TRANE Package Units(both Units Combined) Manual L0905286

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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ISTALLATIO

OPERATION

NT CE

TCY-IOM-lC

18-AB33D9-4

ALL phases of this installation must comply with

NATIONAL, STATE AND LOCAL CODES

Model:

TCY024G1 TCY048G1

TCY030GI TCY060G1

TCY036G1

TCY042G 1 BAYLIFT002AA

LIFTING LUG KIT

14 SEER Single Package

Cooling W/Electric Heat

2 -5Ton

IMPORTANT-- This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of

work.

All phases of this installation must comply with the NATIONAL, STATE & LOCAL CODES. In the absence of local codes, the installa-

tion must conform with National Electric Code -- ANSI/NFPA 70 or "LATEST REVISION."

Since the manufacturer has a policy of continuous

product improvement, it reserves the right to change

specifications and design without notice.

GENERAL INFORMATION

IMPORTANT: Read this entire manual before beginning instal-

lation procedures.

SAFETY NOTICE• THIS INFORMATION IS INTENDED FOR

USE BY INDIVIDUALS POSSESSING ADEQUATE BACK-

GROUNDS OF ELECTRICAL AND MECHANICAL EXPERI-

ENCE. ANY ATTEMPT TO REPAIR A CENTRAL AIR CONDI-

TIONING PRODUCT MAY RESULT IN PERSONAL INJURY

AND/OR PROPERTY DAMAGE. THE MANUFACTURER OR

SELLER CANNOT BE RESPONSIBLE FOR THE INTERPRE-

TATION 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 ORIGI-

NAL POSITION AND PROPERLY FASTENED.

IMPORTANT: ALL POWER LEGS MAY NOT BE BROKEN BY

CONTACTORS. SEE WIRING DIAGRAM ON UNIT CONTROL

BOX COVER.

BEFORE STARTING THE COMPRESSOR, THE CRANKCASE

HEATER SHOULD BE ENERGIZED FOR EIGHT HOURS.

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). J

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.

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.

©TYPICAL ROOFTOP INSTALLATION WITH FULL PERIMETER CURBS

(TCY024-060G Models)

~FIELD SUPPLIED

SUPPORTS

AT EACH END

OF CURB

FIELD SUPPLIED

CANT STRIP

FIELD SUPPLIED

RIGID INSULATION

SUPPLY AIR _ RETURN AIR

DUCT _ DUCT

ROOF MOUNTING

CURB

Page 2

@TYPICAL ROOFTOP iNSTALLATiON WiTH UNIVERSAL BAYCURB030A,038A

(TCY024-060G Models)

FIELD SUPPLIED

RIGIDINSULATION

NOTE 1: The TCY036-042 Models extend out

past this end of the curb only.

NOTE 2: Only the TCY048, 060G Models

extend past both the end and the

side of the curb as illustrated

SUPPLY AIR

DUCT

SEE NOTE2

ROOF MOUNTING

CURB

ROOFING

•FIELD SUPPLIED

SUPPORTS

ATEACH END

OFCURB

FIELD SUPPLIED

CANTSTRIP

(_ CONVERTING HORIZONTAL TO DOWNFLOW

NOTE

SUPPLY OPENING

1 REMOVE THE SCREW NEAREST TO THE

OPENING AND PULL THE PANEL FIRMLY

TOWARD THE OUTSIDE OF THE UNIT TO

DISENGAGE THE BACK ATTACHMENT

RETURN OPENING

2 REMOVE RIGHT-HAND SCREW AND

MOVE PANEL TO THE RIGHT OR

REMOVE BOTH SCREWS

3 REMOVE EXTERIOR GASKET MATERIAL•

HORIZONTAL SUPPLY

AIR COVER

SHEET METAL

SCREWS HORIZONTAL RETURN

AIR COVER

Page 3

DiMENSiONAL DATA

HORIZONTAL

SUPP}Y

OPENING DOWNFL{

SUPPLY

OPEN}NO

SECT, X-X

TYP}CAL CROSS SEC/ION

OF SUPPLY & RETURN

PERIMETER FLANGES

SUPPLY & ECONOM}ZER/FII_TER

I:RE/URN ACCESS

PANEl s

HOR I ZONTAL J/

RETURN OPENING

EVAPORAIOR CO I L &

BLOWER >ANEL

66 MM KNOCKOU &: CONDU I OR

H VO AG( CONN CI I ON

76 MM

BbSH NG & CONDU T FOR

LO VOLTAGE CONNECTION

CONDENSATE DRAIN FOR

19 MM [5\4"] FEMALE NPT

--DOWNFLOW RETURN

OPENING

L & M D667955

} M NS I ONAI

SECT Y-Y

TYPICAL CROSS SECT}ON

OF DOWNFLOW SUPPLY &

RETURN PERIMETER FLANGES

CORNER WEIGHT (LBS) UNIT

MODEL AB C D E F G H J K

Wl W2 W3 W4 WEIGHT

TCYO24G 79 74 74 84 321 21 25-3/8

56-1/2 36 29-3/16 18-9/16 11-1/16 6-9/16 6-13/16 17

TCYO3OG 82 64 86 90 332 21 24-3/8

TCYO36G 110 82 88 98 388

TCYO42G 110 82 88 98 388

19-1/4 27-1/2

64 36 29-3/16 18-9/16 11-1/16 6-9/16 11-1/8 17 19-1/4 27-1/2

TCYO48G 149 104 117 114 494 24-1/4 28-1/2

65-1/4 45 33-3/8 21-1/16 15-1/16 4-15/16 9-I/8 21-15/16

TCYO60G 149 104 117 114 494 24-1/4 28-1/2

L M N P

17-1/2 10 3 4-7/16

17-1/2 10 3 8-3/4

20 14 3-1/2 8-5/16

Page 4

DiMENSiONAL DATA

CONTRO BOX

AOC SS _ANEL

_C©N©ENSER COIL

& GUARD

\ ELEC_R}C HEAIER

ACCESS PANEL

D66Y982

RECOMMENDED SERVICE CLEARANCE

BACK * 6.0"

LEFT SIDE 30.0"

RIGHT SIDE 24.0"

FRONT 42.0"

• 18"WITH FRESHAIR ACCESSORY

• 30" WITH ECONOMIZER

CLEARANCE TO

COMBUSTIBLE MATERIAL

BOTTOM 0.0"

BACK 1.0"

LEFT SIDE 6.0"

RIGHT SIDE 6.0"

FRONT SIDE 12.0"

TOP 36.0"

MODEL A B C

TCY024G 56-1/2 36 29-3/16

TCY030G

TCO36G 64 36 29-3/16

TCY042G

TCY048G 65-1/8 45 33-3/8

TCY060G

From Dwg. 21 D663965 Rev. 0

Page 5

REQUIRED CLEARANCE FOR UNIT iNSTALLATiON

AND ROOF PENETRATION HOLE SiZE REQUIRED

SERVOE/SERVOE

CLEARANCE _. _ _J ! __ "_ CLEARANCE

/L, ES

I I I I

I _ I II

t- i

TCY036-042G 30" 30" "12" 30" 44" 25" _ _ J

TOY048-060G42"3o""12"36"50"_5" "_

* 18" WITH FRESH AIR ACCESSORY

* 30" WITH ECONOMIZER

LOCATIONS AND RECOMMENDATIONS

These units are designed for outdoor installation. For proper instal-

lation, the following recommendations must be considered.

NOTE: Unit shipped for horizontal installation. Convert to

downflow per instruction.

The discharge air from the condenser fans must be unrestricted for

a minimum of 3 feet above the unit.

Roof Mounting Curb (field assembled BAYCURB030A,038A and

BAYCU RB033A, BAYCU RB034A) or a field fabricated curb must be

in place before unit is hoisted to the roof.

Roof Mounting Curb (frame) must be installed on a flat, 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.

1, 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.

NOTE: If any internal accessories are to be added to the unit it

should be done at the shop if at all practical.

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

directly on unit.

3. For"RoofTop Application," unit must be elevated above roof with

a mounting Curb or Frame.

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.

5. Check the handling facilities to insure the safety of personnel and

the unit(s).

6. CAUTION MUST BE TAKEN AT ALL TIMES TO AVOID PER-

SONAL INJURIES AND/OR DAMAGE TO EQUIPMENT.

7. The unit must be mounted level for proper drainage of defrost

water through the holes in the base pan.

Page 6

LOCATIONS AND RECOMMENDATIONS

8. Flexible duct connectors must be of a flame retardant material.

All duct work outside dthe 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. Fig-

ures 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 speci-

fication 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 unob-

structed service access into the compressor compartment. Sug-

gested airflow clearances and service clearances are given in

Figure 5.

PLACING 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 distrib-

uted. Approximate unit weights are given in outline drawing on

page 3.

NOTE: Accessory BA YLIFTOO2M Four (,4)rifting lugs are recom-

mended for rigging the unit for hoisting. See Figure 7insert

"B".

2. Insert the four lifting tugs in openings provided in drip lip on

perimeter of unit. See Figure 7 insert "B".

3. Before hoisting the unit, be sure that the proper method drigging

is used, with straps or slings and spreader bars for protection

during lifting.

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 HARD-

WARE, 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!: "Spreader Bars" must be used when

hoisting unit.

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. rub-

ber seals affixed to mounting curb.

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".

Page 7

SPREADER BARS

OUTDOOR COIL

END OF UNIT

DRIP_ NASA

DIMPLE LIFTING LUGS

GASKET SEAL"

BASE OFUNIT

REST ON TOP OF

CURB RAILS

DRIP LIP ON

PERIMETER OF UNIT

CURB CORNER

NOTE: 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 TCY036-060G Models with

BAYCURB030A,038A.

EXISTING

SHEET METAL

)SCREW

HOLD-DOWN

BRACKET WITH

lIA_l CURB

FLANGE OF

CURB

Page 8

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.

3. Secure the ducts to the roof.

4. Place the unit on the frame or roof curb. Refer to Figures 9 or

10.

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 to the instructions in the

following sections of this manual.

®TYPICAL ROOFTOP APPLICATIONS WITH FRAME

(TCY024=060G) ""

RETURN AIR SUPPLY AIR > ,

WEATHER-PROOF

DUCT

ROOFFLASHING

ANGLE IRON

JFRAME

®TYPICAL ROOFTOP APPLICATION WITH FRAME

(TCY024=060G MODELS)

DUCT

ROOF FLASHING

RETURN AIR

ROOF FLASHING

\ ,,

SUPPLY 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.

3. Insulate any ductwork outside of the structure with at least 2

inches of insulation and weatherproof. There must be a weath-

erproof seal where the duct enters the structure.

Proceed with the installation as follows:

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

provided.

4. Complete the installation according to the instructions in the

following sections of this manual.

®TYPICAL GROUND LEVEL APPLICATION

(TCY024-060G MODELS)

SUPPLY AIR

RETURN AIR DUCT

DUCT _f

SIDING I_'_1V"

OUTDOOR AIR

DISCHARGE

I '

EXTERIOR

WALL

OUTDOOR AIR

INTAKE

SUPPORT PAD

=' FOUNDATION

INSULATE

WEATHERPROOF FLEXIBLE DUCT ISOLATORS

OR RAIN SHIELD CONNECTORS (1 PER CORNER

AND 1 UNDER

UNIT CONTROL BOX) 2046.eps

DUCTWORK

ATTACHING DOWNFLOW DUCTWORK

TO ROOF CURB

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.

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 to mini-

mize air noise and resistance.

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 10

ATTACHING HORIZONTAL DUCTWORK

TO UNIT

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.

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

FLANGE

WEATHERPROOF

THIS SEAM

FIELD DUCT

AIR PROOF.

THIS SEAM

BASE

FIELD DUCT ql X

U 'UNIT DUCT

FLANGE

/AIR PROOF

THIS SEAM

FIELDDucT__IT BASE

UNIT DUCT FLANGE

UNIT EXTERIOR

\ UNIT DUCT FLANGE

....WEATHERPROOF

THIS SEAM

FIELD DUCT

/AIR PROOF

FLANGE _ UNIT BASE

\ FIELD DUCT

UNIT BASE

UNIT

FLANGE SEAr

WITH BUTYL OR

SILICONE

NOT RECOMMENDED

DOWNFLOW

FIELD DUCT

HORIZONTAL

The following warning complies with State of California law, Proposition 65.

ILWARNING: This product 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.

CONDENSATE DRAIN PiPiNG

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 conden-

sate drain must be:

• 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.

(_ TYPICAL CONDENSATE DRAIN PiPiNG

3/4"PVC OR COPPER

TUBING AND FITTINGS

,i]

Page 1

FILTER iNSTALLATiON

AiR FILTERS

Filters are to be used with the TCY024=060G heating/cooling units.

The basic unit does not have filters in it. However, a filter frame

accessory is offered that will allow filters to be installed within the

unit.

Otherwise a filter rack must be installed by the installer in the duct

work,

Affix the filter label supplied with the unit adjacent to the filter area.

TABLE 1

NOMINAL FILTER* FILTER

UNIT CFM (Sq Ft) SIZE RESISTANCE

TCY024G 800 2.67 0.05

TCY030G 1000 3.33 0.05

TCY036G 1200 4.00 0.05

TCY042G 1400 4.67 0.05

TCY048G 1600 5.33 0.05

TCY060G 2000 6.67 0.05

* Filters must be installed in the return air system. The above square

footages are based on 300 F.P.M. face velocity. If permanent filters are

used, size per mfg. recommendation with clear resistance of 0.05" WC.

ELECTRICAL WIRING

ELECTRICAL CONNECTIONS

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 UNIT MUST BE ELECTRICALLY GROUNDED

IN ACCORDANCE WITH LOCAL CODES OR THE NATIONAL

ELECTRIC CODE.

NOTE: Ground the unit internally as provided. See wiring

diagram for location.

CONTROL WIRING (CLASS !!)

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 wires since this will damage the control

transformer.

Recommended wire sizes and lengths for installing the unit thermo-

stat are provided in Table 2. The total resistance dthese 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 2

THERMOSTAT WIRE SIZE AND MAXIMUM LENGTH

WIRE SIZE MAXIMUM LENTGH (Ft)

18 75

16 125

14 200

THERMOSTAT HEAT ANTICIPATOR

The thermostat heat anticipators should be set to equal the amper-

age draw of the Wl thermostat circuit.

IMPORTANT: Upon completion of wiring check all electrical

connections, including factory wiring 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.

Page12

ELECTRICAL WIRING

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.

®TCY-G FIELD WIRING DIAGRAM

PACKAGED COOl ING/EIECTRIC AT UNIT

POWER

k_y

i @

li ............,

u LO Ol (;_ F

.F ELD

_l_lyIwlRI1 "_1 JUMPER

_OTE 6

TYPICAL THERMOSTAT

UNII I AI:R AREA I

££ ............... -1 I

1 I I

I I

\ POLARIZED ! ! !

P_bO BOX

_IECTR C

HEATER

CON_RO[

'ill

COMMON

COMPRESSOR

1ST STAO_ ELECTRIC HEAT

2Nt STATE ELECTRIC HEAT

24 VOLTS

5 PH 5PH

POWER POWER

UN4T HEATER

NOTE 1,8

FIG. 1 SINGLE POWER ENTRY

ACCESSORY CONNECT}ONS

r uN T CONTROC

Box

i€:..........

CONTACTOR

UNIT LOW

VOt AGE AREA

5 PH

POWER

S I NBIE POWER

NTRY

U T H AT R AREA

FACTORY _ROV DED

I I ID CONNEC_ )

WRES

al === ]]] I

II [ K T _=LLL==JJJ I

AUTO CHANGEOVER

FIG.5 THERMOSTAT CONNECTIONS

NOTE 7

TypICAL THERMOSTAT

F}G,2 ECONOMIZER ACCESSORY

CONNECT IONS

TO ECONOMIZER NOT APPLICABLE TO THE TCld F MODELS}

FAC I ORY PROVIDED

FIELD INSTALLED

WmS

I I

.... C:::: £:: }........

I I

L 5znE2Bs'_ 56B_BL} B

NOTES:

1. FUSED DISCONNECT SIZE. POWER WIRING AND

GROUNDING OF EQUIPMENT MUST COMPLY WITH

CODES.

2. BE SURE POWER SUPPLY AGREES WITH

EQUIPMENT AND HEATER NAMEPLATE.

3. LOW VOLTAGE WIRING TO BE 18 AWG MINIMUM

CONDUCTOR

4. SEE HEATER NAMEPLATE FOR CURRENT RATING

OF HEATER USED

5. SEE UNIT AND HEATER DIAGRAM FOR

ELECTRICAL CONNECTION DETAILS

#4 _YL) z_ 6. JUMPER MUST BE CONNECTED BETWEEN 1 AND 2

I_O FOR FAN TO OPERATE IN HEATING.

_/F {BK) 47A(BK} C 7. SOME THERMOSTATS PROVIDE THE 'G' SIGNAL IN

44onto /_ THE COOLING MODE ONLY. TO PROVIDE THE 'G'

........................................................... _ I .............. _4A(Y ) Y S_GNAL _N THE HEATING MODE AN ACCESSORY

-- 41A(BR} Wl RELAY IS REQUIRED SEE FIG 3 FOR PROPER

LN OW -- I41C(BR) W2 CONNECTIONS

VOLTAGE AREA --35A( RD} R 8. FOR COOLING ONLY OMIT THE ELECTRIC

HEATER, ASSOCIATED POWER WIRES, AND THE

'W' SIGNAL THERMOSTAT WIRE

FELD 9. FIG. 4 DEMONSTRATES CONNECTION OF THE

INSTALl/) TWO STAGE ELECTRIC HEAT THERMOSTAT

JUMPER ACCESSORY ONLY FOR FURTHER UNiT

/_dbq_q@@d CONNECTION DETAILS REFER TO THE OTHER

FIGURES,

TYP CA 2 STAGE

?HERMOSTA 10 THE 41A(BR) WIRE IS FIRST STAGE ELECTRIC

HEAT. IF THE ELECTRIC HEATER ACCESSORY

HAS TWO HEATING STAGES THE 410(BR) WiRE IS

SECOND STAGE ELECTRIC HEAT

FIG. 4 lWO STAGE ELECTRIC

HEAl CONNEC1}ONS

INTERCOMPONENT WIRING

............................ 24V _ FACTORY

tlNE v,_ W_RING

24v } F_ELD__ LINE V W_RING

WIRI: COLOR DESIGNAIlON

...........BL_z£ .....................92 .EE2..............

BR BROWN WH WHITE

OR ORANGE

C5_9ZI:>01RV 2 From Dwg. 21C757977P01 Rev. 2

Page 13

START - UP

PRE=START QUICK CHECKLIST

•Is the unit properly located and level with the proper clearance?

See Figure 5.

•Is the duct work correctly sized, run, taped, insulated, and

weatherproofed with proper unit arrangement. See Ductwork

Installation section.

• Is the condensate line properly sized, run, trapped, and pitched?

•Is the filter dthe correct size and number? Is it clean and in

place?

•Is the wiring properly sized and run according to the unit wiring

diagram?

• Are all the wiring connections, including those in the unit, tight?

• Has the unit been properly grounded and fused with the recom-

mended fuse size? See Wiring Data.

•Is the thermostat level, correctly wired, welt located, and set for

the proper heat anticipation?

• Have the air conditioning systems been checked at the service

ports for charge and leak tested if necessary?

•Do the condenser fan and indoor blower turn free without rubbing,

and are they tight on the shafts?

• Has the indoor blower speed been determined and the proper

speed been set? See the Unit Wiring Diagram.

•Has all work been done in accordance with applicable local and

national codes?

•Are all covers and access panels in place to prevent air loss and

safety hazards?

STARTING THE UNIT IN THE COOLING MODE

CAUTION: Before starting the system on the cooling cycle, turn the

thermostat switch to OFF and close the unit disconnect switch. This

procedure energizes the compressor crankcase heater, vaporizing

any liquid refrigerant in the crankcase. This is a precaution against

foaming at start-up which could damage the compressor bearings.

Allow the heater to operate a minimum of eight (8) hours.

NOTE: See the section on "Sequence of Operation" for a descrip-

tion of the cooling operating sequence.

To start the unit in the cooling mode, set the thermostat system

switch to COOL and move the thermostat COOL indicator to a

setting below room temperature. The condenser (outdoor) fan

motor compressor and evaporator (indoor) fan motor will operate

automatically.

OPERATING PRESSURES

After the unit has operated in the cooling mode for a short period of

time, install pressure gauges on the gauge ports of the discharge

and suction line valves. Check the suction and discharge pressures

and compare them to the normal operating pressures provided in

the unit's SERWCE FACTS.

NOTE: Do not use the pressures from the unit's SERVICE FACTS

to determine the unit refrigerant charge. The correct charge is

shown on the unit nameplate. To charge the system accurately,

weigh in the charge according to the unit nameplate.

VOLTAGE

With the compressor operating, check the line voltage at the unit.

The voltage should be within the range shown on the unit name-

plate. If tow voltage is encountered, check the size and length of the

supply line from the main disconnect to the unit. The line may be

undersized for the length of the run.

COOLING SHUT DOWN

Place the system selector in the OFF position or reset thermostat at

a setting above room temperature.

Do not de-energize the main power disconnect except when unit is

to be serviced. Power is required to keep the heat pump compres-

sor warm and boil off refrigerant in the compressor.

STARTING THE UNIT IN THE HEATING MODE

NOTE: See the section on "Sequence of Operation" for a

description of the heating operating sequence.

Check to make sure all grilles and registers are open and all unit

access doors are closed before start-up.

HEATING SHUT=DOWN

Place the system selector switch at OFF or place the heating

selector lever at a setting below room temperature.

WARNING: DO NOT OPERATE THE UNIT

WITHOUT THE EVAPORATOR FAN ACCESS PANEL IN

PLACE. REINSTALL THE ACCESS PANEL AFTER

PERFORMING ANY MAINTENANCE PROCEDURES ON THE

FAN. OPERATING THE UNIT WITHOUT THE ACCESS

PANEL PROPERLY INSTALLED MAY RESULT IN SEVERE

PERSONAL INJURY OR DEATH.

Page 14

SEQUENCE OF OPERATION

GENERAL

Operation of the system cooling (and optional heating) cycles is

controlled by the position of the system switch on the room ther-

mostat. Once the system switch is placed in either the HEAT OR

COOL position, unit operation is automatic. The optional automatic

changeover thermostat, when in the AUTO position, automatically

changes to heat or cool with sufficient room temperature change.

With the unit disconnect closed, voltage is supplied to the unit

control transformer and the crankcase heater (if provided). On

single phase units, the crankcase heater is optionally field installed.

COOLINGmMECHANICALCOMPRESSORCYCLE

On a call for mechanical cooling, the indoor fan "G" and the

compressor circuit "YI" are energized. The indoor fan circuit "G"

starts with power from the control transformer and then energizes

the fan relay coil iF). This closes the fan relay iF) contacts and the

indoor fan motor (IDM) starts.

The compressor circuit starts with power from the control trans-

former through the thermostat switch "YI" to the compressor

contactor (CC) coil. This closes the (CC) contacts and starts the

compressor (CPR) and the outdoor fan motor (ODM). When the call

for cooling is complete, the compressor contactor (CC), outdoor fan

motor (ODM), and indoor fan relay iF) is de-energized.

HEATING m ELECTRIC HEATERS

On a call for heat, power from the thermostat is received at "WI",

which energizes the "AH" contactor coil. The "AH" contactor closes

powering the heater, provided all element limits are closed.

Iftwo stages of heat are provided and additional heat is required, the

thermostat's second stage "W2" circuit is energized powering the

"BH" contactor coil.

['{,] ",I"J,I €-[-.1:,],[,] "J:1N;_ / [,] ,_I [,]_1

NOTE: The indoor thermostat must be configured to provide a "G"

signal to energize the indoor fan relay iF) during the heating mode.

The heater control circuit will not be energized unless the indoor fan

relay iF) is energized.

ICM FAN MOTOR ADJUSTMENTS

If the airflow needs to be increased or decreased, see the Airflow

Table in the Service Facts. Information on changing the speed of the

blower motor is in the Blower Performance Table.

Blower speed changes are made on the ICM Fan Control mounted

in the control box. The ICM Fan Control controls the variable speed

motor.

There is a bank of 8 dip switches (See Figure 15), located at the

upper left side of the board. The dip switches work in pairs to match

the cooling/heat airflow (CFM/TON), Fan off-delay options, and

electric heat airflow adjustment. The switches appear as shown in

Figure 15.

INDOOR BLOWER TIMING

The ICMC Fan Control controls the variable speed indoor blower.

The FAN-OFF period is set on the ICMC Fan Control board by dip

switches #5 and #6. The blower off delay settings are as follows:

COOLING OFF - DELAY OPTIONS

NOMINAL

SWITCH SEI-rlNGS SELECTION AIRFLOW

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF 1.5 MINUTES 100% *

5 - OFF 6 - ON 3 MINUTES 50%

5 - ON 6 - ON **ENHANCED 50 - 100%

* - This setting is equivalent to the BAY24X045 relay benefit

** - This ENHANCED MODE selection provides a ramping up

and ramping down of the blower speed to provide improved

comfort, quietness, and potential energy savings. The graph

below shows the ramping process.

100% if necessary

OFF

80%

Dehumidify

Fast Coil Cooling

_ _ as required

7.5

minute minutes

50%

Efficiency I

minutes

12345678

DIP SWITCHES (TYPICAL SETTINGS)

Page 15

FINAL iNSTALLATiON CHECKLIST

•Does the unit run and operate as described in the section on

"Sequence dOperation" in response to the room thermostat?

•Are the condenser fan and indoor blower operating correctly with

proper rotation and without undue noise?

•Is the compressor operating correctly and has the system been

checked with a charging chart?

• Has the voltage and running current been checked to determine

if it is within limits?

• Has the thermostat been checked for calibration and the air

discharge grilles adjusted to balance the system?

•Has the furnace manifold pressure been checked and adjusted

if necessary?

• Has the heating air temperature rise been checked?

• Has the unit been checked for tubing and sheet metal rattles? Are

there any other unusual noises to be checked?

• Are all covers and panels in place and properly fastened?

• Has the owner or maintenance personnel been given this manual

and the warranty? Has the owner or maintenance been instructed

on proper operation and maintenance of this unit?

• Has the ductwork been checked for air leaks and condensation?

TROUBLESHOOTING CHART

SYSTEM FAULTS

REFRIGERANT CIRCUIT

Liquid Pressure Too high

Liquid Pressure Too Low

Suction Pressure Too High

Suction Pressure Too Low

Liquid Refrigerant floodback (TXV System)

Liquid Refrig. floodback (Cap. Tube System)

I. D. Coil Frosting

Compressor Runs Inadequate or No Cooling

ELECTRICAL

Compressor & O.D. fan Do Not Start

Compressor Will Not Start But O.D. Fan Runs

O.D. Fan Won't Start

Compressor Hums But Will Not Start

Compressor Cycles on IOL

I.D. Blower Won't Start

P SPS S

SP SS S

S PP SP

S SPS

P SS SP

P PS

SP PS SPS

PP SPPP

PSPPP S

P P

P PPPS s

P S P P P S P S P S S S S S

PS SP P

P-PRIMARY CAUSES S-SECONDARY CAUSES X664590

Page 16

MAINTENANCE

ROUTINE MAINTENANCE BY OWNER

You can do some of the periodic maintenance functions for your

TCY-G unit yourself; this includes replacing the disposable or

cleaning the permanent air fitters, cleaning the unit cabinet, clearing

the condenser coil, and conducting a general unit inspection on a

regular basis,

Be sure to inspect them at Neast once each month when the

system is in constant operation. (in new homes, check the filters

every week for the first four (4) weeks.)

If you have disposable-type filters, replace them with new filters of

the same type and size. Do not attempt to clean disposable

filters.

Permanent-type filters can be cleaned by washing them with a mild

detergent and water. Make sure that the filters are thoroughly dry

before reinstalling them in the unit (or duct system).

NOTE: It may be necessary to replace permanent filters annually

if washing fails to clean the filter or if the filter shows signs of

deterioration, Be sure to use the same type and size as was

originally installed,

CONDENSER COIL

Unfiltered air circulates through the unit's condenser coil and can

cause the coil's surface to become clogged with dust, dirt, etc. To

clean the coil, vertically (i.e., with the fins) stroke the coil surface

with a soft-bristled brush.

Be sure to keep all vegetation away from the condenser coil area.

MAINTENANCE PERFORMED BY

SERVICEMAN -- COOLING SEASON

To keep your unit operating safely and efficiently, the manufacturer

recommends that a qualified serviceman check the entire system at

least once each year and any other time that you feet one is needed,

Your serviceman should examine these areas of your TCY-G unit:

•filters (for cleaning or replacement)

• motors and drive system components

•gaskets (for possible replacement)

•safety controls (for mechanical cleaning)

•electrical components and wiring (for possible replacement and

connection tightness)

•condensate drain (for cleaning)

• unit duct connections (to see that they are physically sound and

sealed to the unit casing)

•unit mounting support (for structural integrity)

• the unit (for obvious unit deterioration)

MAINTENANCE PERFORMED BY

SERVICEMAN ==HEATING SEASON

Complete the unit inspections and service routines described below

at the beginning of each heating season.

•Visually inspect the unit to ensure that the airflow required for

condenser coil is not obstructed from the unit.

• Inspect the control panel wiring to verify that all electrical connec-

tions are tight and that the wire insulation is intact.

WARNING: TO PREVENT INJURY OR DEATH

DUE TO ELECTRICAL SHOCK OR CONTACT WITH MOVING

PARTS. LOCK UNIT DISCONNECT SWITCH IN OPEN

POSITION BEFORE SERVICING UNIT.

WARNING: TO PREVENT AN EXPLOSION

OR POSSIBLE INJURY, DEATH AND EQUIPMENT DAMAGE,

DO NOT STORE COMBUSTIBLE MATERIALS, GASOLINE

OR OTHER FLAMMABLE VAPORS OR LIQUIDS NEAR THE

UNIT.

The following warning complies with State of California law, Proposition 65.

AWARNING: This product 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.

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

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 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.

Page 17

LiMiTED WARRANTY

HiGH EFFiCiENCY AiR CONDiTiONER

TCY AND TCX

Models Less Than 20 Tons for Residential Use*

(Parts Only)

This limited warranty is extended by American Standard Inc., to the original purchaser and to any

succeeding owner of the real property to which the Air Conditioner is originally affixed, and applies to

products purchased and retained for use within the U.S.A. and Canada.

If any part of your Air Conditioner fails because of a manufacturing defect within five years from the date

of the original purchase, Warrantor will furnish without charge the required replacement part. Any local

transportation, related service labor, diagnosis calls, refrigerant and related items are not included.

In addition, if the sealed motor-compressor fails or the outdoor coitt should become defective, either or

both events occurring because of a manufacturing defect within the sixth through tenth year from the

date of original purchase, Warrantor will furnish without charge the required replacement compressor

and/or outdoor coil. Any local transportation, related service labor, diagnosis calls, refrigerant and

TRANE Package Units(both Units Combined) Manual L0905286

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