Operation Maintenance

Transcription

1 Installation Operation Maintenance RT-SVX17E-EN Important! This document is customer property and must be retained by the unit's maintenance personnel. Library Service Literature Product Section Unitary Product Rooftop Air Conditioning (27½ - 50 Tons) Model TE*, TC*, & YC* Literature Type Installation/Operation/Maintenance Sequence 17E Date July 2007 File No. SV-UN-RT-SVX17E-EN Supersedes RT-SVX17D-EN 11/06 Voyager TM Commercial 27½ to 50 Ton 60 Hz Commercial 23 to 42 Ton 50 Hz CV or VAV Rooftop Air Conditioners with ReliaTel Controls Models "V" and later Design Sequence TC*, TE*, YC*330A, 360A, 420A, 480A, 600A (60 Hz/3 phase) TC*, TE*, YC*275A, 305A, 350A, 400A, 500A (50 Hz/3 phase) Note: The installation of this equipment must comply with all National, State, and Local Codes. 60 Hz units with standard options are certified by Underwriters Laboratory and the Canadian Standards Association American Standard All rights reserved Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. 1

2 About This Manual Literature Change History... 6 Manual Overview... 6 Warnings and Cautions... 6 Commonly Used Acronyms... 6 About the Unit... 7 Unit Inspection... 7 Storage... 7 Installation General Unit Requirements Downflow Models Only: All Units: Electrical Requirements Field Installed Control Wiring Gas Heat Requirements Recommended Clearances Roof Curb and Ductwork Horizontal Ductwork Unit Rigging and Placement Condensate Drain Connection O/A Sensor & Tubing Installation Field Installed Gas Piping General Requirements Connecting the Gas Supply Line to the Furnace Gas Train Field Installed Electrical Wiring Disconnect Switch External Handle (Factory Mounted Option) Main Power Wiring Low Voltage Wiring Field Installed AC Control Wiring Field Installed DC Control Wiring Zone Sensor Wiring Requirements Conventional Thermostat Wiring Requirements Emergency Stop Wiring Zone Sensor Thermostat Connections Remote Panels and Sensors Constant Volume Mode of Operation Zone Panel (BAYSENS006*) Zone Panel (BAYSENS008*) Remote Panel W/O NSB (BAYSENS010*) Remote Panel with NSB (BAYSENS019*) Variable Air Volume Mode of Operation Default Discharge Air Control Remote Panel with NSB (BAYSENS020*) Remote Panel W/O NSB (BAYSENS021*) Remote Zone Sensor (BAYSENS073*) Remote Zone Sensor (BAYSENS074*) Remote Zone Sensor (BAYSENS077*) High Temperature Sensor (BAYFRST001*) Remote Zone Sensor (BAYSENS016*) Remote Minimum Position Potentiometer (BAYSTAT023A) Space Temperature Averaging Unit Control Modules RTRM - ReliaTel Refrigeration Module ECA - Economizer Actuator (Optional) RTAM - ReliaTel Airhandler Module Conventional Thermostat Connections Economizer Operation with a Coventional Thermostat LCI - LonTalk Communication Interface TCI - Trane Communication Interface (Optional) Table of Contents System Operation ReliaTel Control Features Economizer Operation with CV Controls Mechanical Cooling without an Economizer Zone Temperature - Occupied Cooling Zone Temperature - Occupied Heating Supply Fan Supply Air Tempering Variable Air Volume Applications Supply Air Temperature Control - Occupied Cooling Supply Air Temperature Control with an Economizer Zone Temperature Control without a Night Setback Panel or ICS - Unoccupied Cooling Zone Temperature Control without a Night setback Panel or ICS - Unoccupied Heating Morning Warm-up Control Daytime Warm-up Control Supply Duct Static Pressure Control Supply Air Temperature Reset Constant Volume or Variable Air Volume Applications Off Mode Zone Temperature - Unoccupied Cooling Zone Temperature - Unoccupied Heating Mechanical Cooling with an Economizer Gas Heat Control Electric Heat Control Clogged Filter Ventilation Override Control Emergency Stop Low Pressure Control High Pressure Cutout Power Exhaust Control Compressor Winding Protection Lead/Lag Control Coil Frost Protection Condenser Fan/Compressor Sequencing Control Unit Start-Up Preparing the Unit for Operation Electrical Phasing Voltage Supply and Voltage Imbalance Supply Voltage Voltage Imbalance Starting the Unit Test Modes Verifying Proper Fan Rotation Verifying Proper Air Flow (CFM) (CV, IGV's or VFD's) Exhaust Fan Operation Economizer Damper Adjustment Manual Fresh Air Damper Starting the Compressors Compressor Oil Scroll Compressor Operational Noises Compressor Crankcase Heaters At Shutdown: At Low Ambient Start-Up During Normal Operation Charging by Subcooling

3 Table of Contents (Continued) Heater Start Up Gas Heat Units Electric Heat Units Final Unit Checkout For Constant Volume Units; For Variable Air Volume Units; Mechanical Cooling Sequence Of Operation Units without an Economizer Units with An Economizer Economizer Operation Dry Bulb Economizer Operation Reference Enthalpy Economizer Operation Comparative Enthalpy Electric Heat Sequence Of Operation Service and Maintenance Fan Belt Adjustment Monthly Maintenance Filters Cooling Season Heating Season Coil Cleaning Maintenance Log System Troubleshooting System Status Checkout Method Method Resetting Cooling and Ignition Lockout Method 1 (from the space) Method 2 (from the unit) Zone Temperature Sensor Service Indicator Clogged Filter Switch Fan Failure Switch Zone Temperature Sensor Test Procedures Zone Temperature Thermistor Cooling and Heating Setpoint System Model and Fan Selection LED Indicator Test Programmable & Digital Zone Sensor Test Procedure RTRM Default Operation CV and VAV Units DIP Switch Settings ECA Test Procedure VFD Testing System Troubleshooting Chart Component Failure Mode VFD Programming Parameters Warranty Information UV Lights

4 Figures and Tables Figure 1 Unit Dimensions for TC_, TE_, and YC_330, 360 and 420 MBH Units (Low Heat)... 8 Figure 1 (Continued) Unit Dimensions for YC_330, 360 and 420 MBH Units (High Heat)... 9 Figure 1 (Continued) Unit Dimensions for TC_, TE_, and YC_480 and 600 MBH Units (Low & High Heat) Figure 1 (Continued) Fresh Air and Power Exhaust Hood Dimensions for TC_, TE_, and YC_ Units Figure 2 Location of shipwith Items for TC_, TE_, and YC_ Units Figure 3 Center of Gravity Figure 4 Unit Rigging Figure 5 Condensate Trap Installation Figure 6 O/A Pressure Sensor Kit Figure 7 Gas Train Configuration for Low Heat Units Figure 8 Typical Field Power Wiring Figure 9 Electrical Wire Sizing and Protection Device Equations Figure 10 Typical Field Wiring Requirements for CV Control Options Figure 11 Typical Field Wiring Requirement for VAV Control Options Figure 12 Condenser Fan Location Figure 13 VAV Test Modes Figure 14 Supply Fan Performance Curves Figure 15 Economizer (O/A) Damper Assembly Figure 16 Typical Belt Tension Gauge Figure 17 Belt Deflection Table 1 Minimum Operating Clearances for Unit Installation Table 2 Slope Allowances Table 3 Unit Weights and Point Loading Weights Table 4 Optional Component Weights Table 5 Sizing Natural Gas Pipe Mains & Branches Table 5-1 Specific Gravity Multipliers Table Ton Electrical Service Sizing Data Table 7 AC Conductors Table 8 DC Conductors Table 9-1 RTRM Zone Sensor/Thermostat Connections Table 9 Variable Air Volume Mode Operation Table 10 Temperature versus Resistance Table 12 Percent of Damper Travel Table 13 Compressor Staging with Lead/Lag Disabled Table 14 Economizer Configuration Table Table 15 Ventilation Override Sequence Table 16 Condenser Fan Sequence Table 17 TC*/YC* 330 Through 600 MBH Economizer (R/A) Damper Pressure Drop Table 18 TC*, TE* & YC* Component Pressure Drops Table 19 TC*, TE* & YC* 27.5 through 35 Ton Supply Fan Performance Table 20 Supply Fan Drive Selection Table 21 Power Exhaust Fan Performance Table 22 Economizer (O/A) Damper Static Pressure Setup Table , 35 Operating Pressures (Std. 60 Hz) Table Ton Dual Circuit Operating Pressures (Std. 60 Hz). 51 Table Ton Dual Circuit Operating Pressures (Std. 60 Hz). 52 Table , 35 Ton Operating Pressures (Hi Eff 60 Hz) Table Ton Dual Circuit Oper Pressures (Hi Eff 60 Hz) Table Ton Dual Circuit Oper Pressures (Hi Eff 60 Hz) Table 23a 27.5, 35 Operating Pressures (Std. 50 Hz) Table 24a 40 Ton Dual Circuit Operating Pressures (Std. 50 Hz). 59 Table 25a 50 Ton Dual Circuit Operating Pressures (Std. 50 Hz). 60 Table 26a 27.5, 35 Ton Operating Pressures (Hi Eff 50 Hz) Table 27a 40 Ton Dual Circuit Oper Pressures (Hi Eff 50 Hz) Table 28a 50 Ton Dual Circuit Oper Pressures (Hi Eff 50 Hz) Table 29 Humidity versus Current Input Table 30 Grease Recommendations Table 31 Sample Operator's Maintenance Log Table 32 VFD Programming Parameters

5 Model Number Description All products are identified by a multiple character model number that precisely identifies a particular type of unit. An explanation of the alphanumeric identification code used with the unit is provided below. Its use will enable the owner/operator, installing contractors and service technicians to define the unit's specific components, type of application, i.e. CV or VAV, and control options for a particular unit. When ordering replacement parts or requesting service, be sure to refer to the specific model number, serial number, and DL number (if applicable) stamped on the unit nameplate. Unit Nameplate A Mylar unit nameplate is located on the unit's corner support just below the main power entrance access into the control panel. It includes the unit model number, serial number, electrical characteristics, weight, refrigerant charge, as well as other pertinent unit data. Compressor Nameplate The Nameplate for the Scroll Compressor is located on the compressor lower housing. YCD A 4 H A 1 A 4 A D 1 A B C D E F G H J K L M N P R 5 1,2,3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, Digit 1, 2 Unit Function TC = DX Cooling, No Heat TE = DX Cooling, Electric Heat YC = DX Cooling, Natural Gas Heat Digit 3 Unit Airflow Design D = Downflow Configuration H = Horizontal Configuration Digit 4, 5, 6 Nominal Cooling Capacity 330 = 27½ Tons 360 = 30 Tons 420 = 35 Tons 480 = 40 Tons 600 = 50 Tons Digit 7 Major Development Sequence A = First Digit 8 Power Supply (See Note 1) E = 208/60/3 F = 230/60/3 4 = 460/60/3 5 = 575/60/3 Digit 9 Heating Capacity (See Note 4) 0 = No Heat (TC only) L = Low Heat (YC only) H = High Heat (YC only) J = Low Heat-Stainless Steel Gas Heat Exchangers (YC only) K = High Heat-Stainless Steel Gas Heat Exchanger (YC only) M = Low Heat-Stainless Steel Gas Heat Exchangers w/modulating control (YC only) P = High Heat-Stainless Steel Gas Heat Exchangers w/modulating control (YC only) Note: When second digit is E for Electric Heat, the following values apply in the ninth digit. A = 36 KW B = 54 KW C = 72 KW D = 90 KW E = 108 KW Digit 10 Design Sequence R = R and later Digit 11 Exhaust 0 = None 1 = Barometric Relief (Available w/economizer only) 2 = Power Exhaust Fan (Available w/economizer only) Digit 12 Filter A = Standard 2 Throwaway Filters B = High Efficiency 2 Throwaway Filters C = High Efficiency 4 Throwaway Filters Digit 13 Supply Fan Motor, HP 1 = 7.5 Hp Std. Eff. 2 = 10 Hp Std. Eff. 3 = 15 Hp Std. Eff. 4 = 20 Hp Std. Eff. 5 = 7.5 Hp Hi. Eff. 6 = 10 Hp Hi. Eff. 7 = 15 Hp Hi. Eff. 8 = 20 Hp Hi. Eff. Digit 14 Supply Air Fan Drive Selections (See Note 3) A = 550 RPM H = 500 RPM B = 600 RPM J = 525 RPM C = 650 RPM K = 575 RPM D = 700 RPM L = 625 RPM E = 750 RPM M = 675 RPM F = 790 RPM N = 725 RPM G = 800 RPM Digit 15 Fresh Air Selection A = No Fresh Air B = 0-25% Manual Damper C = 0-100% Economizer, Dry Bulb Control D = 0-100% Economizer, Reference Enthalpy Control E = 0-100% Economizer, Differential Enthalpy Control F = C Option and Low Leak Fresh Air Damper G = D Option and Low Leak Fresh Air Damper H = E Option and Low Leak Fresh Air Damper Digit 16 System Control 1 = Constant Volume 2 = VAV Supply Air Temperature Control w/o Inlet Guide Vanes 3 = VAV Supply Air Temperature Control w/inlet Guide Vanes 4 = VAV Supply Air Temperature Control w/variable Frequency Drive w/o Bypass 5 = VAV Supply Air Temperature Control w/variable Frequency Drive and Bypass Note: Zone sensors are not included with option and must be ordered as a separate accessory. Digit Miscellaneous Options A = Service Valves (See Note 2) B = Through the Base Electrical Provision C = Non-Fused Disconnect Switch with External Handle D = Factory-Powered 15A GFI Convenience Outlet and Non-Fused Disconnect Switch with External Handle E = Field-Powered 15A GFI Convenience Outlet F = Trane Communication Interface (TCI) G = Ventilation Override H = Hinged Service Access J = Condenser Coil Guards K = LCI (LonTalk) L = Unused digit M = Stainless Steel Drain Pans Digit 29 Condenser Coil Options 0 = Standard Efficiency Condenser Coil N = Standard Efficiency Condenser Coil with Black Epoxy Pre-Coating 3 = High Efficiency Condenser Coil Q = High Efficiency Condenser Coil with Black Epoxy Pre-Coating Digit Miscellaneous Options P = Discharge Temperature Sensor R = Clogged Filter Switch Notes: 1. All voltages are across the line starting only. 2. Option includes Liquid, Discharge, Suction Valves. 3. Supply air fan drives A thru G are used with 27½-35 ton units only and drives H thru N are used with 40 & 50 ton units only. 4. Electric Heat KW ratings are based upon voltage ratings of 240/480/600 V. 5. The service digit for each model number contains 31 digits; all 31 digits must be referenced. 5

6 Literature Change History RT-SVN17E-EN (July 2007) Revised issue: Updated with Modulating Natural Gas Information. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "R" and later design sequence. RT-SVN17D-EN (June 2006) Revised issue: Updated with High Efficiency Condenser Coil Information. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "U" and later design sequence. RT-SVN17C-EN (March 2005) Revised issue: Updated Gas Heat Sequence of Operation Section. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "P" and later design sequence. RT-SVN17C-EN (January 2005) Revised issue: Added Capacitor Discharge Warning. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "P" and later design sequence. RT-SVN17C-EN (October 2004) Revised issue: Supply fan proving switch change. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "P" and later design sequence. RT-SVN17B-EN (July 2004) Revised issue: alternate supply fan and belt supplier added. Provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "M" and later design sequence. RT-SVN17A-EN (April 2004) Revised issue: ReliaTel Controls added--provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "M" and later design sequence. YC-IOM-11 (October 2001) Original issue: provides specific installation, operational, and maintenance instructions for TC_, TE_, and YC_ units with "H" and later design sequence. Manual Overview One copy of the appropriate service literature ships inside the control panel of each unit. The procedures discussed in this manual should only be performed by qualified, experienced HVAC technicians. Note: Do Not release refrigerant to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws. This booklet describes the proper installation, start-up, operation, and maintenance procedures for TC_, TE_, and YC_27.5 through 50 Ton CV (Constant Volume) and VAV (Variable Air Volume) applications. Refer to page 2 for a detailed table of contents listing specific topics. Refer to the "System Troubleshooting" section at the end of this manual for troubleshooting information. By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized. It is important that periodic maintenance be performed to help assure trouble free operation. A maintenance schedule is provided at the end of this manual. Should equipment failure occur, contact a qualified service organization with qualified, experienced HVAC technicians to properly diagnose and repair this equipment. About This Manual Hazard Identification 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, may result in minor or moderate injury. It may also be used to alert against unsafe practices. Commonly Used Acronyms/Abbreviations BAS = building automation system CFM = cubic feet per minute COMM = Module Designation for TCI/LCI CV = constant volume CW = clockwise CCW = counterclockwise DSP = direct space pressure control DTS = discharge air sensor DWU = Daytime Warm-up E/A = exhaust air ECA = Economizer Actuator F/A = fresh air FFS = fan failure switch ICS = Integrated Comfort System (See BAS) IDM = indoor fan motor IGV = inlet guide vanes I/O = input/output IOM = installation, operation and maintenance manual (Ships with each unit) LCI = LonTalk Communication Interface LCI-R = LonTalk Communication Interface with ReliaTel LH = left hand MAS = mixed air sensor MAT = mixed air temperature MWU = morning warm up NSB = night setback (programmable ZSM BAYSENS019*, 20*) O/A = outside air OAH = outside air humidity OAT = outside air temperature PSIG = pounds per square inch gauge pressure R/A = return air RAH = return air humidity RAT = return air temperature sensor RH = right hand RPM = revolutions per minute RTAM = ReliaTel Airhandler Module RTOM = ReliaTel Options Module RTRM = ReliaTel Refrigeration Module S/A = supply air SPT = static pressure transducer TCI = Trane communication interface TCO = temperature cutout VAV = variable air volume VFD = Variable Frequency Drive VHR = ventilation heat relay (VAV box relay) W.C. = water column XFSP = exhaust fan setpoint ZSM = sensor, zone sensor, zone sensor module, zone panel

7 About the Unit Each package rooftop unit ships fully assembled and charged with the proper refrigerant quantity from the factory. They are controlled by a microelectronic unit control processor. Several solid state modules are grouped to form the "Control System". The number of modules within any given control system will be dependent upon the options and accessories ordered with the unit. Acronyms are used extensively throughout this manual when referring to the "Control System" (see acronyms/abbreviations previous page). Basic unit components include: Scroll compressors One (1) Intertwined Evaporator Coil One (1) Intertwined Condenser Coil One (1) Supply Fan Three (3) to Four (4) Condenser Fans Filters (type is dependent on option selection) Overall unit dimensional data is illustrated in Figure 1. Unit Inspection As soon as the unit arrives at the job site: [ ] Verify that the nameplate data corresponds to the sales order and bill of lading (including electrical data). [ ] Visually inspect the exterior of the unit, including the roof, for physical signs of shipping damage. [ ] Check for material shortages. Figure 2 illustrates where "ship with" items are placed inside the unit. 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. Do not install a damaged unit without the Appropriate Trane sales representative's approval! [ ] Visually check the internal components for shipping damage as soon as possible after delivery and before it is stored. Do not walk on the sheet metal base pans. WARNING Fiberglass Wool Product contains fiberglass wool. 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. Glass wool fibers may also cause respiratory, skin or eye irritation. Precautionary Measures - Avoid breathing fiberglass dust. - Use a NIOSH approved dust/mist respirator. - Avoid contact with the skin or eyes. Wear longsleeved, loose-fitting clothing, gloves, and eye protection. - Wash clothes separately from other clothing: rinse washer thoroughly. - Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respiration in these situations. First Aid Measures Eye Contact - Flush eyes with water to remove dust. If symptoms persist, seek medical attention. Skin Contact - Wash affected areas gently with soap and warm water after handling. An optional roof curb, specifically designed for the Voyager commercial rooftop units is available from Trane. The roof curb kit must be field assembled and installed according to the latest edition of CURB-IN-35. WARNING No Step Surface! Do not walk on the sheet metal drain pan. Walking on the drain pan could cause the supporting metal to collapse. Failure of the drain pan could result in death or serious injury. Bridging between the unit's main supports may consist of multiple 2 by 12 boards or sheet metal grating. [ ] If concealed damage is discovered, notify the carrier's terminal office immediately by phone and by mail. Concealed damage must be reported within 15 days. Request an immediate joint inspection of the damage by the carrier and the consignee. Do not remove the damaged material from the receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery. Storage Take precautions to prevent condensate formation inside the unit's electrical components and motors when: a. The unit is stored before it is installed; or, b. The unit is set on the roof curb and temporary auxiliary 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) to minimize ambient air from entering the unit until it is ready for start-up. Do not use the unit's heater as temporary heat without completing the start-up procedures detailed under "Unit Start-Up". Trane will not assume responsibility for equipment damage resulting from accumulation of condensate on the unit's electrical components.

8 Figure 1 Unit Dimensions for TC_, TE_, and YC_330, 360 and 420 MBH Units (Low Heat) 8

9 Figure 1 (continued) Unit Dimensions for YC_330, 360 and 420 MBH Units (High Heat) 9

10 Figure 1 (continued) Unit Dimensions for TC_, TE_, and YC_480 and 600 MBH Units (Low & High Heat) 10

11 Figure 1 (continued) Fresh Air and Power Exhaust Hood Dimensions for TC_, TE_, and YC_ Units Figure 2 Location of Shipwith Items for TC_, TE_, and YC_ Units 11

12 Installation The checklist listed below is a summary of the steps required to successfully install a Voyager Commercial rooftop 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. General Unit Requirements Downflow Models Only: [ ] Assemble and install the roof curb, including necessary gaskets. (See the current edition of CURB-IN-35.) Make sure the curb is level. [ ] Install and secure the ductwork to the curb. Refer to the current addition of CURB-IN-35. All Units: [ ] Check unit for shipping damage and material shortage. Refer to page 7, Unit inspection. [ ] Rigging the unit. Refer to page 15, Figure 4. [ ] Placing the unit on curb; check for levelness. Refer to page 13. [ ] Ensure that the unit-to-curb seal is tight and without buckles or cracks. [ ] Install an appropriate drain line to the evaporator condensate drain connections, as required. Refer to Figure 5 on page 16. [ ] Service Valve Option; Refer to page 48, "Starting the Compressors". [ ] Return/Fresh-air damper adjustment. Refer to page 46, Economizer Damper Adjustments. Electrical Requirements (See page 20, Field Installed Electrical Power Wiring) [ ] Inspect all control panel components; tighten any loose connections. [ ] Connect properly sized and protected power supply wiring to a field supplied/installed disconnect and unit power terminal block HTB1, or to the optional unitmounted disconnect switch. [ ] Properly ground the unit. Field Installed Control Wiring (Figure 9 & Figure 10) Note: All field-installed wiring must comply with NEC and applicable local codes. [ ] Complete the field wiring connections for the constant volume controls as applicable. Refer to the "Low Voltage Wiring" section on page 23 for guidelines. [ ] Complete the field wiring connections for the variable air volume controls as applicable. Refer to the "Low Voltage Wiring" section on page 23 for guidelines. Gas Heat Requirements (See page 17, Field Piping) [ ] Gas supply line properly sized and connected to the unit gas train. [ ] All gas piping joints properly sealed. [ ] Drip leg Installed in the gas piping near the unit. [ ] Gas piping leak checked with a soap solution. If piping connections to the unit are complete, do not pressurize piping in excess of 0.50 psig or 14 inches w.c. to prevent component failure. [ ] Main supply gas pressure adequate. [ ] Flue Tubes clear of any obstructions. [ ] Verify that the electrical power supply characteristics comply with the unit nameplate specifications. 12

13 Recommended Clearances Adequate clearance around and above each Voyager Commercial unit is required to ensure proper operation and to allow sufficient access for servicing. If the unit installation is higher than the typical curb elevation, a field constructed catwalk around the unit is recommended to provide safe, easy access for maintenance and servicing. Table 1 lists the recommended clearances for single and multiple unit installation. These clearances are necessary to assure adequate serviceability, cataloged capacities, and peak operating efficiency. If the clearances available on the job site appear to be inadequate, review them with your Trane sales representative. Roof Curb and Ductwork The curbs for the 27.5 to 50 Ton commercial rooftop units enclose the entire unit base area. They are referred to as "full perimeter" type curbs. Step-by-step instructions for the curb assembly and installation with curb dimensions and curb configuration for "A", "B", and "C" cabinets ship with each Trane accessory roof curb kit. (See the latest edition of CURB-IN-35) Follow the instructions carefully to assure proper fit when the unit is set into place. The S/A and R/A ductwork adjoining the roof curb must be fabricated and installed by the installing contractor before the unit is set into place. Trane curbs include flanges around the openings to accommodate duct attachment. Ductwork installation recommendations are included in the instruction booklet that ships with each Trane accessory roof curb kit. Installation (Continued) Note: For sound consideration, cut only the holes in the roof deck for the supply and return duct penetration. Do Not remove the roof decking from the inside perimeter of the curb. If a Trane curb accessory kit is not used; a. The ductwork can be attached directly to the S/A and R/A openings. Be sure to use a flexible duct connector at the unit. b. For "built-up" curbs supplied by others, gaskets must be installed around the curb perimeter flange, S/A opening, and R/A openings. c. Insulation must be installed on the bottom of the condenser section of the unit. Horizontal Ductwork When attaching the ductwork to a horizontal unit, provide a water tight flexible connector at the unit to prevent noise transmission from the unit into the ductwork. Refer to Figure 1 for the S/A and R/A opening dimensions. All outdoor ductwork between the unit and the structure should be weather proofed after installation is completed. If optional power exhaust is selected, an access door must be field-installed on the horizontal return ductwork to provide access to exhaust fan motors. Unit Rigging and Placement 1. Verify that the roof curb has the proper gaskets installed and is level and square to assure an adequate curb-tounit seal. Table 1 Minimum Operating Clearances for Unit Installation Recommended Clearances Condenser Coil** Single Unit Econo / Exhaust Orientation Service Side End End / Side Access TC*, TE*, YC* 6 Feet 8 Feet / 4 Feet 4 Feet 27.5 thru 50 Tons Distance Between Units Multiple Unit Econo / Exhaust Service Side End End / Side Access TC*, TE*, YC* 12 Feet 16 Feet / 8 Feet 8 Feet 27.5 thru 50 Tons * Horizontal and Downflow Units. ** Condenser coil is located at the end and side of the unit. The units must be as level as possible in order to assure proper condensate flow out of the unit. The maximum sideto-side and end-to-end slope allowable in any application is listed in Table 2. 13

14 Table 2 Cabinet End to End Side to Side (inches) (inches) "A" ( Ton Low Heat) 3 1/2 1 5/8 "B" ( Ton High Heat) 4 1 5/8 "C" (All 40 and 50 Ton Units) 4 1/2 1 5/8 Do not exceed these allowances. Correct the improper slope by building up the curb base. The material used to raise the base must be adequate to support both the curb and the unit weight. WARNING Heavy Objects! Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or propertyonly damage. Failure to properly lift unit may result in death or serious injury. Installation (Continued) 2. Attach adequate strength lifting cables to the lifting lugs within the base rail. Table 3 lists the unit weights and corner weights. To obtain the total unit weight, add the accessory weight listed in Table 4 to the base unit weight. The unit center-of-gravity location and dimensions are shown in Figure 3. Figure 4 illustrates the Installation of spreader bars to protect the unit and to assure a uniform lift. Note that the minimum distance between the lifting hook and the top of the unit should be 7 feet. 3. Test-lift the unit to check all rigging and balance; make any rigging adjustments necessary. 4. Lift the unit and position it over the curb. Align the base rails of the unit up with the curb. 5. Lower the unit onto the curb. Make sure that the gasket on the curb remains intact when positioning the unit. Use spreader bars as shown in the diagram. Refer to the Installation manual or nameplate for unit weight. Refer to the Installation instructions located inside the control panel for further rigging information. Figure 3 Center of Gravity Center-of-Gravity (inches) Unit Model YC Low Heat Dimension YC High Heat Dimension TC/TE Dimension X Y Z X Y Z X Y Z (note 2) ***330* ***360* ***420* ***480* ***600* Note: 1. Center-of-gravity dimensions are approximate, and are based on the unit equipped with: standard efficiency coils, standard efficiency motors, economizer, inlet guide vanes, and throwaway filters 2. Z dimension is upward from the base of the unit. Example: Locating the center-of-gravity for a YC-360 MBH High Heat unit with 100% exhaust. X = 40 inches inward from the control panel side Y = 86 inches inward from the compressor end Z = 33 inches upward from the base Y Z (see note 2) X 14

15 Figure 4 Unit Rigging Table 3 Approximate Unit Operating Weights/Average Point Loading Weights lbs./kg (see notes 1,2,3,4,5) Basic Unit Weights 1,2,3 Unit YC YC TC TE Model Low Heat High Heat **D330/ / / / /1626 **H330/ / / / /1644 **D360/ / / / /1662 **H360/ / / / /1681 **D420/ / / / /1701 **H420/ / / / /1719 **D480/ / / / /2091 **H480/ / / / /2123 **D600/ / / / /2168 **D600/ / / / /2200 A B C D E F 899/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /346 Notes 1. Basic unit weight includes minimum horsepower supply fan motor and standard efficiency 2-row condenser coil. 2. Optional high efficiency motor weights are in addition to the standard motor weights included in the basic unit weight (see component weights). 3. Optional high efficiency 3-row condenser coil weights are in addition to the standard 2-row coil weight included in the basic unit weight (see component weights). 4. Point Loading is identified with corner A being the corner with the compressors. As you move clockwise around the unit as viewed from the top, mid-point B, corner C, corner D, mid-point E and corner F. 5. Point load calculations provided are based on the unit weight for YC high heat gas models. Table 4 Approximate Operating Weights 1 Optional Components lbs./kg Var. Freq. Non- Factory. 0-25% Inlet Drives (VFD s) Thru-the Fused GFI with Hi Eff Roof Unit Baro. Power Hi Eff. Supply Man Guide W/O With Serv base Discon. Discon. Cond Curb Model Relief Exhaust Fan Motor 2 Damper Econ. Vanes Bypass Valves Elec. Switch Switch Coil 3 Lo Hi **D330/ /50 165/74 20/9 50/23 260/117 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **H330/ /65 200/90 20/9 50/23 285/128 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **D360/ /50 165/74 20/9 50/23 260/117 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **H330/ /65 200/90 20/9 50/23 285/128 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **D420/ /50 165/74 20/9 50/23 260/117 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **H420/ /65 200/90 20/9 50/23 285/128 55/25 85/39 115/52 18/8 6/3 30/14 85/38 104/47 310/ /150 **D480/ /50 165/74 44/20 50/23 290/131 70/32 115/52 150/68 18/8 6/3 30/14 85/38 162/73 365/ /169 **H480/ /65 200/90 44/20 50/23 300/135 70/32 115/52 150/68 18/8 6/3 30/14 85/38 162/73 365/ /169 **D600/ /50 165/74 44/20 50/23 290/131 70/32 115/52 150/68 18/8 6/3 30/14 85/38 162/73 365/ /169 **H600/ /65 200/90 44/20 50/23 300/135 70/32 115/52 150/68 18/8 6/3 30/14 85/38 162/73 365/ /169 Notes: 1. Basic unit weight includes minimum horsepower supply fan motor and standard efficiency 2-row condenser coil. 2. When an optional high efficiency supply fan motor is selected, the weight shown should be added to the basic unit weight. 3. When an optional high efficiency condenser coil is selected, the weight shown should be added to the basic unit weight. 15

16 Condensate Drain Connection Each commercial rooftop unit is equipped with one (1) 1-1/4 inch Female PVC condensate drain connection. Installation (Continued) Figure 6 Refer to Figure 2 for the location of the connector. A condensate trap must be installed due to the drain connection being on the "negative pressure" side of the fan. Install a P-Trap at the unit using the guidelines in Figure 5. Pitch the drain line at least 1/2 inch for every 10 feet of horizontal run to assure proper condensate flow. Ensure that all condensate drain line installations comply with applicable building and waste disposal codes. Figure 5 Condensate Trap Installation O/A Sensor & Tubing Installation An Outside Air Pressure Sensor is shipped with all units designed to operate on variable air volume applications. A duct pressure transducer and the outside air sensor is used to control the discharge duct static pressure to within a customer-specified controlband. Refer to the illustration in Figure 6 and the following steps to install the sensor and the pneumatic tubing. 1. Remove the O/A pressure sensor kit located inside the fan section. The kit contains the following items; - an O/A static pressure sensor - a sensor mounting bracket - 2' of 3/16" O.D. pneumatic tubing - mounting hardware 2. Using two #10-32 x 1-3/4" screws provided, install the sensor's mounting bracket to the factory provided bracket (near the fan section). 3. Using the #10-32 x 1/2" screws provided, install the O/A static pressure sensor vertically to the sensor bracket. 4. Remove the dust cap from the tubing connector located below the sensor in the vertical support. 5. Attach one end of the 2' x 3/16" O.D. factory provided pneumatic tubing to the sensor's top port, and the other end of the tubing to the connector in the vertical support. Discard any excess tubing. 16

17 General Requirements All internal gas piping for YC* rooftop units are factory installed and leak tested. Once the unit is set into place, a gas supply line must be field installed and connected to the gas train located inside the gas heat compartment. WARNING Hazardous Gases and Flammable Vapors! Exposure to hazardous gases from fuel substances have been shown to cause cancer, birth defects or other reproductive harm. Improper installation, adjustment, alteration, service or use of this product could cause flammable mixtures. To avoid hazardous gases and flammable vapors follow proper installation and set up of this product and all warnings as provided in this manual. Failure to follow all instructions could result in death or serious injury. REFER TO THE INSTALLATION, OPERATION AND MAIN- TENANCE MANUAL PROVIDED WITH THIS UNIT FOR PROPER OPERATION INSTRUCTIONS. Access holes are provided on the unit as shown in Figure 2 to accommodate side panel entry. Following the guidelines listed below will enhance both the installation and operation of the furnace. Note: In the absence of local codes, the installation must conform with the American National Standard Z223.1a of the National Fuel Gas Code, (latest edition). 1. To assure sufficient gas pressure at the unit, use Table 5 to determine the appropriate gas pipe size for the heating capacity listed on the unit's nameplate. If a gas line already exists, verify that it is sized large enough (Table 5) to handle the additional furnace capacity. 2. Take all branch piping from any main gas line from the top at 90 degrees or side at 45 degrees to prevent moisture from being drawn in with the gas. 3. Ensure that all piping connections are adequately coated with joint sealant and properly tightened. Use a piping compound that is resistant to liquid petroleum gases. 4. Provide a drip leg near the unit. Field Installed Gas Piping Note: Gas pressure in excess of 14" w.c. or 0.5 psig will damage the gas train. Failure to use a pressure regulating device will result in incorrect gas pressures. This can cause erratic operation due to gas pressure fluctuations as well as damage to the gas valve. Oversizing the regulator will cause irregular pulsating flame patterns, burner rumble, potential flame outages, as well as possible gas valve damage. 6. Leak test the gas supply line using a soap-and-water solution or equivalent before connecting it to the gas train. WARNING Hazard of Explosion! Never use an open flame to detect gas leaks. Explosive conditions may occur. Use a leak test solution or other approved methods for leak testing. Failure to follow recommended safe leak test procedures could result in death or serious injury or equipment or property-onlydamage. 7. Pressure test the supply line before connecting it to the unit to prevent possible gas valve damage and the unsafe operating conditions that will result. Note: Do not rely on gas train shutoff valves to isolate the unit while conducting gas pressure/leak test. These valves are not designed to withstand pressures in excess of 14" w.c. or 0.5 psig. Connecting the Gas Supply Line to the Furnace Gas Train Follow the steps below to complete the installation between the supply gas line and the furnace. Refer to Figure 7 for the Gas Train configuration. 1. Connect the supply gas piping using a "ground-joint" type union to the furnace gas train and check for leaks. 2. Provide adequate support for the field installed gas piping to avoid stressing the gas train and controls. 3. Adjust the inlet supply gas pressure to the recommended 6" for natural gas or 11" w.c. for LP gas. 5. Install a pressure regulator at the unit that is adequate to maintain 6" w.c. for natural gas and 11" w.c. for LP gas while the unit is operating in the "High Heat" mode. A minimum inlet gas pressure of 2.5" w.c. for natural gas and 8" w.c. for LP gas is required while operating in the "High Heat" mode. 17

18 Table 5 Sizing Natural Gas Pipe Mains & Branches Gas Input (Cubic Feet/Hour)* Notes: 1. If more than one unit is served by Gas Supply 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" the same main gas supply, consider Pipe Run (ft) Pipe Pipe Pipe Pipe Pipe Pipe the total gas input (cubic feet/hr.) and the total length when determining the appropriate gas pipe size Obtain the Specific Gravity and BTU/Cu.Ft. from the gas company The following example demonstrates the considerations necessary when determining the actual pipe size Example: A 40' pipe run is needed to connect a unit with a 500 MBH furnace to a natural gas supply having a rating of 1, BTU/Cu.Ft. and a specific gravity of Cu.Ft/Hour = Furnace MBH Input Gas BTU/Cu.Ft. X Multiplier (Table 5-1) Cu.Ft/Hour = 500 * Table is based on a specific gravity of Use Table 5-1 for the Table 5 indicates that a 1-1/4" pipe is required. specific gravity of the local gas supply. Table 5-1 Specific Gravity Multipliers Specific Gravity Multiplier Figure 7 Gas Train Configuration for Low Heat units (High Heat Units utilize two Gas Trains.) 18

19 Disconnect Switch External Handle (Factory Mounted Option) Field Installed Electrical Wiring Note: All field installed wiring must conform to NEC guidelines as well as State and Local codes. Units ordered with the factory mounted disconnect switch come equipped with an externally mounted handle. This allows the operator to disconnect power from the unit without having to open the control panel door. The handle location and its three positions are shown below; ON - Indicates that the disconnect switch is closed, allowing the main power supply to be applied at the unit. OFF - Indicates that the disconnect switch is open, interrupting the main power supply at the unit. OPEN COVER/RESET - Turning the handle to this position releases the handle from the disconnect switch, allowing the control panel door to be opened. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. Once the door has been opened, it can be closed with the handle in any one of the three positions outlined above, provided it matches the disconnect switch position. The handle can be locked in the "OFF" position. While holding the handle in the "OFF" position, push the spring loaded thumb key, attached to the handle, into the base slot. Place the lock shackle between the handle and the thumb key. This will prevent it from springing out of position. Verify that the power supply available is compatible with the unit's name plate ratings for all components. The available power supply must be within 10% of the rated voltage stamped on the nameplate. Use only copper conductors to connect the 3-phase power supply to the unit. CAUTION Use Copper Conductors Only! Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage. Main Power Wiring 1. Table 6 lists the electrical data. The electrical service must be protected from over current and short circuit conditions in accordance with NEC requirements. Protection devices must be sized according to the electrical data on the nameplate. Refer to Figure 9 for determining: a. The appropriate electrical service wire size based on "Minimum Circuit Ampacity" (MCA), b. The "Maximum Over current Protection" (MOP) device. c. The "Recommended Dual Element fuse size" (RDE). 2. 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 in accordance with the National Electrical Code (NEC latest edition). Refer to Figure 9, DSS calculations, for determining correct size. Location for the electrical service entrance is shown in Figure 1. Complete the unit's power wiring connections onto either the main terminal block HTB1, or the factory mounted nonfused disconnect switch inside the unit control panel. Note: Any electrical entrance holes drilled into the base of the unit when a thru-the-base option is not used, is the responsibility of the installing contractor to prevent water from leaking into the building. 3. Provide proper grounding for the unit in accordance with local and national codes. Thru-the-Base Electrical (Optional Accessory) An overall layout of the field required power wiring is illustrated in Figure 8. To insure that the unit's supply power wiring is properly sized and installed, follow the guidelines outlined below. Liquid-tite conduit couplings are secured to the base of the unit for both power and control wiring. Liquid-tite conduit must be field installed between the couplings and the unit control box to prevent water leaks into the building. If the unit is set on the roofcurb and temporary auxiliary heat is provided in the building, it is recommended that the electrical and control wiring conduit opening in the control box be temporarily sealed to provide a vapor barrier. 19

20 Figure 8 Typical Field Power Wiring Table Ton Electrical Service Sizing Data (Electric Heaters Only) Electric Heat FLA All FLA's in this table are based on heater operation at 208, 240, 480, and 600 v Nominal Nominal Unit Size Unit Heater KW (Tons) Voltage , 30, n/a n/a n/a n/a n/a n/a n/a 575 n/a n/a 40, n/a n/a n/a n/a 230 n/a n/a n/a n/a 460 n/a n/a Note: Heater KW = X Applied Voltage X Amps 20

21 Table 6 (Continued) Ton Electrical Service Sizing Data Supply Fan Condenser Exhaust Compressor Std/Hi-Eff Fan Motors Fan Unit Voltage Voltage RLA LRA FLA FLA Model Range No./Size (Ea) (Ea) HP FLA No. HP (Ea) HP (Ea) 208/60/ /10, / / / /29.0 TC/TE/ 230/60/ / / / YC* / /60/ / / / / /60/ / / / / /60/ / / /28.0 TC/TE/ 230/60/ / YC* / /60/ / / /60/ / / /60/ / / / /41.5 TC/TE/ 230/60/ / YC* / / /60/ / / / /60/ / / / /60/ /14,14, /62.8/ /409/ / /41.5 TC/TE/ 230/60/ /62.8/ /376/ / YC* / /60/ /27.3/ /178/ / / /60/ /21.8/ /143/ / / /60/ / / / /56.1 TC/TE/ 230/60/ / YC* / / /60/ / / / /60/ / / /