Trane YSC060, YSC120, YSC060AD, YSC072AD, YSC090AD Installation Operation & Maintenance

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Page 1

Installation Operation Maintenance

Packaged Gas/Electric YSC060 - YSC120 50 Hz

August 2007

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Introduction

Literature Change History

Y_C-IOM-2 (March 2004) Added Phase Monitor

Y_C-IOM-2 (March 2003) Orginal issue YSC060 - YSC120 models.

Overview of Manual

Note: One copy of this document ships inside the control panel of each unit 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 provided at the end of this manual. Should equipment failure occur, contact a qualified service organization with qualified, experienced HVAC technicians to properly diagnose and repair this equipment.

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.

Model Number Description

All products are identified by a multiplecharacter model number that precisely identifies a particular type of unit. An explanation of the alphanumeric identification code is provided below. 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.

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

CAUTION

Equipment Damage From Ultraviolet (UV) Lights!

The manufacturer does not recommend field installation of ultraviolet lights in its equipment for the intended purpose of improving indoor air quality. High intensity C-band ultraviolet light is known to severely damage polymer (plastic) materials and poses a personal safety risk to anyone exposed to the light without proper personal protective equipment. Polymer materials commonly found in HVAC equipment that may be susceptible include insulation on electrical wiring, fan belts, thermal insulation, various fasteners and bushings. Degradation of these materials can result in serious damage to the equipment.

The manufacturer accepts no responsibility for the performance or operation of our equipment in which ultraviolet devices were installed outside of the manufacturer’s factory or its approved suppliers.

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Contents

Introduction

Literature Change History ................. 2

Overview of Manual .......................... 2

Model Number Description ............... 2

Unit Nomenclature ............................ 4

General Information

Unit Nameplate ................................. 5

Compressor Nameplate .................... 5

Unit Description................................. 5

Economizer Control Actuator

(optional) ........................................... 5

ReliaTel Trane Communication Interface

(optional) ........................................... 5

ReliaTel LonTalk Communication Interface

(optional) ........................................... 5

ReliaTel Options Module

(optional) ........................................... 5

System Input Devices

and Functions .............................6 & 7

Pre - Installation

Unit Inspection .................................. 8

Unit Storage ...................................... 8

Unit Installation Clearances .............. 9

Unit Dimensions .............................. 10

Unit / Accessory Weights ................ 12

Rigging and Center-of-Gravity Data 12

Installation

Foundation ...................................... 13

Unit Supply & Return Air Openings. 14

Ductwork ......................................... 15

Roof Curb........................................ 15

Rigging ............................................ 16

Factory Installed Economizer.......... 16

Temperature Limit Switch Usage

for Gas Heat Units...........................17

Gas Heat Technical Data ................ 17

Horizontal Discharge Conversion

YSCO60 .......................................... 18

YSC072 - 120 ................................. 19

TCO-A Instructions:......................... 20

Requirements for Gas Heat ............ 21

Condensate Drain Configuration..... 21

Condensate Trap Installation .......... 21

Filter Installation .............................. 22

Main Unit Power Wiring .................. 22

Field Installed Control Wiring .......... 22

Control Power Transformer............. 22

Controls using 24 VAC ....................22

24V AC Conductors with Reliatel .... 23

Controls using

DC Analog Input/Outputs ................ 23

Customer Low Voltage Routing- ..... 24

Typical Field wiring

for Optional Controls- ...................... 25

Sp ace Temperature Averaging ........26

Temperature vs Resistance.............27

Sizing Natural Gas Pipe

Mains & Branches ........................... 27

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

Electrical Phasing ........................... 28

(Three Phase Motors) ..................... 28

Pre - Start

Service Test Guide for

Component Operation..................... 30

Verfiying Proper Airflow................... 31

Economizer Start-up........................32

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

Scroll Compressors......................... 32

Gas Heat Units................................ 32

Final System Setup

Final System Setup ......................... 33

Maintenance

Fan Belt Adjustment -......................34

Belt Tension Gauge......................... 35

Filters .............................................. 36

Cooling Season............................... 36

Heating Season .............................. 36

Annual Maintenance ....................... 37

Final Process .................................. 37

Sample Maintenance Log ............... 38

Trouble Shooting

ReliaTel Control...............................39

System Status Checkout Procedure 39

LED 4 (Service)............................... 39

System failure ................................. 39

Heating Failure................................ 39

Cooling Failure ................................ 40

Service Failure ................................ 40

Simultaneous Heat and Cool Failure40

Cool Failure..................................... 40

Cooling and Ignition Lockouts ......... 40

Zone Temperature Sensor

(ZTS) Service Indicator ................... 40

Fan Failure Switch .......................... 41

Zone Temperature Sensor

(ZTS) Test ....................................... 41

Zone Temperature Thermistor

(ZTEMP) ......................................... 41

Cooling Set Point (CSP) and

Heating Set Point (HSP) ................. 41

Testing

serial communication voltage.......... 41

Wiring Schematic

Control Schematic........................... 43

Power Schematic ............................ 44

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Model Number Description

Unit Nomenclature

Digit 1 - Product Type

Y = Packaged Gas/Elect

Digit 2 - Unit Efficiency Level

S = Standard

Digit 3 - Airflow Configuration

C = Convertible

Digit 4, 5, 6 - Cooling Capacity

060 = 5 Ton ( 17.6 KW ) 072 = 6 Ton ( 21.1 KW ) 090 = 7 1/2 Ton ( 26.4 KW ) 102 = 8 1/2 Ton ( 29.9 KW ) 120 = 10 Ton ( 35.1 KW )

Digit 7 - Major Design Sequence A

Digit 8 - Electrical Characteristics

D = 380-415/50/3

Digit 9 - Unit Control

R = Relia Tel

Digit 10 - Heat Capacity

H = Gas Heat - High L = Gas Heat - Low

Digit 11 - Minor Design Sequence

Digit 12, 13 - Service Digit Sequence

Digit 14 - Factory Installed Options

-Fresh Air Section

0 = No Fresh Air A = Manual OA, 0 - 25% B = Motorized OA, 0 - 50% C = Economizer Dry Bulb D = Economizer with Barometric Relief E = Economizer, Reference Enthalpy F = Economizer, Reference Enthalpy, with Barometric Relief G = Economizer Comparative Enthalpy H = Economizer, Comparative Enthalpy, with Barometric Relief

Digit 15 - Factory Installed Options

-Supply Fan

0 = Standard Drive 1 = Oversize Motor

Digit 16 - Factory Installed Options

-Hinged Service Access

0 = Standard Panels A = Hinged Service Panels

Digit 17 - Factory Installed Options

-Condenser Coil Protection

0 = Standard 1= Hail Guard 2 = Epoxy Coated Condenser Coil 3 = Epoxy Coated Condenser Coil and Hail Guard 4 = CompleteCoat Condenser Coil 5 = CompleteCoat Condenser Coil and Hail Guard

Digit 18 - Factory Installed Options

-Through The Base

0 = Without Through The Base Connection

Digit 19 - Factory Installed Options

-Disconnect Switch/Circuit Breaker

0 = Without Disconnect Switch/Circuit Breaker 3 = With Phase Monitor

Digit 20 - Factory Installed Options

-Convenience Outlet

0 = Without Convenience Outlet

Digit 21 - Factory Installed Options

-Communications

0 = Without Communications Options 1 = Trane Communications Interface 2 = LoneTalk Communications Interface

Digit 22 - Factory Installed Options

-Refrigeration System

0 = Without Refrigeration System Option

Digit 23 - Factory Installed Options

-Refrigeration Controls

0 = Without Refrigeration Controls

Digit 24 - Factory Installed Options

-Smoke Detector

0 = Without Smoke Detector

Digit 25 - Factory Installed Options

-System Monitoring Controls

0 = Without Monitoring Controls 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

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General Information

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.

Hazard Identification

Warnings are provided throughout this manual to indicate to installing contractors, operators, and service

personnel of potentially hazardous situations which, if not avoided, COULD result in death or serious injury.

Cautions are provided throughout this manual to indicate to installing contractors, operators, and service

personnel of potentially hazardous situations which, if not avoided, MAY result in minor or moderate injury.

Unit Description

Before shipment, each unit is leak tested, dehydrated, charged with refrigerant 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 ReliaTel™ Control Module 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, supply 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 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, CO2 setpoint, CO2, and 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 (2.82 N-m) of torque and is powered by 24 VAC.

RTCI - ReliaTel™ Trane Communication Interface (Optional)

This module is used when the application calls for an ICS ment 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.

building manage-

RLCI - ReliaTel™ LonTalk Communication Interface (Optional)

This module is used when the application calls for an ICS ment type control system that is LonTalk. 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.

building manage-

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. Refer to system input devices and functions for operation.

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General Information

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 switch connected to the RTOM (factory set point 0.07 “ w.c.(17.4 Pa)) 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 will 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. (124.5 Pa). The contacts will automatically open when the pressure differential across the filters decreases to approximately 0.4" w.c. (99.6 Pa). 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.

Compressor Disable (CPR1/2)

This input incorporates the low pressure control (LPC) of each refrigeration 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 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 the first three minutes of operation, the compressor will be locked out, a diagnostic communicated to ICS manual reset will be required to restart the compressor.

High Pressure Control (Optional) ReliaTel Control

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

On dual circuit units, if the high pressure control opens, the compressor on the

if applicable, and a

affected circuit is locked out. A manual reset for the affected circuit is required.

ReliaTel Control

The power exhaust fan is started whenever the position of the economizer dampers meets or exceed the power exhaust setpoint when the indoor fan is on.

The setpoint panel is located in the return air section and is factory set at 25%.

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. To activate the Lead/ Lag function, simply 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. after a power failure, the control will default to the number one circuit compressor.

Zone Sensor Module (ZSM) (BAYSENS006B)

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) (BAYSENS008B)

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.

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General Information

Zone Sensor (BAYSENS010B)

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 changeover control with dual setpoint capability. It can be used with a remote zone temperature sensor BAYSENS017B.

Programmable Zone Sensor (BAYSENS019B)

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 off 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 F (7.2 C)and 98 F (35.6 C) degrees. The heating set point ranges between 43 F (6.1 C) and 96 F ( 35.6 C) degrees.

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 unoccupied 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 (HEAT, COOL, SYSTEM “ON”, SER-VICE). Four (4) wires from the RTRM should be connected to the appropriate terminals (7, 8, 9 & 10) on the ZSM.

Remote Zone Sensor (BAYSENS013B)

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

building

Remote Zone Sensor (BAYSENS014B)

This electronic sensor features single setpoint capability and timed override with override cancellation. It is used with a Trane Integrated ComfortTM 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 (BAYSENS017B)

This electronic sensor can be used with BAYSENS006B, 008B, 010B, 019B Remote Panels. When this sensor is wired to a BAYSENS019B Remote Panel, wiring must be 18 AWG (.75mm Shielded Twisted Pair (Belden 8760 or

)

equivalent). Refer to The specific Remote Panel for wiring details.

BAYSTAT036A

Single Stage - 1 Heat/1 Cool

BAYSTAT037A

Multi Stage - 2 Heat/2 Cool - Can be Used for Economizer Operation

BAYSENS025A

Remote sensor for BAYSTAT036A and BAYSTAT037A

Phase Monitor (Optional)

ReliaTel Control Only

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 volts and 633 volts.

Unit Inspection

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General Information

As soon as the unit arrives at the job site

[ ] Verify that the nameplate data

matches the data on the sales order and bill of lading (including 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 compo-

nents for shipping damage as soon as possible after delivery and before it is stored. Do metal base pans.

not walk on the sheet

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

a. the unit is stored before it is in-

stalled; or,

b. the unit is set on the roof curb, and

temporary heat is provided in the building. Isolate all side 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.

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 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.

[ ] If concealed damage is discovered,

notify the 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 repre-

sentative before installing or repairing a damaged unit.

Storage

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Pre - Installation

Figure 1

Typical Installation Clearances for Single & Multiple Unit Applications

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Figure 2

Unit Dimensional Data YSC060AD

Unit Clearances

1775

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Figure 2 - Continued

Unit Dimensional Data YSC072AD, YSC090AD

Unit Dimensions

Unit Dimensional Data YS102AD, YSC120AD

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Unit / Accessory Weights

Table 1 Typical Unit Weights & Point Loading Data

Net Net

Unit Weight Unit Weight

Model (lbs) ABCDLengthWidth Model (kg) ABCDLengthWidth

YSC060AD* 574 179 140 119 136 32 20 YSC060AD* 260 81 63 54 62 810 510 YSC072AD* 772 249 198 141 184 39 22 YSC072AD* 350 113 90 64 83 990 560 YSC090AD* 923 306 243 165 210 38 21 YSC090AD* 419 139 110 75 95 970 530 YSC102AD* 957 310 252 175 220 40 22 YSC102AD* 434 141 114 79 100 1020 560 YSC120AD* 1060 342 277 197 245 40 22 YSC120AD* 481 155 126 89 111 1020 560

Corner Wt. (lbs) of Gravit

Center Center

(In.)

Corner Wt. (kg) of Gravity (mm.)

Typical Accessory Weights

Net Weights lbs

Accessory 5 Ton 6 - 10 Tons Accessory 5 Ton 6 - 10 Tons

Economizer 26 36 Economizer 12 16 Barometric Relief 7 10 Barometric Relief 3 5 Motorized Outside Air Damper 20 30 Motorized Outside Air Damper 9 14 Manual Outside Air Damper 16 26 Manual Outside Air Damper 7 12 Roof Curb 70 115 Roof Curb 32 52 Oversized Motor 5 8 Oversized Motor 2 4 Coil Guards 12 20 Coil Guards 5 9 Hinged Doors 10 12 Hinged Doors 5 5 NOTES: (1) Net weight should be added to unit weight when ordering factory-installed accessories.

Net Weights (kg)

Figure 3

LIFTING AND MOVING INSTRUCTIONS!

DO NOT USE CABLES (CHAINS OR SLINGS) EXCEPT AS SHOWN. OTHER LIFTING ARRANGEMENTS MAY CAUSE EQUIPMENT DAMAGE OR SERIOUS PERSONAL INJURY.

EACH OF THE CABLES (CHAINS OR SLINGS) USED TO LIFT UNIT MUST BE CAPABLE OF SUPPORTING THE ENTIRE WEIGHT OF THE UNIT.

LIFTING CHAINS (CABLES OR SLINGS) MAY NOT BE THE SAME LENGTH. ADJUST AS NECESSARY FOR EVEN LEVEL LIFT.

Rigging and Center-of-Gravity Data

USE SPREADER BARS AS SHOWN IN DIAGRAM. REFER TO TABLE 1 FOR UNIT WEIGHT.

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Installation

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 1 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, ensure the roof is strong enough to support the combined unit and support structural weight. Refer to Table 1 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 contractor for proper waterproofing procedures.

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Installation

Figure 4-1

YSC060AD Horizontal Unit Supply & Return Air Opening

YSC072AD - 120AD Horizontal Unit Supply & Return Air Opening

Figure 4-1

YSC060AD Downflow Unit Supply & Return Air Openings

YSC072AD - 120AD Downflow Unit Supply & Return Air Openings

Supply

Return

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Installation

Ductwork

Figure 4-1 illustrates the supply and return air openings as viewed from the rear of the unit.

Elbows with turning vanes or splitters are recommended to minimize air noise due to turbulence and to reduce static pressure.

When attaching the ductwork to the unit, provide a water 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

Note: All Gas/Electric units shall be installed on a roof curb that is a minimum height of 5.0 inches ( 127 mm ), or in any other manner such that the distance between the bottom of the intake vents of the gas section and grade of the surface that the unit is installed on is no less than 19.7 inches ( 500 mm ).

Downflow

The roof curbs for these units consists of a “full perimeter” enclosure to support the unit.

Before installing any roof curb, verify;

1. That it is the correct curb for the unit,

2. That it includes the necessary gaskets and hardware,

3. That the purposed installation location provides the required clearance for proper operation.

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

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 assure proper condensate flow during operation, 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 the 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 not cut out the entire roof deck within the curb perimeter.

If a Curb Accessory Kit is not used:

a. The ductwork can be attached

directly to the factory-provided flanges around the unit’s supply and return air openings. Be sure to use flexible duct connections at the unit.

b. For “built-up” curbs supplied by

others, gaskets must be installed around the curb perimeter flange and the supply and return air opening flanges.

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Installation

Rigging

A Rigging illustration and Center-ofGravity dimensional data table is shown in Figure 3. Refer to the typical unit operating weights table before proceeding.

1. The wooden top is secured to the unit by a plastic strap. The plastic strap is secured to the right front corner post of the unit with one screw. Remove this screw to release the strap. Remove the wooden top and plastic strap. Replace the screw in the right front corner post.

2. Remove protective covering from around the unit.

DO NOT USE CABLES (CHAINS OR SLINGS) EXCEPT AS SHOWN. OTHER LIFTING ARRANGEMENTS MAY CAUSE EQUIPMENT DAMAGE OR SERIOUS PERSONAL INJURY.

EACH OF THE CABLES (CHAINS OR SLINGS) USED TO LIFT UNIT MUST BE CAPABLE OF SUPPORTING THE ENTIRE WEIGHT OF THE UNIT.

LIFTING CHAINS (CABLES OR SLINGS) MAY NOT BE THE SAME LENGTH. ADJUST AS NECESSARY FOR EVEN LEVEL LIFT.

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

4. Install a lifting bar, as shown in Figure 3, to protect the unit and to facilitate a uniform lift. The minimum disbetween the lifting hook and the top of the unit should be 7 feet (21m).

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 two Fork Lift brackets and hardware. Remove the two Fork Lift brackets, two metal runners and three wooden boards as shown.

7. Downflow 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.

General Unit Requirements

Note: Before installation check that local distribution conditions, nature of gas and pressure. and the current state adjustment of the appliance are compatible.

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.

[ ] Verfiy 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; se-

cure ductwork to curb.

[ ] Install pitch pocket 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.

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.

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Installation

pping

Temperature Limit Switch Usage for Gas Heat Units

Units are factory shipped in the downflow discharge confriguration but can be field converted to a horizontal discharge confriguration. Some, but not all units require a different TC01 limit switch, which is attached to the combustion blower motor if horizontal discharge confriguration is used.

Note: The following units require a limit switch change out for horizontal discharge. The additional limit switch is shipped attached to the blower housing. Refer to the Horizontal Discharge Conversion, Step 5 for the following models "ONLY" YSC060A**H, YSC072A**H, YSC090**H, YSC102A**H, YSC120A**H.

If any of the above units are installed in the downflow discharge configuration, remove the additional TC01 limit switch from the combustion blower motor and discard.

Unit Model

TCO1 Tri

Downflow / Horizontal

Values

YSC060 A **H 170F / 200F 77C / 93C YSC072 A **H 180F / 220F 82C / 104C YSC090 A **H 180F / 220F 82C / 104C YSC102 A **H 190F / 260F 88C / 127C YSC120 A **H 190F / 260F 88C / 127C

Gas Heat Technical Data

GENERAL DATA

HEAT E R S IZE G80 G120 G120 G200 G150 G250 INP UT (M BH)(K W) (67)( 19 .6) (100)(29.3) (100)(29. 3) (167)( 48.9) (125)(36.7) (208)(60.9)

HI LI M IT TRIP T E M P ( Down F low / Horz ) HI LI M IT TRIP T E M P ( Down F low / Horz )

NO. OF INJECTORS 2 3 3 4 3 5 INLE T P IPE SIZE ( NP T) 1/2 1/2 1/2 1/2 1/2 1/2

Gas G20

INPUT m INLE T P RE S S URE S ( MIN, NO M ,MAX ) m bar 17|20| 25 17|20| 25 17|20| 25 17|20| 25 17|20|26 17|20| 25 MANIFOLD PRESSURE ( m b ar ) 3.0" w. c .(7.5) 3.0" w.c.(7.5 ) 3.0" w.c.(7. 5) 3.0" w.c .(7.5) 3.0" w.c .(7.5) 3.0" w. c .(7.5) INJ ECTO R SIZ E (DRILL)( m m ) (33)( 2.87) (33) (2.87) (33)( 2.87) (1/8") ( 3.175) (1/ 8")(3.175) ( 1/8") ( 3.175)

Gas G25

INPUT m INLE T P RE S S URE S ( MIN, NO M ,MAX ) m bar 20|25| 30 20|25| 30 20|25| 30 20|25| 30 20|25|31 20|25| 30 MANI FO LD PRE S S URE (m bar ) 4.2" w. c .(10.5) 4.2" w. c . ( 10.5) 4.2" w. c .(10. 5) 4.2" w.c. ( 10.5) 4.2" w. c . (10.5)4.2" w.c. ( 10. 5 ) INJ ECTO R SIZ E (DRILL)( m m ) (33)( 2.87) (33) (2.87) (33)( 2.87) (1/8") ( 3.175) (1/ 8")(3.175) ( 1/8") ( 3.175)

Gas G31

INPUT m INLE T P RE S S URE S ( MIN, NO M ,MAX ) m bar 25|37| 45 25|37| 45 25|37| 45 25|37| 45 25|37|46 25|37| 45 MANIFOLD PRE S SURE ( mb ar ) 10"w.c.(24. 9) 10"w.c .(24.9) 10"w.c.(24.9) 10"w.c.(24. 9) 10"w.c .(24.9) 10"w.c.(24.9) INJ ECTO R SIZ E (DRILL)( m m ) 51(1.70) 51(1.70) 51(1.70 ) 51(1.7 0) 51(1.70) 5 1(1.70)

MODEL # YSC060**L YSC060**H

F 170 170/200 200 180/220 200 190/260

C 77 77/93 93 82/93 93 88/126

/ h 1.9 2.8 2.8 4.7 3.5 5.9

/ h 2.2 3.3 3.3 5.5 4.1 6.9

/ h 1.4 2.1 2.1 3.5 2.6 4.4

YSC072**L YSC090**L

YSC072**H YSC090**H

YSC102**L YSC120**L

YSC102**H YSC120**H

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Page 18

Installation

Horizontal Discharge Conversion

YSC060

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.

RTV Sealant

Note: Certain unit/electric heater combinations require a limit switch change out for horizontal airflow applications. Refer to the following instructions to determine if this process is required for the unit undergoing installation.

6. After completing installation of the duct covers for horizontal discharge, proceed to TCO-1 instructions.

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

4. Slide duct covers into duct openings until inward 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 duct cover engages with the 2 retaining clips on the duct flange. Secure outward edge of the duct cover with two screws.

Supply duct cover with RTV installed

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Installation

Horizontal Discharge Conversion

YSC072 - 120

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.

Supply Duct Cover

Note: The following units require a limit switch change out. The additional limit switch is shipped attached to the blower housing for these models. Proceed to Step 5 for the following models "ONLY". YSC060A**H, YSC072A**H, YSC090A**H, YSC102A**H, YSC120A**H.

5. After completing installation of the duct covers for horizontal discharge, proceed to TCO-1 instructions.

TCO1 Instructions:

If the unit being installed is listed in the following table the limit control TCO1 must be replaced with the extra limit control shipped in the heater compartment. Replace TCO1 following the instructions in steps 1through 4 below. If the unit being installed does not correspond to any in the following table, skip steps1 through 4 and go on to next step in the installation process.

Unit Model Number

Y*C036A* *H, Y * C048A** H, Y *C060A **H, YHC060A**M Y*C072A* *H, Y SC090A**M , Y* C092A** M, Y HC092A**H, Y*C102A* *M , Y*C102A** H, Y *C120A **M , Y *C120A* *H.

1. Remove the heat section access panel.

2. Remove TC01 from shipping location, attached to the combustion blower.

Screw into 4 dimples on top edge

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

RTV Sealant

Note: If Unit is equipped with Return Air Smoke Detector, refer to field conversion instructions for horizontal discharge before installing return air duct.

3. Replace and discard the existing TC01 originally installed at the factory for downflow operation with the TC01 shipped attached to the combustion blower for horizontal operation.

4. Replace heat section access panel.

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Installation

Through the Base Gas Installation

To convert the unit to through the base gas, complete the following procedure. The gas supply line must extend 120 mm (4-5/8 in) above the base-pan. The parts listed in the procedure are all field-supplied, and need to be purchased separately in order to make this conversion. All joints in the assembly should be made using a pipe sealant approved for gas applications.

Note: All field-installed gas piping must comply with applicable state and local codes.

1. Remove the insulation and metal plug from the through the base gas penetration. Route the gas supply pipe so that it extends 120 mm (4-5/8 in) above the base pan.

2. Remove the plastic plug from the upper hole in the center post. Insert a grommet (similar to the one located at the bottom of the center post) in place of the plastic plug.

3. Using pipe sealant attach a 90° street elbow to the outlet side of the gas shut-off valve and a 165 mm (6-1/2 inch) pipe nipple to the inlet side.

4. Using pipe sealant, attach a 90° elbow to the gas supply line that has been routed through the base.

12. Using pipe sealant, assemble the two measured nipples, 90° elbow, and the other side of the union.

13.Using pipe sealant, attach the assembly from step 12 to the 90° street elbow on the gas shut-off valve, and tighten the union.

5. Install 2 grommets in the pipe access holes in the center post.

6. Install the gas shut-off valve/nipple assembly through the upper grommet in the center post.

7. Using pipe sealant, attach the 165 mm (6-1/2 in) pipe nipple, from the assembly completed in step 3, to the 90 elbow on the gas supply line.

8. Attach one side of a union, using pipe sealant, to a 125 mm (5 in) pipe nipple.

9. Install the union/nipple assembly through the lower grommet in the center post.

10. Using pipe sealant, attach the 125 mm (5 in) pipe nipple assembly from step 8 to the 90° elbow on the gas valve located inside the unit.

11. To assemble the remainder of the gas piping, two more nipples and a 90° elbow will be needed. The lengths of the two nipples will vary depending on the unit and installation. Measure the two lengths of pipe that will be needed to connect the union to the 90° street elbow on the gas shut-off valve using a 90° elbow. The lengths of pipe will be approximately 70 mm (2-3/4 in).

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Installation

Main Electrical Power Requirements

[ ] Verify that the power supply complies

with the unit nameplate specifications.

[ ] Inspect all control panel components;

tighten any loose connections.

[ ] Connect properly sized and pro-

tected power supply wiring to a fieldsupplied/installed disconnect switch and to the main power terminal block (HTB1) in the unit control panel.

[ ] Install proper grounding wires to an

earth ground.

Note: All field-installed wiring must comply with applicable State and Local codes.

Requirements for Gas Heat

[ ] Gas supply line properly sized and

connected to the unit gas train. [ ] All gas piping joints properly sealed. [ ] Drip leg Installed in the gas piping

near the unit. [ ] Gas piping leak checked with a soap

solution. If piping connections to the

unit are complete, do not pressurize

piping in excess of 0.50 psig or 14 "

W.C. (3.5 kPa) to prevent compo-

nent failure. [ ] Minimum gas supply pressure should

be 4.5" W.C. (1.1 kPa). [ ] Maximum gas supply pressure must

not exceed 14.0" W.C.(3.5 kPa).

Condensate Drain Configuration

An evaporator condensate drain connection is provided on each unit. Refer to Figure 4-1 for the appropriate drain location.

The condensate drain pan is factory installed to drain condensate to the back side of the unit. See Figure 4-1. It can be converted to drain condensate out the front side of the unit or through the base.

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

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

To convert drain condensate through the base of unit:

1. Remove evaporator access panel and supply air access panels.

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

7. Slide the condensate drain pan back into the unit, align the drain support with the grommeted opening in the rear support panel and push until the support 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-Trap using the guidelines in Figure 5.

A condensate drain line must be connected to the P-Trap. Pitch the drain lines at least 1/2 inch (13 mm) for every 10 feet (3.0 m) of horizontal run to assure proper condensate flow. Do not allow the horizontal run to sag causing a possible double-trap condition which could result in condensate backup due to “air lock”.

Figure 5 Condensate Trap Installation

[ ] Manifold pressure for single stage

heaters should be set to 3.3" W.C. (.8 kPa).

[ ] Manifold pressure for two stage heat-

ers should be set to 3.5" W.C. (.9 kPa) on HIGH FIRE. The low fire setting is not field adjustable.

[ ] Flue Exhaust clear of any obstruc-

tion.

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 drainpan to convert it to through the base drainage.

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Installation

Filter Installation

YSC060AD unit ships with one inch (25 mm) filters. The quantity of filters is determined by unit size. Access to the filters is obtained by removing the indoor fan access panel. To modify the unit’s filter rack to accept two inch (50 mm) filters, remove the L-shaped angle attachment screws and rotate the angles 90 degrees.

Reinstall the screws and insert new filters. 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

An overall dimensional layout for the field installed wiring entrance into the unit is illustrated in Figure 2. To insure that the unit’s supply power wiring is properly sized and installed, follow the guidelines outline d below.

Note: All field installed wiring must conform to State and Local codes.

Verify 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.

USE COPPER CONDUCTORS ONL Y! UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS.

Failure to do so may cause damage to the equipment.

Main Unit Power Wiring

1. The unit is tional factory installed nonfused disconnect switch or circuit breaker. A field supplied disconnect switch must be installed at or near the unit in accordance with the State and Local codes.

2. Location of the applicable electrical service entrance is illustrated in Figure 2. Complete the unit’s power wiring connections onto either; the main terminal wire connectors inside the unit control panel, the field supplied nonfused disconnect switch (UCD) or circuit breaker (UCB). Refer to the customer connection diagram that is shipped with the unit for specific termination points.

3. Provide proper grounding for the unit in accordance with local and national codes.

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 6.

not equipped with an op-

Note: All field wiring must conform to state and local codes.

Control Power Transformer

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

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 Figure 2-1 for the electrical access locations provided on the unit and Table 2 for AC conductor sizing guidelines, and;

a. Use copper conductors unless other-

wise specified.

b. Ensure that the AC control wiring be-

tween 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.

c. Be sure to check all loads and con-

ductors for grounds, shorts, and miswiring.

d. Do not run the AC low voltage wiring

in the same conduit with the high voltage power wiring.

e. Route low voltage wiring per illustra-

tions on page 24.

HAZARDOUS VOLT AGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

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Page 23

Area

Installation

Table 2A 24V AC Conductors with Reliatel

Distance from Unit Recommended

to Control Wire Size

000 - 460 feet 18 gauge

000 - 140 m .75 mm

461 - 732 feet 16 gauge

141 - 223 m 1.3 mm

733 - 10 00 feet 14 gauge

224 - 305 m 2.0 mm

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

Before installing any connecting wiring between the unit and components utilizing a DC analog input\output signal, refer to Figure 2 for the electrical access locations provided on the unit.

a. Table 3 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.

DC Conductors

Table 3

Distance fro

Unit to Control

Fee

0 - 150 0 - 46 22 gauge 0.33 mm 151 - 240 47 - 73 20 gauge 0.50 mm 241 - 385 74 - 117 18 gauge 0.75 mm 386 - 610 118 - 185 16 gauge 1.30 mm 611 - 970 186 - 296 14 gauge 2.00 mm

Met er s

Rec ommended

Wir e Si ze

2 2 2 2 2

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

b. Ensure that the wiring between con-

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

c. Do not run the electrical wires trans-

porting DC signals in or around conduit housing high voltage wires.

d. Route low voltage wiring per illustra-

tions on page 25.

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Installation

Reliatel Conventional Thermostat Field Wiring Diagrams

Reliatel Control Customer Low Voltage Routing-

Reliatel Refrigeration Module

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Page 25

Installation

Figure 6

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

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Installation

Space Temperature Averaging

ReliaTel™

Space temperature averaging is accomplished by wiring a number of remote sensors in a series/parallel circuit. Using the BAYSENS016* or BAYSENS017*, at least four sensors are required to accomplish space temperature averaging.

Example #1 illustrates two series circuits with two sensors in each circiut wired in parallel. The square of any number of remote sensors required. Example #2 illustrates three sensors squared in a series/parallel circuit. Using BAYSENS032*, two sensors are required to accomplish space temperature averaging. Example #3 illustrates the circuit required for this senor. Table 4 lists the temperature versus resistance coefficient for all sensing. 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.

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Installation

Table 4 Temperature versus Resistance

(temperature vs resistance)

Tem

erature

Degrees F°Degrees C°Nominal

-20° - 28.9° 170.1 K - Ohms

-15° - 26.1° 143.5 K - O hms

-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° 19.9 6 K - Ohms 55° 12.8° 17.4 7 K - Ohms 60° 15.6° 15.3 3 K - Ohms 65° 18.3° 13.4 9 K - Ohms 70° 21.1° 11.8 9 K - Ohms 75° 23.9° 10.5 0 K - Ohms 80° 26.7° 9.29 7 K - Ohms 85° 29.4° 8.24 7 K - Ohms 90° 32.2° 7.33 0 K - Ohms 95° 35.0° 6.52 8 K - Ohms

100° 37.8° 5.824 K - Ohms

Resistance

Figure 7

Schematic Diagram for Field Gas Piping to Unit

Table 5

Sizing Natural Gas Pipe Mains & Branches

Iron Pipe Size (IPS) Inches Length of 1/2" 3/4" 1" 1 1/4" 1 1/2" Pipe (Ft.) Pipe Pipe Pipe Pipe Pipe

15 76 176 345 750 1220 30 52 120 241 535 850 45 43 99 199 435 700 60 38 86 173 380 610

75 77 155 345 545 Capacity of Pip e of Diffe r ent Diameter s and Lengths in Cu. Ft. Per Hr. with Pressure Drop of 0.3" and Specific Gravit y of 0.60

Iron Pipe Size (SI) Millimeters

Length of 15 mm 20 mm 25 mm 32 mm 40 mm

Pipe (Meters) Pipe Pipe Pipe Pipe Pipe

4.6 2.15 4.98 9.76 21.23 34.54

9.1 1.47 3.39 6.82 15.14 24.06

13.7 1.21 2.80 5.63 12.31 19.82

18.3 1.07 2.43 4.89 10.76 17.27

22.9 -- 2.18 4.38 9.76 15.40 Capacity of Pip e of Diffe r ent Diameter s and Length s in C u. Meter Per Hr. with Press ur e Drop of 74.6 Pa and S pe c ific Gra v ity of 0.60

Spec ific Gravity Multiplier s

Specific

Gravity

0.50

0.55

0.60

0.65

Multiplier

1.10

1.04

1.00

0.96

Figure 8

Typical Unit Gas Train Configuration

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Installation

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.

HAZARDOUS VOLTAGE! HIGH VOLTAGE IS PRESENT AT THE TERMINAL BLOCK OR UNIT MOUNTED DISCONNECT SWITCH.

[ ] Check all electrical connections for tightness and “point

of termination” accuracy. [ ] Verify 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 ad-

justment, or if the bearings need lubricating, refer to the

maintenance section of this manual for instructions. [ ] Verify that a condensate trap is installed and the piping is

properly sized and pitched. [ ] Verify that the correct size and number of filters are in

place. [ ] Inspect the interior of the unit for tools and debris and in-

stall 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;

VD = Line Voltage reading that deviates the farthest from the average voltage.

Example: If the voltage readings of the supply power measured 403, 402, and 389, the average volts would be:

VD (reading farthest from average) = 389

The percentage of Imbalance equals:

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.

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 starting the unit by using an instrument such as an Associated Research Model 45 Phase Sequence Indicator and following the steps below:

[ ] Turn the field supplied disconnect switch that provides

[ ] Connect the phase sequence indicator leads to the termi-

Black (phase A) to L1 Red (phase B) to L2 Yellow (phase C) to L3

[ ] Close the field supplied main power disconnect switch or

403 + 402 + 389 = 398 Avg.

100 X

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

nal block or to the “Line” side of the optional factory mounted disconnect switch as follows;

circuit protector switch that provides the supply power to the unit.

398 - 389 = 2.2%

398

AV (Average Voltage) =

V1, V2, V3 = Line Voltage Readings

Volt 1 + Volt 2 + Volt 3

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Installation

HAZARDOUS VOLTAGE! HIGH VOLTAGE IS PRESENT AT THE TERMINAL BLOCK OR UNIT MOUNTED DISCONNECT SWITCH.

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.

[ ] 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 switch or circuit protection switch and reverse any two power wires.

[ ] Restore the main electrical power and recheck the phas-

ing. If the phasing is correct, open the disconnect switch or circuit protection switch and remove the phase sequence indicator.

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Pre - Start

HAZARDOUS VOLTAGE! HIGH VOLTAGE IS PRESENT AT THE TERMINAL BLOCK OR UNIT MOUNTED DISCONNECT SWITCH.

ReliaTel Controls

Upon power initialization, the RTRM 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 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 “Test” procedure to bypass some time delays and to start the unit at the control panel. Each step of unit operation can be ac-

tivated individually by temporarily shorting across the “Test” 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 terminated, the Liteport LED will glow continuously and the unit will revert to the “System” control.

Test Modes

There are three methods in which the “Test” 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 check.

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 Test 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.

Table 6

Service Test Guide for Component Operation

TEST MODE Fan Econ Comp Com p He at H ea t Ohms STEP (Note 2)1212

1 Setpoint 2.2K

2 Economizer

3 Cool Minim u m (Not e 1)

4 Cool Minim u m (Note 1) (Note 1)

(Note 3) Stage 2 On Posit ion On On Off Off 6.8K

(Note 3)

6Heat

(Note 3) Stage 1 On Minimum Of f Off On Off 10K

7Heat

(Note 3) Stage 2 On Minimum Of f Off On On 15K

Notes:

1 - The condenser f ans will operat e any t im e a com pres sor is "On" providing the outdoor air t emper at ur es are wit hin t he operating values. 2 - The exhaust fan will turn on anytim e t he economizer damper posit ion is equal to or greater than the exhaust fan setpoint. 3 - Steps for optional accessories and non-applicable modes in unit will be skipped.

Fan On Position Off Off Off Off

Minimum

Ventilation On Selectable Off Off Off Off

Test Open On Open Off Off Off Off 3.3K

Stage 1 On Position On Off Off Off 4.7K

Reheat On Minimum On On Off Off 3 3K

Minimum

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Pre - Start

Verifying Proper Air Flow

(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 changed 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, momentarily jump across the Test 1 & Test 2 terminals on LTB1 one time to start the Minimum Ventilation Test.

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

Use the following procedure to determine the proper adjustment of the evaporator fan for a specific application.

1. With the fan operating properly, determine the total system airflow CFM (m

/h) by;

3. If the required CFM is too high, (external static pressure is low causing motor HP output to be above table value), perform one or both of the following:

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

To Increase Fan RPM; Loosen the pulley adjustment set

screw and close the sheave by moving the two halves closer together.

To Decrease Fan RPM; Loosen the pulley adjustment set

screw and open the sheave by moving the two halves farther apart..

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.

a. Measuring the actual RPM, b. Measure the amperage at the supply fan contactor

and compare it with the full load amp (FLA) rating stamped on the motor nameplate.

c. Calculate the theoretical BHP (KW)

Actual Motor Amps X Motor HP (KW) Motor Nameplate Amps

d. Using the fan performance tables in the unit Service

Facts, plot the actual RPM (step 1) and the theoretical BHP (KW) (step 2c) to obtain the operating Air Flow.

2. If the required Air Flow is too low, (external static pressure is high causing motor HP (KW) output to be below table value), perform one or both of the following.

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

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Start Up

Economizer Start-Up

ReliaTel Control

Using the Service Test Guide in Table 6, momentarily jump across the Test 1 & Test 2 terminals on LTB1 one time to start the Minimum Ventilation Test.

ROTATING PARTS! UNIT STARTS AUTOMATICALLY

Verify that the dampers stroked to the

minimum position.

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 start-up component Test is started.

Verify that the dampers stroked to the full open position.

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

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 backwards, it will not pump and 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. Refer to the illustration in Figure 5-1 for the compressor terminal/phase identification. 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.

c. Check the compressor oil levels.

The oil level in each compressor sight glass should be 1/2 to 3/4 full when they are “Off”.

Note: The scroll compressor uses

Trane OIL42 without substitution. The appropriate oil charge for a 9 and 10 Ton scroll compressor is 8 pints ( 3.8 liters). For a 14 and 15 Ton scroll compressor, use 14 pints ( 6.6 liters).

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. Follow the

instruction listed on the superheat charging curve in the Service Facts.

Superheat should be within ±5 F (15C) of the superheat chart value.

4. Repeat steps 1 through 4 for each

refrigerant circuit.

Gas Heat Units

Open the main disconnect switch to shut the unit off and to reset the RTRM.

Follow the Test Guide in Table 6 to start the unit in the heating mode. 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 start-up component Test is started.

5. 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).

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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 Setback (NSB)

panel (if applicable) for proper unoccupied operation. Refer to the programming instructions for the specific panel.

[ ] Verify that the Remote panel “Sys-

tem” selection switch, “Fan” selection switch, and “Zone Temperature” settings for automatic operation are correct.

[ ] Inspect the unit for misplaced tools,

hardware, and debris.

[ ] Verify that all exterior panels includ-

ing 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 block or the unit mounted disconnect switch.

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Maintenace

ROTATING PARTS! UNIT STARTS AUTOMATICALLY

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

Fan Belt Adjustment

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

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

When removing or installing the new belts, do not stretch 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 9; adjust the belt tension as follows;

1. To determine the appropriate belt de-

flection;

4. Place the large end of the gauge at the center of the belt span; then depress the gauge plunger until the large O-ring is even with the top of the next belt or even with a straightedge placed across the fan and motor sheaves. Refer to Figure 9.

5. Remove the belt tension gauge. The small O-ring now indicates a number other than zero on the plunger’s force scale. This number represents the force in pounds or newtons 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.

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”.

a. Measure the center-to-center

shaft distance in inches or millimeters between the fan and motor sheaves.

b. Divide the distance measured in

Step 1a by 64 inches or 152 millimeters; 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 Step 1b.

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

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Maintenace

Figure 9

Belt Tension Gauge

Table 7 Belt Tension Measurement and Deflection

Deflection Force (Lbs.)

Belts Super Steel Cable

Cross Small P.D Gripbelts Gripnotch Gripbelts

Section Range

(in)

3.0 - 3 .6 3 4 1 /2 3 7/8 5 1/ 2 3 1/4 4

Belts Super Steel Cable

Cross Small P.D Gripbelts Gripnotch Gripbelts

Section Range

3.8 - 4 .8 3 1/2 5 4 1/2 6 1/4 3 3/4 4 3/4

5.0 - 7 .0 4 5 1 /2 5 6 7/8 4 1/ 4 5 1/ 4

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

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

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

(mm)

13.3 - 1 6.0 13.3 20.0 17.2 24.5 14.5 17.8

16.9 - 2 1.4 15.6 22.2 20.0 27.8 16.7 21.1

22.0 - 3 1.1 17.8 24.5 22.2 30.6 18.9 23.4

15.1 - 1 8.7 17.8 24.5 25.6 35.6 20.0 24.5

19.6 - 2 4.9 22.8 31.7 28.9 40.6 25.6 32.3

25.8 - 3 9.1 28.4 38.9 32.8 45.0 31.1 38.9

(in) (in) (in)

Min. Max. Min. Max. Min. Max

Deflection Force (N.)

(mm) (mm) (mm)

Min. Max. Min. Max. Min. Max

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Page 36

Maintenance

Monthly Maintenance

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

HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING.

Failure to disconnect power before servicing can cause severe personal injury or death.

Filters

[ ] Inspect the return air filters. Clean or

replace them if necessary. Refer to the unit Service Facts for filter information.

Cooling Season

[ ] Check the unit’s drain pans and con-

densate piping to ensure that there are no blockages.

[ ] Inspect the evaporator and con-

denser 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; re-

pair 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 connec-

tions are tight.

[ ] Remove any corrosion present on

the exterior surfaces of the unit and repaint these areas.

[ ] Generally inspect the unit for unusual

conditions (e.g., loose access panels, leaking piping connections, etc.)

[ ] Make sure that all retaining screws

are reinstalled in the unit access panels once these checks 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 Table 8. If the operating 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.

Heating Season

[ ] Inspect the unit’s air filters. If neces-

sary, clean or replace them.

[ ] Check supply fan motor bearings; re-

pair or replace the motor as 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.

[ ] Clean burner area, verify gas 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.

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”, “OAKITE 166” and “COILOX”. If the detergent selected is strongly alkaline (ph value exceeds 8.5), add an inhibitor.

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

2. Protect all electrical devices 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 instructions. If desired, heat the solution to

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Page 37

Maintenance

150o F 65.6o C maximum to improve its cleansing capability.

CONTAINS REFRIGERANT! SYSTEM CONTAINS OIL AND REFRIGERANT

Do not heat the detergent-and-water solution above 150 uids sprayed on the exterior of the coil will raise the coil’s internal pressure and may cause it to burst. Failure to follow proper procedures can result in personal illness or injury or severe equipment damage.

5. Pour the cleaning solution into the sprayer. If a high-pressure sprayer is used:

a. do not allow sprayer pressure

to exceed 600 psi (41.4 bar).

b. the minimum nozzle spray

angle is 15 degrees.

c. maintain a minimum clearance

of 6" (152.4 mm) between the sprayer nozzle and the coil.

d. spray the solution

perpendicular (at 90 degrees) to the coil face.

F (-9.4C). Hot liq-

[ ] Clean and repaint any corroded sur-

face.

Final Process

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

(1) Com plete Unit Model Num ber :

(2) Unit Serial Number:

(3) Wiring Diagram Numbers (from unit control panel):

— schematic(s)

— connection(s)

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 Steps 6 and 7.

9. Reinstall all of the components and panels removed in Step 1 and any protective covers installed in step 2.

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

Annual Maintenance

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Page 38

Table 8 Sample Maintenance Log

Current

Ambient Com

. Oil Press. Press. Press. heat cool. Oil Press. Press. Press. heat cool.

Tem

Date F/C Level Psi

r. Suct. Disch. Liquid Super- Sub- Compr. Suct. Disch. Liquid Super- Sub-

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

Maintenance

Refrigerant Circuit #1 Refrigerant Circuit #2

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

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

- ok - o

- low - low

Check and record the data request ed a bov e ea c h m on th during the c o oling season with the unit running.

Note:

ReliaTel Control

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

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Trouble Shooting

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”.

HAZARDOUS VOLTAGE! HIGH VOLTAGE IS PRESENT AT THE TERMINAL BLOCK OR UNIT MOUNTED DISCONNECT SWITCH.

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 presence between J1-1 and J1-2. If 24 VAC is present, proceed to Step

3. If 24 VAC is not present, check the unit main power supply, check transformer (TNS1). Proceed to Step 3 if necessary.

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, recheck Steps 1 and 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 check 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 Step 6.

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 operations for each mode, to assist in verifying proper operation. Make the necessary repairs and proceed to Steps 7 and 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 checked 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. BAYSENS010B, BAYSENS011B, BAYSENS019A, BAYSENS020A, BAYSENS021A & BAYSENS023A all have the remote panel indication feature. The LED descriptions are listed below.

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.

Heating Failure

Verify Heat Failure by Ignition Module (IGN) LED indicator:

OFF: No Power or Failure ON: Normal Slow Flash: Normal, Heat Call Fast Flash: Error Code: 1 Flash: Communication Failure 2 Flashes: System Lockout 3 Flashes: Pressure Switch Fail 4 Flashes TC01 or TC02 Open 5 Flashes: Flame w/o Gas Valve 6 Flashes: Flame Rollout Open

LED 1 (System)

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

39RT-SVX31A-EN

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Trouble Shooting

Cooling Failure

1. Cooling and heating set point (slide pot) on the zone sensor has failed. Refer to the “Zone Sensor Test 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 & J3-2 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 switch has closed, the unit will not operate (when connected to RTOM), check the fan motor, belts, and proving switch.

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

Simultaneous Heat and Cool Failure

1. Emergency Stop is activated

Method 2

The second method for determining system status is done by checking 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 = voltage alternates 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 BAYSENS010B ZSM and connect wires with alligator clamps to terminals 6 through 10. 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, BAYSENS019B the LED indicators will not function while the BAYSENS010A is connected.

Resetting Cooling and Ignition Lockouts

Cooling Failures and Ignition Lockouts are reset in an identical manner. Method 1 explains resetting 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 the building management 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 any 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.

Clogged Filter Switch

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

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Trouble Shooting

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 closed, indicating a fan failure, and it will shut the 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)

Zone

Tem

erature

50 F° 10.0 C° 55 F° 12.8 C° 60 F° 15.6 C° 65 F° 18.3 C° 70 F° 21.1 C° 75 F° 23.9 C° 80 F° 26.7 C° 85 F° 29.4 C° 90 F° 32.2 C°

Nominal ZTEMP Nominal CSP or

Resistance HSP Resistance

19.9 K-O h m s 889 O hm s

17.47 K-O hm s 812 Ohm s

15.3 K-O h m s 695 O hm s

13.49 K-O hm s 597 O hm s

11.9 K-O h m s 500 O hm s

10.50 K-O hm s 403 Ohm s

9.3 K-O hms 305 O hm s

8.25 K-O hm s 208 Ohm s

7.3 K-O hms 110 O hm s

The resistance of these potentiometers are measured between the following ZSM terminals. Refer to the chart above for approximate resistances 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, HEAT, COOL & SERVICE)

Method 1

Testing the LED using a meter with diode test function. Test 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 Load, 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, LED is shorted.

Method 3

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

Note: Measurements should be made from LED common (ZSM terminal 6 to respective LED terminal). Refer to the Zone Sensor Module (ZSM) Terminal Identification table at the beginning of this section.

Programmable & Digital Zone Sensor Test

Testing serial communication voltage

1. Verify 24 VAC is present between terminals J6-14 & J6-11.

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

3. Reconnect wires to terminals J6-11 and J6-12. Measure voltage again between J6-11 and J6-12, voltage should flash high and low every 0.5 seconds. The voltage 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”.

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 management 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

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Trouble Shooting

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.

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: Communications Failure Pulse Flash: 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 6 Flashes: OA Humidity Sensor 7 Flashes: OA Temp Sensor 8 Flashes: MA Temp Sensor 9 Flashes: RAM Fault 10 Flashes: ROM Fault 11 Flashes: EEPROM Fault

Before turning the main power disconnect switch “Off”, follow the steps below to check the Ignition Module (IGN).

HAZARDOUS VOLTAGE! HIGH VOLTAGE IS PRESENT AT THE TERMINAL BLOCK OR UNIT MOUNTED DISCONNECT SWITCH.

1. Verify that the LED on the IGN 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 R and B. If the LED is not lit and 24 VAC is present replace the IGN. If 24 VAC is not present, check transformer (TNS1). Proceed to Step 3 if necessary.

3. If no failures are indicated, use the TEST mode procedures described in the “Unit Start-Up” section or thermostat to start the unit. This procedure will allow you to check all of the external controls (relays, contactors, etc) and the IGN.

4. Test the system through all of the available modes, and verify operation of all outputs, controls, and modes. Refer to the sequence of operations for each mode, to assist in verifying proper operation. Make the necessary repairs and proceed to Steps 5 and 6.

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 and removing the test mode connections.

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

Verify Heat Failure by Ignition Module (IGN) LED indicator:

OFF: No Power or Failure ON: Normal Slow Flash: Normal, Heat Call Fast Flash: Error Code: 2 Flashes: System Lockout 3 Flashes: Pressure Switch Fail 4 Flashes TC01 or TC02 Open 5 Flashes: Flame w/o Gas Valve 6 Flashes: Flame Rollout Open

Cooling Failure

1. Cooling and heating set point (slide pot) on the thermostat has failed.

2. 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, LPC1, LPC2, Frostat™).

Resetting Cooling and Ignition Lockouts

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

Method 1

To reset the system from the space, turn the “Mode” selection switch at the thermostat 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”.

Heating Failure

RT-SVX31A-EN42

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