T_C-IOM-1C18-AB60D22-4

Library Service Literature

Product Section Unitary

Product Rooftop AC – Lt. Comm. SZ

Model T_

Literature Type Installation/ Oper/ Maint

Sequence 1B

Date August 2003

File No. SV-UN-RT-T_C-IOM-1C 8/03

Supersedes T_C-IOM-1B 4/03

Since the manufacturer has a policy of continuous product improve-ment, it reserves the right to change specifications and design withoutnotice. The installation and servicing of the equipment referred to in thisbooklet should be done by qualified, experienced technicians.© American Standard Inc. 2003

Models:TSC036A - TSC120ATHC036A - THC120A

INSTALLATIONOPERATIONMAINTENANCECustomer Property — Contains wiring, service,and operation information. Please retain.

Packaged Electric/Electric3 Through 10 Ton

IMPORTANT NOTE: All phases of this installation must comply with the NATIONAL, STATE & LOCAL CODES. Inaddition to local codes, the installation must conform with National Electric Code -ANSI/NFPA NO. 70 LATESTREVISION and NFPA 90 STANDARD LATEST REVISION for the installation of Air Conditioning and VentilatingSystems.

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General InformationOverview of Manual ................................................... 3Model Number Description ........................................ 3Unit Nomenclature ..................................................... 4Unit Description ......................................................... 5System Input Devices ................................................ 5

Pre-Installation ChecklistUnit Inspection ........................................................... 8Precautionary Measures ........................................... 8Unit Clearances ......................................................... 8

Unit DimensionsUnit Dimensional Data ........................................ 10,11

InstallationRigging and Center-of-Gravity Data .............. 12,13,15Foundation ............................................................... 13Ductwork ................................................................. 15Roofcurb .................................................................. 16Rigging .................................................................... 16General Unit Requirements ..................................... 17Horizontal Discharge Conversion ( 3 - 5 Ton) .......... 18Discharge Air Sensing Tube ( 3 - 5 Ton) ................. 18Horizontal Discharge Conversion ( 6 - 10 Ton) ........ 19Return Air Smoke Detector ..................................... 20Condensate Drain Connection ................................ 21Condensate Trap Installation ................................... 21Filter Installation ...................................................... 22Field Installed Power Wiring .................................... 22Main Unit Power Wiring ........................................... 22Field Installed Control Wiring ................................... 23Control Power Transformer ...................................... 23Controls using 24 VAC ............................................. 23AC Conductors ........................................................ 23Controls using DC Analog Input/Outputs ................ 23DC Conductors ........................................................ 23Customer Low Voltage Routing ............................... 25Smoke Detector Low Voltage Wiring ....................... 26Typical Field Wiring .................................................. 27Space Temperature Averaging ................................ 28

Pre-StartVoltage Imbalance ................................................... 30Electrical Phasing .................................................... 30Compressor Crankcase Heaters ............................. 31Test Modes .............................................................. 31Service Test Guide for Component Operation ......... 32Airflow - Direct Drive Indoor Fan ............................. 32Airflow - Belt Drive Indoor Fan ................................ 33Electro Mechanical Control ..................................... 34

Start-UpReturn Air Smoke Detector ..................................... 35Economizer Start-Up ............................................... 35Compressor Start-Up .............................................. 35Heating Start-Up...................................................... 36Final System Setup ................................................. 36

MaintenanceFan Belt Adjustment - Belt Drive Units .................... 37Filters ....................................................................... 37Return Air Smoke Detector Maintenance ................ 37Cooling Season ....................................................... 38Heating Season ....................................................... 38Coil Cleaning ........................................................... 38Sample Maintenance Log ........................................ 40

Trouble ShootingReliaTel Control ....................................................... 41System Status Checkout Procedure ........................ 41System Failure ......................................................... 41Cooling Failure ........................................................ 41Service Failure ......................................................... 42Simultaneous Heat and Cool Failure ....................... 42Resetting Cooling and Ignition Lockouts ................. 42Zone Temperature Sensor (ZTS) Service Indicator ................................................... 42Clogged Filter Switch .............................................. 42Fan Failure Switch ................................................... 43Zone Temperature Sensor (ZTS) Test ..................... 43Zone Temperature Thermistor (ZTEMP) .................. 43Cooling Set Point (CSP) and Heating Set Point (HSP) ....................................... 43Testing serial communication voltage ...................... 43ReliaTel Refrigeration Module (RTRM)2 Default Chart ........................................................ 44Electro Mechanical Control ..................................... 44Cooling Failure ........................................................ 44Resetting Cooling and Heating Lockouts ................ 44Unit Economizer Control (ECA) Troubleshooting ..... 44Testing the ECA resistors and sensors .................... 45

Table of Contents

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Literature Change History

T_C-IOM-1C (August 2003)Added Hail Guard information.Updated warnings and cautions.

T_C-IOM-1B (April 2003)Added Dehumidification Option

T_C-IOM-1B (July 2002)Added TBUE sealing instructions. Updated riggingverbage.

T_C-IOM-1B (March 2002)Added Supply Air Tubing and Smoke Detector information.

T_C-IOM-1A (October 2001)Added 6 1/4 through 10 Ton models to product offering.

Overview of Manual

Note: One copy of this document ships inside thecontrol panel of each unit and is customerproperty. It must be retained by the unit’smaintenance personnel.

This booklet describes proper installation, operation, andmaintenance procedures for air cooled systems. By care-fully reviewing the information within this manual and fol-lowing the instructions, the risk of improper operation and/or component damage will be minimized.

General Information

It is important that periodic maintenance be performed tohelp assure trouble free operation. A maintenance scheduleis provided at the end of this manual. Should equipment fail-ure occur, contact a qualified service organization with quali-fied, experienced HVAC technicians to properly diagnoseand repair this equipment.

Note: Do Not release refrigerant to the atmosphere!If adding or removing refrigerant is required, theservice technician must comply with all federal,state, and local laws.

Model Number Description

All products are identified by a multiple-character modelnumber that precisely identifies a particular type of unit. Anexplanation of the alphanumeric identification code is pro-vided below. Its use will enable the owner/operator, installingcontractors, and service engineers to define the operation,specific components, and other options for any specific unit.

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

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General Information

Unit Nomenclature

Digit 1 - Product TypeT = Packaged Cooling

Digit 2 - Unit Efficiency LevelS = StandardH = High

Digit 3 - Airflow ConfigurationC = Convertible

Digit 4, 5, 6 - Cooling Capacity(MBH)036 = 3 Ton048 = 4 Ton060 = 5 Ton072 = 6 Ton090 = 7 1/2 Ton (Single Compressor)092 = 7 1/2 Ton (Dual Compressor)102 = 8 1/2 Ton120 = 10 Ton

Digit 7 - Major Design SequenceA

Digit 8 - Electrical Characteristics1 = 208-230/60/13 = 208-230/60/34 = 460/60/3W = 575/60/3

Digit 9 - Unit ControlR = Relia TelE = Electro-mechanical

Digit 10 - Heat Capacity0 = No HeatA = 5KWB = 6KWC = 9KWD = 10KWE = 12KWF = 14KWG = 18KWJ = 23KWK = 27KWN = 36KWP = 54KW

Digit 11 - Minor Design Sequence*

Digit 12, 13 - Service Digit Sequence**

Digit 14 - Factory Installed Options-Fresh Air Section0 = No Fresh AirA = Manual OA, 0 - 25%B = Motorized OA, 0 - 50%C = Economizer Dry BulbD = Economizer with Barometric ReliefE = Economizer, Reference EnthalpyF = Economizer, Reference Enthalpy, with Barometric ReliefG = Economizer, Comparative EnthalpyH = Economizer, Comparative Enthalpy, with Barometric Relief

Digit 15 - Factory Installed Options-Supply Fan0 = Standard Drive1 = Oversize Motor2 = Option Belt Drive

Digit 16 - Factory Installed Options-Hinged Service Access0 = Standard Panels/Standard FiltersA = Hinged Access Panels/Standard FiltersB = Standard Panels/2” Pleated FiltersC = Hinged Access Panels/2” Pleated Filters

Digit 17 - Factory Installed Options-Condenser Coil Protection0 = Standard1= Hail Guard2 = Epoxy Coated Condenser Coil3 = Epoxy Coated Condenser Coil and Hail Guard

Digit 18 - Factory Installed Options-Through The Base0 = Without Through The Base ConnectionA = Through The Base Electrical Connection

Digit 19 - Factory Installed Options-Disconnect Switch/Circuit Breaker0 = Without Disconnect Switch/Circuit Breaker1 = Unit Mounted Non-Fused Disconnect Switch2 = Circuit Breaker

Digit 20 - Factory Installed Options-Convenience Outlet0 = Without Convenience OutletA = Convenience Outlet UnpoweredB = Convenience Outlet Powered

Digit 21 - Factory Installed Options-Communications0 = Without Communications Options1 = Trane Communications Interface2 = Lontalk Communications Interface3 = Novar Communications Interface

Digit 22 - Factory Installed Options-Refrigeration System0 = Standard Refrigeration System OptionA = Expansion ValveB = Dehumidification Option

Digit 23 - Factory Installed Options-Refrigeration Controls0 = Without Refrigeration Controls1 = High Pressure Control2 = FrostatTM

3 = Crankcase Heater4 = High Pressure Control and Frostat5 = High Pressure Control and Crankcase Heater6 = Frostat and Crankcase Heater7 = High Pressure Control, Frostat and Crankcase Heater

Digit 24 - Factory Installed Options-Smoke Detector0 = Without Smoke DetectorA = Return Air Smoke DetectorB = Supply Air Smoke DetectorC = Return and Supply Air Smoke Detector

Digit 25 - Factory Installed Options-System Monitoring Controls0 = Without Monitoring Controls1 = Clogged Filter Switch2 = Fan Failure Switch3 = Air Sensing Tube4 = Clogged Filter Switch and Fan Failure Switch5 = Clogged Filter Switch and Discharge Air Sensing Tube6 = Fan Failure Switch and Discharge Air Sensing Tube7 = Clogged Filter Switch, Fan Failure Switch and Discharge Air Sensing Tube8 = Novar Return Air Sensor

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General InformationUnit Nameplate

A Mylar unit nameplate is located on the unit’s corner sup-port next to the filter access panel. It includes the unit modelnumber, serial number, electrical characteristics, refrigerantcharge, as well as other pertinent unit data.

Compressor Nameplate

The nameplate for the compressors are located on the sideof the compressor.

NOTICE:Warnings and Cautions appear at appropriate sections

throughout this manual. Read these carefully.

WARNING– Indicates a potentially hazardoussituation which, if not avoided, could result in death orserious injury.

CAUTION – Indicates a potentially hazardoussituation which, if not avoided, may result in minor ormoderate injury. It may also be used to alert againstunsafe practices.

CAUTION – Indicates a situation that may result inequipment or property-damage-only accidents.

Unit Description

Before shipment, each unit is leak tested, dehydrated,charged with refrigerant and compressor oil, and run testedfor proper control operation.

The condenser coils are aluminum fin, mechanically bondedto copper tubing.

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

There are two control systems offered for these units.

The electro mechanical control option uses a thermostat toperform unit functions.

The ReliaTel™ Control Module is a microelectronic controlsystem that is referred to as “Refrigeration Module” (RTRM).The acronym RTRM is used extensively throughout thisdocument when referring to the control system network.

These modules through Proportional/Integral control algo-rithms perform specific unit functions that governs unit op-eration in response to; zone temperature, supply air tempera-ture, and/or humidity conditions depending on the applica-tion. The stages of capacity control for these units areachieved by starting and stopping the compressors.

The RTRM is mounted in the control panel and is factorywired to the respective internal components. The RTRM re-ceives and interprets information from other unit modules,sensors, remote panels, and customer binary contacts tosatisfy the applicable request for cooling.

Economizer Control Actuator (Optional)

Electro Mechanical ControlThe ECA monitors the mixed air temperature, ambient drybulb temperature and local minimum position setpoint sen-sors, if selected, to control dampers to an accuracy of +/- 5%of stroke. The actuator is spring returned to the closed posi-tion any time that power is lost to the unit. It is capable of de-livering up to 25 inch pounds of torque and is powered by 24VAC.

ReliaTel™ ControlThe ECA monitors the mixed air temperature, return air tem-perature, minimum position setpoint (local or remote), powerexhaust setpoint, CO2 setpoint, CO2, and ambient dry bulb/enthalpy sensor or comparative humidity (return air humidityagainst ambient humidity) sensors, if selected, to controldampers to an accuracy of +/- 5% of stroke. The actuator isspring returned to the closed position any time that power islost to the unit. It is capable of delivering up to 25 inchpounds of torque and is powered by 24 VAC.

RTCI -- ReliaTel™ Trane CommunicationInterface (Optional)This module is used when the application calls for an ICSTM

building management type control system. It allows the con-trol and monitoring of the system through an ICS panel. Themodule can be ordered from the factory or ordered as a kit tobe field installed. Follow the installation instruction that shipswith each kit when field installation is necessary.

RLCI - ReliaTel™ LonTalk CommunicationInterface (Optional)This module is used when the application calls for an ICSTM

building management type control system that is LonTalk. Itallows the control and monitoring of the system through anICS panel. The module can be ordered from the factory or or-dered as a kit to be field installed. Follow the installation in-struction that ships with each kit when field installation isnecessary.

RTOM – ReliaTel™ Options Module (Optional)The RTOM monitors the supply fan proving, clogged filter,supply air temperature, exhaust fan setpoint, supply air tem-pering, Frostat™ and smoke detector. Refer to system inputdevices and functions for operation.

System Input Devices & Functions

The RTRM must have a zone sensor or thermostat input inorder to operate the unit. The flexibility of having severalmode capabilities depends upon the type of zone sensor orthermostat selected to interface with the RTRM.

The descriptions of the following basic Input Devices usedwithin the RTRM network are to acquaint the operator withtheir function as they interface with the various modules. Re-fer to the unit’s electrical schematic for the specific moduleconnections.

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General InformationThe following controls are available from the factory for fieldinstallation.

Supply Fan Failure Input (Optional)The Fan Failure Switch can be connected to sense indoorfan operation:

FFS (Fan Failure Switch) If air flow through the unit is notproven by the differential pressure switch connected to theRTOM (factory set point 0.07 “ w.c.) within 40 seconds nomi-nally, the RTRM will shut off all mechanical operations, lockthe system out, send a diagnostic to ICS, and the SERVICEoutput will flash. The system will remain locked out until a re-set is initiated either manually or through ICS.

Clogged Filter Switch (Optional)The unit mounted clogged filter switch monitors the pressuredifferential across the return air filters. It is mounted in the fil-ter section and is connected to the RTOM. A diagnostic SER-VICE signal is sent to the remote panel if the pressure differ-ential across the filters is at least 0.5" w.c. The contacts willautomatically open when the pressure differential across thefilters decreases to approximately 0.4" w.c. The clogged filteroutput is energized when the supply fan is operating and theclogged filter switch has been closed for at least 2 minutes.The system will continue to operate regardless of the statusof the filter switch.

Compressor Disable (CPR1/2)This input incorporates the low pressure control (LPC) ofeach refrigeration circuit and can be activated by opening afield supplied contact installed on the LTB.

If this circuit is open before the compressor is started, thecompressor will not be allowed to operate. Anytime this cir-cuit is opened for 1 continuous second during compressoroperation, the compressor for that circuit is immediatelyturned “Off”. The compressor will not be allowed to restart fora minimum of 3 minutes should the contacts close.

If four consecutive open conditions occur during the firstthree minutes of operation, the compressor for that circuit willbe locked out, a diagnostic communicated to the remotepanel (if installed), and a manual reset will be required to re-start the compressor.

Low Pressure Control

ReliaTel ControlWhen the LPC is opened for 1 continuous second, the com-pressor for that circuit is turned off immediately. The com-pressor will not be allowed to restart for a minimum of 3 min-utes.

If four consecutive open conditions occur during the firstthree minutes of operation, the compressor will be lockedout, a diagnostic communicated to ICSTM if applicable, and amanual reset will be required to restart the compressor.

Electromechanical ControlWhen the LPC is opened, the compressor for that circuit isturned off immediately. The compressor will restart when theLPC closes.

High Pressure Control (Optional)ReliaTel ControlThe high pressure controls are wired in series between thecompressor outputs on the RTRM and the compressorcontactor coils. If the high pressure control switch opens, theRTRM senses a lack of current while calling for cooling andlocks the compressor out.

On dual circuit units, if the high pressure control opens, thecompressor on the affected circuit is locked out. A manual re-set for the affected circuit is required.

Electromechanical ControlWhen the HPC is opened, the compressor for that circuit isturned off immediately. The compressor will restart when theHPC closes.

Power Exhaust Control (Optional)The power exhaust fan is started whenever the position ofthe economizer dampers meets or exceed the power ex-haust setpoint when the indoor fan is on.

With the optional ventilation override accessory, the powerexhaust fan is independent of the indoor fan.

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

Electromechanical ControlThe power exhaust fan is started whenever the indoor fan ison and the adjustable damper limit switch DLS is closed.

Lead/Lag Control (Dual Circuit Only)ReliaTel Control OnlyLead/Lag is a selectable input located on the RTRM. TheRTRM is configured from the factory with the Lead/Lagcontrol disabled. To activate the Lead/Lag function, simplycut the wire connected to J3-8 at the RTRM. When it isactivated, each time the designated lead compressor is shutoff due to the load being satisfied, the lead compressor orrefrigeration circuit switches. When the RTRM is powered up,i.e. after a power failure, the control will default to the numberone 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 isa manual changeover control with single setpoint. (CoolingSetpoint Only)

Zone Sensor Module (ZSM) (BAYSENS008B)This electronic sensor features four system switch settings(Heat, Cool, Auto, and Off) and two fan settings (On andAuto). It is a manual or auto changeover control with dualsetpoint capability. It can be used with a remote zone tem-perature sensor BAYSENS017B.

Zone Sensor (BAYSENS010B)This electronic sensor features four system switch settings(Heat, Cool, Auto, and Off) and two fan settings (On andAuto) with four system status LED’s. It is a manual or autochangeover control with dual setpoint capability. It can beused with a remote zone temperature sensorBAYSENS017B.

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General InformationWall Mounted Relative Humidity Sensor (BAYSENS036A)Field installed, wall mounted humidity sensor is used tocontrol activation of the hot gas reheat dehumidificationoption. Humidity set points can be selected for relativehumidity levels between 40% and 60% by adjusting theDEHUMID setting on the ReliaTel Options Module. See page24.

Duct Mounted Relative Humidity Sensor BAYSENS037A)Field installed, wall mounted humidity sensor is used tocontrol activation of the hot gas reheat dehumidificationoption. Humidity set points can be selected for relativehumidity levels between 40% and 60% by adjusting theDEHUMID setting on the ReliaTel Options Module. See page24.

Programmable Zone Sensor - BAYSENS019BThis 7 day programmable sensor features 2, 3 or 4 periods forOccupied or Unoccupied programming per day. If the power isinterrupted, the program is retained in permanent memory. Ifpower is off for an extended period of time, only the clock andday 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). Ithas dual temperature selection with programmable start timecapability.

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

A liquid crystal display (LCD) displays zone temperature, tem-perature set points, day of the week, time, and operationalmode symbols.

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

During an occupied period, an auxiliary relay rated for 1.25amps @ 30 volts AC with one set of single pole double throwcontacts is activated. Electronic Timeclock (BAYCLCK001A)This electronic timeclock is designed to control the occupied/unoccupied switching of up to four rooftop units. Once theunit(s) has entered an unoccupied status, night setback tem-peratures can be controlled by utilizing a standard zone sen-sor wired to the RTRM. The timeclock contains four binary out-puts (RE1, RE2, RE3, RE4), a liquid crystal display (LCD),and four programming Keys (Time/Day Key, Occupied/Unoc-cupied Program Key, Run Key, and an Advance/Override Key).A 18 to 30 VAC power source is required either from one ofthe units being controlled or from a separate class 2 powersource.

Status Inputs (4 Wires Optional)The ZSM can be wired to receive four (4) operating statussignals from the RTRM (HEAT, COOL, SYSTEM “ON”, SER-VICE).Four (4) wires from the RTRM should be connected tothe appropriate terminals (7, 8, 9 & 10) on the ZSM.

Remote Zone Sensor (BAYSENS013B)This electronic sensor features remote zone sensing andtimed override with override cancellation. It is used with aTrane Integrated ComfortTM

building management system.

Remote Zone Sensor (BAYSENS014B)This electronic sensor features single setpoint capabilityand timed override with override cancellation. It is used witha Trane Integrated ComfortTM building management system.

Remote Zone Sensor (BAYSENS016A)This bullet type temperature sensor can be used for; out-side air (ambient) sensing, return air temperature sensing,supply air temperature sensing, remote temperature sens-ing (uncovered. Wiring procedures vary according to theparticular application and equipment involved. Refer to theunit’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 iswired to a BAYSENS019B Remote Panel, wiring must be18 AWG Shielded Twisted Pair (Belden 8760 or equivalent).Refer to the specific Remote Panel for wiring details.

Electro Mechanical ControlThe unit must have a Thermostat to operate.

BAYSTAT036ASingle Stage - 1 Heat/1 Cool

BAYSTAT037AMulti Stage - 2 Heat/2 Cool - Can be Used for EconomizerOperation

BAYSENS025A Remote sensor for BAYSTAT036A,037A.

High Temperature Sensor (BAYFRST001A)This sensor connects to the RTRM Emergency Stop Inputon the LTB and provides high limit “shutdown” of the unit.The sensor is used to detect high temperatures due to firein the air conditioning or ventilation ducts. The sensor is de-signed to mount directly to the sheet metal duct. Each kitcontains two sensors. The return air duct sensor(X1310004001) is set to open at 135°F. The supply air ductsensor (X1310004002) is set to open at 240°F. The controlcan be reset after the temperature has been lowered ap-proximately 25°F below the cutout setpoint.

Evaporator Frost Control(ReliaTel™ Option)This input incorporates the Frostat™ control (FOS)mounted in the indoor coil and can be activated by closinga field supplied contact installed in parallel with the FOS.

If this circuit is open before the compressor is started, thecompressor will not be allowed to operate. Anytime this cir-cuit is opened for 5 continuous seconds during compressoroperation, the compressor for that circuit is immediatelyturned “Off”. The compressor will not be allowed to restartfor a minimum of 3 minutes should the FOS close.

(Electro Mechanical Option)This input incorporates the Frostat™ control (FOS)mountedin the indoor coil and can be activated by opening a fieldsupplied contact installed in series with the FOS.

If this circuit is open before the compressor is started, thecompressor will not be allowed to operate. Anytime this cir-cuit is opened during compressor operation, the compres-sor for that circuit is immediately turned “Off”. The compres-sor will restart when the FOS closes.

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Pre-Installation ChecklistSmoke Detector Sensor (Optional)This sensor is only applicable on units equipped with aRTOM. It provides high limit “shutdown” of the unit and re-quires a manual reset. The sensor is used to detect smokedue to fire in the air conditioning or ventilation ducts.

Important: The supply and return air smokedetectors are designed to shut off the unit if smokeis sensed in the supply air stream or return airstream. This function is performed by sampling theairflow entering the unit at the return air opening.Follow the instructions provided below to assurethat the airflow through the unit is sufficient foradequate sampling. Failure to follow theseinstructions will prevent the smoke detectors fromperforming it's design function.

Important: Airflow through the unit is affected bythe amount of dirt and debris accumulated on theindoor coil and filters. To insure that airflow throughthe unit is adequate for proper sampling by thereturn air smoke detector, complete adherence tothe maintenance procedures, includingrecommended intervals between filter changes, andcoil cleaning is required.

Important: Periodic checks and maintenanceprocedures must be performed on the smokedetector to insure that it will function properly. Fordetailed instructions concerning these checks andprocedures, refer to the appropriate section(s) of thesmoke detector Installation and MaintenanceInstructions provided with the literature package forthis unit.

In order for the supply air smoke detector or return air smokedetector to properly sense smoke in the supply air stream orreturn air stream, the air velocity entering the smoke detectorunit must be between 500 and 4000 feet per minute. Equip-ment covered in this manual will develop an airflow velocitythat falls within these limits over the entire airflow rangespecified in the evaporator fan performance tables.

There are certain models, however, if operated at low airflow,will not develop an airflow velocity that falls within the re-quired 500 to 4000 feet per minute range. For these models,the design airflow shall be greater than or equal to 1000 feetper minute MINIMUM.

Unit Inspection

As soon as the unit arrives at the job site

[ ] Verify that the nameplate data matches the data on thesales order and bill of lading (including electrical data).

[ ] Verify that the power supply complies with the unit name-plate specifications.

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

WARNINGFiberglass Wool !Product contains fiberglass wool. Disturbing the insula-tion in this product during installation, maintenance orrepair will expose you to airborne particles of glasswool fibers and ceramic fibers known to the state ofCalifornia to cause cancer through inhalation. Glasswool fibers may also cause respiratory, skin or eye irri-tation.

Precautionary Measures

· Avoid breathing fiberglass dust.

· Use a NIOSH approved dust/mist respirator.

· Avoid contact with the skin or eyes. Wear long-sleeved, loose-fitting clothing, gloves, and eye protec-tion.

· Wash clothes separately from other clothing: rinsewasher thoroughly.

· Operations such as sawing, blowing, tear-out,and spraying may generate fiber concentrationsrequiring additional respiratory protection. Usethe appropriate NIOSH approved respiration inthese situations.

First Aid Measures

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

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

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Pre-Installation ChecklistIf the job site inspection of the unit reveals damage or mate-rial shortages, file a claim with the carrier immediately.Specify the type and extent of the damage on the “bill of lad-ing” before signing.

[ ] Visually inspect the internal components for shipping dam-age as soon as possible after delivery and before it isstored. Do not walk on the sheet metal base pans.

[ ] If concealed damage is discovered, notify the carrier’s ter-minal of damage immediately by phone and by mail. Con-cealed damage must be reported within 15 days.

Request an immediate joint inspection of the damage bythe carrier and the consignee. Do not remove damagedmaterial from the receiving location. Take photos of thedamage, if possible. The owner must provide reasonableevidence that the damage did not occur after delivery.

[ ] Notify the appropriate sales representative before install-ing or repairing a damaged unit.

Storage

Take precautions to prevent condensate from forming insidethe unit’s electrical compartments and motors if:a. the unit is stored before it is installed; or,b. the unit is set on the roof curb, and temporary heat is pro-

vided in the building. Isolate all side panel service en-trances and base pan openings (e.g., conduit holes, S/Aand R/A openings, and flue openings) from the ambientair until the unit is ready for start-up.

Note: Do not use the unit’s heater for temporary heatwithout first completing the start-up proceduredetailed under “Starting the Unit”.

The manufacturer will not assume any responsibility forequipment damage resulting from condensate accumulationon the unit’s electrical and/or mechanical components.

Unit ClearancesFigure 1 illustrates the minimum operating and service clear-ances for either a single or multiple unit installation. Theseclearances are the minimum distances necessary to assureadequate serviceability, cataloged unit capacity, and peakoperating efficiency.

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

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Unit ClearancesFigure 1Typical Installation Clearances for Single & Multiple Unit Applications

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Unit DimensionsFigure 2Unit Dimensional DataT(H/S)C036A, T(H/S)C048ATSC060A

Unit Dimensional DataTHC060A

Figure 2 - Continued

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Unit DimensionsUnit Dimensional DataT(H/S)C072A, TSC090A, TSC092A

Unit Dimensional DataTHC092A, T(H/S)C102A, T(H/S)C120A

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Table 1Typical Unit Weights & Point Loading Data

Net Net Unit Weight Unit WeightModel (lbs) A B C D Length Width Model (kg) A B C D Length Width

TSC036A1* 409 132 104 79 94 31 19 TSC036A1* 186 60 47 36 43 796 474TSC036A(3,4,W)* 409 132 104 79 94 31 19 TSC036A(3,4,W)* 186 60 47 36 43 796 474TSC048A1* 434 140 110 91 94 32 19 TSC048A1* 197 63 50 41 43 821 475TSC048A(3,4,W)* 421 135 109 90 88 33 19 TSC048A(3,4,W)* 191 61 49 41 40 838 471TSC060A1* 451 149 114 88 99 31 18 TSC060A1* 204 68 52 40 45 799 465TSC060A(3,4,K,W)* 451 149 114 88 99 31 18 TSC060A(3,4,K,W)* 204 68 52 40 45 799 465TSC072A(3,4,K,W)* 681 236 177 119 150 38 21 TSC072A(3,4,K,W)* 309 107 80 54 68 978 531TSC090A(3,4,K,W)* 754 257 188 129 180 37 22 TSC090A(3,4,K,W)* 342 117 85 59 82 948 552TSC092A(3,4,W)* 756 261 202 131 162 39 21 TSC092A(3,4,W)* 343 118 92 59 73 992 521TSC102A(3,4,K,W)* 835 281 223 149 181 40 21 TSC102A(3,4,K,W)* 378 128 101 67 82 1003 532TSC120A(3,4,K,W)* 909 306 241 164 197 40 21 TSC120A(3,4,K,W)* 412 139 109 74 90 1005 536

THC036A1* 426 139 108 84 95 32 19 THC036A1* 193 63 49 38 43 802 470THC036A(3,4,W)* 426 139 108 84 95 32 19 THC036A(3,4,W)* 193 63 49 38 43 802 470THC048A1* 468 146 113 97 111 31 20 THC048A1* 212 66 51 44 50 799 497THC048A(3,4,W)* 468 146 113 97 111 31 20 THC048A(3,4,W)* 212 66 51 44 50 799 497THC060A1* 518 165 124 105 124 31 19 THC060A1* 235 75 56 48 56 787 493THC060A(3,4,W)* 506 164 121 100 122 31 19 THC060A(3,4,W)* 229 74 55 45 55 775 489THC072A(3,4,W)* 718 235 182 128 173 38 22 THC072A(3,4,W)* 325 107 82 58 79 971 564THC092A(3,4,W)* 857 289 222 148 197 38 21 THC092A(3,4,W)* 389 131 101 67 89 975 543THC102A(3,4,W)* 893 294 233 159 207 39 22 THC102A(3,4,W)* 405 134 105 72 94 988 552THC120A(3,4,W)* 982 323 253 178 229 39 22 THC120A(3,4,W)* 446 147 115 81 104 987 557

Corner Wt. (lbs)Center of

Gravity (In.)Center of

Gravity (mm)Corner Wt. (kg)

Installation

14

Option / Accessory Description

TH/TS036-060 TH/TS072-120Economizer 26 36

Motorized Damper 20 30Manual Damper 16 26Barometric Relief 7 10Power Exhaust N/A 80Oversize Motor 5 8

Belt Drive Motor (3 phase only) 31 StandardHinged Access 10 12

Hail Guard 12 20Through the Base: Electrical 8 13

Electric Heat 15 15Unit Disconnect Switch 5 5

Unit Circuit Breaker 5 5Conv. Outlet: Unpowered 2 2

Conv. Outlet: Powered 38 38TCI, LCI 1 1NOVAR 8 8

HPC 1 1Frostat 1 1

Crankcase Heater 1 1Smoke Detector, Return 7 7Smoke Detector, Supply 5 5

Clogged Filter Switch 1 1Fan Fail Switch 1 1

Discharge Air Tube 3 3Roofcurb 70 115

All Zone Sensors 3 1Hard Start Kit 3 N/AReheat Coil 15 25

Weight - Net lbs WARNINGHeavy Objects!

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

WARNINGImproper Unit Lift!

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

Figure 3Rigging and Center-of-Gravity Data

Foundation

Horizontal UnitsIf the unit is installed at ground level, elevate it above thesnow line. Provide concrete footings at each support locationwith a “full perimeter” support structure or a slab foundationfor support. Refer to Table 1 for the unit’s operating and pointloading weights when constructing a footing foundation.

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

For rooftop applications, ensure the roof is strong enough tosupport the combined unit and support structural weight. Re-fer to Table 1 for the unit operating weights. If anchoring is re-quired, anchor the unit to the roof with hold-down bolts orisolators.

Check with a roofing contractor for proper waterproofing pro-cedures.

15

Ductwork

Figures 4A & 4B illustrates the supply and return air open-ings.

Elbows with turning vanes or splitters are recommended tominimize air noise due to turbulence and to reduce staticpressure.

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

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

Figure 4A3 through 5 TonHorizontal Unit Supply & Return Air Openings

Figure 4B6 1/4 through 10 TonHorizontal Unit Supply & Return Air Openings

Installation

3 through 5 TonDownflow Unit Supply & Return Air Openings

6 1/4 through 10 TonDownflow Unit Supply & Return Air Openings

16

InstallationRoof Curb

DownflowThe 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 re-quired clearance for proper operation.

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

WARNINGCombustible Materials!Maintain proper clearance between the unit heat ex-changer, vent surfaces and combustible materials. Referto unit nameplate and installation instructions for properclearances. Improper clearances could result in a firehazard. Failure to maintain proper clearances could re-sult in death or serious injury or property damage.

5. Verify that appropriate materials were used in the con-struction of roof and ductwork. Combustible materialsshould not be used in the construction of ductwork or roofcurb that is in close proximity to heater elements or anyhot surface. Any combustible material on the inside of theunit base should be removed and replaced with appropri-ate material.

Step-by-step curb assembly and installation instructions shipwith each accessory roof curb kit. Follow the instructionscarefully to assure proper fit-up when the unit is set intoplace.

Note: To assure proper condensate flow duringoperation, the unit (and curb) must be level.

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

Recommendations for installing the Supply Air and ReturnAir ductwork joining the roof curb are included in the curb in-struction booklet. Curb ductwork must be fabricated and in-stalled by the installing contractor before the unit is set intoplace.

Note: For sound consideration, cut only the holes inthe roof deck for the ductwork penetrations. Do notcut out the entire roof deck within the curbperimeter.

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 returnair openings. Be sure to use flexible duct connectionsat the unit.

b. For “built-up” curbs supplied by others, gaskets mustbe installed around the curb perimeter flange and thesupply and return air opening flanges.

Rigging

A Rigging illustration and Center-of-Gravity dimensional datatable is shown in Figure 3. Refer to the typical unit operatingweights table before proceeding.

1. Remove all drill screws fastening wood protection to metalbaserail. Remove all screws securing wooden protectionto wooden top crate.

2. Remove Wooden Top Crate.

WARNINGHeavy Objects!

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

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

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

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

6. Lift the unit enough to allow the removal of two Fork Liftbrackets and hardware. Remove the two Fork Lift brack-ets, two metal runners and three wooden boards asshown in the following Figure.

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

17

Installation

General Unit Requirements

The checklist listed below is a summary of the steps requiredto successfully install a commercial unit. This checklist is in-tended to acquaint the installing personnel with what is re-quired in the installation process. It does not replace the de-tailed instructions called out in the applicable sections of thismanual.

[ ] Check the unit for shipping damage and material short-age; file a freight claim and notify appropriate sales repre-sentative.

[ ] Verify correct model, options and voltage from nameplate.

[ ] Verify that the installation location of the unit will providethe required clearance for proper operation.

[ ] Assemble and install the roof curb (if applicable). Refer tothe latest edition of the curb installers guide that shipswith each curb kit.

[ ] Fabricate and install ductwork; secure ductwork to curb.

[ ] Rigging the unit.

[ ] Set the unit onto the curb; check for levelness.

[ ] Ensure unit-to-curb seal is tight and without buckles orcracks.

[ ] Install and connect a condensate drain line to the evapora-tor drain connection.

Factory Installed Economizer

[ ] Ensure the economizer has been pulled out into the oper-ating position. Refer to the economizer installers guide forproper position and setup.

[ ] Install all access panels.

Temperature Limit Switch Usage for Electric HeatUnits

Units are factory shipped in the downflow dischargeconfriguration but can be field converted to a horizontaldischarge confriguration. Some, but not all units requirea different TC0-A limit switch, which is wire tied near theterminal block in the heater compartment if horizontaldischarge confriguration is used.

Note: The following units require a limit switchchange out for horizontal discharge. Theadditional limit switch is shipped attached to theblower housing. Proceed to the HorizontalDischarge Conversion, Step 5 on page 18 for thefollowing model / heater combination.

Unit Electric Heater Model Number Model Number

WSC072A4, 090A4 BAYHTRS427A, 436AWSC072AW, 090AW BAYHTRSW27, W36

WSC120A4 BAYHTRT454AWSC120AW BAYHTRTW54A

If any of the units listed in the preceding table are in-stalled in the downflow discharge configuration, removethe wire tied TCO-A near the terminal block in theheater compartment and discard.

18

InstallationHorizontal Discharge Conversion3 through 5 Ton Units

If a unit is to be converted to Horizontal discharge, the fol-lowing conversion must be preformed:

1. Remove the return and supply duct covers.

2. Apply white gasket to the supply duct cover as shown.White gasket is located in the Ship With bag located in thecontrol box.

3. Position duct covers as shown below. Rotate supply ductcover 90 degrees to allow it to be slid into supply opening.

Note: If unit is equipped with Discharge Air Sensingoption refer to the following figure for proper tubepositioning based on unit tonnage.

Note: If unit is equipped with Return Air SmokeDetector refer to field conversion for horizontaldischarge on page 20 before installing return airduct cover.

4. Slide duct covers into duct openings until endward edge ofthe duct cover engages with the 2 retaining clips on theduct flanges. Secure the outward edge of the each ductcover with 2 screws.

Note: Certain unit/electric heater combinationsrequire a limit switch change out for horizontalairflow applications. Refer to the followinginstructions to determine if this process is requiredfor the unit undergoing installation.

5. After completing installation of the duct covers for hori-zontal discharge,proceed to TCO-A instructions.

19

Horizontal Discharge Conversion6 Through 10 Ton Units

If a unit is to be converted to Horizontal discharge, the fol-lowing conversion must be preformed:

1. Remove the return and supply duct covers.

2. Apply white gasket to the supply duct cover as shown.White gasket is located in the Ship With bag located in thecontrol box.

3. Position duct covers as shown below. The supply ductcover is installed ( insulation side down ) over thedownflow return opening by engaging one side of thepanel under a retaining angle and securing the other sidewith 3 screws.

Note: If unit is equipped with Return Air SmokeDetector refer to field conversion for horizontaldischarge on page 20 before installing return airduct cover.

4. Slide return duct cover ( insulation side up ) into supplyopenings until endward edge of the duct cover engageswith the 2 retaining clips on the duct flanges. Secure theoutward edge of the each duct cover with 2 screws.

5. After completing installation of the duct covers for hori-zontal discharge, proceed to TCO-A instructions.

InstallationTCO-A Instructions:

If the unit being installed is listed in the following table and isequipped with the corresponding model number of factory in-stalled electric heater package in the table, the limit controlTCO-A must be replaced with the extra limit control shippedin the heater compartment. Replace TCO-A following the in-structions in steps 1through 3 below. If the unit being in-stalled does not have a factory installed electric heater pack-age or is equipped with a factory installed electric heatermodel that does not correspond to any in this table, skipsteps1 through 3 and go on to next step in the installationprocess.

Unit Electric Heater Model Number Model Number

WSC072A4, 090A4 BAYHTRS427A, 436AWSC072AW, 090AW BAYHTRSW27, W36

WSC120A4 BAYHTRT454AWSC120AW BAYHTRTW54A

1. Remove the heater section access panel and open theelectric heater dead front panel.

2. TCO-A is the limit control located in the central part of theheater mounting plate and that is located on the bottom ofthe two heater element assemblies. To replace this de-vice, first remove the two wires connected to the termi-nals. Next, remove the two screws which secure it to theheater element mounting plate. Once TCO-A has beenremoved form the heater element mounting plate, discardthis device.

3. Obtain the replacement TCO-A which is secured by awire tie near the electric heater terminal block in theheater compartment . Attach it to the heater elementmounting plate with the two screws that were removed instep 8 above. Connect the two wires that were un-hookedin step 8 to the terminals on the new TCO-A. Refer to theheater package wiring diagram to assure that the wiring isconnected properly.

4. Close the electric heater dead front panel and replaceheat section access panel.

20

Return Air Smoke Detector

The factory installed Return Air Smoke Detector is installedin the Downflow discharge position. No additional field setupis required.

If a unit is to be converted to Horizontal discharge, the fol-lowing conversion must be performed:

1. If the unit has an economizer, it must be pulled out in theoperating position.

2. Remove the 3 screws from the mounting brackets. Refer toDownflow View for screw locations.

3. Lift the tube and bracket from the downflow duct opening.Rotate the tube and bracket assembly 180° degrees en-suring that the holes on the copper sensing tube faceaway from the unit and face the return air ductwork. Referto Horizontal View.

Note: Check to insure that the flexible tubing lies flaton the base pan surface.

4. Slide the top bracket down the copper sensing tube, insertthe tab on the left side into the slot on the indoor coilblockoff and secure the right side of the bracket with oneof the 3 screws removed in step 2. Refer to HorizontalView.

5. Using the remaining 2 screws removed in step 2, securethe bottom bracket. Refer to Horizontal View.

Installation

21

Main Electrical Power Requirements

[ ] Verify that the power supply complies with the unit name-plate specifications.

WARNINGHazardous Voltage!

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

[ ] Inspect all control panel components; tighten any looseconnections.

[ ] Connect properly sized and protected power supply wiringto a field-supplied/installed disconnect switch and to themain power terminal block (HTB1) in the unit controlpanel.

[ ] Install proper grounding wires to an earth ground.

Note: All field-installed wiring must comply withNEC and applicable local codes.

Electric Heat Requirements

[ ] Verify that the power supply complies with the electricheater specifications on the unit and heater nameplate.

[ ] Inspect the heater junction box and control panel; tightenany loose connections.

[ ] Check electric heat circuits for continuity.

Low Voltage Wiring (AC & DC) Requirements

[ ] Install the zone thermostat, with or without switching sub-base.

[ ] Connect properly sized control wiring to the proper termi-nation points between the zone thermostat and the unitcontrol panel.

Condensate Drain Configuration

An evaporator condensate drain connection is provided oneach unit. Refer to Figure 3 for the appropriate drain location.

The condensate drain pan is factory installed to drain con-densate to the back side of the unit. See Figure 3. It can beconverted to drain condensate out the front side of the unit orthrough 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 panexits through.

3. Slide the condensate drain pan out of the unit and rotate180°.

4. Slide the condensate drain pan back into the unit, align thedrain with the grommeted opening in the rear support

Installationpanel and push until the coupling is seated in the grom-met.

5. Replace the front support panel by aligning the panel withtabs in the raceway. Align the condensate drain pan sup-port in the grommeted hole as the panel is put in place.

6. Replace evaporator access panel and supply air accesspanels.

To convert drain condensate through the base of unit:1. Remove evaporator access panel and supply air access

panels.

2. Remove the support panel that the condensate drain panexits through.

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

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

5. Remove the plug knockout in the bottom of the drainpan toconvert it to through the base drainage.

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

7. Slide the condensate drain pan back into the unit, align thedrain support with the grommeted opening in the rear sup-port panel and push until the support is seated in thegrommet.

8. Replace the front support panel by aligning the panel withtabs in the raceway. Align the plugged condensate drainpan coupling in the grommeted hole as the panel is put inplace.

9. Replace evaporator access panel and supply air accesspanels.

A condensate trap must be installed at the unit due to thedrain connection being on the “negative pressure” side of thefan. 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 for every 10 feet of hori-zontal run to assure proper condensate flow. Do not allow thehorizontal run to sag causing a possible double-trap condi-tion which could result in condensate backup due to “airlock”.

Figure 5Condensate Trap Installation

22

Filter Installation

Each unit ships with filters installed. The quantity of filters isdetermined by unit size. Access to the filters is obtained byremoving the indoor fan access panel. To modify the 3, 4 or 5ton unit’s filter rack to accept two inch filters, remove the L-shaped angle attachment screws and rotate the angles 90degrees.

Reinstall the screws and insert new filters. Refer to the unitService Facts (shipped with each unit) for filter requirements.

Note: Do not operate the unit without filters.

Field Installed Power WiringAn overall dimensional layout for the standard field installedwiring entrance into the unit is illustrated in Figure 2. To in-sure that the unit’s supply power wiring is properly sized andinstalled, follow the guidelines outlined below.

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

Verify that the power supply available is compatible with theunit’s nameplate ratings. The available supply power must bewithin 10% of the rated voltage stamped on the nameplate.Use only copper conductors to connect the power supply tothe unit.

CAUTIONUse Copper Conductors Only!

Unit terminals are not designed to accept other types ofconductors. Failure to use copper conductors may resultin equipment damage.

Failure to do so may cause damage to the equipment.

Note: If the unit is not equipped with an optionalfactory installed nonfused disconnect switch orcircuit breaker, a field supplied disconnect switchmust be installed at or near the unit in accordancewith the National Electrical Code (NEC latestedition).

Main Unit PowerStandard Wiring

1. Location of the applicable electrical service entrance is il-lustrated in Figure 2. Complete the unit’s power wiringconnections at Compressor Contactor # 1 (CC1) insidethe unit control panel. Refer to the customer connectiondiagram that is shipped with the unit for specific termina-tion points.

2. Provide proper grounding for the unit in accordance withlocal and national codes.

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

1. Location of the applicable electrical service is illustratedbelow. Refer to the customer connection diagram that isshipped with the unit for specific termination points. Thetermination points, depending on the customer option se-lected would be a factory mounted nonfused disconnectswitch (UDC) or circuit breaker (UCB). If neither a factorymounted nonfused disconnect switch (UDC) or circuitbreaker (UCB) was factory mounted, field wiring connec-tions should be terminated in the control box at Compres-sor Contactor # 1 (CC1).

2. Provide proper grounding for the unit in accordance withlocal and national codes.

Note: Black Gasket is shipped from the factory andis located in the literature Ship With bag in thecontrol box. Apply Black Gasket around conduitplate on all 4 sides after installation to prevent airleakage from the building entering the electricalenclosures.

Note: Seal between wiring and conduit with BlackGasket or weather proof sealer to prevent airleakage from the building entering the electricalenclosures. Also seal around conduit and wiring atall roof and curb penetrations.

Installation

23

Field Installed Control Wiring

An overall layout of the various control options available withthe required number of conductors for each control device isillustrated in Figure 6.

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

Control Power Transformer

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

WARNINGHazardous Voltage!

Disconnect all electric power, including remote discon-nects before servicing. Follow proper lockout/tagoutprocedures to ensure the power can not be inadvert-ently energized. Failure to disconnect power before ser-vicing could result in death or serious injury.

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

Controls using 24 VAC

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

a. Use copper conductors unless otherwise specified.

b. Ensure that the AC control wiring between the controlsand 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 conductormay cause component failure due to insufficient ACvoltage supply.

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

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

e. Route low voltage wiring per illustrations on page 25.

InstallationTable 2A - Electromechanical Thermostat24V AC Conductors with Reliatel

Distance from Unit Recommendedto Control Wire Size

000 - 460 feet 18 gauge

000 - 140 m .75 mm2

461 - 732 feet 16 gauge

Table 2B - Electromechanical Thermostat24V AC Conductors with Electromechanical Unit

Distance from RecommendedUnit to Control Wire Size

0 - 30 feet 22 gauge0 - 9.1 m .33 m2

31 - 50 feet 20 gauge9.5 - 15.2 m .50m2

51 - 75 feet 18 gauge

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

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

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

Note: Resistance in excess of 2.5 ohms perconductor can cause deviations in the accuracy ofthe controls.

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

c. Do not run the electrical wires transporting DC signals inor around conduit housing high voltage wires.

d. Route low voltage wiring per illustrations on page 25.

DC ConductorsTable 3

e Sensor Module wiringDistance from RecommendedUnit to Control Wire Size

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

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

241 -385 feet 18 gauge

24

Installation

Typical Field Wiring Diagrams for Electro Me-chanical Thermostat

Reliatel Conventional Thermostat Field WiringDiagrams

Reliatel Refrigeration Module

Typical Field Wiring Diagrams for Electro Me-chanical Thermostat

Note: If digit 9 in the unit model number equals "E"(Electro Mechanical Control), accessory relayBAY24X042 is required if the thermostat does notenergize the fan circuit in the heating mode. SeeFigure 1 for wiring information.

ReliaTel Relative Humidity Sensor(Dehumidification Option)

ReliaTel Humidistat(Dehumidification Option)

25

Electro Mechanical ControlCustomer Low Voltage Routing-

Reliatel ControlCustomer Low Voltage Routing-

Installation

26

InstallationSmoke Detector - (ReliaTel™ only)Customer Low Voltage Wiring-

When interlocking System Sensor smoke detectors together,all of the detectors must be powered from the same powersupply. If multiple smoke detectors are required, all detectorsmust be disconnected from the HVAC unit power supply andconnected together from another single source supply.

Note: Do not interconnect smoke detectors togetherthat have separate power supplies. Do not exceedten smoke detectors on one power supply.

Note: Multiple System Sensor smoke detectors areconnected together using terminals 1 and 12 oneach detector.

If you have supply and return smoke detectors in all HVACunits, you can connect a maximum of 5 HVAC units (10 de-tectors) up to one power supply. See the following field wiringexample below.

If you have more than 5 HVAC units, you can connect all thesupplies together on one power supply (up to 10 HVACunits), and all the returns together (up to 10 HVAC units) onanother power supply. See the following field wiring examplebelow.

27

Figure 6Typical Field Wiring Diagrams for Optional Controls (ReliaTel™ only)

Installation

28

InstallationSpace Temperature Averaging(ReliaTel™ only)

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

Using the BAYSENS016* or BAYSENS017*, at least foursensors are required to accomplish space temperatureaveraging. Example #1 illustrates two series circuits with twosensors in each circiut wired in parallel. The square of anynumber of remote sensors required. Example #2 illustratesthree sensors squared in a series/parallel circuit. UsingBAYSENS032*, two sensors are required to accomplishspace temperature averaging. Example #3 illustrates thecircuit required for this senor. Table 3-7 lists the temperatureversus resistance coefficient for all sensingUse the checklist provided below in conjunction with the“General Unit Requirements” checklist to ensure that the unitis properly installed and ready for operation.

29

InstallationTable 4Temperature versus Resistance(temperature vs resistance) Degrees F° Nominal Resistance

-20° 170.1 K - Ohms-15° 143.5 K - Ohms-10° 121.4 K - Ohms -5° 103.0 K - Ohms 0° 87.56 K - Ohms 5° 74.65 K - Ohms

10° 63.80 K - Ohms 15° 54.66 K - Ohms20° 46.94 K - Ohms25° 40.40 K - Ohms30° 34.85 K - Ohms35° 30.18 K - Ohms40° 26.22 K - Ohms45° 22.85 K - Ohms50° 19.96 K - Ohms55° 17.47 K - Ohms60° 15.33 K - Ohms65° 13.49 K - Ohms70° 11.89 K - Ohms75° 10.50 K - Ohms80° 9.297 K - Ohms85° 8.247 K - Ohms90° 7.330 K - Ohms95° 6.528 K - Ohms

100° 5.824 K - Ohms

30

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

WARNINGHazardous Voltage!

Disconnect all electric power, including remote discon-nects before servicing. Follow proper lockout/tagoutprocedures to ensure the power can not be inadvert-ently energized. Failure to disconnect power before ser-vicing could result in death or serious injury.

[ ] Check all electrical connections for tightness and “pointof termination” accuracy.

[ ] Verify that the condenser airflow will be unobstructed.

[ ] Verify that the condenser fan and indoor blower turnfreely without rubbing and are properly tightened on theshafts.

[ ] Check the supply fan belts for proper tension and the fanbearings for sufficient lubrication. If the belts require ad-justment, or if the bearings need lubricating, refer to themaintenance section of this manual for instructions.

[ ] Verify that a condensate trap is installed and the piping isproperly sized and pitched.

[ ] Verify that the correct size and number of filters are inplace.

[ ] 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 strin-gent requirements for the unit to operate properly. Measureeach leg (phase-to-phase) of the power supply. Each read-ing must fall within the utilization range stamped on the unitnameplate. If any of the readings do not fall within theproper tolerances, notify the power company to correct thissituation before operating the unit.

Excessive three phase voltage imbalance between phaseswill cause motors to overheat and eventually fail. The maxi-mum allowable voltage imbalance is 2%. Measure andrecord the voltage between phases 1, 2, and 3 and calcu-late the amount of imbalance as follows:

% Voltage Imbalance = 100 X AV - VD where;AV

AV (Average Voltage) = Volt 1 + Volt 2 + Volt 33

V1, V2, V3 = Line Voltage ReadingsVD = Line Voltage reading that deviates the farthestfrom the average voltage.

Example: If the voltage readings of the supply powermeasured 221, 230, and 227, the average volts would

Pre-startbe:

221 + 230 + 227 = 226 Avg.3

VD (reading farthest from average) = 221

The percentage of Imbalance equals:

100 X 226 - 221 = 2.2%226

The 2.2% imbalance in this example exceeds the maximumallowable imbalance of 2.0%. This much imbalance betweenphases can equal as much as a 20% current imbalance witha resulting increase in motor winding temperatures that willdecrease motor life. If the voltage imbalance is over 2%, notifythe proper agencies to correct the voltage problem before op-erating this equipment.

Electrical Phasing(Three Phase Motors)

The compressor motor(s) and the supply fan motor are inter-nally connected for the proper rotation when the incomingpower supply is phased as A, B, C.

Proper electrical supply phasing can be quickly determinedand corrected before starting the unit by using an instrumentsuch as an Associated Research Model 45 Phase SequenceIndicator and following the steps below:

[ ] Turn the field supplied disconnect switch that providespower to the main power terminal block or to the “Line”side of the optional factory mounted disconnect switch tothe “Off” position.

[ ] Connect the phase sequence indicator leads to the termi-nal block or to the “Line” side of the optional factorymounted disconnect switch as follows;

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

[ ] Close the field supplied main power disconnect switch orcircuit protector switch that provides the supply power tothe unit.

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions when ex-posed to live electrical components could result in deathor serious injury.

To prevent injury or death from electrocution, it is the respon-sibility of the technician to recognize this hazard and useextreme care when performing service procedures with theelectrical power energized.

31

[ ] Observe the ABC and CBA phase indicator lights on theface of the sequencer. The ABC indicator light will glow ifthe phase is ABC. If the CBA indicator light glows, open thedisconnect switch or circuit protection switch and reverseany two power wires.

[ ] Restore the main electrical power and recheck the phasing.If the phasing is correct, open the disconnect switch or cir-cuit protection switch and remove the phase sequence indi-cator.

Compressor Crankcase Heaters (Optional)

Each compressor can be equipped with a crankcase heater.The proper operation of the crankcase heater is important tomaintain an elevated compressor oil temperature during the“Off” cycle to reduce oil foaming during compressor starts. Oilfoaming occurs when refrigerant condenses in the compres-sor and mixes with the oil. In lower ambient conditions, refrig-erant migration to the compressor could increase.

When the compressor starts, the sudden reduction in crank-case pressure causes the liquid refrigerant to boil rapidlycausing the oil to foam. This condition could damage com-pressor bearings due to reduced lubrication and could causecompressor mechanical failures.

Before starting the unit in the “Cooling” mode, set the systemswitch to the “Off” position and turn the main power discon-nect to the “On” position and allow the crankcase heater tooperate a minimum of 8 hours.

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

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

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshootingof this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions when ex-posed to live electrical components could result in deathor serious injury.

To prevent injury or death from electrocution, it is the respon-sibility of the technician to recognize this hazard and use ex-treme care when performing service procedures with the elec-trical power energized.

Pre-startReliaTel ControlsUpon power initialization, the RTRM performs self-diagnos-tic checks to insure that all internal controls are functional. Italso checks the configuration parameters against the com-ponents connected to the system. The Liteport LED locatedon the RTRM module is turned “On” within one second ofpower-up if internal operation is okay.

Use one of the following “Test” procedure to bypass sometime delays and to start the unit at the control panel. Eachstep of unit operation can be activated individually by tem-porarily shorting across the “Test” terminals for two to threeseconds. The Liteport LED located on the RTRM modulewill blink when the test mode has been initiated. The unitcan be left in any “Test” step for up to one hour before it willautomatically terminate, or it can be terminated by openingthe main power disconnect switch. Once the test mode hasbeen terminated, the Liteport LED will glow continuouslyand the unit will revert to the “System” control.

Test Modes

There are three methods in which the “Test” mode can becycled at LTB-Test 1 and LTB-Test 2.

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

For the initial start-up of the unit, this method allows thetechnician to cycle a component “On” and have up to onehour to complete the check.

2. Resistance Test Mode - This method can be used forstart-up providing a decade box for variable resistanceoutputs is available. This method initiates the differentcomponents of the unit, one at a time, when a specificresistance value is placed across the two test terminals.The unit will remain in the specific test mode for approxi-mately one hour even though the resistance is left on thetest terminals.

3. Auto Test Mode - This method is not recommended forstart-up due to the short timing between individual com-ponent steps. This method initiates the different compo-nents of the unit, one at a time, when a jumper is in-stalled across the test terminals. The unit will start thefirst test step and change to the next step every 30 sec-onds. At the end of the test mode, control of the unit willautomatically revert to the applied "System" controlmethod.

For unit test steps, test modes, and step resistance valuesto cycle the various components, refer to Table 5.

32

Table 5Service Test Guide for Component Operation

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

MinimumFan On Position Off Off Off Off

1 Setpoint 2.2K0%

MinimumVentilation On Selectable Off Off Off Off

2 EconomizerTest Open On Open Off Off Off Off 3.3K

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

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

5(Note 3)

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

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

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

Reheat On Minimum On On Off Off 33K

Pre-start

Electro Mechanical ControlsTest Procedure

See unit schematic for correct wire numbers.

Fan Test and Minimum VentilationConnect red thermostat wire (R) to black thermostat wire(G).

Economizer CoolingConnect a jumper wire across OTS on Economizer Control(ECA) Connect red thermostat (R) wire to yellow thermostatwire (Y1).

Cool 1Connect red thermostat wire (R) to yellow thermostat wire(Y1).

Coo1 2Connect red thermostat wire (R) to yellow thermostat wire(Y2).

Heat 1Connect red thermostat wire (R) to brown thermostat wire(W1).

Heat 2Connect red thermostat wire (R) to brown thermostat wire(W2).

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

Much of the systems performance and reliability is closelyassociated with, and dependent upon having the proper air-flow supplied both to the space that is being conditioned andacross the evaporator coil.

The indoor fan motor is factory wired to operate on lowspeed in the cooling and heating mode. It can be rewired forhigh speed operation should the application require it. Referto the wiring diagram that shipped in the unit.

The indoor fan motors are specifically designed to operatewithin the BHP parameters listed in the fan performancetables of the unit Service Facts. By understanding that thesemotors will safely work within these conditions, before anoversized motor is required, will allow the air distribution sys-tem to be set up properly and diagnostics enhanced shoulda problem occur.

When verifying direct drive fan performance, the tables mustbe used somewhat differently than those of belt driven fans.Fan performance diagnostics can be easily recognized whenthese tables are used correctly.

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

33

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

Electro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections.

With the fan operating properly, determine the total systemexternal static pressure (inches w.c.) by;

1. Measuring the supply and return duct static pressure,

2. Using the accessory pressure drop table in the ServiceFacts, calculate the total static pressure drop for all of theaccessories installed on the unit; i.e., curb, economizer,etc.

Note: Static pressure is based on desired CFM andmay not be actual static pressure.

3. Add the total accessory static pressure drop (step 2) to theduct external static pressure (step 1). The sum of thesetwo values represents the total system external staticpressure.

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury.4. Measure the amperage at the supply fan contactor and

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

a. Calculate the theoretical BHP

Actual Motor Amps X Motor HP Motor Nameplate Amps

b. Using the fan performance tables in the unit Service Facts,plot the total external static pressure (step 3) and the BHP(step 4a) to obtain the operating CFM.

c. When plotted, if the two values can not be interpolated cor-respondingly, the static pressure will most likely be the

Pre-startleast accurate measurement. Because of the direct drivemotor operation, the RPM performance is relatively con-stant making the operating current a very reliable diagnos-tic tool.

Example: T_D060 single phase, low speed.

Actual Motor Amp (5.25) = .99%Motor Nameplate Amps (5.3)

0.99 X Motor HP (0.6) = .59 BHP

The actual external static pressure is approximately 0.45”w.c., airflow equals 2100 CFM.

If the static pressure reading was higher, motor currentwould have to be lower proportionately to get an accurateCFM measurement in direct drive applications.

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

a. Relieve supply and/or return duct static.

b. Change indoor fan speed to “High” and repeat steps 1through 4.

6. If the required CFM is too high, (external static pressure islow causing motor HP output to be above table value), in-crease supply and/or return duct static.

7. To stop the SERVICE TEST, turn the main power discon-nect switch to the “Off” position or proceed to the nextcomponent start-up procedure. Remove electro mechani-cal test mode connections (if applicable).

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

Much of the systems performance and reliability is closelyassociated with, and dependent upon having the proper air-flow supplied both to the space that is being conditioned andacross the evaporator coil.

The indoor fan speed is changed by opening or closing theadjustable motor sheave.

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

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

34

Pre-startElectro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections.

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

With the fan operating properly, determine the total systemairflow (CFM) by;

1. Measuring the actual RPM,

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

a. Calculate the theoretical BHP

Actual Motor Amps X Motor HPMotor Nameplate Amps

b. Using the fan performance tables in the unit ServiceFacts, plot the actual RPM (step 1) and the BHP (step2a) to obtain the operating CFM.

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

a. Relieve supply and/or return duct static.

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

1. To Increase Fan RPM; Loosen the pulley adjustment setscrew and turn sheave clockwise.

2. To Decrease Fan RPM; Loosen the pulley adjustment setscrew and turn sheave counterclockwise.

3. If the required CFM is too high, (external static pressure islow causing motor HP output to be above table value),change indoor fan speed and repeat steps 1 and 2.

4. To stop the SERVICE TEST, turn the main power discon-nect switch to the “Off” position or proceed to the nextcomponent start-up procedure. Remove electro mechani-cal test mode connections (if applicable).

35

Return Air Smoke DetectorThe return air smoke detector is designed to shut off the unitif smoke is sensed in the return air stream. Sampling the air-flow entering the unit at the return air opening performs thisfunction.

In order for the smoke detector to properly sense smoke inthe return air stream, the air velocity entering the unit mustbe between 500 and 4000 feet per minute. Equipment cov-ered in this manual will develop an airflow velocity that fallswithin these limits over the entire airflow range specified inthe evaporator fan performance tables.

There are certain models however, if operated at low airflow,will not develop an airflow velocity that falls within the re-quired 500 to 4000 feet per minute range. For these models,the design airflow shall be greater than or equal to the mini-mum CFM specified in the table provided below. Failure tofollow these instructions will prevent the smoke detector fromperforming its design function.

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

Electro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections.

1. Set the minimum position setpoint for the economizer tothe required percentage of minimum ventilation using thesetpoint potentiometer located on the Economizer Control(ECA).

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

WARNINGRotating Components!

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

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

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

ReliaTel Control Momentarily jump across the Test 1 & Test 2 terminals

on LTB one additional time if continuing from previouscomponent start-up or until the desired start-upcomponent Test is started.

Electro Mechanical ControlUsing the Service Test Guide perform the proper testmode connections.

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

4. To stop the SERVICE TEST, turn the main power discon-nect switch to the “Off” position or proceed to the nextcomponent start-up procedure. Remove electro mechani-cal test mode connections (if applicable).

Compressor Start-Up

1. Attach a set of service gauges onto the suction and dis-charge gauge ports for each circuit. Refer to the refriger-ant circuit illustration in the Service Facts.

ReliaTel ControlUsing the Service Test Guide in Table 5, continue theSERVICE TEST start-up procedure for each compressorcircuit.

Momentarily jump across the Test 1 & Test 2 terminals onLTB1 one additional time if continuing from previous compo-nent start-up or until the desired start-up component Test isstarted.

Electro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections.

Scroll Compressorsa. Once each compressor has started, verify that the rotation

is correct. If a scroll compressor is rotating backwards, itwill not pump and a loud rattling sound can be observed.

b. If the electrical phasing is correct, before condemning acompressor, interchange any two leads (at the compres-sor Terminal block) to check the internal phasing. Refer tothe illustration in Figure 5-1 for the compressor terminal/phase identification. If the compressor runs backward foran extended period (15 to 30 minutes), the motor windingcan overheat and cause the motor winding thermostat toopen.

c. Check the compressor oil levels. The oil level in each com-pressor sight glass should be 1/2 to 3/4 full when they are“Off”.

The scroll compressor uses Trane OIL-42 withoutsubstitution. The appropriate oil charge for a 9 and10 Ton scroll compressor is 8 pints. For a 14 and 15Ton scroll compressor, use 14 pints.

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

3. Check system superheat. Follow the instruction listed onthe superheat charging curve in the Service Facts.

Superheat should be within ±5 F of the superheat chartvalue.

4. Repeat steps 1 through 4 for each refrigerant circuit.

5. To stop the SERVICE TEST, turn the main power discon-nect switch to the “Off” position or proceed to the nextcomponent start-up procedure. Remove electro mechani-cal test mode connections (if applicable).

Start-Up

36

Dehumidification OptionMomentarily jump across the Test 1 and Test 2 terminals ofthe LTB1 until the unit enters test mode 7. (See Table 6.)Once the unit is in the reheat test mode, verify that the 3 wayvalve has shifted to the reheat position and that the supplytemperature rises 10 deg F more than when in cooling modestage 2. Monitor the suction pressure for 15 minutes. Thesuction pressure should remain within 5 psi of normal coolingoperation. If the unit has a 2 speed Outdoor fan and if theOutdoor air temperature is below 70° F, verify that the ODfan is in low speed.

Heating Start-Up

1. Clamp an amp meter around one of 1st stage heaterpower wires at the heater contactor.

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury.

2. ReliaTel ControlUsing the Service Test Guide in Table 5, continue the SER-VICE TEST start-up procedure for each compressor circuit.Momentarily jump across the Test 1 & Test 2 terminals onLTB one additional time if continuing from previous compo-nent start-up or until the desired start-up component Test isstarted.

Electro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections;

3. Verify that the heater stage is operating properly.

4. Clamp an amp meter around one of 2nd stage heaterpower wires at the heater contactor (if applicable).

5. ReliaTel Control Using the Service Test Guide in Table 5, continue the

SERVICE TEST start-up procedure for each compressorcircuit. Momentarily jump across the Test 1 & Test 2 termi-nals on LTB one additional time if continuing from previ-ous component start-up or until the desired start-up com-ponent Test is started.

Start-Up

Electro Mechanical ControlUsing the Service Test Guide perform the proper test modeconnections;

6. Verify that the heater stage is operating properly

7. To stop the SERVICE TEST, turn the main power discon-nect switch to the “Off” position or proceed to the nextcomponent start-up procedure. Remove electro mechani-cal test mode connections (if applicable).

Final System SetupAfter completing all of the pre-start and start-up proceduresoutlined in the previous sections (i.e., operating the unit ineach 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) forproper unoccupied operation. Refer to the programminginstructions for the specific panel.

[ ] Verify that the Remote panel “System” selection switch,“Fan” selection switch, and “Zone Temperature” settingsfor automatic operation are correct.

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

[ ] Verify that all exterior panels including the control paneldoors and condenser grilles are secured in place.

[ ] Close the main disconnect switch or circuit protectorswitch that provides the supply power to the unit’s terminalblock or the unit mounted disconnect switch.

37

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury.

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

Fan Belt Adjustment - Belt Drive Units

WARNINGRotating Components!

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

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

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

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

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

1. To determine the appropriate belt deflection;

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

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

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

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

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

Maintenance

5. Remove the belt tension gauge. The small O-ring now indi-cates a number other than zero on the plunger’s forcescale. This number represents the force (in pounds) re-quired to give the needed deflection.

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

Note: Actual belt deflection “force” must not exceedthe maximum “force” value shown inTable 6.

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

Figure 7Belt Tension Gauge

Table 6Belt Tension Measurement and Deflection Ranges

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

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

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

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

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

38

Monthly Maintenance

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

WARNINGRotating Components!

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

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

Filters

[ ] Inspect the return air filters. Clean or replace them if nec-essary. Refer to the unit Service Facts for filter informa-tion.

Return Air Smoke Detector Maintenance

Airflow through the unit is affected by the amount of dirt anddebris accumulated on the indoor coil and filters. To insurethat airflow through the unit is adequate for proper samplingby the return air smoke detector, complete adherence to themaintenance procedures, including recommended intervalsbetween filter changes, and coil cleaning is required.

Periodic checks and maintenance procedures must be per-formed on the smoke detector to insure that it will functionproperly. For detailed instructions concerning these checksand procedures, refer to the appropriate section(s) of thesmoke detector Installation and Maintenance Instructionsprovided with the literature package for this unit.

Cooling Season

[ ] Check the unit’s drain pans and condensate piping to en-sure that there are no blockages.

[ ] Inspect the evaporator and condenser coils for dirt, bentfins, etc. If the coils appear dirty, clean them according tothe instructions described in “Coil Cleaning” later in thissection.

[ ] Manually rotate the condenser fan(s) to ensure free move-ment and check motor bearings for wear. Verify that all ofthe fan mounting hardware is tight.

[ ] Inspect the F/A-R/A damper hinges and pins to ensurethat all moving parts are securely mounted. Keep theblades clean as necessary.

[ ] Verify that all damper linkages move freely; lubricate withwhite grease, if necessary.

[ ] Check supply fan motor bearings; repair or replace themotor as necessary.

[ ] Check the fan shaft bearings for wear. Replace the bear-ings as necessary.

Maintenance

[ ] Check the supply fan belt. If the belt is frayed or worn, re-place it. Refer to the “Fan Belt Adjustment” section for beltreplacement and adjustments.

[ ] Verify that all wire terminal connections are tight.

[ ] Remove any corrosion present on the exterior surfaces ofthe 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 theunit access panels once these checks are complete.

[ ] With the unit running, check and record the: ambient tem-perature; compressor suction and discharge pressures(each circuit); superheat (each circuit);

Record this data on an “operator’s maintenance log” like theone shown in Table 7. If the operating pressures indicate arefrigerant shortage, measure the system superheat. Forguidelines, refer to the “Compressor Start-Up” section.

Note: Do Not release refrigerant to the atmosphere!If adding or removing refrigerant is required, theservice technician must comply with all federal,state and local laws.

Heating Season

[ ] Inspect the unit’s air filters. If necessary, clean or replacethem.

[ ] Check supply fan motor bearings; repair or replace themotor as necessary.

[ ] Inspect both the main unit control panel and heat sectioncontrol box for loose electrical components and terminalconnections, as well as damaged wire insulation. Makeany necessary repairs.

[ ] Verify that the electric heat system operates properly.

Coil Cleaning

Regular coil maintenance, including annual cleaning, en-hances the unit’s operating efficiency by minimizing: com-pressor head pressure and amperage draw; evaporator wa-ter carryover; fan brake horsepower, due to increase staticpressure losses; airflow reduction.

At least once each year, or more often if the unit is located ina “dirty” environment, clean the evaporator and condensercoils using the instructions outlined below. Be sure to followthese instructions as closely as possible to avoid damagingthe coils.

39

Note: For units equipped with hail guards followremoval procedure listed below.

Hail Guard Removal� To remove the hail guards, turn all bail-style fasteners 90

degrees counter-clockwise.

� Pull the top of the hail guard outward until the fastenerstuds are free of the retaining nuts.

��Lift the hail guard from the lower retaining bracket and setaside.

To clean refrigerant coils, use a soft brush and a sprayer (ei-ther a garden pump-up type or a high-pressure sprayer). Ahigh-quality detergent is also required; suggested brands in-clude “SPREX A.C.”, “OAKITE 161”, “OAKITE 166” and“COILOX”. If the detergent selected is strongly alkaline (phvalue exceeds 8.5), add an inhibitor.

WARNINGHazardous Chemicals!

Coil cleaning agents can be either acidic or highly alka-line. Handle chemical carefully. Proper handling shouldinclude goggles or face shield, chemical resistantgloves, boots, apron or suit as required. For personalsafety refer to the cleaning agent manufacturer’s Materi-als Safety Data Sheet and follow all recommended safehandling practices. Failure to follow all safety instruc-tions could result in death or serious injury.

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

2. Protect all electrical devices such as motors and control-lers from any over spray.

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

4. Mix the detergent with water according to themanufacturer’s instructions. If desired, heat the solutionBUT DO NOT EXCEED 150 F maximum to improve itscleansing capability.

WARNINGHazardous Pressures!

Coils contain refrigerant under pressure. When cleaningcoils, maintain coil cleaning solution temperature under150°F to avoid excessive pressure in the coil. Failure tofollow these safety precautions could result in coilbursting, which could result in death or serious injury.

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

Maintenance

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

a. do not allow sprayer pressure to exceed 600 psi.

b. the minimum nozzle spray angle is 15 degrees.

c. maintain a minimum clearance of 6" between thesprayer nozzle and the coil.

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

6. Spray the leaving-airflow side of the coil first; then spraythe opposite side of the coil. Allow the cleaning solution tostand 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 inStep 1 and any protective covers installed in step 2.

Note: For units equipped with hail guards followreinstallation procedure listed below.

Hail Guard Reinstallation� To reinstall the hail guard, locate the bottom of the hail

guard in the lower bracket and secure it to the upper unitbracket with the attached fasteners.

Note: Orient the fastener latch handle vertically.Push the fastener into the recievers and turn 90degrees clockwise to secure.

HAIL GUARD

10. Restore the unit to it’s operational status and check sys-tem operation.

40

For units with the Dehumidification OptionFor access to the leaving face of the evaporator, locate thereheat coil, locking bracket above the reheat coil. Thisbracket attaches the reheat coil to the Evaporator topblockoff. Initially there are 2 screws approximately 2 inchesfrom the top of the unit. Remove and discard the screw onthe left, which is in place for shipping. Loosen the screw onthe right. Do not remove. Slide the locking bracket towardsthe front of the unit to unlock the coil. Pivot the reheat coil tothe vertical position to access the evaporator face.

Note: Clean the reheat coil on the same interval andmethod as the evaporator coil.

Replace the reheat coil to its proper location once cleaning iscomplete. Align the screw heads in the top of the reheat coilwith the slots in the evaporator top blockoff. Press the coilassembly into place and verify that the reheat coil is flushagainst the evaporator top blockoff. Set the locking bracketon the top of the reheat coil flush with the evaporator coil topblockoff. Apply pressure to the center of the bracket andslide the bracket towards the rear of the unit. Tighten thescrew to secure the bracket and the coil in place.

MaintenanceFinal Process

For future reference, you may find it helpful to record the unitdata requested below in the blanks provided.(1) Complete Unit Model Number:

(2) Unit Serial Number:

(3) Wiring Diagram Numbers (from unit control pane

— schematic(s)

— connection(s)

Table 7Sample Maintenance Log

Refrigerant Circuit #1 Refrigerant Circuit #2 Current

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

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

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

- ok - ok- low - low

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

41

Trouble ShootingReliaTel ControlThe RTRM has the ability to provide the service personnelwith some unit diagnostics and system status information.

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

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury.

To prevent injury or death from electrocution, it is the respon-sibility of the technician to recognize this hazard and use ex-treme care when performing service procedures with theelectrical power energized.

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

2. If the LED is not lit, verify that 24 VAC is presence be-tween J1-1 and J1-2. If 24 VAC is present, proceed toStep 3. If 24 VAC is not present, check the unit mainpower supply, check transformer (TNS1). Proceed to Step3 if necessary.

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

System statusHeating statusCooling status

If a System failure is indicated, proceed to Step 4. If nofailures are indicated, proceed to Step 5.

4. If a System failure is indicated, recheck Steps 1 and 2. Ifthe LED is not lit in Step 1, and 24 VAC is present in Step2, the RTRM has failed. Replace the RTRM.

5. If no failures are indicated, use one of the TEST mode pro-cedures described in the “Unit Start-Up” section to startthe unit. This procedure will allow you to check all of theRTRM outputs, and all of the external controls (relays,contactors, etc.) that the RTRM outputs energize, for eachrespective mode. Proceed to Step 6.

6. Step the system through all of the available modes, andverify operation of all outputs, controls, and modes. If aproblem in operation is noted in any mode, you may leavethe system in that mode for up to one hour while trouble-shooting. Refer to the sequence of operations for eachmode, to assist in verifying proper operation. Make thenecessary repairs and proceed to Steps 7 and 8.

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

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

System Status Checkout Procedure

“System Status” is checked by using one of the following twomethods:

Method 1

If the Zone Sensor Module (ZSM) is equipped with a remotepanel with LED status indication, you can check the unitwithin the space. If the ZSM does not have LED’s, useMethod 2. BAYSENS010B, BAYSENS011B, BAYSENS019A,BAYSENS020A, BAYSENS021A & BAYSENS023A all havethe remote panel indication feature. The LED descriptionsare listed below.

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

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

LED 3 (Cool)“On” when the cooling cycle is operating.“Off” when the cooling cycle terminates or the LED fails.“Flashing” indicates a cooling failure.

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

Below is the complete listing of failure indication causes.

System FailureCheck the voltage between terminals 6 and 9 on J6, it shouldread approximately 32 VDC. If no voltage is present, a Sys-tem failure has occurred. Refer to Step 4 in the previous sec-tion for the recommended troubleshooting procedure.

Cooling Failure1. Cooling and heating set point (slide pot) on the zone sen-

sor has failed. Refer to the “Zone Sensor Test Procedure”section.

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

3. CC1 or CC2 24 VAC control circuit has opened, checkCC1 & CC2 coils, and any of the controls below that applyto the unit (HPC1, HPC2).

4. LPC1 has opened during the 3 minute minimum “on time”during 4 consecutive compressor starts, check LPC1 orLPC2 by testing voltage between the J1-8 & J3-2 termi-nals on the RTRM and ground. If 24 VAC is present, theLPC’s has not tripped. If no voltage is present, LPC’s hastripped.

42

Service Failure1. 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 Failure1. Emergency Stop is activated.

Method 2

The second method for determining system status is done bychecking voltage readings at the RTRM (J6). The system in-dication descriptions and the approximate voltages are listedbelow.

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

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

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

Service FailureMeasure the voltage between terminals J6-10 & J6-6.Clogged Filter = Approximately 32 VDC.Normal = Less than 1 VDC, approximately 0.75 VDC FanFailure = voltage alternates between 32 VDC & 0.75 VDC.

To use LED’s for quick status information at the unit, pur-chase a BAYSENS010B ZSM and connect wires with alliga-tor clamps to terminals 6 through 10. Connected each re-spective terminal wire (6 through 10) from the Zone Sensorto the unit J6 terminals 6 through 10.

Note: If the system is equipped with aprogrammable zone sensor, (BAYSENS019A,BAYSENS020A or BAYSENS023A), the LEDindicators will not function while the BAYSENS010Ais connected.

Trouble Shooting

Resetting Cooling and Heating Lockouts

Cooling Failures and Heating Lockouts are reset in an identi-cal manner. Method 1 explains resetting the system from thespace; Method 2 explains resetting the system at the unit.

Note: Before resetting Cooling Failures and HeatingLockouts check the Failure Status Diagnostics bythe methods previously explained. Diagnostics willbe lost when the power to the unit is disconnected.

Method 1

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

Method 2

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

Lockouts can be cleared through the building managementsystem. Refer to the building management system instruc-tions for more information.

Zone Temperature Sensor (ZTS) Service Indicator

The ZSM SERVICE LED is a generic indicator, that will sig-nal the closing of a Normally Open switch at any time, pro-viding the Indoor Motor (IDM) is operating. This indicator isusually used to indicate a clogged filter, or an air side fan fail-ure.

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

Clogged Filter SwitchThis LED will remain lit the entire time that the NormallyOpen switch is closed. The LED will be turned off immedi-ately after resetting the switch (to the Normally Open posi-tion), or any time that the IDM is turned “Off”.

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

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

43

Trouble Shooting

Fan Failure SwitchWhen the “Fan Failure” switch is wired to the RTOM, the LEDwill remain flashing the entire time the fan proving switch isclosed, indicating a fan failure, and it will shut the unit opera-tions down.

Zone Temperature Sensor (ZTS) Test

Note: These procedures are not for programmable ordigital models and are conducted with the ZoneSensor Module electrically removed from thesystem.

Test 1Zone Temperature Thermistor (ZTEMP)

This component is tested by measuring the resistance be-tween terminals 1 and 2 on the Zone Temperature Sensor.Below are some typical indoor temperatures, and corre-sponding resistive values.

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

N o m in a l Z T E M P R e s is t a n c e

5 0 F ° 1 0 .0 C 1 9 .9 K - O h m s 5 5 F 1 2 .8 C 1 7 .4 7 K - O h m s6 0 F 1 5 .6 C 1 5 .3 K - O h m s 6 5 F 1 8 .3 C 1 3 .4 9 K - O h m s7 0 F 2 1 .1 C 1 1 .9 K - O h m s 7 5 F 2 3 .9 C 1 0 .5 0 K - O h m s8 0 F 2 6 .7 C 9 .3 K - O h m s 8 5 F 2 9 .4 C 8 .2 5 K - O h m s9 0 F 3 2 .2 C 7 .3 K - O h m s

Z o n e T e m p e r a t u r e

The resistance of these potentiometers are measured be-tween the following ZSM terminals. Refer to the chart abovefor approximate resistances at the given setpoints.

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

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

Test 3System Mode and Fan Selection

The combined resistance of the Mode selection switch andthe Fan selection switch can be measured between terminals2 and 4 on the Zone Sensor. The possible switch combina-tions are listed below with their corresponding resistance val-ues.

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

Method 1

Testing the LED using a meter with diode test function. Testboth forward and reverse bias. Forward bias should measurea voltage drop of 1.5 to 2.5 volts, depending on your meter.Reverse bias will show an Over Load, or open circuit indica-tion if LED is functional.

Method 2

Testing the LED with an analog Ohmmeter. Connect Ohm-meter across LED in one direction, then reverse the leads forthe opposite direction. The LED should have at least 100times more resistance in reverse direction, as compared withthe 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 atLED terminals on ZSM. A measurement of 32 VDC, acrossan unlit LED, means the LED has failed.

Relative Humidity Sensor TestThis component is measured by measuring the mA outputsignal on the Relative Humidity Sensor. Verify accuracy ofthe sensor annually. If the output reading is 0 mA, first verifythat power is applied to the sensor. A reading of 4 mAcorresponds to 0% RH and 20 mA corresponds to 100% RH.

% RH mA30 8.840 10.450 12.060 13.670 15.280 16.8

Note: Measurements should be made from LEDcommon (ZSM terminal 6 to respective LEDterminal). Refer to the Zone Sensor Module (ZSM)Terminal Identification table at the beginning of thissection.

44

Trouble ShootingProgrammable & Digital Zone Sensor Test

Testing serial communication voltage1. Verify 24 VAC is present between terminals J6-14 & J6-11.

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

3. Reconnect wires to terminals J6-11 and J6-12. Measurevoltage again between J6-11 and J6-12, voltage shouldflash high and low every 0.5 seconds. The voltage on thelow end will measure about 19 VDC, while the voltage onthe high end will measure from approximately 24 to 38VDC.

4. Verify all modes of operation, by running the unit throughall 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 thebutton with the fan symbol. If the fan comes on and runscontinuously, the ZSM is good. If you are not able to turnthe fan on, the ZSM is defective.

ReliaTel Refrigeration Module (RTRM) Default Chart

If the RTCI loses input from the building management sys-tem, the RTRM will control in the default mode after approxi-mately 15 minutes. If the RTRM loses the Heating and Cool-ing setpoint input, the RTRM will control in the default modeinstantaneously. The temperature sensing thermistor in theZone 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 econo-mizer and condenser fan cycling functions are disabled.

1. Open and Lock the unit disconnect switch.

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

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

4. Locate the RTRM (J6). Connect two (2) wires to terminalsJ6-1 and 2.

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

Unit Economizer Control (ECA) TroubleshootingReliaTel Control

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

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

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

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

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

Electro Mechanical Control

WARNINGLive Electrical Components!

During installation, testing, servicing and troubleshoot-ing of this product, it may be necessary to work with liveelectrical components. Have a qualified licensed electri-cian or other individual who has been properly trained inhandling live electrical components perform these tasks.Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury.

To prevent injury or death from electrocution, it is the respon-sibility of the technician to recognize this hazard and use ex-treme care when performing service procedures with theelectrical power energized.

Cooling Failure1. Cooling and heating set point (slide pot) on the thermostat

has failed.

2. CC1 or CC2 24 VAC control circuit has opened, checkCC1 & CC2 coils, and any of the controls below that applyto the unit (HPC1, HPC2, LPC1, LPC2, Frostat™).

45

Resetting Cooling and Heating LockoutsCooling Failures and Heating Lockouts are reset in an identi-cal manner. Method 1 explains resetting the system from thespace; Method 2 explains resetting the system at the unit.

Method 1

To reset the system from the space, turn the “Mode” selec-tion switch at the thermostat to the “Off” position. After ap-proximately 30 seconds, turn the “Mode” selection switch tothe desired mode, i.e. Heat, Cool or Auto.

Method 2

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

Unit Economizer Control (ECA) Test ProceduresElectro Mechanical Control

This series of tests will allow you to diagnose, and determinewhere, and if a problem exists in the system economizer op-eration. Test 1 determines if the problem is in the Unit, or if itis in the ECA. Test 2 tests sensor inputs. Test 3 tests the re-sistors and sensors. Conduct the tests in numerical order un-til problem is found.

Test 1Verifying that the economizer actuator (ECA) is functional:

1. Using the “Test Mode” described in the “System Start-Up”section, put the unit into the economizer mode and verifythat the economizer actuator (ECA) drives fully open (ap-proximately 90 seconds).

2. If the ECA is not driving the dampers, verify that 24 VAC isbetween the ECA terminals TR and TR1 is present. If 24volts is not present, a wiring or terminal problem existsfrom the control transformer. Make any necessary repairs,see wiring diagrams to troubleshoot.

3. If 24 VAC is present, adjust the minimum position potenti-ometer fully clockwise. If the actuator does not drive, theeconomizer actuator is bad. Replace the ECA.

Test 2Testing the ECA resistors and sensors

1. Testing the Mixed Air Sensor (MAS). Disconnect the wiresconnected to T and T1 on the ECA, and;

a. Measure the resistance of the sensor between the wires180B and 181B.

b. Measure the temperature at the MAS location. Using theTemperature versus Resistance chart, verify the accuracyof the MAS.

Replace the sensor if it is out of range.

Trouble Shooting

2. Testing the Outdoor Air Switch. If the temperature is above60 degrees, it will need to be chilled. Measure the resis-tance of the sensor on the ECA SO and +.

The resistance should be approximately 390 Ohms.

Replace the Switch if it is open.

Replace the ECA if it is out of range.

3. Testing the R1 Resistance.

Measure the resistance of the sensor on the ECA SR and +.

The resistance should be approximately 420 Ohms.

Replace the ECA if it is out of range.

4. Testing the R2 Resistance.

Measure the resistance of the sensor on the ECA P andP1.

The resistance should be approximately 130 Ohms.

Replace the ECA if it is out of range.

46

Limited Warranty

Central Air ConditionerTCY, TCX, TCC, TCD, TCH, TCM,TCP, TSC and THC (Parts Only)Models Less Than 20 Tons for Residential Use*

This limited warranty is extended by American Standard Inc., to the original purchaser and to any succeeding owner ofthe real property to which the Air Conditioner is originally affixed, and applies to products purchased and retained for usewithin the U.S.A. and Canada.

If any part of your Air Conditioner fails because of a manufacturing defect within five years from the date of the originalpurchase, Warrantor will furnish without charge the required replacement part. Any local transportation, related servicelabor, diagnosis calls, refrigerant and related items are not included.

If the sealed motor-compressor fails because of a manufacturing defect within five years from the date of originalpurchase, Warrantor will furnish without charge the required replacement compressor. Any local transportation, relatedservice labor, diagnosis calls, refrigerant and related items are not included.

This limited warranty does not cover failure of your Central Air Conditioner if it is damaged while in your possession,failure attributable or caused by unreasonable use of the Central Air Conditioner and/or failure to properly maintain theCentral Air Conditioner as set forth in the Use and Care manual.

This limited warranty applies to product installed on or after 10/1/2001 where product is manufactured after 1/1/2000. Thislimited warranty is not retroactive to any installations prior to 10/1/2001 or on product produced prior to 2000.

THE LIMITED WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES ANDLIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDINGBUT NOT SPECIFICALLY LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORPARTICULAR USE, AND IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIALDAMAGES.

Some states do not allow limitations on how long an implied limited warranty lasts or do not allow the exclusion orlimitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This limitedwarranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Parts will be provided by our factory organization through an authorized service organization in your area listed in theyellow pages. If you wish further help or information concerning this limited warranty, contact:

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

GW-609-4001

* This limited warranty is for residential usage of this equipment and not applicable when this equipment is used for acommercial application. A commercial use is any application where the end purchaser uses the product for other thanpersonal, family or household purposes.

47

Limited Warranty

Central Air ConditionerTCY, TCX, TCC, TCD, TCH, TCK, TCM,TCP, TSC and THC (Parts Only)Models Less Than 20 Tons for Commercial Use*

This warranty is extended by American Standard Inc., to the original purchaser and to any succeeding owner of the real prop-erty to which the Air Conditioner is originally affixed, and applies to products purchased and retained for use withinthe U.S.A. and Canada. There is no warranty against corrosion, erosion or deterioration.

If any part of your Air Conditioner fails because of a manufacturing defect within one year from the date of the original pur-chase, Warrantor will furnish without charge the required replacement part.

In addition, if the sealed motor-compressor fails because of a manufacturing defect within the second through fifth year fromthe date of original purchase, Warrantor will furnish without charge the required replacement compressor.Warrantor’s obligations and liabilities under this warranty are limited to furnishing F.O.B. Warrantor factory or warehouse re-placement parts for Warrantor’s products covered under this warranty. Warrantor shall not be obligated to pay forthe cost of lost refrigerant. No liability shall attach to Warrantor until products have been paid for and then liability shall be lim-ited solely to the purchase price of the equipment under warranty shown to be defective.

THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES,WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING BUT NOTSPECIFICALLY LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE,AND IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied warranty lasts or do specific legal rights, and you may also haveother rights which vary from state to state.

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

GW-602-4800* This warranty is for commercial usage of said equipment and not applicable when the equipment is used for a residential ap-plication. Commercial use is any application where the end purchaser uses the product for other than personal, family orhousehold purposes.

48