Trane EBC036-060 Packaged Rooftop Air Conditioners Foundation Installation Guide

Trane EBC036-060 Packaged Rooftop Air Conditioners Foundation

Product Specifications

• Model Number: EBC036-060
• Product Type: Packaged Rooftop Air Conditioner
• Cooling Capacity: 3 to 5 Tons
• Electric Heat: Yes
• Frequency: 60 Hz

Product Usage Instructions

Installation

• Only qualified personnel should install the equipment. Follow all safety warnings and guidelines provided in the manual. Ensure proper field wiring and grounding as per NEC and local codes.
  

Operation

• Read the manual thoroughly before operating the unit. Make sure to comply with all safety advisories and precautions mentioned in the manual.
  

Maintenance

• Regular maintenance is essential for the proper functioning of the equipment. Follow the maintenance schedule outlined in the manual and keep the unit clean and well-maintained.

Frequently Asked Questions

Q: Who should install and service the equipment?
A: Only qualified personnel should install and service the equipment. Improper installation or servicing could result in hazards.

Q: What precautions should be taken during installation?
A: Ensure proper field wiring and grounding as described in the NEC and local electrical codes. Failure to do so could pose fire and electrocution hazards.

Q: How often should maintenance be performed?
A: Regular maintenance should be performed as per the outlined schedule in the manual to ensure optimal performance of the equipment.

Introduction

• Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

• Safety advisories appear throughout this manual as required. Your safety and the proper operation of this machine depend upon the strict observance of these precautions.
• The three types of advisories are defined as follows:
• WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.
• NOTICE Indicates a situation that could result in equipment or property damage only accidents.

Important Environmental Concerns

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

Important Responsible Refrigerant Practices

• Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules.
• For the USA, the Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering, and recycling certain refrigerants and the equipment that is used in these service procedures.
• In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.
• WARNING Proper Field Wiring and Grounding Required!
• Failure to follow the code could result in death or serious injury.
• All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards.
• To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

Personal Protective Equipment (PPE) Required!

• Failure to wear proper PPE for the job being undertaken could result in death or serious injury.
• Technicians, to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:
• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut-resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE, and arc flash clothing).
• ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.
• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.
• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit.
• NEVER PERFORM ANY  SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING.
• ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.
• WARNING Follow EHS Policies!
• Failure to follow instructions below could result in death or serious injury.
• All Trane personnel must follow the company’s Environmental, Health, and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc.
• Where local regulations are more stringent than these policies, those regulations supersede these policies.
• Non-Trane personnel should always follow local regulations.
• NOTICE Water Damage! Failure to follow the instructions below could result in equipment and property damage.
• Non-factory penetrations through the base of this unit are not allowed. Any penetration in the base of the unit may affect the water-tight integrity of the unit and lead to water leaks into the conditioned space.

Overview of Manual

• One copy of this document ships inside the control panel of each unit and is customer property. It must be retained by the unit’s maintenance personnel.
• Important: Do not release refrigerant into the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws.
• This booklet describes the proper installation, startup, operation, and maintenance procedures for air-cooled systems.
• By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized.
• Periodic maintenance must be performed to help assure trouble-free operation. A maintenance schedule is provided at the end of this manual.
• Should equipment failure occur, contact a qualified service organization with qualified, experienced HVAC technicians to properly diagnose and repair this equipment.

Copyright

• This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission.
• Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

• All trademarks referenced in this document are the trademarks of their respective owners.

Factory Training

• Factory training is available through Trane University™ to help you learn more about the operation and maintenance of your equipment.
• To learn about available training opportunities contact Trane University™.
• Online: www.trane.com/traneuniversity
• Email: traneuniversity@trane.com

Model Number Description

• Digit 1 — Unit Type
  • E = Packaged Cooling, Electric Heat
• Digit 2 — Efficiency
  • B = ASHRAE 90.1 – 2019
• Digit 3 — Airflow Configuration
  • C = Convertible
• Digit 4, 5, 6 — Nominal Gross Cooling Capacity (MBh)
  • 036 = 3 Tons
  • 048 = 4 Tons
  • 060 = 5 Tons
• Digit 7 — Major Design Sequence
  • A = Rev A
• Digit 8 — Voltage Selection
  • 3 = 208-230/60/3
  • 4 = 460/60/3
• Digit 9 — Unit Controls
  • E = Electromechanical
• Digit 10 — Heating Capacity
  • 0 = No Heat
  • A = 5 kW Electric Heat
  • B = 7.5 kW Electric Heat
  • C = 10 kW Electric Heat
  • D = 14.4 kW Electric Heat
  • E = 20 kW Electric Heat
  • F = 25 kW Electric Heat

Model Number Notes

Notes:

1. Must be ordered with Through-the-Base Electrical option.
2. All Factory Installed Options are Built-to-Order. Check order services for the estimated production cycle.
3. Factory-installed economizers are only available in downflow configuration.
4. Fault Detection and Diagnostics (FDD) is available on Low Leak Economizers only.

• Digit 11 — Minor Design Sequence

  • A = Rev A

• Digit 12, 13 — Service Sequence

  • 00 = None

• Digit 14 — Fresh Air Selection2, 3

  • 0 = No Fresh Air
  • A = Manual Outside Air Damper 0-50%
  • B = Motorized Outside Air Damper 0-50%
  • C = Economizer, Dry Bulb 0-100% without Barometric Relief
  • E = Economizer, Reference Enthalpy 0-100%without Barometric Relief
  • G = Economizer, Comparative Enthalpy 0-100%without Barometric Relief
  • J = Downflow Low Leak Economizer, Dry Bulb without Barometric Relief
  • L = Downflow Low Leak Economizer, Reference Enthalpy without Barometric Relief
  • N = Downflow Low Leak Economizer, Comparative Enthalpy without Barometric Relief
  • Digit 15 — Supply Fan/Drive Type/Motor
  • 0 = Standard Motor
  • 1 = Oversized Motor
  • Digit 16 — Access
  • Not Used

• Digit 17 — Condenser Coil Protection

  • 0 = Standard Coil
  • 4 = CompleteCoat™ Condenser Coil

• Digit 18 — Through-the-Base Provisions

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

• Digit 19 — Disconnect Switch
  0 = No Disconnect

  • 1 = Unit Mounted Non-Fused Disconnect Switch1
  • Digit 20–24
  • Not Used

• Digit 25 — System Monitoring Controls

  • 0 = No Monitoring Controls
  • A = Condensate Drain Pan Overflow Switch

• Digit 26 — System Monitoring Controls

  • 0 = No Economizer Fault Detection and Diagnostics (FDD)
  • B = Economizer Fault Detection and Diagnostics (FDD)4

General Information

WARNING Fiberglass Wool!

• Exposure to glass wool fibers without all necessary PPE equipment could result in cancer, respiratory, skin, or eye irritation, which could result in death or serious injury.
• Disturbing the insulation in this product during installation, maintenance or repair will expose you to airborne particles of glass wool fibers and ceramic fibers known to the state of California to cause cancer through inhalation.
• You MUST wear all necessary Personal Protective Equipment (PPE) including gloves, eye protection, a NIOSH-approved dust/mist respirator, long sleeves, and pants when working with products containing fiberglass wool.

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 protection.
• Wash clothes separately from other clothing; rinse the washer thoroughly.
• Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH-approved respirator.

First Aid Measures:

• Eye Contact – Flush eyes with water to remove dust. If symptoms persist, seek medical attention.
• Skin Contact – Wash affected areas gently with soap and warm water after handling.

Unit Inspection

• To protect against loss due to damage incurred in transit, perform an inspection immediately upon receipt of the unit. Check carefully for shipping damage.
• If any damage is found, report it immediately, and file a claim against the transportation company.

Exterior Inspection

• If the job site inspection reveals damage or material shortages, file a claim with the carrier immediately. Specify the type and extent of the damage on the bill of lading before signing. Notify the appropriate sales representative.
• Important: Do not proceed with the installation of a damaged unit without the sales representative approval.
• Inspect the complete exterior for signs of shipping damages to the unit or packing material.
• Verify that the nameplate data matches the sales order and bill of lading.
• Verify that the unit is properly equipped and there are no material shortages.
• Verify the power supply complies with the unit nameplate specifications.

Inspection for Concealed Damage

• Inspect the components for concealed damage as soon as possible after delivery and before it is stored.

If concealed damage is discovered:

• Notify the carrier’s terminal of the damage immediately by phone and by mail.
• Concealed damage must be reported within 15 days.
• Request an immediate, joint inspection of the damage with the carrier and consignee.
• Stop unpacking the unit.
• Do not remove damaged material from receiving location.
• Take photos of the damage, if possible.
• The owner must provide reasonable evidence that the damage did not occur after delivery.

Unit Storage

• Take precautions to prevent condensation from forming inside the unit’s electrical compartments and motors.
• The unit is stored before it is installed; or,
• The unit is set on the roof curb, and temporary heat is provided in the building. Isolate all side panel service entrances and base pan openings (e.g., conduit holes, S/A and R/A openings, and flue openings) from the ambient air until the unit is ready for start-up.
• Note: Do not use the unit heater for temporary heat without first completing the start-up.
• The manufacturer will not assume any responsibility for equipment damage resulting from condensate accumulation on the unit’s electrical and/or mechanical components.

Unit Description

• Before shipment, each unit is leak-tested, dehydrated, charged with refrigerant and compressor oil, and run-tested for proper control operation.
• Direct-drive, vertical discharge condenser fans are provided with built-in thermal overload protection.
• The stages of capacity control for these units are achieved by starting the Economizer Control Actuator (ECA).

Economizer Control Actuator Electromechanical Control

• The ECA monitors the mixed air temperature, return air temperature, minimum position setpoint (local or remote), power exhaust setpoint, CO2 setpoint, CO2, and ambient dry bulb/ enthalpy sensor or comparative humidity (return air humidity against ambient humidity) sensors if selected, to control dampers to an accuracy of ±5 percent of stroke.
• The actuator is spring returned to the closed position any time that power is lost to the unit. It is capable of delivering up to 25 in﹒lb of torque and is powered by 24 Vac.

JADE Economizer Control – Low Leak Economizer (LLE) Only

• The JADE controller is a standalone economizer controller that provides outdoor air dry-bulb economizer control standards. With optional Sylk Bus sensors, the controller can provide comparative or reference enthalpy control.
• Dampers are controlled to an accuracy of ±3.2 percent of stroke. The actuator is spring returned to the closed position any time that power is lost to the actuator. It is capable of delivering up to 44 in﹒lb of torque and is powered by 24 Vac.

System Input Devices and Functions

• The unit must have a thermostat input to operate.
• The descriptions of the following basic input devices used within the unit are to acquaint the operator with their function as they interface with the various features.
• Refer to the unit’s electrical schematic for the specific device connections. The following controls are available from the factory for field installation.

Drain Pan Condensate Overflow Switch (Optional)

• This input incorporates the Condensate Overflow Switch (COF) mounted on the drain pan.
• When the condensate level reaches the trip point, the COF relay energizes and opens the 24 Vac control circuit, disabling the unit. A delay timer prevents the unit from starting for 3 minutes.

Phase Monitor

• The Phase Monitor is a three-phase line monitor module that protects against phase loss, phase reversal, and phase unbalance. It is intended to protect compressors from reverse rotation.
• It has an operating input voltage range of 180 to 600 Vac, and LED indicators for ON and FAULT. There are no field adjustments and the module will automatically reset from a fault condition.

Discharge Line Thermostat Control

• When LSD is present in the unit, the high-pressure controls and the discharge line thermostat signals are wired in series and connected to the safety input of the LSD. The compressor contactor coil is connected to the CC terminal of the LSD.
• If the high-pressure control switch or the discharge line thermostat is open, the 24 Vac signal to the SI input of the LSD is interrupted and the compressor contactor coil supply is disabled by the LSD. It has an automatic lockout.

Power Exhaust Control (Optional)

• The power exhaust fan is started whenever the position of the economizer dampers meets or exceeds the power exhaust setpoint when the indoor fan is on.
• The setpoint panel is located in the return air section and is factory-set at 25% (50% for LLE).
• To configure the LLE controller, set EXH1 SET (or EXH1 L and EXH1 H with a two-speed fan) in the SETPOINTS menu. 2-speed fan mode requires AUX2 I set as W.

Evaporator Frost Control (Optional)

• This input incorporates the Frostat™ control (FOS) mounted in the indoor coil and can be activated by closing a field-supplied contact installed in parallel with the FOS.
• If this circuit is open before the compressor is started, the compressor will not be allowed to operate. Anytime this circuit is opened for 5 continuous seconds during compressor operation, the compressor for that circuit is immediately turned Off.
• The compressor will not be allowed to restart for a minimum of 3 minutes should the FOS close.

*Sensors High Temperature Sensor (BAYFRST003)**

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

Thermostat (TCONT802AS32DA)

• This thermostat is a multi-stage 3 heat/2 cool, auto changeover digital display thermostat. It is a programmable thermostat, and a 7-day programmable stat with night setback shall be available. In addition, it is wall-mounted.

Thermostat (TCONT402AN32DA)

• This thermostat is a multi-stage 3 heat/2 cool, auto changeover digital display thermostat. It is a non-programmable, wall-mounted thermostat, and it can be used for economizer operation.

CO2 Sensor

• This optional sensor can be added for Demand Control Ventilation (DCV) functionality. On units with a low leak economizer, configure the JADE controller by setting the following parameters:

Setpoints Menu

• DCV SET = desired CO2 ppm to start DCV
• VENTMAX = desired maximum position w/DCV and occupied status (2-speed applications require LO and HI settings)
• VENTMIN = desired minimum position w/DCV and occupied status (2-speed applications require LO and HI settings)

ADVANCED SETUP Menu:

• CO2 ZERO = set to detectors start level
• CO2 SPAN = detector’s max level minus start level
• Attach the sensor to the CO2 and R terminals (at customer connections).
• Note: When using any 0 to 10 Vdc CO2 sensor with the JADE you will need to set CO2 ZERO to 400 ppm and the CO2 SPAN to 1600 ppm in the ADVANCED SETUP menu sensor must utilize a normally open contact for proper operation.
• If an occupancy sensor is not used, another option for controlling occupied and unoccupied status is to use the G input (fan is running).
• Connect the G input to the OCC SENSOR wire (at customer connections). The controller will then operate in the occupied mode every time the indoor fan is running.

Initiation of Operating Modes – JADE Controller

• The JADE controller can initiate the following modes: Compressor, Economizer, Fans, Heating System, and Cooling System.
• The Compressor mode is initiated by either the OAT going above the DRYBLB SET setting or by the thermostat initiating a call to cool when the damper is at 100 percent open.
• The Economizer mode is controlled by the MAT getting above the MAT SET setting while the OAT is below the DRYBLB SET setting.
• While the fans are not controlled by the controller, the Fan mode is dependent on what state the system is in (OCC or Y1 states will cause the damper to go to a LOW fan speed damper setting, while Y2 or W states will cause the controller to open the damper to the HIGH fan speed damper setting). The Heating System mode requires an input to the AUX2-1 terminal from the thermostat, and the Cooling System mode requires an input to the Y2 IN and/or the Y1 IN terminals from the thermostat.

Fan Failure Switch

• In electric heat mode, heaters will not be energized until the differential pressure switch proves airflow. The factory set point is 0.07-inch w.c.

Dimensional Data

• The below figure illustrates the minimum operating and service clearances for either a single or multiple-unit installation.
• These clearances are the minimum distances necessary to assure adequate serviceability, cataloged unit capacity, and peak operating efficiency.
• Providing less than the recommended clearances may result in condenser coil starvation, short-circuiting of exhaust and economizer airflows, or recirculation of hot condenser air.

NOTES:

1. FOR THE HORIZONTAL DISCHARGE UNIT, THIS MEASUREMENT IS REDUCED TO 1’ 6” TO MINIMIZE DUCT EXTENSION.
2. WHEN EQUIPPED WITH ECONOMIZER OR BAROMETRIC RELIEF DAMPER, CLEARANCE DISTANCE IS TO BE MEASURED FROM THE PROTRUDING HOOD INSTEAD OF THE BASE.
3. CLEARANCE IS THE SAME IF ANY UNIT IS ROTATED 180°.
4. ADDITIONAL CLEARANCE REQUIRED WHEN BAROMETRIC DAMPER OR ECONOMIZER IS INSTALLED.

NOTES:

1. THROUGH THE BASE ELECTRICAL IS NOT STANDARD ON ALL UNITS.
2. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION.

Weights

Table 1. Maximum unit and corner weights (lb) and center of gravity Dimensions (in.) cooling with optional electric heat (electric/electric) units only

**Tons| ****Unit Model No.| Weights (lb) (a) , (b)| Corner Weights (c)| Center of Gravity (in.)
---|---|---|---|---
Shipping| Net| A| B| C| D| Length| Width*
3| EBC036| 523| 473| 87| 98| 153| 135| 41| 29
4| EBC048| 566| 516| 103| 107| 155| 150| 39| 28
5| EBC060| 586| 536| 112| 112| 156| 156| 38| 28

• (a) Weights are approximate.
• (b) Weights do not include additional factory or field-installed options/accessories.
• (c) Corner weights are given for information only.

Rigging

WARNING Heavy Object!

• Failure to follow instructions below could result in unit dropping which could result in death or serious injury, and equipment or property-only damage. Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted.
• Each of the cables (chains or slings), hooks, and shackles used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift.

WARNING Improper Unit Lift!

• Failure to properly lift the unit in a LEVEL position could result in the unit dropping and possibly crushing the operator/technician which could result in death or serious injury, and equipment or property-only damage.
• Test lift unit approximately 24 inches (61 cm) to verify the proper center of gravity lift point. To avoid dropping of unit, reposition the lifting point if the unit is not level.
• Refer to Figure 11, p. 14 and for typical unit operating weights rigging before proceeding.

1. Remove the shipping crate from around the unit. Do not remove the crating from the top of the unit.
2. Rig the unit as shown in Figure 11, p. 14. Attach adequate strength lifting slings to all four lifting brackets in the unit base rail. Do not use cables, chains, or slings except as shown.
3. Install a lifting bar, as shown in Figure 11, p. 14, to protect the unit and to facilitate a uniform lift. The minimum distance between the lifting hook and the top of the unit should be 7 feet.
4. Test-lift the unit to ensure it is properly rigged and balanced, make any necessary rigging adjustments.
5. Lift the unit and position it into place.
6. Downflow units; align the base rail of the unit with the curb rail while lowering the unit onto the curb. Make sure that the gasket on the curb is not damaged while positioning the unit.

Installation

Unit Foundation™

WARNING Risk of Roof Collapsing!

• Failure to ensure proper structural roof support could cause the roof to collapse, which could result in death or serious injury and property damage.
• Confirm with a structural engineer that the roof structure is strong enough to support the combined weight of the roofcurb, the unit, and any accessories.

CAUTION Water Damage!

• Flexible hose can burst.
• Flexible hose should never be used for an indoor installation. Failure to follow this recommendation could lead to equipment or property-only damage.

Notes:

• For units with an optional Condensate Overflow Switch (COF) accessory kit, the switch will not work properly if a unit is not level or slightly sloped toward the switch.
• To assure proper condensate flow during operation the unit and the curb must be level.
• If the unit is installed at ground level, elevate it above the snow line. Provide concrete footings at each support location with a full perimeter support structure or a slab foundation for support. Refer to Table 1, p. 14 for the unit’s operating and point-loading weights when constructing a footing foundation.
• If anchoring is required, anchor the unit to the slab using hold-down bolts or isolators. Isolators should be installed to minimize the transmission of vibrations into the building.
• For rooftop applications, if anchoring is required, anchor the unit to the roof with hold-down bolts or isolators.
• Check with a roofing contractor for proper waterproofing procedures.

Ductwork

• Elbows with turning vanes or splitters are recommended to minimize air noise due to turbulence and to reduce static pressure.
• When attaching the ductwork to the unit, provide a watertight flexible connector at the unit to prevent operating sounds from transmitting through the ductwork.
• All outdoor ductwork between the unit and the structure should be weatherproofed after installation is completed.
• Note: For sound consideration, cut only the holes in the roof deck for the ductwork penetrations. Do not cut out the entire roof deck within the curb perimeter.

If a Curb Accessory Kit is not used:

1. The ductwork can be attached directly to the factory-provided flanges around the unit’s supply and return air openings. Be sure to use flexible duct connections at the unit.
2. For built-up curbs supplied by others, gaskets must be installed around the curb perimeter flange and the supply and return air opening flanges.

General Unit Requirements

• WARNING Proper Field Wiring and Grounding Required!
• Failure to follow the code could result in death or serious injury.
• All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards.
• To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.
• The checklist listed below is a summary of the steps required to successfully install a commercial unit. This checklist is intended to acquaint the installing personnel with what is required in the installation process.
• It does not replace the detailed instructions called out in the applicable sections of this manual.
• Check the unit for shipping damage and material shortage; file a freight claim and notify the appropriate sales representative.
• Verify the correct model, options, and voltage from the nameplate.
• Verify that the installation location of the unit will provide the required clearance for proper operation.
• Assemble and install the roof curb (if applicable). Refer to the latest edition of the curb installers guide that ships with each curb kit.
• Fabricate and install ductwork; secure ductwork to curb.
• Rigging the unit.
• Set the unit onto the curb; check for levelness.
• Ensure the unit-to-curb seal is tight and without buckles or cracks.
• Install and connect a condensate drain line to the evaporator drain connection.

Factory Installed Economizer

• Ensure the economizer has been pulled out into the operating position.
• Refer to the standard or low leak economizer Installation Instructions for proper position and setup.
• Install all access panels.

Controller Wiring Schematic – LLE

• For additional information, see 0 to 100% Low Leak Economizer — Downflow – Foundation™ Packaged Cooling and Gas/Electric 3 to 5 Tons – Installation Instructions (ACC-SVN203*-EN) and 0 to 100% Low Leak Economizer — Horizontal – Foundation™
• Packaged Cooling and Gas/Electric 3 to 5 Tons – Installation Instructions (ACC-SVN205*-EN).

Main Electrical Power Requirements

• Verify that the power supply complies with the unit nameplate specifications.
• Inspect all control panel components; tighten any loose connections.
• Connect properly sized and protected power supply wiring to a field-supplied/ installed disconnect switch and the main power terminal block (HTB1) in the unit control panel.
• Install proper grounding wires to an earth ground.
• Note: All field-installed wiring must comply with NEC and applicable local codes.
• Electric Heat Requirements
• Verify that the power supply complies with the electric heater specifications on the unit and heater nameplate.
• Inspect the heater junction box and control panel; tighten any loose connections.
• Check electric heat circuits for continuity.
• Low Voltage Wiring (AC and DC) Requirements.
• Install the zone thermostat, with or without switching subbase.
• Connect properly sized control wiring to the proper termination points between the zone thermostat and the unit control panel.

Condensate Drain Configuration

• An evaporator condensate drain connection is provided on each unit. Refer to the unit overview figure in “Dimensional Data,” p. 9 for the appropriate drain location.
• Note: Use a 1-inch PVC pipe to connect to the drain pan outlet provided in the unit. This is a slip-fit joint (no threads).
• Do not use PVC glue to connect the condensate drain, thread-sealing compound or Teflon tape may be used.
• A condensate trap must be installed at the unit due to the drain connection being on the negative pressure side of the fan.
• A condensate drain line must be connected to the P-Trap. Pitch the drain lines at least 0.5 inches for every 10 feet of horizontal run to ensure proper condensate flow.
• Do not allow the horizontal run to sag causing a possible double trap condition which could result in condensate backup due to airlock.

Filter Installation

• Each unit ships with 2-inch filters installed. The quantity of filters is determined by unit size. Access to the filters is obtained by removing the filter access panel.
• Refer to the unit Service Facts (shipped with each unit) for filter requirements
• Note: Do not operate the unit without filters.

Field Installed Power Wiring

• An overall dimensional layout for the standard field installed wiring entrance into the unit is illustrated in“Dimensional Data To ensure the unit’s supply power wiring is properly sized and installed, follow the guidelines outlined below.
• Note: All field-installed wiring must conform to NEC guidelines as well as state and Local codes.
• Verify that the power supply available is compatible with the unit’s nameplate ratings. The available supply power must be within 10 percent of the rated voltage stamped on the nameplate.
• Use only copper conductors to connect the power supply to the unit.

NOTICE Use Copper Conductors Only!

• Failure to use copper conductors could result in equipment damage as the equipment was not designed or qualified to accept other types of conductors.
• Note: If the unit is not equipped with an optional factory-installed nonfused disconnect switch or circuit breaker, a field-supplied disconnect switch must be installed at or near the unit under the National Electrical Code (NEC latest edition).

Main Unit Power

• WARNING Proper Field Wiring and Grounding Required!
• Failure to follow the code could result in death or serious injury.
• All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards.
• To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

Standard Wiring

• The electrical service must be protected from over-current and short-circuit conditions under NEC requirements.
• Protection devices must be sized according to the electrical data on the nameplate.
• If the unit is not equipped with an optional factory-installed nonfused disconnect switch, a field-supplied disconnect switch must be installed at or near the unit under the National Electrical Code (NEC latest edition).
• The location of the applicable electrical service entrance is illustrated in “Dimensional Data Complete the unit’s power wiring connections onto either; the main terminal block HTB1 inside the unit control panel, the factory mounted nonfused disconnect switch (UCD), or the electric heat terminal block. Refer to the customer connection diagram that shipped with the unit for specific termination points.
• Provide proper grounding for the unit in accordance with local and national codes.

Optional TBUE Wiring (Through-the-Base Electrical Option)

• The location of the applicable electrical service is illustrated below. Refer to the customer connection diagram that is shipped with the unit for specific termination points.
• The termination points, depending on the customer option selected, would be a factory-mounted nonfused disconnect switch (see Figure 14 ), the electric heat terminal block (if equipped), or the main terminal block.
• Provide proper grounding for the unit under local and national codes.

Control Power Transformer

• The 24-volt control power transformers are to be used only with the accessories called out in this manual.
• Transformers rated greater than 50 Vac are equipped with internal circuit breakers. If a circuit breaker trips, turn Off all power to the unit before attempting to reset it.
• The transformer is located in the control panel. The circuit breaker is located on the left side of the transformer and can be reset by pressing the black reset button.

Controls using 24-vac

• Before installing any connecting wiring, refer to “Dimensional Dat for the electrical access locations provided on the unit and Table 2, p. 18 for AC conductor sizing guidelines.

NOTICE Use Copper Conductors Only!

Failure to use copper conductors could result in equipment damage as the equipment was not designed or qualified to accept other types of conductors.

1. Use copper conductors unless otherwise specified.
2. Ensure that the AC control wiring between the controls and the unit’s termination point does not exceed three (3) ohms/conductor for the length of the run.
   • Note: Resistance above 3 ohms per conductor could cause component failure due to insufficient AC voltage supply.
3. Be sure to check all loads and conductors for grounds, shorts, and miswiring.
4. Do not run the AC low voltage wiring in the same conduit with the high voltage power wiring.
5. Route low voltage wiring as per Figure 13 Table 2. Electromechanical thermostat 24 Vac conductors

Voltage Imbalance

• Three-phase electrical power to the unit must meet stringent requirements for the unit to operate properly. Measure each leg (phase-to-phase) of the power supply.
• Each reading must fall within the utilization range stamped on the unit nameplate. If any of the readings do not fall within the proper tolerances, notify the power company to correct this situation before operating the unit.
• Excessive three-phase voltage imbalance between phases will cause motors to overheat and eventually fail.
• The maximum allowable voltage imbalance is 2 percent.
• Measure and record the voltage between phases 1, 2, and 3 and calculate the amount of imbalance as follows: % Voltage Imbalance = (100 x AV – VD) / AV where; AV (Average Voltage) = Volt1 + Volt2 + Volt3 / 3
• V1, V2, V3 = Line voltage readings
• VD = Line voltage reading that deviates the farthest from the average voltage.
• Example: If the voltage readings of the supply power measured 221, 230, and 227, the average volts would be: (221 + 230 + 227) / 3 = 226 Avg.
• VD (reading farthest from average) = 221
• The percentage of Imbalance equals: (100 + 226 + 221) / 226 = 2.2%
• The 2.2 percent imbalance in this example exceeds the maximum allowable imbalance of 2.0 percent.
• This much imbalance between phases can equal as much as a 20 percent current imbalance with a resulting increase in motor winding temperatures that will decrease motor life.
• If the voltage imbalance is over 2 percent, notify the proper agencies to correct the voltage problem before operating this equipment.

Electrical Phasing (Three Phase Motors)

• The compressor motor(s) and the supply fan motor are internally connected for the proper rotation when the incoming power supply is phased as A, B, and C.
• Proper electrical supply phasing can be quickly determined and corrected before starting the unit by using an instrument like an Associated Research Model 45 Phase Sequence Indicator. Follow the steps below.

WARNING Hazardous Voltage!

• Failure to disconnect power before servicing could result in death or serious injury.
• Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Verify that no power is present with a voltmeter.

1. Turn the field-supplied disconnect switch that provides power to the main power terminal block or to the Line side of the optional factory-mounted disconnect switch to the Off position.
2. Connect the phase sequence indicator leads to the terminal block or to the Line side of the optional factory mounted disconnect switch as follows:
   • Black (phase A) to L1
   • Red (phase B) to L2
   • Yellow (phase C) to L3
3. Close the field-supplied main power disconnect switch or circuit protector switch that provides the supply power to the unit.
   • WARNING Live Electrical Components!
   • Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.
   • When it is necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks.
4. Observe the ABC and CBA phase indicator lights on the face of the sequencer. The ABC indicator light will glow if the phase is ABC. If the CBA indicator light glows, open the disconnect switch or circuit protection switch and reverse any two power wires.
5. Restore the main electrical power and recheck the phasing. If the phasing is correct, open the disconnect switch or circuit protection switch and remove the phase sequence indicator.

Compressor Crankcase Heaters

NOTICE Compressor Failure!

• Failure to follow the instructions below could result in compressor failure.
• The unit must be powered and crankcase heaters energized at least 8 hours BEFORE compressors are started.
• Each compressor can be equipped with a crankcase heater. The proper operation of the crankcase heater is important to maintain an elevated compressor oil temperature during the Off-cycle to reduce oil foaming during compressor starts.
• Oil foaming occurs when refrigerant condenses in the compressor and mixes with the oil. In lower ambient conditions, refrigerant migration to the compressor could increase.
• When the compressor starts, the sudden reduction in crankcase pressure causes the liquid refrigerant to boil rapidly causing the oil to foam.
• This condition could damage compressor bearings due to reduced lubrication and could cause compressor mechanical failures.
• Before starting the unit in the Cooling mode, set the system switch to the Off position turn the main power disconnect to the On position, and allow the crankcase heater to operate for a minimum of 8 hours.
• Before closing the main power disconnect switch, ensure that the System selection switch is in the Off position and the Fan selection switch is in the Auto position.
• Close the main power disconnect switch and the unit-mounted disconnect switch, if applicable.

Checklist

• Use the following checklist in conjunction with the general checklist (“General Unit Requirements, to ensure that the unit is properly installed and ready for operation.

WARNING Hazardous Voltage!

• Failure to disconnect power before servicing could result in death or serious injury.
• Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Verify that no power is present with a voltmeter.
• Check all electrical connections for tightness and point of termination accuracy.
• Verify that the condenser airflow is unobstructed.
• Verify that the condenser fan and indoor blower turn freely without rubbing and are properly tightened on the shafts.
• Check the supply fan belts for proper tension and the fan bearings for sufficient lubrication.
• If the belts require adjustment, or if the bearings need lubricating, refer to the maintenance section of this manual for instructions.
• Verify that a condensate trap is installed and the piping is properly sized and pitched.
• Verify that the correct size and number of filters are in place.
• Inspect the interior of the unit for tools and debris and install all panels in preparation for starting the unit.

Factory-Mounted Unit Options Unit Disconnect (FIYUDC)

• WARNING Hazardous Voltage and Equipment Damage!
• Failure to follow the instructions below could result in death or serious injury.
• CT terminals are referenced to neutral on the meter and may be at elevated voltages. Do not contact meter terminals while the unit is connected. Do not connect or short other circuits to the CT terminals.
• Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.
• Verify that no power is present with a CAT III or IV voltmeter rated per NFPA 70E.
• WARNING Proper Field Wiring and Grounding Required!
• Failure to follow the code could result in death or serious injury.
• All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards.
• To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.
• Important: All phases of this installation must comply with NATIONAL, STATE, and LOCAL CODES. In addition to local codes, the installation must comply with the National Electric Code – ANSI/NFPA NO. 70 LATEST REVISION.

1. Field connections are made by first removing the compressor access panel on the front of the unit. Unscrew the assembly around the outside of the disconnect switch. This assembly is located in the condenser section of the unit.

   • Both high and low-voltage power can be routed through the base or through the front corner post where the disconnect enclosure is mounted. The hole is sized for 1 1/2–in. conduit.

2. If the conduit required for your application is larger than 1 1/2–in., remove the termination plate and connect to the larger hole using field-supplied reducing washers.

3. Route the power wires and ground conductor through a conduit and into the bottom of the factory-installed disconnect switch. Connect the power conductors to the lugs provided. Connect the ground wire to the unit ground lug.

   • Note: Wire size for the length of run should be determined using the circuit ampacity found on the unit nameplate and the N.E.C.

4. Route low voltage (class II), control wiring through a hole in base of the unit but not through high voltage conduit
   (refer to Figure 12, p. 17 for high and low volts. conduits location). Feed control wiring through bushing provided on the side panel. Route wires through loose wire ties provided.

5. Tighten the wire ties. Secure the excess wire bundle under the wire ties in the outdoor section. Do not leave excess wire in the electrical enclosure. Use the unit wiring diagram to make the low voltage connections.

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

• Much of the system performance and reliability is closely associated with, and dependent upon having the proper airflow supplied both to the space that is being conditioned and across the evaporator coil.
• The indoor fan speed is changed by opening or closing the adjustable motor sheave.
• Before starting the SERVICE TEST, set the minimum position setpoint for the economizer to 0% using the setpoint potentiometer located on the Economizer Control (ECA), if applicable.

Electromechanical Controls Test Procedure

• See the unit schematic for the correct wire numbers.
• Fan Test and Minimum Ventilation. Connect the red thermostat wire (R) to the black thermostat wire (G).
• Economizer Cooling. Connect a jumper wire across OAT on Economizer Control (ECA).
• Connect the red thermostat (R) wire to the yellow thermostat wire (Y1).
• Cool 1. Connect the red thermostat wire (R) to the yellow thermostat wire (Y1).
• Cool 2. Connect the red thermostat wire (R) to the yellow thermostat wire (Y2).
• Heat 1. Connect the red thermostat wire (R) to the brown thermostat wire (W1).
• Heat 2. Connect the red thermostat wire (R) to the brown thermostat wire (W2).

Start-Up Standard Economizer Start-Up

1. Set the minimum position setpoint for the economizer to the required percentage of minimum ventilation using the setpoint potentiometer located on the Economizer Control (ECA).
   • The economizer will drive to its minimum position setpoint, exhaust fans (if applicable) may start at random, and the supply fan will start when the SERVICE TEST is initiated.
   • The Exhaust Fan will start anytime the economizer damper position is equal to or greater than the exhaust fan setpoint.
2. Verify that the dampers stroked to the minimum position.
3. Verify that the dampers stroked to the full open position.
4. To stop the SERVICE TEST, turn the main power disconnect switch to the Off position or proceed to the next component start-up procedure. Remove electro mechanical test mode connections (if applicable).

LLE Controls Test Procedure

• See the unit schematic for the correct wire numbers.
• Use the CHECKOUT menu in the Installation Instructions to test the damper operation and any configured outputs. Only items that are configured are shown in the Checkout menu.

To Perform Checkout Tests:

1. Scroll to the desired test in the checkout menu using the and buttons.
2. Press the button to select the item.
3. RUN? is displayed.
4. Press to start the test.
5. The unit pauses and then displays IN PROGRESS.
6. When the test is complete, DONE appears.
7. When all parameters have been tested, press (Menu Up) to end the test (e.g. turn off the relay).

Notes:

• The checkout tests can all be performed at the time of installation or any time during the operation of the system.
• JADE will be in setup mode for the first 60 minutes after power. If the OA sensor or Sylk
• Bus device (sensor or actuator) is disconnected during the setup mode, the JADE will not alarm that failure. The MA sensor is a system-critical sensor, if the MA sensor is removed during the setup mode, the JADE will alarm.
• After 60 minutes the JADE controller will change to operation mode and all components removed or failed will alarm in the operation mode.
• Upon power-up (or after a power outage or brownout), the JADE controller module begins a 5-minute power-up delay before enabling mechanical cooling.

Compressor Start-Up

1. Attach a set of service gauges onto the suction and discharge gauge ports for each circuit. Refer to the refrigerant circuit illustration in the Service Facts. Using the Service Test Guide, perform the proper test mode connections.
   • Scroll Compressors
   • a. Once each compressor has started, verify that the rotation is correct. If wired correctly the suction pressure should drop and the discharge pressure should rise. If a scroll compressor is rotating backward, it will not pump and a loud rattling sound can be observed.
   • b. If the electrical phasing is correct, before condemning a compressor, interchange any two leads (at the compressor Terminal block) to check the internal phasing. Refer to the following illustration for the compressor terminal/phase identification. Do not allow the compressor to operate backward for more than 5 seconds. Operation for a while longer than this will result in compressor damage.
   • Note: Copeland SXA scroll compressors for R–410A units use Trane OIL00094. Compressor types are listed in Table 3, p. 22. The appropriate oil charge is listed in Table 4, p. 23.
   • Table 3. Compressor types**
     Tonnage| Compressor 1*
     ---|---
     EB036| SXA031
     EB048| SXA042
     EB060| SXA051
   • Table 4. POE Oil recharge amount (fl. oz.)**
     Tonnage| Compressor 1*
     ---|---
     EB036| 21
     EB048| 38
     EB060| 38
2. After the compressor and condenser fan have started and operated for approximately 30 minutes, observe the operating pressures. Compare the operating pressures to the operating pressure curve in the Service Facts.
3. Check system subcooling. Follow the instruction listed on the subcooling charging curve in the Service Facts.
4. Repeat Step 1 through Step 3 for each refrigerant circuit.
5. To stop the SERVICE TEST, turn the main power disconnect switch to the Off position or proceed to the next component start-up procedure. Remove electromechanical test mode connections (if applicable).

Heating Start-Up

1. Clamp an amp meter around one of 1st stage heater power wires at the heater contactor.
2. Verify that the heater stage is operating properly.
3. Clamp an amp meter around one of 2nd stage heater power wires at the heater contactor (if applicable).
4. Verify that the heater stage is operating properly.
5. To stop the SERVICE TEST, turn the main power disconnect switch to the Off position or proceed to the next component start-up procedure. Remove electromechanical test mode connections.

Final System Setup

• After completing all of the pre-start and startup procedures outlined in the previous sections (i.e., operating the unit in each of its modes through all available stages of cooling and heating), perform these final checks before leaving the unit:
• Program the Night Setback (NSB) panel (if applicable) for proper unoccupied operation. Refer to the programming instructions for the specific panel.
• Verify that the Remote panel System selection switch, Fan selection switch, and Zone Temperature settings for automatic operation are correct.
• Inspect the unit for misplaced tools, hardware, and debris.
• Verify that all exterior panels including the control panel doors and condenser grilles are secured in place.
• Close the main disconnect switch or circuit protector switch that provides the supply power to the unit’s terminal block or the unit-mounted disconnect switch.

Maintenance

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

Fan Belt Adjustment-Belt Drive Units

WARNING Rotating Components!

• Failure to disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury.
• Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.
• The fan belts must be inspected periodically to ensure proper unit operation. Replacement is necessary if the belts appear frayed or worn. Units with dual belts require a matched set of belts to ensure equal belt length.
• When removing or installing the new belts, do not stretch them over the sheaves. Loosen the belts using the belt tension adjustment bolts on the motor mounting base.
• Once the new belts are installed, using a Browning or Gates tension gauge (or equivalent) illustrated in Figure 15, p. 24, adjust the belt tension as follows:

1. To determine the appropriate belt deflection:
   • a. Measure the center-to-center shaft distance (in inches) between the fan and motor sheaves.
   • b. Divide the distance measured in Step 1a by 64; the resulting value represents the amount of belt deflection that corresponds to the proper belt tension.
2. Set the large O-ring on the belt tension gauge at the deflection value determined in Step 1b.
3. Set the small O-ring at zero on the force scale of the gauge plunger.
4. Place the large end of the gauge at the center of the belt span; then depress the gauge plunger until the large O-ring is even with the top of the next belt or even with a straightedge placed across the fan and motor sheaves.
5. Remove the belt tension gauge. The small O-ring now indicates a number other than zero on the plunger force scale. This number represents the force (in pounds) required to give the needed deflection.
6. Compare the force scale reading (Step 5) with the appropriate force value listed in the Belt tension table. If the force reading is outside the range, readjust the belt tension.
   • Note: Actual belt deflection force must not exceed the maximum force value shown in the Belt tension measurement and deflection ranges table.
7. Recheck the belt tension at least twice during the first 2 to 3 days of operation. Belt tension may decrease until the new belts are run in.

Table 5. Belt tension measurement and deflection ranges (in./lb.)

**Belts Cross Section| ****Smallest Sheave Diameter Range (in.)| ****RPM Range| Deflection Force (lb)
---|---|---|---
Super Gripbelts and Unnotched Gripbands| Gripnotch Belts and Notched Gripbands
Used Belt| New Belt| Used Belt| New Belt
** A, AX| 3.0 to 3.6| 1000 to 2500| 3.7| 5.5| 4.1| 6.1
2501 to 4000| 2.8| 4.2| 3.4| 5.0
3.8 to 4.8| 1000 to 2500| 4.5| 6.8| 5.0| 7.4
2501 to 4000| 3.8| 5.7| 4.3| 6.4
**** 5.0 to 7.0| 1000 to 2500| 5.4| 8.0| 5.7| 8.4
2501 to 4000| 4.7| 7.0| 5.1| 7.6

Monthly Maintenance

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

WARNING Hazardous Voltage!

• Failure to disconnect power before servicing could result in death or serious injury.
• Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Verify that no power is present with a voltmeter.

Filters

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

Condensate Overflow Switch

• During maintenance, the switch float (black ring) must be checked to ensure free movement up and down.

Cooling Season

• Check the unit’s drain pans and condensate piping to ensure that there are no blockages.
• Inspect the evaporator and condenser coils for dirt, bent fins, etc. If the coils appear dirty, clean them according to the instructions described in “Coil Cleaning.
• Manually rotate the condenser fans to ensure free movement and check motor bearings for wear. Verify that all of the fan mounting hardware is tight.
• Inspect the F/A-R/A damper hinges and pins to ensure that all moving parts are securely mounted. Keep the blades clean as necessary.

WARNING Rotating Components!

• Failure to disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury.
• During installation, testing, servicing, and troubleshooting of this product it may be necessary to work with live and exposed rotating components.
• Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components, perform these tasks.

NOTICE Equipment Damage!

• Forcibly turning the motor shaft can damage the gear train and motor beyond repair.
• Never turn the motor shaft by hand or with a wrench.
• Verify that all damper linkages move freely; lubricate with white grease, if necessary.
• Check supply fan motor bearings; repair or replace the motor as necessary.
• Check the fan shaft bearings for wear. Replace the bearings as necessary.
• Check the supply fan belt(s). If the belts are frayed or worn, replace them. Refer to the “Fan Belt Adjustment-Belt Drive Units for belt replacement and adjustments.
• Verify that all wire terminal connections are tight.
• Remove any corrosion present on the exterior surfaces of the unit and repaint these areas.
• Generally inspect the unit for unusual conditions (e. g. loose access panels, leaking piping connections, etc.)
• Make sure that all retaining screws are reinstalled in the unit access panels once these checks are complete.
• With the unit running, check and record the following:
• Ambient temperature
• Compressor oil level (each circuit)
• Compressor suction and discharge pressures (each circuit)
• Superheat and subcooling (each circuit)
• Record this data on an operator’s maintenance log like the one shown in Table 7. If the operating pressures indicate a refrigerant shortage, measure the system superheat and system subcooling.
• For guidelines, refer to “Compressor Start-Up.
• Important: Do not release refrigerant into the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws. Refer to General Service Bulletin (MSCU-SB-1) (latest edition).

Heating Season

• Inspect the unit’s air filters. If necessary, clean or replace them.
• Check supply fan motor bearings; repair or replace the motor as necessary.
• Inspect both the main unit control panel and heat section control box for loose electrical components and terminal connections, as well as damaged wire insulation. Make any necessary repairs.
• Verify that the electric heat system operates properly.

Coil Cleaning

• Regular coil maintenance, including annual cleaning, enhances the unit’s operating efficiency by minimizing the following:
• Compressor head pressure and amperage draw
• Evaporator water carryover
• Fan brake horsepower
• Static pressure losses
• Airflow reduction
• At least once each year, or more often if the unit is located in a dirty environment, clean the condenser coils using the instructions outlined below. Be sure to follow these instructions as closely as possible to avoid damaging the coils.

WARNING Hazardous Chemicals!

• Failure to follow this safety precaution could result in death or serious injury. Coil cleaning agents can be either acidic or highly alkaline and can burn severely if contact with skin or eyes occurs.
• Handle chemicals carefully and avoid contact with the skin. ALWAYS wear Personal Protective Equipment (PPE) including goggles or face shields, chemical-resistant gloves, boots, apron, or suit as required.
• For personal safety refer to the cleaning agent manufacturer’s Materials Safety Data Sheet and follow all recommended safe handling practices.

Microchannel (MCHE) Coils

NOTICE Coil Damage!

• Failure to follow the instructions below could result in coil damage.
• DO NOT use any detergents with microchannel condenser coils.
• Use pressurized water or air ONLY, with pressure no greater than 600psi.
• For additional information regarding the proper microchannel coil cleaning procedure, refer to RT-SVB83*-EN Due to the soft material and thin walls of the MCHE coils, the traditional field maintenance method recommended for Round Tube Plate Fin (RTPF) coils does not apply to microchannel coils.
• Moreover, chemical cleaners are a risk factor to MCHE due to the material of the coil. The manufacturer does not recommend the use of chemical cleaners to clean microchannel coils. Using chemical cleaners could lead to warranty claims being further evaluated for validity and failure analysis.
• The recommended cleaning method for microchannel condenser coils is pressurized water or air with a nonpinpoint nozzle and an ECU of at least 180 with pressure no greater than 600 psi.
• To minimize the risk of coil damage, approach the cleaning of the coil with the pressure washer aimed perpendicular to the face of the coil during cleaning. The optimum clearance between the sprayer nozzle and the microchannel coil is 1-inch to 3-inch.

Final Process

• For future reference, record the unit data below in the blanks provided.

Table 6. Unit data log

Complete Unit Model Number|
---|---
Unit Serial Number|
Wiring Diagram Numbers (from unit control panel)|
-schematic(s)|
|
|
-connections|
|
Network ID|

Table 7. Sample maintenance log

Date

| ****

Current Ambient Temp F/C

| Refrigerant Circuit #1
---|---|---

Compr. Oil Level

| Suct. Press. Psig/kPa| Disch. Press. Psig/kPa| Liquid Press. Psig/kPa| ****

Superheat F/C

| ****

Sub-cool F/C

| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |
| | – ok

– low

| | | | |

Troubleshooting

WARNING Hazardous Service Procedures!

• Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or serious injury.
• Technicians, to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the following instructions.
• Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy-storing devices such as capacitors before servicing.
• Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.
• When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

Standard Troubleshooting

Failures Cooling Failure

1. Cooling and heating set points (slide pot) on the thermostat have failed.
   • Note: Not used on electromechanical units.
2. CC1 24 Vac control circuit has opened. Check CC1 coils and Frostat™ status. Check the status of the LED indicator in LSD:
   • a. LED will be flashing to indicate that a Safety Input has opened while a Y call is present.
   • b. Compressor lockout is indicated by a solid (nonflashing) red LED.
   • To reset LSD – Power cycle on R input.

Simultaneous Heat and Cool Failure

Emergency Stop is activated.

Low Leak Economizer – (LLE) Troubleshooting

1. The economizer controller provides alarm messages that are displayed on the 2-line LCD. If one or more alarms are present and there has been no keypad activity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms.
   • Note: You can also navigate to the Alarms menu at any time.
2. Once the alarm has been identified and the cause has been removed (for example, replaced faulty sensor), the alarm can be cleared from the display.
   • Note: If an alarm still exists after you clear it, it re-displays within 5 seconds.

To Clear an Alarm

Once the alarm has been identified and the cause has been removed (for example, replaced faulty sensor), the alarm can be cleared from the display.

1. Navigate to the desired alarm.
2. Press .
3. ERASE? is displayed.
4.  Press.
5. ALARM ERASED is displayed.
6. Press (Menu Up) to complete the action and return to the previous menu.

• Note: If an alarm still exists after you clear it, it redisplays within 5 seconds.

Low Leak Economizer Fault Codes

Low Leak Economizer Alarms:

• CO2 Sensor Error
• SYS Alarm
• Actuator Undervoltage
• Actuator Overvoltage
• Actuator Stalled
• The FDD system shall detect the following faults:
• Air temperature sensor failure/fault
• Not economizing when it should
• Economizing when it should not
• Damper not modulating
• Excess outdoor air
• The JADE controller is a certified FDD product (HJW10) by
• California Title 24, Part 6. The FDD system is required for meeting California Energy Commission’s Title 24 regulations.
• Table 8 shows the various tests that can be performed (rows) and the five faults that are defined by FDD (columns). The x means that the test has to be conducted to see if it is causing the fault to occur.

Table 8. FDD troubleshooting

| Faults
---|---
**Tests| Air temp. sensor failure/fault| Not economizing when it should| Economizing when it should not| Damper not modulating| Excess outdoor air
Damper Stuck Open| | | x| x| x
The Damper Stuck at the Minimum| | x| | x|
Bad or Unplugged Actuator| | x| x| x|
Sensor Hard Failure| x| x| x| | x
Actuator Mechanically Disconnected| | **

x

| ****

x

| ****

x

| ****

x

Resetting Cooling and Heating Lockouts

• Cooling Failures and Heating Lockouts are reset in an identical manner.
• Method 1,” p. 29 section explains resetting the system from the space; “Method 2,” p. 29 section explains resetting the system at the unit.
• Note: Before resetting Cooling Failures and Heating
• Lockouts check the Failure Status Diagnostics by the methods previously explained. Diagnostics will be lost when the power to the unit is disconnected.

Method 1

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

Method 2

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

Condensate Overflow Switch

• When the condensate overflow switch is closed, a drain pan overflow condition is indicated and it will shut unit operations down.

Fan Failure Switch

• In electric heat mode, the fan failure switch is connected in series with the electric heat relay. There is a set point of 0.07 +/- 0.05-inch w.c.
• If the fan failure switch is open, indicating a no airflow condition, it prevents the electric heat from being activated or shuts down if already running.
• This safety feature allows the electric heat system to function effectively only when there is proper airflow.

Unit Economizer Control (ECA)

• Verify Economizer Status by Economizer Actuator (ECA)

LED indicator:

• OFF: No Power or Failure
• ON: Normal, OK to Economize
• Slow Flash: Normal, Not OK to Economize
• Fast Flash – 1/4 Second On / 2 Seconds Off:
• Error Code: Communications Failure
• Pulse Flash: 1/30 Second On / 1/4 Second Off: (2 Seconds between pulse sequences)

Error Code

• Flash: Actuator Fault
• Flashes: CO2 Sensor
• Flashes: RA Humidity Sensor
• Flashes: RA Temp Sensor
• Flashes: OA Humidity Sensor
• Flashes: OA Temp Sensor
• Flashes: MA Temp Sensor
• Flashes: On-board Setpoint Failure

Wiring Diagrams

• Note: Wiring diagrams can be accessed via e-Library by entering the diagram number in the literature order number search field or by contacting technical support.

Table 9. Wiring diagrams

Type of Airflow| Schematic Type| Voltage| Diagram Number| Description
---|---|---|---|---
__

__

__

__

Constant Volume

| Power| 208–575| 12134757| Cooling only or Electric Heat
Control| 208–575| 12134762| Cooling only or Electric Heat
__ Control Box Connection| 208–575| 12131531| Electric Heat-208/575- 5-15 kW
208–230| 12131532| Electric Heat-208/230-20-25 kW
460/575| 12131533| Electric Heat-460/575-20-25 kW
Component Location| 208-575| 12134785| Cooling only or Electric Heat

Warranty

For Commercial Unitary Equipment Rated 25 Tons and Under and Related Accessories

• Products Covered — This warranty is extended by Trane and applies to the following products:
• All packaged and split system air conditioners and heat pumps have a rated capacity of 25 tons and under.
• All packaged combinations gas/electric air conditioners having a rated capacity of 25 tons and under.
• All packaged combination gas/electric air conditioners having a rated capacity of 1.5 through 5 tons single phase electric power and used for commercial applications.
• (As used in this warranty, a commercial application is any application where the end purchaser uses the product for other than personal, family or household purposes).
• All accessories for the above products which are sold by Trane and applied in accordance with Trane specifications.

Basic Warranty

• The warrantor warrants for a period of twelve (12) months from the initial start-up or eighteen (18) months from date of shipment, whichever is sooner, that the products covered by this warranty (1) are free from defects in material and manufacture, and (2) have the capacities and ratings set forth in the warrantor’s catalogs and bulletins. If any part of your air conditioner fails because of a manufacturing defect, Warrantor will furnish without charge the required replacement part.
• If the heat exchanger fails because of a manufacturing defect within five years from the date of start-up, Warrantor will furnish without charge a replacement heat exchanger.
• In addition, if the optional, factory installed, stainless steel heat exchanger fails because of a manufacturing defect within ten years from the date of start-up, Warrantor will furnish without charge a replacement heat exchanger. Any local transportation, related service labor and diagnosis calls are not included. In addition, if the sealed motor-compressor fails because of a manufacturing defect within the second through fifth year from the date of original purchase, Warrantor will furnish without charge the required replacement compressor.

Exclusions and Limitations

• The warrantor’s obligations and liabilities under this warranty are limited to furnishing F.O.B. factory or warehouse at the warrantor-designated shipping point, freight allowed to Buyer’s city (or port of export for shipments outside the conterminous United States) a replacement product or, at the option of the warrantor, parts for the repair of the product not conforming to this warranty and which have been returned to the warrantor.
• The warrantor’s warranty is conditional on the Customer providing written notice to the warrantor within thirty (30) days of the discovery of the defect. No product shall be returned to the warrantor without the warrantor’s written permission. No liability whatever shall attach to warrantor until said products have been fully paid for and then said liability shall be limited to the purchase price of the equipment shown to be defective.
• The warranty does not apply to any compressor or gasfired heat exchanger which has been repaired or altered in such manner as, in the judgement of the warrantor, affects its stability or reliability. This warranty does not cover (1) any heat exchanger which has been fired with an improper type of fuel (2) a heat exchanger which is installed in a beauty parlor, dry cleaning establishment, de-greasing plant or in any corrosive atmosphere; or (3) any heat exchanger which is not shown to be defective by the warrantor’s inspection.
• This warranty does not cover damage due to accident, abuse, improper use, external causes, freezing, corrosion, erosion or deterioration. Local transportation, related service labor, air filters, diagnosis calls, refrigerant and related items are not covered.
• 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 IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY IMPLIED WARRANTIES OTHERWISE ARISING FROM THE COURSE OF DEALING OR TRADE. IN NO EVENT SHALL THE WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.
• The warrantor makes certain further warranty protection available on an optional, extra-cost basis. Any further warranty must be in writing. If you wish further help or information concerning this warranty, contact: Trane — Warrantor, 2701 Wilma Rudolph Blvd., Clarksville, TN 37040
• Trane and American Standard create comfortable, energy-efficient indoor environments for commercial and residential applications. For more information, please visit trane.com or americanstandardair.com.
• Trane and American Standard have a policy of continuous product and product data improvement and reserve the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
• RT-SVX083B-EN 23 Aug 2024
• Supersedes RT-SVX083A-EN (July 2024)

References

• American Standard® | Air Conditioning and Heating | HVAC Systems
• Trane Heating & Air Conditioning

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