TRANE Package Units(both Units Combined) Manual L0904650

User Manual: TRANE TRANE Package Units(both units combined) Manual TRANE Package Units(both units combined) Owner's Manual, TRANE Package Units(both units combined) installation guides

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18-AB33D7-3

I STALLATIO
OPERATION
NT
CE
ALL phases of this installation must comply with
NATIONAL, STATE AND LOCAL CODES

Model:
TCX024G1
TCX030GI
TCX036G 1,3,4
TCX042G1,3

IMPORTANT-work.

This Document

TCX048G1,3,4
TCX060G1,3,4
BAYLIFT002AA
LIFTING LUG KIT
is customer

12 SEER Single Package
Cooling W/Electric Heat
2 -5Ton

property and is to remain with this unit. Please return to service information

All phases of this installation must comply with the NATIONAL, STATE & LOCAL CODES.
tion must conform with National Electric Code -- ANSI/NFPA 70 or "LATEST REVISION."

pack upon completion

In the absence of local codes, the installa-

Since American-Standard
has a policy of continuous product improvement,
it reserves the right to change the specifications and design without notice.

07/02

GENERAL
IMPORTANT: Read this entire manual before beginning
lation procedures.

INFORMATION

instal-

SAFETY NOTICE• THIS INFORMATION IS INTENDED FOR
USE BY INDIVIDUALS POSSESSING ADEQUATE BACKGROUNDS OF ELECTRICAL AND MECHANICAL EXPERIENCE. ANY ATTEMPT TO REPAIR A CENTRAL AIR CONDITIONING PRODUCT MAY RESULT IN PERSONAL INJURY
AND/OR PROPERTY DAMAGE. THE MANUFACTURER OR
SELLER CANNOT BE RESPONSIBLE FOR THE INTERPRETATION OF THIS INFORMATION, NOR CAN IT ASSUME
LIABILITY IN CONNECTION WITH ITS USE•
IMPORTANT:
RECONNECT ALL GROUNDING DEVICES•
ALL PARTS OF THIS PRODUCT CAPABLE OF CONDUCTING
ELECTRICAL CURRENT ARE GROUNDED. IF GROUNDING
WIRES, SCREWS, STRAPS, CLIPS, NUTS OR WASHERS
USED TO COMPLETE A PATH TO GROUND ARE REMOVED
FOR SERVICE, THEY MUST BE RETURNED TO THEIR ORIGINAL POSITION AND PROPERLY FASTENED.
IMPORTANT: ALL POWER LEGS MAY NOT BE BROKEN BY
CONTACTORS. SEE WIRING DIAGRAM ON UNIT CONTROL
BOX COVER.

Read this manual carefully before attempting to install, operate, or
perform maintenance on this unit. Installation and maintenance
should be performed by qualified service technicians only.
NOTE:
"Warnings" and "Cautions" appear at appropriate
places in this manual
Your personal safety and the proper
operation of this air conditioning product require that you foflow
them carefully• The manufacturer assumes no liability for
installations or servicing performed by unqualified personnel.

INSPECTION
1. Check for damage after the unit is unloaded• Report promptly,
to the carrier, any damage found to the unit. Do not drop the unit.
IMPORTANT: The use of"spreader bars" is required when
hoisting the unit (to prevent damage to sides and top).

TYPICAL

ROOFTOP

INSTALLATION

(TCX024-036G

3. Check to be sure the refrigerant charge has been retained during
shipment. Access to 1/4" flare pressure taps may be gained by
removing the furnace compartment access panel.

WITH FULL PERIMETER

CURBS

Models on BAYCURB030,038)

FIELD
SUPPLIED
SUPPORTS
AT EACH
END
OF CURB

FIELD
SUPPLIED
CANT
STRIP

FIELD
SUPPLIED
RIGID INSULATION

ROOF MOUNTING
CURB

Page 2

2. Check the unit's nameplate to determine if the unit is correct for
the intended application. The power supply must be adequate
for both the unit and all accessories.

BEFORE STARTING THE COMPRESSOR, THE CRANKCASE
HEATER SHOULD BE ENERGIZED FOR EIGHT HOURS.

SUPPLY AIR

RETURN AIR

DUCT

TYPICAL

ROOFTOP

iNSTALLATiON
WiTH UNIVERSAL
(TCX024=060G IVlodels)

SEE NOTE

BAYCURB030A,038A

SEE NOTE2

FIELD SUPPLIED
SUPPORTS
ATEACNEND
OFCURB

,_J_ROOFINSULATION
FIELD SUPPLIED
CANT STRIP
ROOF

FIELD
RIGID

SUPPLIED
iNSULATiON

NOTE 1: The TCX042G Models extend out
past this end of the curb only•
NOTE 2: Only the TCX048, 060F Models
extend past both the end and the

DUCT
SUPPLY

AIR

ROOFMOUNTING

)

CURB

RETURNAIR
DUCT

side of the curb as illustrated

CONVERTING

HORIZONTAL

TO DOWNFLOW

NOTE
SUPPLY
1

RETURN
2

OPENING

REMOVE THE SCREW
NEAREST TO THE
OPENING AND PULL THE PANEL FIRMLY
TOWARD
THE OUTSIDE
OF THE UNIT TO
DISENGAGE
THE BACK ATTACHMENT
OPENING

REMOVE RIGHT-HAND
SCREW AND
MOVE PANEL TO THE RIGHT OR
REMOVE BOTH SCREWS

SHEET METAL
SCREWS

HORIZONTAL RETURN
AIR COVER

HORIZONTAL SUPPLY
AIR COVER

Page 3

DiMENSiONAL

DATA

_>_
SUPPLY
I:RE/URN
PANEl

ECONOM}ZER/FII_TER
ACCESS

EVAPORA1OR
CO I L
BLOWER
>ANEL

66 MM
KNOCKOU
H

8( CONDU I

AO(

CONN

8( CONDU

I ON

76 MM

BbSH
LO
HOR I ZONTAL
SUPP}Y
OPEN I NG

VOLTAGE

T FOR

CONNECTION

_"f

DOWNF LC
SUPP Y
OPEN NO

CONDENSATE
.....
j_

NOR I ZONTAL
RETURN
OPENING

DRAIN

[5\4"]

--DOWNFLOW
OPENING

FOR

FEMALE

NPT

RETURN

D66 Z955

2
SECT

SECT.

X-X

TYPICAL
CROSS
BEC/ION
OF SUPPLY
& RETURN
PERIMETER
FLANGES

MODEL

CORNER WEIGHT

(LBS)

Y-Y

TYPICAL
CROSS
SECT
ON
OF DOWNFLOW
SUPPLY
8(
RETURN
PER METER
FLANGES

UNIT
WEIGHT

TCX024G

W1
75

W2
57

W3
78

W4
101

311

TCXO30G

106

323

TCXO36G

106

334

TCXO42G

111

334

TCXO48G

111

128

430

TCXO69G

112

114

144

457

56-1/2

253/16

56-1/2

65-1/4

29-3/16

33-3/8

18-9/16 11-1/16

6-9/16

6-13/16

24-I/4

17-I/2

4-7/16

24-7/8

20-1/2

25-I/4

17-I/2

4-7/16

20-1/2

25-7/8

25-3/8

30-1/4

25-3/16

28-7/8

3-1/2

8-5/16

6-9/16

21-1/16 15-1/16 4-15/16

6-13/16

9-1/8

21-15/16

From Dwg. 21 D663966 Rev. 0

Page 4

DiMENSiONAL

DATA

CON I I:RO
BOX
ACCESS
PANE}

CONDENSER
&

"E[ECTR}C

CO!L
GUARD

HEATER

ACCESS

PANEl

0667982

CLEARANCE TO
COMBUSTIBLE MATERIAL
BOTTOM
0.0"

RECOMMENDED
SERVICE
CLEARANCE
BACK
LEFT
RIGHT

SIDE
SIDE

FRONT

* 6.0"
30.0"

BACK

1.0"

24.0"

LEFT SIDE

6.0"

42.0"

RIGHT SIDE

6.0"

18" WITH FRESH AIR ACCESSORY
• 30" WITH ECONOMIZER

FRONT SIDE

12.0"

TOP

36.0"

MODEL

TCX024G

56 1/2

25 3/16

TCX030G
TCX036G
TCX042G

56-1/2

29-3/16

TCX048G
TCX06OG

65-1/8

33-3/8
From Dwg. 21 D663965 Rev. 0

Page 5

REQUIRED CLEARANCE
FOR UNIT iNSTALLATiON
AND ROOF PENETRATION
HOLE SiZE REQUIRED

SERVICE
SERVICE
CLEARANCE
LINES

LINES
SUPPLY

AIR

RETURN
SIDE RAIL

WOOD

SERVICE CLEARANCE
MODEL NO.

AIR

NAILER _

& PENETRATION

DIMENSIONS

TCX024-042G

42"

30"

"12"

24"

36"

25"

TCX048-060G

42"

30"

"12"

36"

50"

25"

* 18" WITH FRESH AIR ACCESSORY
* 30" WITH ECONOMIZER

LOCATIONS AND RECOMMENDATIONS
These units are designed for outdoor installation. For proper installation, the following recommendations must be considered.

NOTE: If any internal accessories are to be added to the unit it
should be done at the shop if at all practical.

NOTE: Unit shipped for horizontal
downflow per instruction.

2. Unit should be positioned so Roof-Run-Off water does not pour
directly on unit.

The discharge air from the condenser fans must be unrestricted for
a minimum of 3 feet above the unit.

3. For"RoofTop Application," unit must be elevated above roof with
a mounting Curb or Frame.

Roof Mounting Curb (field assembled
BAYCURB030A
and
BAYCURB034A) or a field fabricated curb must be in place before
unit is hoisted to the roof.

4. Exhaust vents or other sources of contaminated air should not be
near unit air inlet if outside air is to be introduced as a make-up
air or the economizer ventilation feature is to be used.

Roof Mounting Curb (frame) must be installed on a fiat, level
section of the roof(max, of 1/4" per foot pitch), providing a level
mounting surface for the unit. In addition, provide sufficient
height above the roof to prevent water from entering unit.

5. Check the handling facilities to insure the safety of personnel and
the unit(s).

Be sure the mounting curb spans structural members (trusses)
of the roof, thereby providing sufficient support for weight of the
unit, curb and duct(s) plus any accessories (factory or field
installed). See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9,10,11 and 12.

7. The unit must be mounted level for proper drainage of defrost
water through the holes in the base pan.

Page 6

installation.

Convert

6. CAUTION MUST BE TAKEN AT ALL TIMES TO AVOID PERSONAL INJURIES AND/OR DAMAGE TO EQUIPMENT.

LOCATIONS AND RECOMMENDATIONS
8. Flexible duct connectors must be of a flame retardant material.
All duct work outside d the structure must be insulated and
weatherproofed in accordance with local codes.
9. Roof flashing must be installed to seal the roof curb cavity and
must conform to local building codes.
10. Holes through exterior walls must be sealed in accordance with
local codes.
11. Access and service clearances for the unit must be given careful
consideration when locating the duct entrance openings. Figures 6 and 8 provide unit dimensions.
12. All fabricated outdoor ducts should be as short as possible.
13. Be sure the hole in the structure for the ducts is large enough to
accommodate the fabricated ducts and the insulation surrounding
them. (See Figure 6.)

CLEARANCES
1. The recommended clearances for single-unit installations are
illustrated in Figures 5 and 6. These minimum requirements are not
only an important consideration when determining unit placement,
but they are also essential to ensure adequate serviceability,
maximum capacity, and peak operating efficiency.
2. Any reduction of the unit clearances indicated in this illustration
may result in condenser coil starvation, or the recirculation of warm
condenser air. Actual clearances which appear to be inadequate
should be reviewed with a local sales engineer.
IMPORTANT!: To convert to downflow remove covers from
the downflow supply and return air openings and place them
over the horizontal supply and return air openings (painted
side out) and secure with sheet metal screws.

INSTALLATION
UNIT SUPPORT
If unit is to be roof mounted, check building codes for weight
distribution requirements. Refer to accessory roof curb mounting
instructions. Check unit nameplate for supply voltage required.
Determine if adequate electrical power is available. Refer to specification sheet.

LOCATION

AND CLEARANCES

Installation of the unit should conform to local building codes or, in
the absence of local codes, to the ANSI/NFPA No. 70-1987 National
Electrical Code or "Latest Revision." Canadian installations must
conform to CSA and local codes.
Select a location that will permit unobstructed airflow into the
condenser coil and away from the fan discharge and permit unobstructed service access into the compressor compartment. Suggested airflow clearances and service clearances are given in
Figure 5.

PLACING

IMPORTANT!:
DO NOT LIFT THE UNIT WITHOUT TEST=
LIFTING FOR BALANCE AND RIGGING. DO NOT LIFT THE
UNIT IN WINDY CONDITIONS OR ABOVE PERSONNEL. DO
NOT LIFT THE UNIT BY ATTACHING A CLEVIS, HOOKS,
PINS OR BOLTS TO THE UNIT CASING, CASING HARDWARE, ANGLES, TABS OR FLANGES. FAILURE TO OB=
SERVE THESE WARNINGS MAY RESULT IN EQUIPMENT
DAMAGE.
4. When the curb and air ducts have been properly installed, the unit
is ready to be hoisted to the roof and set in position.

IMPORTANT!:
hoisting unit.

"Spreader

Bars"

must

used

when

5. IMPORTANT: The unit must be lowered into position P.V.C.
rubber tape on the curb flange permits the unit to be
repositioned
if required without destroying the P.V.C. rubber seals affixed to mounting curb.

AND RiGGiNG

1. Before preparing the unit for lifting, check the outline drawing for
center of gravity for lifting safety. Because of placement of
internal components, the unit weight may be unevenly distributed. Approximate unit weights are given in outline drawing on
page 3.
NOTE: Accessory BA YLI FTOO2M Four (,4) rifting lugs are recommended for rigging the unit for hoisting. See Figure 7 insert
"B".
2. Insert the four lifting tugs in openings provided
perimeter of unit. See Figure 7 insert "B".

in drip lip on

6. PLACING UNIT ON MOUNTING CURB--The unit is designed
with a perimeter drip lip that is lower than the unit base ban, see
Figure 7 insert "A".
7. Position the unit drip tip down over and in contact with the outside
corner of the curb, as illustrated in Figure 7 insert "A". Continue
to lower unit on top of curb, with the unit drip tip is astraddle and
in contact with both the end and side rail of curb, the unit is now
resting on top of curb.
8. Take the two (2) hold down brackets shipped with curb and
secure unit to curb with hold down brackets as illustrated in
Figure 8 insert "A".

3. Before hoisting the unit, be sure that the proper method d rigging
is used, with straps or slings and spreader bars for protection
during lifting.

Page 7

BARS

OUTDOOR
COIL
END OF UNIT

BASE OFUNIT
REST ON TOP OF
CURB RAILS

DRIP_

NASA

DIMPLE

LIFTING

DRIP LIP ON
PERIMETER
OF UNIT

LUGS

CURB CORNER

J
GASKET

NOTE:

SEAL"

The inner perimeter of the Drip Lip on all
units should be flush with the outer perimeter
of the curb on the two sides shown here. See
Figure 2 for the location of the unit overhang
on the TCX036-060G
Models with
BAYCURB030A,038A.

EXISTING
SHEET METAL
)

SCREW

HOLD-DOWN
BRACKET WITH
lIA_l

FLANGE OF
CURB

Page 8

CURB

INSTALLATION
ROOFTOP

==UNITS

For roof top applications using a field fabricated frame and ducts,
use the following procedure:
1. The frame must be located and secured by bolting or welding to
the roof. Flashing is required.
2. The hole in the roof must be prepared in advance of installing the
unit.

TYPICAL
RETURN

ROOFTOP
AIR

SUPPLY

AIR

9 or

5. Secure the unit to the frame or roof curb.
6. Insulate any ductwork outside of the structure with at least two
(2) inches of insulation and then weatherproof. There must be
a weatherproof seal where the duct enters the structure.
7. Complete the installation according
following sections of this manual.

3. Secure the ducts to the roof.

4. Place the unit on the frame or roof curb. Refer to Figures
10.

APPLICATIONS

to the instructions

in the

WITH FRAME

(TCX024=060G)

•

WEATHER-PROOF
DUCT

ROOFFLASHING

TYPICAL

ROOFTOP

APPLICATION

(TCX024=060G

ANGLE
IRON
FRAME

WITH FRAME

MODELS)

DUCT

ROOF

SUPPLY
ROOF

FLASHING

AIR

FLASHING
RETURN

AIR

IRON
FRAME

Page 9

iNSTALLATiON
GROUND

LEVEL -- HORIZONTAL

UNITS

For ground level installations, the unit should be positioned on a pad
the size of the unit or larger. The unit must be level on the pad. The
pad must not come in contact with the structure (See Figure 11 .) Be
sure the outdoor portion of the supply and return air ducts are as
short as possible.

2. Attach the supply and return air ducts to the unit.

Proceed with the installation

4. Complete the installation according
following sections of this manual.

as follows:

3. Insulate any ductwork outside of the structure with at least 2
inches of insulation and weatherproof. There must be a weatherproof seal where the duct enters the structure.
to the instructions

in the

1. Place the unit on the pad and the five (5) rubber isolators
provided.

TYPICAL GROUND LEVEL APPLICATION
(TCX024-060G MODELS)

OUTDOOR
AIR
DISCHARGE

I
RETURN

AIR

SUPPLY
AIR
DUCT

DUCT
SIDING

'
I"

I_'_1V"
OUTDOOR
INTAKE

AIR

SUPPORT
PAD
FOUNDATION

EXTERIOR
WALL

INSULATE
WEATHERPROOF
OR RAIN SHIELD

FLEXIBLE
DUCT
CONNECTORS

ISOLATORS
(1 PER CORNER
AND 1 UNDER
UNIT

CONTROL

BOX)

2046.eps

DUCTWORK
ATTACHING
DOWNFLOW
TO ROOF CURB

DUCTWORK

ATTACHING
TO UNIT

Supply and return air flanges are provided on the roof curb for easy
duct installation. All ductwork must be run and attached to the curb
before the unit is set into place.

HORIZONTAL

DUCTWORK

All conditioned air ductwork should be insulated to minimize heating
and cooling duct losses. Use a minimum of two (2) inches of
insulation with a vapor barrier. The outside ductwork must be
weatherproofed between the unit and the building.

Follow these guidelines for ductwork construction:
Connections to the unit should be made with three-inch canvas
connectors to minimize noise and vibration transmission.
Elbows with turning vanes or splitters are recommended
mize air noise and resistance.

to mini-

The first elbow in the ductwork leaving the unit should be no closer
than two feet from the unit, to minimize noise and resistance.
Page

When attaching ductwork to a horizontal unit, provide a flexible
watertight connection to prevent noise transmission from the unit to
the ducts. The flexible connection must be indoors and made out
of heavy canvas.
I NOTE: Do not draw the canvas taut between the solid

ducts. J

DUCT

ATTACHMENT

METHODS

AIR PROOF.
THIS SEAM

AIR PROOF
THIS

SEAM

DUCT

FLANGE

BASE
WEATHERPROOF
THIS SEAM
FLANGE

FIELD

FIELD DUCT ql

X
U

DUCT

FIELDDucT
_

'UNIT DUCT
FLANGE

_IT
UNIT

BASE

UNIT

/
UNIT

BASE

AIR PROOF

EXTERIOR

UNIT

DUCT

FLANGE

SEAr

WITH BUTYL OR
SILICONE

....
WEATHERPROOF
FLANGE

THIS SEAM
FIELD

_
\ FIELD

UNIT
DUCT

BASE

NOT RECOMMENDED
FIELD

DUCT

DOWNFLOW
The following

warning

complies

with State of California

ILWARNING:

law, Proposition

This product

65.

contains

fiberglass wool insulation! Fiberglass dust and ceramic
fibers are believed by the State of California to cause
cancer through inhalation. Glasswool fibers may also
cause respiratory, skin, or eye irritation.

HORIZONTAL

CONDENSATE
A 3/4-inch female NPT condensate drain connection is provided on
the evaporator access panel end of the unit. See Figure 4. Provide
a trap and fitt it with water before starting the unit to avoid air from
being drawn through.
Follow local codes and standard piping
practices when running the drain line. Pitch the line downward away
from the unit. Avoid long horizontal runs. See Figure 13.
NOTE: Do not use reducing fittings in the drain lines. The condensate drain must be:

DRAIN PiPiNG
(_

TYPICAL

CONDENSATE

DRAIN PiPiNG

3/4" PVC OR COPPER
TUBING AND FITTINGS

• Made of 3/4" pipe size.
• Pitched 1/4" per foot to provide free drainage to convenient drain
system.
• Trapped.
• Must not be connected to closed drain system.

,i]
Page 1

ELECTRICAL
ELECTRICAL

CONNECTIONS

CONTROL

Electrical wiring and grounding must be installed in accordance with
local codes or, in the absence of local codes, with the National
Electrical Code ANSI/NFPA 70, Latest Revision.

ELECTRICAL

POWER

It is important that proper electrical power be available for the unit.
Voltage variation should remain within the limits stamped on the unit
nameplate.

DISCONNECT

SWITCH

Provide an approved weatherproof disconnect either on the side of
the unit or within close proximity and within sight of the unit.

OVER CURRENT

PROTECTION

The branch circuit feeding the unit must be protected as shown on
the unit rating plate.

POWER

WIRING

The power supply lines must be run in weathertight conduit to the
disconnect and into the bottom of the unit control box. Provide strain
relief for all conduit with suitable connectors.
Provide flexible conduit supports whenever vibration transmission
may cause a noise problem within the building structure.
Be sure all connections are made tight. See Figure 14.
NOTES: For branch circuit wiring (main power supply to unit
disconnect), wire size for the length of run should be determined
using the circuit ampacity found on the unit nameplate and the
N.E.C.
For more than 3 conductors in a raceway or cable, see the
N.E. C. for derating the ampacity of each conductor.
GROUNDING: THE UNITMUST BE ELECTRICALLY GROUNDED
IN ACCORDANCE WITH LOCAL CODES OR THE NATIONAL
ELECTRIC CODE.
NOTE: Ground the unit internally
diagram for location.

COMPRESSOR

as provided.

MOTOR

See wiring

ROTATION

DISCONNECT ALL POWERTO COMPRESSORWHEN
COMPRESSOR MOTOR ROTATION IS REVERSED. CHANGE
ANY TWO CUSTOMER POWER LEADS TO CORRECT ROTATION
Failure to change customer power leads to correct compressor
rotation may result in compressor
damage during operation.

Page12

WIRING
WIRING

(CLASS

ll)

Low voltage control wiring should not be run in conduit with power
wiring unless Class 1 wire of proper voltage rating is used. Route
the thermostat cable or equivalent single leads of No. 18 AWG
colored wire from the thermostat subbase terminals through the
rubber gromment on the unit. See Figure 5 for the control entry
location. Make connections as shown on the unit wiring diagram
and in Figure 14.
Do not short thermostat
transformer.

wires since this wilt damage the control

Recommended wire sizes and lengths for installing the unit thermostat are provided in Table 2. The total resistance of these low
voltage wires must not exceed one (1) ohm. Any resistance in
excess of 1 ohm may cause the control to malfunction because of
the excessive voltage drop

TABLE

THERMOSTAT

WiRE SIZE AND MAXIMUM LENGTH

WIRE SIZE
18

MAXIMUM LENTGH (Ft)
75

16
14

125
200

THERMOSTAT

HEAT ANTICIPATOR

The thermostat heat anticipators should be set to equal the amperage draw of the Wl thermostat circuit.

IMPORTANT:
Upon completion
of wiring check all electrical
connections, including factorywiring
within the unit. Make sure
all connections are tight. Replace and secure all electrical box
covers and access doors before leaving the unit or turning on the
power to the unit.
After all electrical wiring is complete, set the thermostat system
switch in the OFF position so that the compressor will not run
and then apply power by closing the system main disconnect switch.
This will activate the compressor sump heat. Do not change the
Thermostat System Switch until power has been applied
long
enough to evaporate any liquid R-22 in the compressor.
It is
recommended that the sump heater be energized for eight (8) hours
prior to starting.

ELECTRICAL

WIRING

TCX-G FIELD WiRiNG
>ACKAC

COOL

Ls / ({NIRO

NO/EL

R I C

30X

DIAGRAM

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