. It allows the control and monitoring of the system through an ICS panel. The module can be ordered from the factory or ordered as a kit to be field installed. Follow the installation instruction that ships with each kit when field installation is necessary.

RLCI - ReliaTel™ LonTalk Communication Interface (Optional)

This module is used when the application calls for an ICSTM building management type control system that is LonT alk. It allows the control and monitoring of the system through an ICS panel. The module can be ordered from the factory or ordered as a kit to be field installed. Follow the installation instruction that ships with each kit when field installation is necessary.

RTOM - ReliaTel™ Options Module (Optional)

The RTOM monitors the supply fan proving, clogged filter, supply air temperature, exhaust fan setpoint, supply air tempering, Frostat™ and smoke detector. R efer to system input devices and functions for operation.

System Input Devices & Functions

The RTRM must have a zone sensor or thermostat input in order to operate the unit. The flexibility of having several mode capabilities depends upon the type of zone sensor or thermostat selected to interface with the RTRM.

The descriptions of the following basic input devices used within the RTRM network are to acquaint the operator with their function as they interface with the various modules. Refer to the unit’s electrical schematic for the specific module connections.

The following controls are available from the factory for field installation.

Supply Fan Failure Input (Optional)

The Fan Failure Switch can be connected to sense indoor fan operation:

FFS (Fan Failure Switch) If air flow through the unit is not proven by the differential pressure switc h connected to the RTOM (factory set point 0.07 “w.c.) within 40 seconds nominally, the RTRM will shut off all mechanical operations, lock the system out, send a diagnostic to ICS, and the SERVICE output wi ll flash. The system will remain locked out until a reset is initiated either manually or through ICS.

Clogged Filter Switch (Optional)

The unit mounted clogged filter switch monitors the pressure differential across the return air filters. It is mounted in the filter section and is connected to the RTOM. A diagnostic SERVICE signal is sent to the remote panel if the pressure differential across the filters is at least

0.5" w.c. The contacts will automatically open when the pressure differential across the filters decreases to approximately 0.4" w.c. The clogged filter output is energized when the supply fan is operating and the clogged filter switch has been closed for at least 2 minutes. The system will continue to operate regardless of the status of the filter switch.

Note: On units equipped with factory installed MERV 13

filters, a clogged filter switch with different pressure settings will be installed. This switc h will close when the differential pressure is approximately 0.8' w.c. and open when the differential falls to 0.7" w.c.

Condensate Drain Pan Overflow Switch (Optional)

This input incorporates the Condensate Overflow Switch (COF) mounted on the drain pan and the ReliaTel Options Module (RTOM). When the condensate level reaches the trip point for 6 continuous seconds, the RTOM will shut down all unit functions until the overflow condition has cleared.The unit will return to normal operation after 6 continuous seconds with the COF in a non-tripped condition. If the condensate level causes unit shutdown more than 2 times in a 3 days period, the unit will be locked-out of operation requiring manual reset of diagnostic system through Zone Sensor or Building Automation System (BAS). Cycling unit power will also clear the fault.

Compressor Disable (CPR1/2)

This input incorporates the low pressure control (LPC) of each refrig eration circuit and can be activated by opening a field supplied contact installed on the LTB.

If this circuit is open before the compressor is started, the compressor will not be allowed to operate. Anytime this circuit is opened for 1 continuous second during compressor operation, the compressor for that circuit is

RT-SVX37B-EN 7

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General Information

immediately turned “Off”. The compressor will not be allowed to restart for a minimum of 3 minutes should the contacts close.

If four consecutive open conditions occur during the first three minutes of operation, the compressor for that circuit will be locked out, a diagnostic communicated to the remote panel (if installed), and a manual reset will be required to restart the compressor.

Low Pressure Control

ReliaTel Control

When the LPC is opened for 1 continuous second, the compressor for that circuit is turned off immediately . The compressor will not be allowed to restart for a minimum of 3 minutes.

If four consecutive open conditions occur during an active call for cooling, the compressor will be locked out, a diagnostic communicated to ICS™, if applicable, and a manual reset required to restart the compressor. On dual compressor units only the affected compressor circuit is locked out.

High Pressure Control

ReliaTel Control

The high pressure controls are wired in series between the compressor outputs on the RTRM and the compress or contactor coils. If the high pressure control switc h opens, the RTRM senses a lack of current while calling for cooling and locks the compressor out.

Lead/Lag Control (Dual Circuit Only)

ReliaTel Control Only

Lead/Lag is a selectable input located on the RTRM. The RTRM is configured from the factory with the Lead/Lag control disabled. T o activate the Lead/Lag function, s imply cut the wire connected to J3-8 at the RTRM. When it is activated, each time the designated lead compressor is shut off due to the load being satisfied, the lead compressor or refrigeration circuit switches. When the RTRM is powered up, i.e. af ter a power failure, the control will default to the number one circuit compressor.

Zone Sensor Module (ZSM) (BAYSENS106*)

This electronic sensor features three system switch settings (Heat, Cool, and Off) and two fan settings (On

and Auto). It is a manual changeover control with single setpoint. (Cooling Setpoint Only)

Zone Sensor Module (ZSM) (BAYSENS108*)

This electronic sensor features four system switch settings (Heat, Cool, Auto, and Off) and two fan settings (On and Auto). It is a manual or auto changeover control with dual setpoint capability. It can be used with a remote zone temperature sensor BAYSENS017B.

Zone Sensor (BAYSENS110*)

This electronic sensor features four system switch settings (Heat, Cool, Auto, and Off) and two fan settings (On and Auto) with four system status LED’ s. It is a manual or auto changeo ver control with dual setpoint capabili ty. It can be used with a remote zone temperature sensor BAYSENS017B.

Programmable Zone Sensor (BAYSENS119*)

This 7 day programmable sensor features 2, 3 or 4 periods for Occupied or Unoccupied programming per day. If the power is interrupted, the program is retained in permanent memory. If power is of f for an extended period of time, only the clock and day may have to be reset.

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

The occupied cooling set point ranges between 45 and 98 degrees Fahrenheit. The heating set point ranges between 43 and 96 degrees Fahrenheit.

A liquid crystal display (LCD) displays zone temperature, temperature set points, day of the week, time, and operational mode symbols.

The Option Menu is used to enable or disable applicable functions, i.e.; Morning Warm-up, Economizer minimum position override during uno ccupied status, Fahrenheit or Centigrade, Supply air tempering, Remote zone temperature sensor, 12/24 hour time display, Smart fan, and Computed recovery.

During an occupied period, an auxiliary relay rated for 1 .25 amps @ 30 volts AC with one set of single pole double throw contacts is activated.

Status Inputs (4 Wires Optional)

The ZSM can be wired to receive four (4) operating status signals from the RTRM (HEA T, COOL, SYS TEM “ ON”, SERVICE).

Four (4) wires from the RTRM should be connected to the appropriate terminals (7, 8, 9 & 10) on the ZSM.

Remote Zone Sensor (BAY SENS073*)

This electronic sensor features remote zone sensing and timed override with over ride cancellation. It is used with a Trane Integrated Comfort™ building management system.

8 RT-SVX37B-EN

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General Information

Remote Zone Sensor (BAYSENS074*)

This electronic sensor features single setpoint capability and timed override with override cancellation. It is used with a Trane Integrated Comfort™ building management system.

Remote Zone Sensor (BAYSENS016A)

This bullet type temperature sensor can be used for; outside air (ambient) sensing, return air temperature sensing, supply air temperature sensing, remote temperature sensing (uncovered. Wiring procedures vary according to the particular application and equipment involved. Refer to the unit’s wiring diagrams for proper connections.

Remote Zone Sensor (BAYSENS077*)

This electronic sensor can be used with BAYSENS006B, 008B, 010B, 019B Remote Panels. When this sensor is wired to a BA YSENS0 19B Remote P anel, wiring must be 18 AWG Shielded Twisted Pair (Belden 8760 or equivalent). Refer to The specific Remote Panel for wiring details.

Wireless Zone Sensor (BAYSENS050)

This electronic sensor features five system settings (Auto, Off, Cool, Heat, and Emergency Heat) and with On and Auto fan settings. It is a manual or auto changeover control with dual setpoint capability. Other features include a timed override function, lockable system settings, and Fahrenheit or Celsius temperature display. In cluded with the wireless zone sensor will be a receiver that is to be mounted inside the unit, a mounting bracket, and a wire harness.

allowed to restart for a minimum of 3 minutes should the FOS close.

Discharge Line Temp Switch (DLTS)

The DLTS is looped in series with HPC and LPC. It prevents compressor from overheating (over 300ºF dome temp) in case of ID fan failure (cooling) or OD fan failure (heating).

Phase Monitor

This sensor monitors voltage between the 3 conductors of the 3 phase power supply. Two LED lights are provided. The green light indicates that a balanced 3 phase supply circuit is properly connected. The red light indicates that unit operation has been prevented. There are two conditions that will prevent unit operation.The power supply circuit is not balanced with the proper phase sequence of L1, L2, L3 for the 3 conductors of a 3 phase circuit. The line to line voltage is not between 180 v olts and 633 volts

High Temperature Sensor (BAYFRST001A)

This sensor connects to the RTRM Emergency Stop Input on the L TB and provides high limit “shutdown” of the unit. The sensor is used to detect high temperatures due to fire in the air conditioning or ventilation ducts. The sensor is designed to mount directly to the sheet metal duct. Each kit contains two sensors. The return air duct sensor (X1310004001) is set to open at 135ºF. The supply air duct sensor (X1310004002) is set to open at 240ºF. The control can be reset after the temperature has been lowered approximately 25ºF below the cutout setpoint.

Evaporator Frost Control (ReliaTel™ Option)

This input incorporates the Frostat™ control (FOS) mounted in the indoor coil circuit and can be activated by closing a field supplied contact installed in parallel with the FOS.

RT-SVX37B-EN 9

Page 10

Pre-Installation

WARNING

Fiberglass Wool!

Product contains fiberglass wool. Disturbing the insulation in this product during installation, maintenance or rep air will expose you to airborne particles of glass wool fibers and ceramic fibers known to the state of California to cause cancer through inhalation. Glass wool fibers may also cause respiratory, skin or eye irritation.

Precautionary Measur es

• Avoid breathing fiberglass dust.

• Use a NIOSH approved dust/mist respirator.

• Avoid contact with the skin or eyes. W ear long-sleeved, loose-fitting clothing, gloves, and eye protection.

• Wash clothes separately from other clothing: rinse washer thoroughly.

• Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respiration in these situations.

First Aid Measures

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

Skin Contact - Wash affected areas gently with soap and warm water after handling.

Heater Inspection

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.

Remove power to the unit and gain access to the electric heat elements by removing the horizontal supply cover. Visually inspect the heater elements for the following.

• Elements that are no longer secured to the white ceramic insulator.

• Elements touching each other or touching metal.

• Severely kinked, drooping, or broken elements.

If an element has detached from its ceramic insulator, carefully put it back into place.

Replace the heater elements if they present symptoms noted in item 2 or 3 above.

10 RT-SVX37B-EN

Page 11

Unit Dimensions

TSC060E unit

TSC072-120E units

Unit Clearances

Figure 1 illustrates the minimum operating and service

clearances for either a single or multiple unit installation. These clearances are the minimum distances necessary to

Figure 1. Typical installation clearances for single & multiple unit applications

assure adequate serviceability, cataloged unit capacity, and peak operating efficiency.

Providing less than the recommended clearances may result in condenser coil starvation, “short-circuiting” of exhaust and economizer airflows, or recirculation of hot condenser air.

TSC060E unit

RT-SVX37B-EN 11

TSC072-120E units

Page 12

Unit Dimensions

4444 MMMM

10381038 MMMM

10531053 MMMM

Figure 2. 5 ton units

Note: All dimensions are in inches/millimeters.

Figure 3. 5 ton units - roof curb

Note: All dimensions are in inches/millimeters.

12 RT-SVX37B-EN

Page 13

Figure 4. 5 ton units - unit clearance and roof opening

CLEARANCE 36” (914 MM)

Note: All dimensions are in inches/millimeters.

Figure 5. 6, 7½ ton units

Note: All dimensions are in inches/millimeters.

Unit Dimensions

RT-SVX37B-EN 13

Page 14

Unit Dimensions

(2130 MM)

(356 MM)

Figure 6. 6, 7½ ton units - roof curb

Note: All dimensions are in inches/millimeters.

Figure 7. 6, 7½ ton units - unit clearance and roof opening

Note: All dimensions are in inches/millimeters.

14 RT-SVX37B-EN

Page 15

Figure 8. 8½ - 10 tons units

(2130 MM)

(356 MM)

Note: All dimensions are in inches/millimeters.

Unit Dimensions

Figure 9. 8½ - 10 tons units - roof curb

Note: All dimensions are in inches/millimeters.

RT-SVX37B-EN 15

Page 16

Unit Dimensions

Figure 10. 8½ - 10 tons units - unit clearance and roof opening

Note: All dimensions are in inches/millimeters.

16 RT-SVX37B-EN

Page 17

Installation

WARNING

Heavy Objects!

Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or property-only damage. F ailure to pr operly lift unit could result in death or serious injury.

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.

Figure 11. Corner weights

Figure 12. Rigging and center of gravity

Table 1. Factory installed options (fiops)/accessory net

weights (lbs/kgs)

Accessory 5 Ton 6-10 Ton

Barometric Relief 7/3 10/5 Coil Guards 12/5 20/9 Economizer 26/12 36/16 Hinged Doors 10/5 12/5 Manual Outside Air Damper 16/7 26/12 Motorized Outside Air Damper 20/9 30/14 Oversized Motor - 8/4 Roof Curb 61/28 78/35

(a)Weights for options not listed are <5 lbs (3kgs). (b)Net weight should be added to unit weight when ordering factory-in-

stalled accessories.

(a),(b)

TSC060ED TSC072E-120ED

Net Weight Net Weight

Table 2. Maximum unit & corner weights (lbs/kgs) and center of gravity dimensions (in./mm) - cooling models

Maximum Model

(a)

Tons

5 TSC060ED 633/288 528/240 167/76 128/58 108/49 125/59 40/1006 597/23

6 TSC072ED 915/415 783/355 281/127 192/87 143/65 167/76 38/963 535/21 7½ TSC090ED 956/434 824/374 331/150 181/82 144/65 168/76 35/889 512/20 8½ TSC102ED 1054/478 916/415 307/139 257/117 156/79 195/89 40/1015 520/20

10 TSC120ED 1078/489 940/426 326/ 148 244/111 175/71 196/88 40/1003 532/21

(a) Weights are approximate. (b)Corner weights are given for information only.

RT-SVX37B-EN 17

Unit

Model No.

Weights

Shipping Net A B C D Length Width

(lbs/kgs) Corner Weights

(b)

(lbs/kgs)

Center of Gravity

(in./mm)

Page 18

Installation

Supply

Return

Foundation

Horizontal Units

If the unit is installed at ground level, elevate it above the snow line. Provide concrete footings at each support location with a “full perimeter” support structure or a slab foundation for support. Refer to Table 2, p. 17 for the unit’ s operating and point loading weights when constructing a footing foundation.

If anchoring is required, anchor the unit to the slab using hold down bolts or isolators. Isolators should be installed to minimize the transmission of vibrations into the building.

For rooftop applications, ens ure the roof is strong enough to support the combined unit and support structural weight. Refer to Table 2, p. 17 for the unit operating weights. If anchoring is required, anchor the unit to the roof with hold-down bolts or isolators.

Check with a roofing contract or for proper w aterp roofing procedures.

Figure 13. 5 ton units - Horizontal supply & return air

openings

Figure 15. 5 ton units - Down flow supply & return air

openings w/ through the base utilities

Figure 16. 6 - 10 ton units - Down flow supply & return

air openings w/ through the base utilities

Ductwork

Figure 13, p. 18 to Figure 14, p. 18 illustrate the supply and

return air openings as viewed from the rear of the unit.

Figure 15 and Figure 16 illustrate the supply and return air

Figure 14. 6 - 10 ton units - Horizontal supply & return

air openings

openings in a downflow configuration. Elbows with turning vanes or split ters are recommended

to minimize air noise due to turbulence and to reduce static pressure.

When attac hing the ductwork to the unit, prov ide a w ater tight flexible connector at the unit to prevent operating sounds from transmitting through the ductwork.

All outdoor ductwork between the unit and the structure should be weather proofed after installation is completed.

Roof Curb

18 RT-SVX37B-EN

Down flo w

The roof curbs for these units consists of a “fu ll perimeter” enclosure to support the unit just inside of the unit base rail.

Page 19

Installation

Before installing any roof curb, verify;

• it is the correct curb for the unit,

• it includes the necessary gaskets and hardware,

• the purposed installation location provides the required clearance for proper operation,

• the curb is level and square. The top surface of the curb must be true to assure an adequate curb-to-unit seal.

WARNING

Combustible Materials!

Maintain proper clearance between the unit heat exchanger, vent surfaces and combustible materials. Refer to unit nameplate and installation instructions for proper clearances. Improper clearances could result in a fire hazard. Failure to maintain proper clearances could result in death or serious injury or property damage.

Verify that appropriate materials were used in the construction of roof and ductwork. Combustible materials should not be used in the construction of ductwork or roof curb that is in close proximity to heater elements or any hot surface. Any combustible material on the inside of the unit base should be removed and replaced with appropriate material.

Step-by-step curb assembly and installation instructions ship with each accessory roof curb kit. Follow the instructions carefully to assure proper fit-up when the unit is set into place.

Note: To ensure proper condensate flow during

operation, as well as proper operation of the condensate overflow switch (if equipped), the unit and curb must be level.

If the unit is elevated, a field constructed catwalk around the unit is strongly recommended to provide easy access for unit maintenance and service.

Recommendations for installing t he Supply Air and Return Air ductwork joining the roof curb are included in the curb instruction booklet. Curb ductwork must be fabricated and installed by the installing contractor before the unit is set into place.

Note: For sound consideration, cut only the holes in the

roof deck for the ductwork penetrations. Do n ot cut out the entire roof deck within the curb perimeter.

Rigging

A Rigging illustration and Center-of-Gravity dimensional data table is shown in Figure 12, p. 17. Refer to the typical unit operating weights table before proceeding.

1. Remove all drill screws fastening wood protection to metal baserail. Remove all screws securing wooden protection to wooden top crate.

2. Remove Wooden Top Crate.

WARNING

Heavy Objects!

Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used t o lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or property -only damag e. Failure to prop er ly lif t uni t could result in death or serious injury. See details below.

3. Rig the unit as shown in Figure 12, p. 17. Attach adequate strength lifting slings to all four lifting brackets in the unit base rail. Do not use cables, c hains, or slings except as shown.

4. Install a lifting bar, as shown in Figure 12, p. 17, to protect the unit and to facilitate a uniform lift. The minimum distance between the lifting hook and the top of the unit should be 7 feet.

5. Test-lift the unit to ensure it is properly rigged and balanced, make any necessary rigging adjustments.

6. Lift the unit enough to allow the removal of base fork pocket protection components as shown in the following figure.

Figure 17. Fork pockets

If a Curb Accessory Kit is not used:

• The ductwork can be attached directly to the factoryprovided flanges around the unit’s supply and return air openings. Be sure to use flexible duct connections at the unit.

• For “built-up” curbs supplied by others, gaskets must be installed around the curb perimeter flange and the supply and return air opening flanges.

RT-SVX37B-EN 19

7. Down flow units; align the base rail of the unit with the curb rail while lowering the unit onto the curb. Make sure that the gasket on the curb is not damaged while positioning the unit.

Page 20

Installation

RTV Sealant

Supply Duct Cover

Screw into 4 dimples on top edge

General Unit Requirements

The checklist listed below is a summary of the steps required to successfully install a commercial unit. This checklist is intended to acquaint the installing personnel with what is required in the installation process. It does not replace the detailed instructions called out in the applicable sections of this manual.

• Check the unit for shipping damage and material shortage; file a freight claim and notify appropriate sales representative.

• Verify correct model, options and voltage from unit nameplate.

• Verify that the installation location of the unit will provide the required clearance for proper operation.

• Assemble and install the roof curb (if applicable). Refer to the latest edition of the curb installers guide that ships with each curb kit.

• Fabricate and install ductwork; secure ductwork to curb.

• Install pitch p oc ket for power supply through building roof. (If applicable)

• Rigging the unit.

• Set the unit onto the curb; check for levelness.

• Ensure unit-to-curb seal is tight and without buckles or cracks.

• Install and connect a condensate drain line to the evaporator drain connection.

Note: Condensate Overflow Switc h (if equipped) will not

work if unit is not level properly.

Factory Installed Economizer

• Ensure the economizer has been pulled out into the operating position. Refer to the economizer installers guide for proper position and setup.

• Install all access panels.

Horizontal Discharge  Conversion (5 Ton Unit)

Figure 18.

3. Position duct cover as show n, rotate 90 degrees to allow entrance into supply opening.

4. Slide duct covers into duct openings until in ward edge of duct cover engages with the 2 retaining clips on the duct flanges. Secure the outward edge of each duct cover with 2 screws.

5. Slide RETURN DUCT COVER (insulation side up) into supply opening until inward edge of du ct cover engages with the 2 retaining clips on the duct flange. Secure outward edge of the duct co ver with two screws.

Horizontal Discharge Conversion (6 Through 10 Ton Units)

Supplies Needed by Installer for Conversion: 3 oz. tube of high Temperature RTV sealant. (500°F / 260°C: Similar to Dow Corning 736)

Note: Failure to use recommended sealant could result in

unit performance loss.

If a unit is to be converted to a Horizontal discharge, the following conversion must be performed:

1. Remove RETURN and SUPPLY duct covers.

2. Place SUPPLY DUCT COVER over down-flow return opening. (insulation side down)

3. Using self-drilling screws, (or screws removed from duct cover), screw through dimples to attach DUCT COVER to base.

Figure 19.

Supplies Needed by Installer for Conversion: 3 oz. tube of High Temperature RTV sealant. (500°F / 260°C: Similar to Dow Corning 736)

Note: Failure to use recommended sealant could result in

unit performance loss.

If a unit is to be converted to a Horizontal discharge, the following conversion must be performed:

1. Remove RETURN and SUPPLY duct covers.

2. Locate supply cover. Apply ¼ in. (6mm.) continuous bead of 500°F RTV sealant to the flange as shown.

20 RT-SVX37B-EN

4. On original RETURN DUCT COVER, apply ¼”(6mm.) continuous bead of 500°F RTV sealant around flange (opposite insulation side), as shown.

Page 21

Installation

Downow application

Horizontal application

Cap assembly with insulation

Insulation side down

Supply duct cover

Insulation side up

Return duct cover

Figure 20.

RTV Sealant

5. Slide RETURN DUCT COVER (insulation side up) into supply opening until inward edge of duct cover engages with the 2 retaining clips on the duct flange. Secure outward edge of the duct cover with two screws.

Note: If unit is equipped with Return Air Smoke Detector,

refer to field conversion instructions for horizontal discharge before installing return air duct.

Note: If unit is equipped with Discharge Air Sensing

option refer to the following figure for proper tube positioning based on unit tonnage.

Figure 21.

Figure 22. Duct cover

Low Voltage Wiring (AC & DC) Requirements

• Install the zone thermostat, with or without switching subbase.

• Connect properly sized control wiring to the proper termination points between the zone thermostat and the unit control panel.

Condensate Drain Configur ation

An evaporator condensate drain connection is provided on each unit. R efer to Figure 13, p. 18 and Figure 14, p. 18 for the appropriate drain location.

The condensate drain pan is factory installed to drain condensate to the back side of the unit. See Figu re 13, p. 18 and Figure 14, p. 18. It can be converted to drain condensate out the front side of the unit or through the base.

RT-SVX37B-EN 21

To convert drain condensate out the front of unit:

1 . Remove evaporator access panel and supply air access

panels.

2. Remove the support panel that the condensate drain pan exits through.

3. Slide the condensate drain pan out of the unit and rotate 180°.

4. Slide the condensate drain pan back into the unit, align the drain with the grommeted opening in the rear support panel and push until the coupling is seated in the grommet.

5. Replace the front support panel b y aligning the panel with tabs in the raceway. Align the condensate drain pan support in the grommeted hole as the panel i s put in place.

6. Replace evaporator access panel and supply air access panels.

Page 22

Installation

To convert drain condensate through the base of unit:

1 . Remove evaporator access panel and supply air access

panels.

2. Remove the support panel that the condensate drain pan exits through.

3. Slide the condensate drain pan out of the unit.

4. Place on a level surface in the position it was removed from the unit.

5. Remove the plug knockout in the bottom of the drain pan to convert it to through the base drainage.

6. Plug the original condensate drain opening with a field supplied 3/4” NPT plug.

7. Slide the condensate drain pan bac k into the unit, align the drain support with the grommeted opening in the rear support panel and push until the suppor t is seated in the grommet.

8. Replace the front support panel by aligning the panel with tabs in the raceway . Align the plugged condensate drain pan coupling in the grommeted hole as the panel is put in place.

9. Replace evaporator access panel and supply air access panels.

A condensate trap must be installed at the unit due to the drain connection being on the “negative pressure” side of the fan. Install the P -T rap using the guidelines in Figure 23,

p. 22.

A condensate drain line must be connected to the P-Tr ap. Pitch the drain lines at least 1/2 inch for every 10 feet of horizontal run to assure proper condensate flow. Do not allow the horizontal run to sag causing a possible doubletrap condition which cou ld result in cond en sate backup due to “air lock”.

Figure 23. Condensate trap installation

Drain Pan Removal (Units with Condensate Overflow Switch Option)

Before drain pan removal, the switch wire must be disconnected from wire tie on panel and/or any tape.

Care must be taken so the wire does not catch on the bottom of indoor coil or any protrusion.

Note: When reversing the drain pan, on some units, the

condensate overflow switch will need to be moved to the second hole in its bracket to avoid contact with headers or indoor coil.

Filter Installation

The quantity of filters is determined by unit size. Access to the filters is obtained by removing the filter access panel.

Refer to the unit Service Facts (shipped with each unit) for filter requirements.

Note: Do not operate the unit without filters.

Field Installed Power Wiring

WARNING

Proper Field Wiring and Grounding Required!

• All field-installed wiring must be completed by qualified personnel. All field- installed wiring must comply with NEC and applicable local codes.

• Follow proper local and state electrical code on requirements for grounding.

Failure to follow this instructions could result in death or serious injuries.

An overall dimensional layout for the field installed wiring entrance into the unit is illustrated in “Unit Dimensions,”

p. 11. To insure that the unit’s supply power wiring is

properly sized and installed, follow the following guidelines.

Ve rify that the power supply available is compatible with the unit’s nameplate ratings. The available supply power must be within 10% of the rated voltage stamped on the nameplate. Use only copper conductors to connect the power supply to the unit.

22 RT-SVX37B-EN

NOTICE:

Equipment Damage!

Use copper conductors only. Unit terminals are not designed to accept other types of conductors. F ailure t o use copper conductors may result in equipment damage.

Note: If the unit is not equipped with an optional factory

installed non-fused disconnect switch or circuit breaker, a field supplied disconnect switch must be

Page 23

Installation

installed at or near the unit in accordance with the National Electrical Code (NEC latest edition).

Main Unit Power

WARNING

Proper Field Wiring and Grounding Required!

• All field-installed wiring must be completed by qualified personnel. All field-installed wir ing must comply with NEC and applicable local codes.

• Follow proper local and state electrical code on requirements for grounding.

Failure to follow this instructions could result in death or serious injuries.

WARNING

Hazardous Voltage!

Standard Wiring

1 . Location of the applicable electrical service entrance is

illustrated in “Unit Dimensions,” p. 11. Complete the unit’s power wiring connections at Compressor Contactor # 1 (CC1) inside the unit control panel. Refer to the customer connection diagram that is shipped with the unit for specific termination points.

2. Provide proper grounding f or the unit in accordance with local and national codes.

Figure 24. All units

Field Installed Control Wiring

An overall layout of the various control options available with the required number of conductors for each control device is illustrated in Figure 29, p. 27.

Control Power Transformer

The 24 volt control power transformers are to be used only with the accessories called out in this manual. T ransformers rated greater than 50 V A are equipped with internal circuit breakers. If a circuit breaker trips, turn “Off ” all power to the unit before attempting to reset it.

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the pow er can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

The transformer is located in the control panel. The circuit breaker is located on the left side of the transformer and can be reset by pressing in on the black reset button.

Controls using 24 VAC

Before installing any connecting wiring, refer to “Unit

Dimensions,” p. 11 for the electrical access locations

provided on the unit and Table 3 for AC conductor sizing guidelines, and;

1. Use copper conductors unless otherwise specified.

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

Note: Resistance in excess of 3 ohms per conductor may

cause component failure due to insufficient AC voltage supply.

Note: Be sure to check all loads and conductors for

grounds, shorts, and mis-wiring.

3. Do not run the AC low voltage wiring in the same conduit with the high voltage power wiring.

4. Route low voltage wiring per Figure 26, p. 24.

Table 3. Electromechanical thermostat 24V AC

conductors with ReliaTel

Distance from Unit

to Control

000 - 460 feet 18 gauge 000 - 140 m .75 mm2 461 - 732 feet 16 gauge 141 - 223 m 1.3 mm2 733 - 1000 feet 14 gauge 224 - 305 m 2.0 mm2

Recommended

Wire Size

RT-SVX37B-EN 23

Page 24

Installation

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

Before installing any connecting wiring between the unit and components utilizing a DC an alog input\output signal, refer to “Unit Dimensions,” p. 11 for the electrical access locations provided on the unit.

• Table 4 lists the conductor sizing guidelines that must be followed when interconnecting the DC binary output devices and the system components utilizing a DC analog input\output signal to the unit.

Note: Resistance in excess of 2.5 ohms per conductor can

cause deviations in the accuracy of the controls.

Note: Ensure that the wiring between controls and the

unit’ s termination point does not exceed two and a half (2.5) ohms/conductor for the length of the run.

• Do not run the electrical wires transporting DC signals in or around conduit housing high voltage wires.

• Route low voltage wiring per Figure 26, p. 24.

Table 4. Zone Sensor Module wiring

Distance from Unit to Control

0 - 150 feet 22 gauge 0 - 45.7 m .33 mm2 151 - 240 feet 20 gauge 46 - 73.1 m .50 mm2 241 -385 feet 18 gauge

73.5 - 117.3 m .75 mm2 386 - 610 feet 16 gauge

117.7 - 185.9 m 1.3 mm2 611 - 970 feet 14 gauge

186.2 - 295.7 m 2.0 mm2

Recommended Wire Size

Figure 26. ReliaTel control customer low voltage

routing

Figure 27. ReliaTel options module

Figure 25. ReliaTel conventional thermostat field wiring

diagrams

RTRM

24 RT-SVX37B-EN

Space Temperature Averaging

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

Using the BAYSENS016* or BAYSENS077*, at least four sensors are required to accomplish space temperature averaging.

Example #1 in Figure 28, p. 26 illustrates two series circuits with two sensors in each circuit wired in parallel. The square of any number of remote sensors is required.

Example #2 Figure 28, p. 26 illustrates three sensors squared in a series/parallel circuit. Using BAYSENS077*, two sensors are required to accomplish space temperature averaging.

Page 25

Example #3 Figure 28, p. 26 illustrates the circuit required for this sensor.

Table 5 lists the temperature versus resistance coefficient

for all sensors.

Table 5. Temperature vs resistance

Temperature

Degrees F°Degrees

C°

-20° -28.9° 170.1 K - Ohms

-15° -26.1° 143.5 K - Ohms

-10° -23.3° 121.4 K - Ohms

-5° -20.6° 103.0 K - Ohms

0° -17.8° 87.56 K - Ohms 5° -15.0° 74.65 K - Ohms

10° -12.2° 63.80 K - Ohms

15° -9.4° 54.66 K - Ohms 20° -6.7° 46.94 K - Ohms 25° -3.8° 40.40 K - Ohms 30° -1.1° 34.85 K - Ohms 35° 1.7° 30.18 K - Ohms 40° 4.4° 26.22 K - Ohms 45° 7.2° 22.85 K - Ohms 50° 10.0° 19.96 K - Ohms 55° 12.8° 17.47 K - Ohms 60° 15.6° 15.33 K - Ohms 65° 18.3° 13.49 K - Ohms 70° 21.1° 11.89 K - Ohms 75° 23.9° 10.50 K - Ohms 80° 26.7° 9.297 K - Ohms 85° 29.4° 8.247 K - Ohms 90° 32.2° 7.330 K - Ohms 95° 35.0° 6.528 K - Ohms

Nominal

Resistance

Installation

RT-SVX37B-EN 25

Page 26

Installation

Figure 28. Examples

26 RT-SVX37B-EN

Page 27

Figure 29. Typica l field wiring diagrams for optional controls (ReliaTel only)

BAYSENS106* Zone Sensor

BAYSENS077* ASYSTAT111*

BAYSENS108* Zone Sensor

BAYSENS077* ASYSTAT111*

BAYSENS110* Zone Sensor

BAYSENS073* Zone Sensor

BAYSENS074* Zone Sensor

BAYSENS119* ASYSTAT777* Zone Sensor

BAYSENS077*/ASYSTAT111*

Installation

RT-SVX37B-EN 27

Page 28

Pre-Start

Use the checklist provided below in conjunction with the “General Unit Requirements” checklist to ensure that the unit is properly installed and ready for operation.

WARNING

Hazardous Voltage w/Capacitors!

Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have disc har g ed. Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury.

• Check all electrical connections for tightness and “point of termination” accuracy.

• V erify that the condenser airflow will be unobstructed.

• Verify that the condenser fan and indoor blower turn freely without rubbing and are properly tightened on the shafts.

• Check the supply fan belts for proper tension and the fan bearings for sufficient lubrication. If the belts require adjustment, or if the bearings need lubricati ng, refer to the maintenance section of this manual for instructions.

• V erify that a condensate trap is installed and the piping is properly sized and pitched.

• V erify that the correct size and number of filters are in place.

• Inspect the interior of the unit for tools and debris and install all panels in preparation for starting the unit.

Voltage Imbalance

Three phase electrical power to the unit must meet stringent requirements for the unit to operate properly.

Measure each leg (phase-to-phase) of the power supply. Each reading must fall within the utilization range stamped on the unit nameplate. If any of the readings do not fall within the proper tolerances, notify the power company to correct this situation before operating the unit.

Excessive three phase voltage imbalance between phases will cause motors to overheat and eventually fail. The maximum allowable voltage imbalance is 2%. Measure and record the voltage between phases 1, 2, and 3 and calculate the amount of imbalance as follows:

% Voltage Imbalance = 100 X AV - VD

where;

AV (Average Voltage) = Volt 1 + Volt 2 + Volt 3

V1, V2, V3 = Line Voltage Readings VD = Line Voltage reading that deviates the far thest from

the average voltage.

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

221 + 230 + 227 = 226 Avg.

3 VD (reading farthest from average) = 221 The percentage of Imbalance equals:

100 X 226 - 221 =

226 The 2.2% imbalance in this example exceeds the

maximum allowable imbalance of 2.0%. This much imbalance between phases can equal as much as a 20% current imbalance with a resulting increase in motor winding temperatures that will decrease motor life. If the voltage imbalance is over 2%, notify the proper agencies to correct the voltage problem before operating this equipment.

2.2%

Electrical Phasing (Three Phase Motors)

The compressor motor(s) and the supply fan motor are internally connected for the proper rotation when the incoming power supply is phased as A, B, C.

Proper electrical supply phasing can be quickly determined and corrected before star ting the unit by using an instrument such as an Associated Research Model 45 Phase Sequence Indicator and following the steps below:

• T urn the field supplied disconnect switch that provides

power to the main power terminal block or to the “Line” side of the optional factory mounted disconnect switch to the “Off” position.

• Connect the phase sequence indicator leads to the

terminal block or to the “Line” side of the optional

factory mounted disconnect switch as follows; Black (phase A) to L1 Red (phase B) to L2 Yellow (phase C) to L3

• Close the field supplied main power disconnect switch

or circuit protector switch that provides the supply

power to the unit

28 RT-SVX37B-EN

Page 29

Pre-Start

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this pr odu ct, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

To prevent injury or death from electrocution, it is the responsibility of the technician to recogniz e this hazard and use extreme care when performing service procedures with the electrical power energized.

• Observe the ABC and CBA phase indicator lights on the face of the sequencer. The ABC indicator light will glow if the phase is ABC. If the CBA indicator light glows, open the disconnect switc h or circuit protection switc h and reverse any two power wires.

• Restore the main electrical power and recheck the phasing. If the phasing is cor rect, open the disconnect switch or circuit protection switch and remove the phase sequence indicator.

Compressor Crankcase Heaters (Standard with all units)

Each compressor is equipped with a crankcase heater . The proper operation of the crankcase heater is important to maintain an elevated compressor oil temperature during the “Off” cycle to reduce oil foaming during compressor starts.

Oil foaming occurs when refrigerant condenses in the compressor and mixes with the oil. In lower ambient conditions, refrigerant migration to the compressor could increase.

When the compressor starts, the sudden reduction in crankcase pressure causes the liquid refrigerant to boil rapidly causing the oil to foam. This condition could damage compressor bearings due to reduced lubrication and could cause compressor mechanical failures.

Before starting the unit in the “Cooling” mode, set the system switch to the “Off” position and turn the main power disconnect to the “On” position and allow the crankcase heater to operate a minimum of 8 hours.

Before closing the main power disconnect switch, insure that the “System” selection switch is in the “Off” position and the “Fan” selection switch is in the “Auto” position.

Close the main power disconnect switch and the unit mounted disconnect switch, if applicable.

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this p roduct, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

To prevent injury or death from electrocution, it is the responsibility of the technician to recognize this hazard and use extreme care when performing service procedures with the electrical power energized.

ReliaTel™ Controls

Upon power initialization, the RTRM performs selfdiagnostic checks to insure that all internal controls are functional. It also checks the configuration parameters against the components connected to the system. The Liteport LED located on the RTRM module is turned “On” within one second of power-up if internal operation is okay.

Use one of the following “T est” procedure to bypass some time delays and to start the unit at the control panel. Each step of unit operation can be activated individually by temporarily shorting across the “T est” terminals for two to three seconds. The Liteport LED located on the RTRM module will blink when the test mode has been initiated. The unit can be left in any “Test” step for up to one hour before it will automatically terminate, or it can be terminated by opening the main power disconnect switch. Once the test mode has been termin ated, the Liteport LED will glow continuously and the unit will revert to the “System” control.

RT-SVX37B-EN 29

Page 30

Pre-Start

Table 6. Service test guide for component operation

Test Step Mode Fan

Fan On

4 (Note 3)

5 (Note 3)

6 (Note 3)

Minimum Ventilation

Economizer Test Open

Cool Stage 1

Cool Stage 2

Heat Stage 1

Heat Stage 2

On Selectable Off Off Off Off

On Open Off Off Off O ff 3.3K

On Minimum Off Off On Off 10K

On Minimum Off Off On On 15K

Econ  (Note 2) Comp1 Comp 2 Heat 1 Heat 2 Ohms

Minimum Position Setpoint 0%

Minimum Position

Off Off Off Off

(Note 1) On

(Note 1)On(Note 1)

2.2K

OffOffOff4.7K

Off Off 6.8K

Notes:

1. The condenser fans will operate any time a compressor is On,

providing the outdoor air temperatures are within the operating values.

2. The exhaust fan will turn on anytime the economizer damper position

is equal to or greater than the exhaust fan setpoint.

3. Steps for optional accessories and non- applicable modes in unit will be

skipped.

Test Modes

There are three methods in which the “T est” mode can be cycled at LTB-Test 1 and LTB-Test 2.

1. Step Test Mode - This method initiates the different components of the unit, one at a time, by temporarily shorting across the two test terminals for two to three seconds.

For the initial start-up of the unit, this method allows the technician to cycle a component “ On” and have up to one hour to complete the chec k.

2. Resistance Test Mode - This method can be used for start-up providing a decade box for variable resistance outputs is available. This method initiates the different components of the unit, one at a time, when a specific resistance value is placed across the two test terminals. The unit will remain in the specific test mode for approximately one hour even though the resistance is left on the test terminals.

3. Auto T est Mode - This method is not recommended for start-up due to the short timing between individual component steps. This method initiates the different components of the unit, one at a time, when a jumper is installed across the test terminals. The unit will start the first test step and change to the next step every 30 seconds.

At the end of the test mode, control of the unit will automatically revert to the applied “System” control method.

For unit test steps, test modes, and step resistance values to cycle the various components, refer to Table 6.

Upon power initialization, the Gas Ignition Module (IGN) performs self-diagnostic checks to insure that all internal controls are functional. It also checks the configuration parameters against the components connected to the system. The System LED located on the IGN module is turned “On” within one second of power-up if internal operation is okay.

30 RT-SVX37B-EN

Page 31

Start-Up

Verifying Proper Air Flow

WARNING

Live Electrical Components!

Units with Belt Drive Indoor Fan

Much of the systems performance and reliability is closely associated with, and dependent upon having the proper airflow supplied both to the space that is being conditioned and across the evaporator coil.

The indoor fan speed is c hanged by opening or closing the adjustable motor sheave.

Before starting the SERVICE TEST, set the minimum position setpoint for the economizer to 0 percent using the setpoint potentiometer located on the Economizer Control (ECA), if applicable.

ReliaTel Control: Using the Service Test Guide in

Table 6, p. 30, momentarily jump across the Test 1 & T est

2 terminals on L T B1 one time to start the Minimum Ventilation Test.

Once the supply fan has started, c hec k for proper rotation. The direction of rotation is indicated by an arrow on the fan housing.

With the fan operating properly, determine the total system airflow (CFM) by:

1. Measuring the actual RPM,

2. Measure the amperage at the supply fan contactor and compare it with the full load amp (FLA) rating stamped on the motor nameplate.

a. Calculate the theoretical BHP using (Actual Motor

Amps/ Motor Nameplate Amps) X Motor HP.

b. Using the fan performance tables in the unit Service

Facts, plot the actual RPM (step 1) and the BHP (step 2a) to obtain the operating CFM.

3. If the required CFM is too low, (external static pressure is high causing motor HP output to be below table value),

a. Relieve supply and/or return duct static. b. Change indoor fan speed and repeat Step 1 and

Step 2.

• T o Increase Fan RPM; Loosen the pulley adjustment set screw and turn sheave clockwise.

• To Decrease Fan RPM; Loosen the pulley adjustment set screw and turn sheave counterclockwise.

• If the required CFM is too high, (external static pressure is low causing motor HP output to be above table value), change indoor fan speed and repeat

1 and Step 2.

• To stop the SERVICE TEST, turn the main power disconnect switch to the "Off" position or proceed to the next component start-up procedure.

Step

Economizer Start-Up

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this p roduct, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

ReliaTel Control: Using the Service Test Guide in

Table 6, p. 30, momentarily jump across the Test 1 & Test

2 terminals on LTB1 one time to start the Minimum V entilation T e st belo w.

1 . Set the minimum position setpoint for the economizer

to the required percentage of minimum ventilation using the setpoint potentiometer located on the Economizer Control (ECA).

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

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product it may be necessary to measure the speed of rotating components. Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components, perform these tasks. Failure to follow all safety precautions when exposed to rotating components could result in death or serious injury.

The Exhaust Fan will start anytime the economizer damper position is equal to or greater than the exhaust fan setpoint.

2. Verify that the dampers stroked to the minimum position.

RT-SVX37B-EN 31

Page 32

Start-Up

ReliaTel Control

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

3. Verify that the dampers stroked to the full open position.

4. To stop the SERVICE TEST, turn the main power disconnect switch to the “Off” position or proceed to the next component start-up procedure. Remove electro mechanical test mode connections (if applicable).

Compressor Start-Up

WARNING

Live Electrical Components!

1. Attach a set of service gauges onto the suction and discharge gauge ports for each circuit. Refer to the refrigerant circuit illustration in the Service Facts.

ReliaTel Control

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

Scroll Compressors

a. Once each compressor has started, verify that the

rotation is correct. If a scroll compressor is rotating backw ard s, it will no t pum p an d a loud rattling sound can be observed.

b. If the electrical phasing is correct, before

condemning a compressor, interchange any two leads (at the compressor Terminal block) to check the internal phasing. If the compressor runs backward for an extended period (15 to 30 minutes), the motor winding can overheat and cause the motor winding thermostat to open.

2. After the compressor and condenser fan have started and operated for approximately 30 minutes, observe the operating pressures. Compare the operating pressures to the operating pressure curve in the Service Facts.

3. Check system superheat. Fo llow the in struction listed on the superheat charging curve in the S ervice Facts.

4. Superheat should be within ±5 F of the superheat c hart value.

5. Repeat Step 1 through Step 4 for each refrigerant circuit.

6. To stop the SERVICE TEST, turn the main power disconnect switch to the “Off” position or proceed to the next component start-up procedure. Remove electro mechanical test mode connections (if applicable).

Final System Setup

After completing all of the pre-start and start-up procedures outlined in the previous sections (i.e., operating the unit in each of its Modes through all available stages of cooling & heating), perform these final checks before leaving the unit:

• Program the Night S etback (NSB) panel (if applicable) for proper unoccupied operation. Refer to the programming instructions for the specific panel.

• Verify that the Remote panel “System” selection switch, “Fan” selection switch, and “Zone Temperature” settings for automatic operation are correct.

• Inspect the unit for misplaced tools, hardware, and debris.

• V eri fy that al l exterior panels including the control panel doors and condenser grilles are secured in place.

• Close the main disconnect switch or circuit protector switch that provides the supply power to the unit’s terminal bloc k or the u nit moun ted disco nnect switch.

Make sure all person nel are standing clear of the unit before proceeding. The system components will start when the power is applied.

32 RT-SVX37B-EN

Page 33

Maintenance

Fan Belt Adjustment - Belt Drive Units

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product it may be necessary to measure the speed of rotating components. Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components, perform these tasks. Failure t o follow all safety precautions when exposed t o rotating components could result in death or serious injury.

The fan belts must be inspected periodically to assur e proper unit operation.

Replacement is necessary if the belts appear frayed or worn. Units with dual belts require a matc hed set of belts to ensure equal belt length.

When removing or installing the new belts, do no t stretc h them over the sheaves. Loosen the belts using the belt tension adjustment bolts on the motor mounting base.

Once the new belts are installed, using a Browning or Gates tension gauge (or equivalent) illustrated in

Figure 30; adjust the belt tension as follows;

1. To determine the appropriate belt deflection; a. Measure the center-to-center shaft distance (in

inches) between the fan and motor sheaves.

b. Divide the distance measured in Step a by 64; the

resulting value represents the amount of belt deflection that corresponds to the proper belt tension.

2. Set the large O-ring on the belt tension gauge at the deflection value determined in

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

4. Place the large end of the gauge at the center of the belt span; then depress the gauge plunger until the large Oring is even with the top of the next belt or even with a straightedge placed across the fan and motor sheaves. Refer to

5. Remove the belt tension g auge. The small O-ring now indicates a number other than zero on the plunger’s force scale. This number represents the force (in pounds) required to give the needed deflection.

6. Compare the “force” scale reading (Step 5) with the appropriate “force” value listed in Table 7. If the “force” reading is outside the range, readjust the belt tension.

Note: Actual belt deflection “force” must not exceed the

maximum “force” value shown in Table 7.

Figure 9.

Step b.

7. Recheck the belt tension at least twice during the first 2 to 3 days of operation. Belt tension may decrease until the new belts are “run in”.

Figure 30. Belt tension gauge

Table 7. Belt Tension Measurement and Deflection

Deflection Force (Lbs.)

Belts Cross Section

A 3.8 - 4.8 3 1/2 5 4 1/2 6 1/4 3 3/4 4 3/4

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

Small P.D Range

3.0 - 3.6 3 4 1/2 3 7/8 5 1/2 3 1/4 4

5.0 - 7.0 4 5 1/2 5 6 7/8 4 1/4 5 1/4

3.4 - 4.2 4 5 1/2 5 3/4 8 4 1/2 5 1/2

5.8 - 8.8 6 3/8 8 3/4 7 3/8 10 1/8 7 8 3/4

Super

Gripbelts Gripnotch

Min. Max. Min. Max. Min. Max

Steel Cable

Gripbelts

Monthly Maintenance

Before completing the following chec ks, turn the unit OFF and lock the main power di scon nect sw itch open.

WARNING

Rotating Components!

Filters

Inspect the return air filters. Clean or replace them if necessary. Refer to the unit Service Facts for filter information.

Condensate Overflow Switch

During maintenance, the switch float (black ring) must be

RT-SVX37B-EN 33

Page 34

Maintenance

checked to ensure free movement up and down.

Cooling Season

• Check the unit’s drain pans and condensate piping to ensure that there are no blockages.

• Inspect the evaporator and condenser coils for dirt, bent fins, etc. If the coils appear dirty, clean them according to the instructions described in “Coil Cleaning” later in this section.

• Manually rotate the condenser fan(s) to ensure free movement and check motor bearings for wear. Verify that all of the fan mounting hardware is tight.

• Inspect the F/A-R/A damper hinges and pins to ensure that all moving parts are securely mounted. Keep the blades clean as necessary.

• Verify that all damper linkages move freely; lubricate with white grease, if necessary.

• Check supply fan motor bearings; repair or replace the motor as necessary.

• Check the fan shaft bearings for wear. Replace the bearings as necessary.

• Check the supply fan belt. If the belt is frayed or worn, replace it. Refer to the “Fan Belt Adjustment” section for belt replacement and adjustments.

• Verify that all wire terminal connections are tight.

• Remove any corrosion present on the exterior surfaces of the unit and repaint these areas.

• Generally inspect the unit for unusual condition s (e.g., loose access panels, leaking piping connections, etc.)

• Make sure that all retaining screws are reinstalled in the unit access panels once these chec ks are complete.

• With the unit running, check and record the: ambient temperature; compressor suction and discharge pressures (each circuit); superheat (each circuit);

• Record this data on an “operator’s maintenance log” like the one shown in pressures indicate a refrigerant shortage, measure the system superheat. For guidelines, refer to the “Compressor Start-Up” section.

Note: Do not release refrigerant to the atmosphere! If

adding or removing refrigerant is required, the service technician must comply with all federal, state and local laws.

Table 8, p. 36. If the operating

Heating Season

• Inspect the unit’s air filters. If necessary, clean or replace them.

• Check supply fan motor bearings; repair or replace the motor as necessary.

• Inspect both the main unit control panel and heat section control box for loose electrical components and terminal connections, as well as damaged wire insulation. Make any necessary repairs.

• Verify that the electric heat system operates properly.

Coil Cleaning

Regular coil maintenance, including annual cleaning, enhances the unit’s operating efficiency by minimizing: compressor head pressure and amperage draw; evaporator water carryover; fan brake horsepower, due to increase static pressure losses; airflow reduction.

At least once each year , or more often if the unit is located in a “dirty” environment, clean the evaporator and condenser coils using the instructions outlined below. Be sure to follow these instructions as closely as possible to avoid damaging the coils.

Note: For units equipped with hail guards follow removal

procedure listed below.

Hail Guard Removal

• Unlatch hail guard.

• Pull the top of the hail guard outward unt il the fastener studs are free of the retaining nuts.

• Lift the hail guard from the lower retaining bracket and set aside.

To clean refrigerant coils, use a soft brush and a sprayer (either a garden pump-up type or a high-pressure sprayer). A high-quality detergent is also required; suggested brands include “SPREX A.C.”, “ OAKITE 161”, “O AKITE 166” and “COIL OX”. If the detergent selected is strongly alkaline (ph value exceeds 8.5), add an inhibitor.

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.

1 . Remove enough panels from the unit to gain access to

the coil.

2. Protect all electrical dev ices such as motors and controllers from any over spray.

3. Straighten any bent coil fins with a fin comb.

4. Mix the detergent with water according to the manufacturer’s instructi ons. If desired, heat the solution BUT DO NOT EXCEED 150ºF maximum to improve its cleansing capability.

34 RT-SVX37B-EN

Page 35

WARNING

Hazardous Pressures!

Coils contain refriger ant under pressur e. When cleaning coils, maintain coil cleaning solution temperatu re under 150°F to avoid excessive pressure in the coil. Failure to follow these safety precautions could result in coil bursting, which could result in death or serious injury.

5. Pour the cleaning solution into the sprayer. If a highpressure sprayer is used:

a. do not allow sprayer pressure to exceed 600 psi. b. the minimum nozzle spray angle is 15 degrees. c. maintain a minimum clearance of 6" between the

sprayer nozzle and the coil.

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

the coil face.

6. Spray the leaving-airflow side of the coil first; then spray the opposite side of the coil. Allow the cleaning solution to stand on the coil for five minutes.

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

8. Inspect both sides of the coil; if it still appears to be dirty, repeat

9. Reinstall all of the components and panels removed in

Step 1 and any protective covers installed in Step 2.

Note: For units equipped with hail guards follow

reinstallation procedure listed below.

Step 6 and Step 7.

Maintenance

Hail Guard Reinstallation

• T o reinstall the hail gu ard, locate the bottom of the hail guard in the lower bracket and secure it to the upper unit bracket with the attached fasteners.

Note: Secure hail guard latches.

Figure 31. Slide latch

1. Restore the unit to it’s operational status and check system operation.

Annual Maintenance

• Clean and repaint any corroded surface.

RT-SVX37B-EN 35

Page 36

Maintenance

Final Process

For future reference, you may find it helpful to record the unit data requested in the blanks provided.

Wiring Diagram Numbers (from unit control panel)

Schematics

Complete Model Number

Connections

Unit Serial Number

Table 8. Sample maintenance log

Current

Date

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

Temp. F/C

Ambient

Compr. Oil Level

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

Refrigerant Circuit #1 Refrigerant Circuit #2

Suct. Press. Psig/ kPa

Disch. Press. Psig/ kPa

Liquid Press. Psig/ kPa

Super

-heat F/C

Subcool. F/C

Compr. Oil Level

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

- ok

- low

Suct. Press. Psig/kPa

Disch. Press. Psig/ kPa

Liquid Press. Psig/ kPa

Superheat F/C

Subcool. F/C

36 RT-SVX37B-EN

Page 37

Trouble Shooting

ReliaTel™ Control

The RTRM has the ability to provide the service personnel with some unit diagnostics and system status information.

Before turning the main power disconnect switch “Off”, follow the steps below to check the ReliaTel Refrigeration Module (RTRM). All diagnostics & system status information stored in the RTRM will be lost when the main power is turned “Off”.

WARNING

Live Electrical Components!

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

2. If the LED is not lit, Verify that 24 VAC is present between J1-1 and J1-2. If 24V AC is present, proceed to

Step 3. If 24VAC is not present, check the unit main

power supply, transformer (TNS1), and make sure the condensate overflow switch (if equipped) is not open.

3. Utilizing “Method 1” or “Method 2” in the “System Status Diagnostic” section, check the following:

System status Heating status Cooling status

If a System failure is indicated, proceed to Step 4. If no failures are indicated, proceed to Step 5.

4. If a System failure is indicated, rechec k Step 1 and Step

2. If the LED is not lit in Step 1, and 24 VAC is present

in Step 2, the RTRM has failed. Replace the RTRM.

5. If no failures are indicated, use one of the TEST mode procedures described in the “Unit Start-Up” section to start the unit. This procedure will allow you to c heck all of the RTRM outputs, and all of the external controls (relays, contactors, etc.) that the RTRM outputs energize, for each respective mode. Proceed to

6. Step the system through all of the available modes, and verify operation of all outputs, controls, and modes. If a problem in operation is noted in any mode, you may leave the system in that mode for up to one hour while troubleshooting. Refer to the sequence of

Step 6.

operations for each mode, to as sist in verifying proper operation. Make the necessary repairs and proceed to

Step 7 and Step 8.

7. If no abnormal operating conditions appear in the test mode, exit the test mode by turning the power “Off ” at the main power disconnect switch.

8. Refer to the individual component test procedures if other microelectronic components are suspect.

System Status Checkout Procedure

“System Status” is ch ec ked by using one of the following two methods:

Method 1

If the Zone Sensor Module (ZSM) is equipped with a remote panel with LED status indication, you can check the unit within the space. If the ZSM does not have LED’s, use Method 2. BAYSENS110*, BAYSENS109*, BAYSENS1 19*, BAYSENS023A all have the remote panel indication feature. The LED descriptions are listed below.

LED 1 (System)

“On” during normal operation. “Off” if a system failure occurs or the LED fails. “Flashing” indicates test mode.

LED 2 (Heat)

“On” when the heat cycle is operating. “Off” when the heat cycle terminates or the LED fails. “Flashing” indicates a heating failure.

LED 3 (Cool)

“On” when the cooling cycle is operating. “Off” when the cooling cycle terminates or the LED fails. “Flashing” indicates a cooling failure.

LED 4 (Service)

“On” indicates a clogged filter. “Off” during normal operation. “Flashing” indicates an evaporator fan failure Below is the complete listing of failure indication causes.

System failure

Check the voltage between terminals 6 and 9 on J6, it should read approximately 32 VDC. If no voltage is present, a system failure has occurred. Refer to Step 4 in the previous section for the recommended troubleshooting procedure.

RT-SVX37B-EN 37

Page 38

Trouble Shooting

Cooling Failure

1. Cooling and heating set point (slide pot) on the zone sensor has failed. Refer to the “Zone S e nsor Te st Procedure” section.

2. Zone temperature thermistor ZTEMP on ZTS failed. Refer to the “Zone Sensor Test Procedure” section.

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

4. LPC1 has opened during the 3 minute minimum “on time” during 4 consecutive compressor starts, check LPC1 or LPC2 by testing voltage between the J1-1 & J32 terminals on the RTRM and ground. If 24 VAC is present, the LPC’s has not tripped. If no voltage is present, LPC’s has tripped.

Service Failure

1 . If the supply fan proving switc h has closed, the unit will

not operate (when connected to RTOM), c hec k the fan motor, belts, and proving switch.

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

3. If the condensate overflow switch is closed, the unit will not operate, check the float position is not in a tripped condition and verify an “ open ” between wires connecting to RTOM J6-1, J6-2.

Simultaneous Heat and Cool Failure

1. Emergency Stop is activated

Method 2

The second method for determining system statu s is done by chec king voltage readings at the RTRM (J6). The system indication descriptions and the approximate voltages are listed below.

System Failure

Measure the voltage between terminals J6-9 & J6-6. Normal Operation = approximately 32 VDC System Failure = less than 1 VDC, approximately 0.75 VDC Test Mode = voltage alternates between 32 VDC & 0.75

VDC

Heat Failure

Measure the voltage between terminals J6-7 & J6-6. Heat Operating = approximately 32 VDC Heat Off = less than 1 VDC, approximately 0.75 VDC Heating Failure = v olta g e al ternates between 32 VDC &

0.75 VDC

Cool Failure

Measure the voltage between terminals J6-8 & J6-6. Cool Operating = approximately 32 VDC Cool Off = less than 1 VDC, approximately 0.75 VDC

Cooling Failure = voltage alternates between 32 VDC &

0.75 VDC

Service Failure

Measure the voltage between terminals J6-10 & J6-6. Clogged Filter = Approximately 32 VDC. Normal = Less than 1 VDC, approximately 0.75 VDC Fan

Failure = voltage alternates between 32 VDC & 0.75 VDC. To use LED’s for quick status information at the unit,

purchase a BAYSENS110* ZSM and connect wires with alligator clamps to terminals 6 through 1 0. Connected each respective terminal wire (6 through 10) from the Zone Sensor to the unit J6 terminals 6 through 10.

Note: If the system is equipped with a programmable

zone sensor, (BAYSENS119*, or BAYSENS023A), the LED indicators will not function while the BAYSENS110* is connected.

Resetting Cooling and Ignition Lockouts

Cooling Failures and Heating Lockouts are reset in an identical manner. Method 1 explains reset ting the system from the space; Method 2 explains resetting the system at the unit.

Note: Before resetting Cooling Failures and Ignition

Lockouts check the Failure Status Diagnostics by the methods previously explained. Diagnostics will be lost when the power to the unit is disconnected.

Method 1

To reset the system from the space, turn the “Mode” selection switch at the zone sensor to the “Off” position. After approximately 30 seconds, turn the “Mode” selection switch to the desired mode, i.e. Heat, Cool or Auto.

Method 2

To reset the system at the unit, cycle the unit power by turning the disconnect switch “Off” and then “On”.

Lockouts can be cleared through the building management system. Refer to t he b uil di ng m an age ment system instructions for more information.

Zone Temperature Sensor (ZTS) Service Indicator

The ZSM SERVICE LED is a generic indicator, that will signal the closing of a Normally Open switch at an y time, providing the Indoor Motor (IDM) is operating. This indicator is usually used to indicate a clogged filter, or an air side fan failure.

The RTRM will ignore the closing of this Normally Open switch for 2 (±1) minutes. This helps prevent nuisance SERVICE LED indications. The exception is the LED will flash 40 seconds after the fan is turned “On” if the Fan Proving Switch is not made.

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Trouble Shooting

Clogged Filter Switch

This LED will remain lit the entire time that the Normally Open switch is closed. Th e LE D will be turned off immediately after resetting the switch (to the Normally Open position), or any time that the IDM is turned “Off”.

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

This LED being turned “On”, will have no other affect on unit operation. It is an indicator only.

Fan Failure Switch

When the “Fan Failure” switch is wired to the RTOM, the LED will remain flashing the entire time the fan proving switch is clos ed, indicating a fan failure, and it will shut the unit operations down.

Condensate Overflow Switch

When the “Condensate Overflow Switch” is closed, a drain pan overflow condition is indicated and it will shut unit operations down.

Zone Temperature Sensor (ZTS) Test

Note: These procedures are not for programmable or

digital models and are conducted with the Zone Sensor Module electrically removed from the system.

Test 1 - Zone Temperature Thermistor (ZTEMP)

This component is tested by measuring the resistance between terminals 1 and 2 on the Zone Temperature Sensor . Below are some typical indoor temperatures, and corresponding resistive values.

Test 2 - Cooling Set Point (CSP) and Heating Set Point (HSP)

Table 9. Cooling setpoint and heating setpoint

Zone Temperature

50 F° 10.0 C° 19.9 K-Ohms 55 F° 12.8 C° 17.47 K-Ohms 60 F° 15.6 C° 15.3 K-Ohms 65 F° 18.3 C° 13.49 K-Ohms 70 F° 21.1 C° 11.9 K-Ohms 75 F° 23.9 C° 10.50 K-Ohms 80 F° 26.7 C° 9.3 K-Ohms 85 F° 29.4 C° 8.25 K-Ohms 90 F° 32.2 C° 7.3 K-Ohms

Nominal ZTEMP

Resistance

The resistance of these potentiometers are measured between the following ZSM terminals. Refer to the chart above for approxim ate re sistanc es at the given setpoints.

Cool SP = Terminals 2 and 3 Range = 100 to 900 Ohms approximate Heat SP = Terminals 2 and 5 Range = 100 to 900 Ohms approximate

Test 3 - System Mode and Fan Selection

The combined resistance of the Mode selection switch and the Fan selection switch can be measured between terminals 2 and 4 on the Zone Sensor. The possible switch combinations are listed below with their corresponding resistance values.

Test 4 - LED Indicator Test, (SYS ON, HEA T, COOL & SERVICE)

Method 1

T esting the LED using a meter with diode test function. T est both forward and reverse bias. Forward bias should measure a voltage drop of 1.5 to 2.5 volts, depending on your meter . Reverse bias will show an Over L oad, or open circuit indication if LED is functional.

Method 2

Testing the LED with an analog Ohmmeter. Connect Ohmmeter across LED in one direction, then reverse the leads for the opposite direction. The LED should have at least 100 times more resistance in reverse direction, as compared with the forward direction. If high resistance in both directions, LED is open. If low in both directions, LE D is shorted.

Method 3

To test LED’ s with ZSM connected to unit, test v oltages at LED terminals on ZSM. A measurement of 32 VDC, across an unlit LED, means the LED has failed.

Programmable & Digital Zone Sensor Test

Testing serial communication voltage 1 . Verify 24 VAC is present between terminals J6-1 4 & J6-

11.

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

3. Reconnect wires to terminals J6-1 1 and J6-12. Measure voltage again between J6-1 1 and J6-12, voltage should flash high and low every 0.5 seconds. The v olt ag e on the low end will measure about 19 VDC, while the voltage on the high end will measure from approximately 24 to 38 VDC.

4. Verify all modes of operation, by running the unit through all of the steps in the “Test Modes” section discussed in “Unit Start-Up”.

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Trouble Shooting

5. After verifying proper unit operation, exit the test mode. Turn the fan on continuously at the ZSM, by pressing the button with the fan symbol. If the fan comes on and runs continuously, the ZSM is good. If you are not able to turn the fan on, the ZSM is defective.

ReliaTel Refrigeration Module (RTRM) Default Chart

If the RTCI loses input from the building manageme nt system, the RTRM will control in the default mode after approximately 15 minutes. If the RTRM loses the Heating and Cooling setpoint input, the RTRM will control in the default mode instantaneously. The temperature sensing thermistor in the Zone Sensor Module is the only component required for the “Default Mode” to operate.

Unit Operation without a Zone Sensor

This procedure is for temporary operation only. The economizer and condenser fan cycling functions are disabled.

1. Open and Lock the unit disconnect switch.

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

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

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

5. Connect the sensor (OAS) using two wire nuts to the two (2) field supplied wires that were connected to terminals 1 and 2 on J6.

6. Flashes: OA Humidity Sensor

7. Flashes: O A Temp Sensor

8. Flashes: MA Temp Sensor

9. Flashes: RAM Fault

10. Flashes: ROM Fault

11. Flashes:EEPROM Fault

Unit Economizer Control (ECA) Troubleshooting

ReliaTel Control

Verify Economizer Status by Economizer Actuator (ECA) LED indicator:

OFF: No Power or Failure ON: Normal, OK to Economize Slow Flash: Normal, Not OK to Economize Fast Flash - 1/2 Second On / 2 Seconds Off: Error Code: Communications Failure Pulse Flash: 2 S e con ds On / 1/2 Second Off: Error Code:

1. Flash: Actuator Fault

2. Flashes: CO2 Sensor

3. Flashes: RA Humidity Sensor

4. Flashes: RA Temp Sensor

5. Flashes: OA Quality Sensor

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Wiring Diagrams

Cooling

Capacity

060E 4366-1509-0104 4366-1020-0104 4366-1026-0104 072E 4366-1541-0110 4366-1020-0104 4366-1026-0104 090E 4366-1541-0110 4366-1020-0104 4366-1026-0104 102E 4366-1534-0110 4366-1037-0110 4366-1044-0110 120E 4366-1534-0110 4366-1037-0110 4366-1044-0110

Connection

Diagram Power Diagram Control Diagram

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