Trane WC IOM 7 7_ User Manual To The E5ad48dc 4d6f 47a7 8983 95bbd8519c60

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Installation
Operation
Maintenance
December 2004 WC-IOM-7
Model Number
WC*150B***G* WC*155B***G* WC*180B***G*
WC*200B***G* WC*240B***G*
Packaged Heat Pump
Warnings and Cautions
© 2008 Trane All rights reserved WC-IOM-7
Overview of Manual
Note: One copy of this document ships inside the control panel of each unit and
is customer property. It must be retained by the unit’s maintenance
personnel.
This booklet describes proper installation, operation, and maintenance
procedures for air cooled systems. By carefully reviewing the information within
this manual and following the instructions, the risk of improper operation and/or
component damage will be minimized.
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.
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 is provided below. Its use will enable the owner/operator,
installing contractors, and service engineers to define the operation, specific
components, and other options for any specific unit.
When ordering replacement parts or requesting service, be sure to refer to the
specific model number and serial number printed on the unit nameplate.
NOTICE: Warnings and Cautions appear at appropriate sections throughout this
literature. Read these carefully.
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.
NOTICE: Indicates a situation that may result in equipment or property-damage
only accidents.
WC-IOM-7 • Packaged Heat Pump 3
WARNING
Contains Refrigerant!
System contains oil and refrigerant under high pressure. Recover refrigerant to
relieve pressure before opening the system. See unit nameplate for refrigerant
type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant
additives.
Failure to follow proper procedures or the use of non-approved refrigerants,
refrigerant substitutes, or refrigerant additives could result in death or serious
injury or equipment damage.
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote disconnects and discharge all
motor start/run capacitors before servicing. Follow proper lockout/tagout
procedures to ensure the power cannot be inadvertently energized. Verify with
an appropriate voltmeter that all capacitors have discharged. Failure to
disconnect power and discharge capacitors before servicing could result in death
or serious injury.
NOTICE
Equipment Damage From Ultraviolet (UV) Lights!
The manufacturer does not recommend field installation of ultraviolet lights in
its equipment for the intended purpose of improving indoor air quality. High
intensity C-band ultraviolet light is known to severely damage polymer (plastic)
materials and poses a personal safety risk to anyone exposed to the light
without proper personal protective equipment. Polymer materials commonly
found in HVAC equipment that may be susceptible include insulation on
electrical wiring, fan belts, thermal insulation, various fasteners and bushings.
Degradation of these materials can result in serious damage to the equipment.
The manufacturer accepts no responsibility for the performance or operation of
our equipment in which ultraviolet devices were installed outside of the
manufacturer’s factory or its approved suppliers.
4WC-IOM-7
Contents
Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unit Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compressor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Economizer Control Actuator ReliaTel™ Control . . . . . . . . . . . . . . . . . . . . . . . 7
RTCI -- ReliaTel™ Trane Communication Interface (Optional) . . . . . . . . . . . . . 7
RLCI - ReliaTel™ LonTalk Communication Interface (Optional) . . . . . . . . . . . . 8
RTOM – ReliaTel™ Options Module (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 8
System Input Devices & Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Supply Fan Failure Input (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clogged Filter Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High Pressure Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Horizontal Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General Unit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Factory Installed Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electric Heat Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Low Voltage Wiring (AC & DC) Requirements . . . . . . . . . . . . . . . . . . . . . . . . 22
Condensate Drain Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Field Installed Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main Unit Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Smoke Detector Customer Low Voltage Wiring . . . . . . . . . . . . . . . . . . . . . . . 28
Space Temperature Averaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Voltage Imbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compressor Crankcase Heaters (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ReliaTel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Verifying Proper Air Flow
(Units with Belt Drive Indoor Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Economizer Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Heating Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Final System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fan Belt Adjustment - Belt Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contents
WC-IOM-7 5
Contents
Cooling Season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Heating Season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Final Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ReliaTel Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
System Status Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Resetting Cooling and Heating Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Programmable & Digital Zone Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ReliaTel Refrigeration Module (RTRM) Default Chart . . . . . . . . . . . . . . . . . . . 54
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
WCZ, WCY, WCX, WCC, WCD, WCH, WCM, WCP and WSC (Parts Only). . . . 57
Models Less Than 20 Tons for Commercial Use*. . . . . . . . . . . . . . . . . . . . . . 57
Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Standard Equipment Warranty Terms and Conditions. . . . . . . . . . . . . . . . . . 58
Commercial Equipment Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . 58
Models Larger that 20 Tons for Commercial Use* . . . . . . . . . . . . . . . . . . . . 58
6WC-IOM-7
Digits 1, 2 - Product Type Digit 8 - Electrical characteristics
WC = Packaged cooling, electric heat 3 = 208-230/60/3
WF = With factory installed options 4 = 460/60/3
D = 400/50/3
Digit 3 - Airflow Configuration T = 380/60/3
D = Downflow W = 575/60/3
H = Horizontal
Digit 9, 10 - Factory installed options
Digit 4, 5, 6 - Nominal gross cooling capacity (MBh) 00 = No factory installed options
150 = 12 1/2 tons standard efficiency 0A = Factory-installed economizer
180 = 15 tons standard efficiency 0B = Oversized motor
240 = 20 tons standard efficiency 0C = Downflow economizer/oversized motor
0F = Trane communications interface (TCI)
Digit 7 - Major development sequence 0G = Downflow economizer/TCI
Digit 11 - Minor design sequence
Digit 12 - Service digit
Model Number Description
WC D 1 5 0 C 3 0 0 B A
1 2 3 4 5 6 7 8 9 10 11 12
WC-IOM-7 • Packaged Heat Pump 7
Unit Nameplate
A Mylar unit nameplate is located on the unit’s corner support next to the control
box. It includes the unit model number, serial number, electrical characteristics,
refrigerant charge, as well as other pertinent unit data.
Compressor Nameplate
The nameplate for the compressors are located on the side of the compressor.
Unit Description
Before shipment, each unit is leak tested, dehydrated, charged with refrigerant
and compressor oil, and run tested for proper control operation.
The condenser coils are aluminum fin, mechanically bonded to copper tubing.
Direct-drive, vertical discharge condenser fans are provided with built-in thermal
overload protection.
The ReliaTel™ Control Module is a microelectronic control system that is referred
to as “Refrigeration Module” (RTRM). The acronym RTRM is used extensively
throughout this document when referring to the control system network.
This module through Proportional/Integral control algorithms perform specific
unit functions that governs unit operation in response to; zone temperature,
supply air temperature, and/or humidity conditions depending on the
application. The stages of capacity control for these units are achieved by starting
and stopping the compressors.
The RTRM is mounted in the control panel and is factory wired to the respective
internal components. The RTRM receives and interprets information from other
unit modules, sensors, remote panels, and customer binary contacts to satisfy
the applicable request for cooling.
Economizer Control Actuator ReliaTel™ Control
The ECA monitors the mixed air temperature, return air temperature, minimum
position setpoint (local or remote), power exhaust setpoint, CO2 setpoint, CO2,
and ambient dry bulb/enthalpy sensor or comparative humidity (return air
humidity against ambient humidity) sensors, if selected, to control dampers to an
accuracy of +/- 5% of stroke. The actuator is spring returned to the closed
position any time that power is lost to the unit. It is capable of delivering up to 25
inch pounds of torque and is powered by 24 VAC.
RTCI -- ReliaTel™ Trane Communication Interface (Optional)
This module is used when the application calls for an ICSTM building
management type control system. It allows the control and monitoring of the
system through an ICS panel. The module can be ordered from the factory or
General Information
8Packaged Heat Pump • WC-IOM-7
General Information
ordered as a kit to be field installed. Follow the installation instruction that ships
with each kit when field installation is necessary.
RLCI - ReliaTel™ LonTalk Communication Interface (Optional)
This module is used when the application calls for an ICSTM building
management type control system that is LonTalk. It allows the control and
monitoring of the system through an ICS panel. The module can be ordered from
the factory or ordered as a kit to be field installed. Follow the installation
instruction that ships with each kit when field installation is necessary.
RTOM – ReliaTel™ Options Module (Optional)
The RTOM monitors the supply fan proving, clogged filter, supply air
temperature, exhaust fan setpoint, supply air tempering, Frostat™ and smoke
detector. Refer to system input devices and functions for operation.
System Input Devices & Functions
The RTRM must have a zone sensor or thermostat input in order to operate the
unit. The flexibility of having several mode capabilities depends upon the type of
zone sensor or thermostat selected to interface with the RTRM.
The descriptions of the following basic Input Devices used within the RTRM
network are to acquaint the operator with their function as they interface with the
various modules. Refer to the unit’s electrical schematic for the specific module
connections.
The following controls are available from the factory for field installation.
Supply Fan Failure Input (Optional)
The Fan Failure Switch can be connected to sense indoor fan operation:
FFS (Fan Failure Switch) If air flow through the unit is not proven by the
differential pressure switch connected to the RTOM (factory set point 0.07 “ w.c.)
within 40 seconds nominally, the RTRM will shut off all mechanical operations,
lock the system out, send a diagnostic to ICS, and the SERVICE output will flash.
The system will remain locked out until a reset is initiated either manually or
through ICS.
Clogged Filter Switch (Optional)
The unit mounted clogged filter switch monitors the pressure differential across
the return air filters. It is mounted in the filter section and is connected to the
RTOM. A diagnostic SERVICE signal is sent to the remote panel if the pressure
differential across the filters is at least 0.5" w.c. The contacts will automatically
open when the pressure differential across the filters decreases to approximately
0.4" w.c. The clogged filter output is energized when the supply fan is operating
and the clogged filter switch has been closed for at least 2 minutes. The system
will continue to operate regardless of the status of the filter switch.
WC-IOM-7 • Packaged Heat Pump 9
General Information
Compressor Disable (CPR1/2)
This input incorporates the low pressure control (LPC) of each refrigeration
circuit and can be activated by opening a field supplied contact installed on the
LTB.
If this circuit is open before the compressor is started, the compressor will not be
allowed to operate. Anytime this circuit is opened for 1 continuous second during
compressor operation, the compressor for that circuit is immediately turned
“Off”. The compressor will not be allowed to restart for a minimum of 3 minutes
should the contacts close.
If four consecutive open conditions occur during the first three minutes of
operation, the compressor for that circuit will be locked out, a diagnostic
communicated to the remote panel (if installed), and a manual reset will be
required to restart the compressor.
Low Pressure Control
ReliaTel Control
When the LPC is opened for 1 continuous second, the compressor for that circuit
is turned off immediately. The compressor will not be allowed to restart for a
minimum of 3 minutes.
If four consecutive open conditions occur during the first three minutes of
operation, the compressor will be locked out, a diagnostic communicated to
ICSTM if applicable, and a manual reset will be required to restart the
compressor.
High Pressure Control (Optional)
ReliaTel Control
The high pressure controls are wired in series between the compressor outputs
on the RTRM and the compressor contactor coils. If the high pressure control
switch opens, the RTRM senses a lack of current while calling for cooling and
locks the compressor out.
On dual circuit units, if the high pressure control opens, the compressor on the
affected circuit is locked out. A manual reset for the affected circuit is required.
Power Exhaust Control (Optional)
The power exhaust fan is started whenever the position of the economizer
dampers meets or exceed the power exhaust setpoint when the indoor fan is on.
The setpoint panel is located in the return air section and is factory set at 25%.
10 Packaged Heat Pump • WC-IOM-7
General Information
Lead/Lag Control (Dual Circuit Only)
Lead/Lag is a selectable input located on the RTRM. The RTRM is configured from
the factory with the Lead/Lag control disabled. To activate the Lead/Lag function,
simply cut the wire connected to J3-8 at the RTRM. When it is activated, each
time the designated lead compressor is shut off due to the load being satisfied,
the lead compressor or refrigeration circuit switches. When the RTRM is powered
up, i.e. after a power failure, the control will default to the number one circuit
compressor.
Zone Sensor Module (ZSM) (BAYSENS007B)
This electronic sensor features three system switch settings (Heat, Cool, and Off)
and two fan settings (On and Auto). It is a manual changeover control with single
setpoint. (Cooling Setpoint Only)
Zone Sensor Module (ZSM) (BAYSENS009B)
This electronic sensor features four system switch settings (Heat, Cool, Auto, and
Off) and two fan settings (On and Auto). It is a manual or auto changeover control
with dual setpoint capability. It can be used with a remote zone temperature
sensor BAYSENS017B.
Zone Sensor (BAYSENS011B)
This electronic sensor features four system switch settings (Heat, Cool, Auto, and
Off) and two fan settings (On and Auto) with four system status LED’s. It is a
manual or auto changeover control with dual setpoint capability. It can be used
with a remote zone temperature sensor BAYSENS017B.
Programmable Zone Sensor - BAYSENS019B
This 7 day programmable sensor features 2, 3 or 4 periods for Occupied or
Unoccupied programming per day. If the power is interrupted, the program is
retained in permanent memory. If power is off for an extended period of time,
only the clock and day may have to be reset.
The Zone Sensor allows selection of 2, 3 or 4 system modes (Heat, Cool, Auto,
and Off), two fan modes (On and Auto). It has dual temperature selection with
programmable start time capability.
The occupied cooling set point ranges between 45 and 98 degrees Fahrenheit.
The heating set point ranges between 43 and 96 degrees Fahrenheit.
A liquid crystal display (LCD) displays zone temperature, temperature set points,
day of the week, time, and operational mode symbols.
The Option Menu is used to enable or disable applicable functions, i.e.; Morning
Warm-up, Economizer minimum position override during unoccupied status,
Fahrenheit or Centigrade, Supply air tempering, Remote zone temperature
sensor, 12/24 hour time display, Smart fan, and Computed recovery.
WC-IOM-7 • Packaged Heat Pump 11
General Information
Remote Zone Sensor (BAYSENS013C)
This electronic sensor features remote zone sensing and timed override with
override cancellation. It is used with a Trane Integrated ComfortTM building
management system.
Remote Zone Sensor (BAYSENS014C)
This electronic sensor features single setpoint capability and timed override with
override cancellation. It is used with a Trane Integrated ComfortTM building
management system.
Remote Zone Sensor (BAYSENS016A)
This bullet type temperature sensor can be used for; outside air (ambient)
sensing, return air temperature sensing, supply air temperature sensing, remote
temperature sensing (uncovered. Wiring procedures vary according to the
particular application and equipment involved. Refer to the unit’s wiring
diagrams for proper connections.
Remote Zone Sensor (BAYSENS017B)
This electronic sensor can be used with BAYSENS006B, 008B, 010B, 019B Remote
Panels. When this sensor is wired to a BAYSENS019B Remote Panel, wiring must
be 18 AWG Shielded Twisted Pair (Belden 8760 or equivalent). Refer to the
specific Remote Panel for wiring details.
High Temperature Sensor (BAYFRST001A)
This sensor connects to the RTRM Emergency Stop Input on the LTB and
provides high limit “shutdown” of the unit. The sensor is used to detect high
temperatures due to fire in the air conditioning or ventilation ducts. The sensor is
designed to mount directly to the sheet metal duct. Each kit contains two
sensors. The return air duct sensor (X1310004001) is set to open at 135°F. The
supply air duct sensor (X1310004002) is set to open at 240°F. The control can be
reset after the temperature has been lowered approximately 25°F below the
cutout setpoint.
Evaporator Frost Control
This input incorporates the Frostat™ control (FOS) mounted in the indoor coil
and can be activated by closing a field supplied contact installed in parallel with
the FOS.
If this circuit is open before the compressor is started, the compressor will not be
allowed to operate. Anytime this circuit is opened for 5 continuous seconds
during compressor operation, the compressor for that circuit is immediately
turned “Off”. The compressor will not be allowed to restart for a minimum of 3
minutes should the FOS close.
12 Packaged Heat Pump • WC-IOM-7
General Information
Smoke Detector Sensor (Optional)
This sensor is only applicable on units equipped with a RTOM. It provides high
limit “shutdown” of the unit and requires a manual reset. The sensor is used to
detect smoke due to fire in the air conditioning or ventilation ducts.
Important: The supply and return air smoke detectors are designed to shut off the
unit if smoke is sensed in the supply air stream or return air stream. This function
is performed by sampling the airflow entering the unit at the return air opening.
Follow the instructions provided below to assure that the airflow through the unit
is sufficient for adequate sampling. Failure to follow these instructions will
prevent the smoke detectors from performing it's design function. Important:
Airflow through the unit is affected by the amount of dirt and debris accumulated
on the indoor coil and filters. To insure that airflow through the unit is adequate
for proper sampling by the return air smoke detector, complete adherence to the
maintenance procedures, including recommended intervals between filter
changes, and coil cleaning is required.
Note: Important! Periodic checks and maintenance procedures must be
performed on the smoke detector to insure that it will function properly.
For detailed instructions concerning these checks and procedures, refer to
the appropriate section(s) of the smoke detector Installation and
Maintenance Instructions provided with the literature package for this
unit.
In order for the supply air smoke detector or return air smoke detector to
properly sense smoke in the supply air stream or return air stream, the air
velocity entering the smoke detector unit must be between 500 and 4000 feet per
minute. Equipment covered in this manual will develop an airflow velocity that
falls within these limits over the entire airflow range specified in the evaporator
fan performance tables.
Unit Inspection
As soon as the unit arrives at the job site:
• Verify that the nameplate data matches the data on the sales order and bill of
lading (including electrical data).
• Verify that the power supply complies with the unit nameplate specifications.
• Visually inspect the exterior of the unit, including the roof, for signs of
shipping damage.
• Visually inspect 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.
• If concealed damage is discovered, notify the carrier’s terminal of damage
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 damaged material from the receiving location.
WC-IOM-7 • Packaged Heat Pump 13
General Information
Take photos of the damage, if possible. The owner must provide reasonable
evidence that the damage did not occur after delivery.
• Notify the appropriate sales representative before installing or repairing a
damaged unit.
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 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 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.
Storage
Take precautions to prevent condensate from forming inside the unit’s electrical
compartments and motors if:
1. the unit is stored before it is installed; or,
2. the unit is set on the roof curb, and temporary heat is provided in the
building. Isolate all side panel service entrances and base pan openings (e.g.,
conduit holes, S/A and R/A openings, and flue openings) from the ambient air
until the unit is ready for start-up.
Note: Do not use the unit’s heater for temporary heat without first completing
the start-up procedure detailed under “Starting the Unit”.
14 Packaged Heat Pump • WC-IOM-7
General Information
The manufacturer will not assume any responsibility for equipment damage
resulting from condensate accumulation on the unit’s electrical and/or
mechanical components.
Unit Clearances
Figure 1 illustrates the minimum operating and service clearances for either a
single or multiple unit installation. These clearances are the minimum distances
necessary to assure adequate serviceability, cataloged unit capacity, and peak
operating efficiency.
Providing less than the recommended clearances may result in condenser coil
starvation, “short-circuiting” of exhaust and economizer airflows, or recirculation
of hot condenser air.
WC-IOM-7 • Packaged Heat Pump 15
Unit Dimensions
Figure 1. Typical Installation Clearances for Single & Multiple Unit Applications
16 Packaged Heat Pump • WC-IOM-7
Unit Dimensions
Figure 2. Unit Dimensional Data 12 1/2 Ton, 15 Ton
Figure 3. Roof Curb Dimensional Data 12 1/2 Ton, 15 Ton
WC-IOM-7 • Packaged Heat Pump 17
Unit Dimensions
Figure 4. Unit Dimensional Data 20 Ton
Figure 5. Roofcurb Dimensional Data 20 Ton
18 Packaged Heat Pump • WC-IOM-7
Unit Dimensions
Figure 6. Horizontal Duct Dimensional Data 12 1/2 Ton, 15 Ton
Figure 7. Horizontal Duct Dimensional Data 20 Ton
WC-IOM-7 • Packaged Heat Pump 19
Unit Dimensions
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 property-only damage. Failure to properly lift unit may result in death or
serious injury. See details below.
WARNING
Improper Unit Lift!
Test lift unit approximately 24 inches to verify proper center of gravity lift point.
To avoid dropping of unit, reposition lifting point if unit is not level. Failure to
properly lift unit could result in death or serious injury or possible equipment or
property-only damage.
Table 1. Typical weights and point loading data
Corner Weights (lbs.) Center of
Gravity (in.)
Unit
Description Net
Weight A B C D Length Width
WC*150B 1375 465 344 231 311 46 29
WC*155B 1412 547 638 231 343 43 27
WC*180B 1412 547 638 231 343 43 27
WC*200B 1916 640 497 340 438 51 34
WC*240B 1916 640 497 340 438 51 34
Note: Corner weights are given for information only. Unit is to be supported continuously by
a curb or equivalient frame support.
Figure 8. Rigging and center of gravity data
20 Packaged Heat Pump • WC-IOM-7
Unit Dimensions
Rigging
Refer to Figure 8 and Ta b l e 1 for typical unit operating weights riffing before
proceeding.
1. Remove the shipping crate from around the unit. Do not remove the crating
from the top of the unit.
2. Rig the unit as shown in Figure 8. Attach adequate strength lifting slings to all
four lifting brackets in the unit base rail. Do not use cables, chains, or slings
except as shown.
3. Install a lifting bar, as shown in Figure 8, to protect the unit and to facilitate a
uniform lift. The minimum distance between the lifting hook and the top of
the unit should be 7 feet.
4. Test-lift the unit to ensure it is properly rigged and balanced, make any
necessary rigging adjustments.
5. Lift the unit and position it into place.
6. Downflow units; align the base rail of the unit with the curb rail while
lowering the unit onto the curb. Make sure that the gasket on the curb is not
damaged while positioning the unit.
WC-IOM-7 • Packaged Heat Pump 21
Foundation
Horizontal Units
If the unit is installed at ground level, elevate it above the snow line. Provide
concrete footings at each support location with a “full perimeter” support
structure or a slab foundation for support. Refer to Table 1 on page 19 for the
unit’s operating and point loading weights when constructing a footing
foundation.
If anchoring is required, anchor the unit to the slab using hold down bolts or
isolators. Isolators should be installed to minimize the transmission of vibrations
into the building.
For rooftop applications, ensure the roof is strong enough to support the
combined unit and support structural weight. Refer to Table 1 on page 19 for the
unit operating weights. If anchoring is required, anchor the unit to the roof with
hold-down bolts or isolators.
Check with a roofing contractor for proper waterproofing procedures.
Ductwork
Elbows with turning vanes or splitters are recommended to minimize air noise
due to turbulence and to reduce static pressure.
When attaching the ductwork to the unit, provide a water- tight flexible connector
at the unit to prevent operating sounds from transmitting through the ductwork.
All outdoor ductwork between the unit and the structure should be weather
proofed after installation is completed.
Note: For sound consideration, cut only the holes in the roof deck for the
ductwork penetrations. Do not cut out the entire roof deck within the curb
perimeter.
If a Curb Accessory Kit is not used:
1. The ductwork can be attached directly to the factory-provided flanges around
the unit’s supply and return air openings. Be sure to use flexible duct
connections at the unit.
2. For “built-up” curbs supplied by others, gaskets must be installed around the
curb perimeter flange and the supply and return air opening flanges.
General Unit Requirements
The checklist listed below is a summary of the steps required to successfully
install a commercial unit. This checklist is intended to acquaint the installing
Installation
22 Packaged Heat Pump • WC-IOM-7
Installation
personnel with what is required in the installation process. It does not replace the
detailed instructions called out in the applicable sections of this manual.
• Check the unit for shipping damage and material shortage; file a freight claim
and notify appropriate sales representative.
• Verify correct model, options and voltage from nameplate.
• Verify that the installation location of the unit will provide the required
clearance for proper operation.
• Assemble and install the roof curb (if applicable). Refer to the latest edition of
the curb installers guide that ships with each curb kit.
• Fabricate and install ductwork; secure ductwork to curb.
• Rigging the unit.
• Set the unit onto the curb; check for levelness.
• Ensure unit-to-curb seal is tight and without buckles or cracks.
• Install and connect a condensate drain line to the evaporator drain
connection.
Factory Installed Economizer
• Ensure the economizer has been pulled out into the operating position. Refer
to the economizer installers guide for proper position and setup.
• Install all access panels.
Main Electrical Power Requirements
• Verify that the power supply complies with the unit nameplate specifications.
• Inspect all control panel components; tighten any loose connections.
• Connect properly sized and protected power supply wiring to a field-
supplied/installed disconnect switch and to the main power terminal block
(HTB1) in the unit control panel.
• Install proper grounding wires to an earth ground.
Note: All field-installed wiring must comply with NEC and applicable local
codes.
Electric Heat Requirements
• Verify that the power supply complies with the electric heater specifications
on the unit and heater nameplate.
• Inspect the heater junction box and control panel; tighten any loose
connections.
• Check electric heat circuits for continuity.
Low Voltage Wiring (AC & DC) Requirements
• Install the zone thermostat, with or without switching subbase.
WC-IOM-7 • Packaged Heat Pump 23
Installation
• Connect properly sized control wiring to the proper termination points
between the zone thermostat and the unit control panel.
Condensate Drain Configuration
An evaporator condensate drain connection is provided on each unit. Refer to
Unit Dimensions for the appropriate drain location.
A condensate trap must be installed at the unit due to the drain connection being
on the “negative pressure” side of the fan. Install the P-Trap using the guidelines
in Figure 9.
A condensate drain line must be connected to the P-Trap. Pitch the drain lines at
least 1/2 inch for every 10 feet of horizontal run to assure proper condensate flow.
Do not allow the horizontal run to sag causing a possible double-trap condition
which could result in condensate backup due to “air lock”.
Filter Installation
Each unit ships with 2 inch filters installed. The quantity of filters is determined
by unit size. Access to the filters is obtained by removing the indoor fan access
panel.
Refer to the unit Service Facts (shipped with each unit) for filter requirements.
Note: Do not operate the unit without filters.
Field Installed Power Wiring
An overall dimensional layout for the standard field installed wiring entrance into
the unit is illustrated in Unit Dimensions. To insure that the unit’s supply power
wiring is properly sized and installed, follow the guidelines outlined below.
Figure 9. Condensate Trap Installation
24 Packaged Heat Pump • WC-IOM-7
Installation
Note: All field installed wiring must conform to NEC guidelines as well as State
and Local codes.
Verify that the power supply available is compatible with the unit’s nameplate
ratings. The available supply power must be within 10% of the rated voltage
stamped on the nameplate. Use only copper conductors to connect the power
supply to the unit.
NOTICE
Use Copper Conductors Only!
Unit terminals are not designed to accept other types of conductors. Failure to
use copper conductors may result in equipment damage. Failure to do so may
cause damage to the equipment.
Note: If the unit is not equipped with an optional factory installed nonfused
disconnect switch or circuit breaker, a field supplied disconnect switch
must be installed at or near the unit in accordance with the National
Electrical Code (NEC latest edition).
Main Unit Power
Standard Wiring
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.
1. If the unit is not equipped with an optional factory installed nonfused
disconnect switch or circuit breaker, a field supplied disconnect switch must
be installed at or near the unit in accordance with the National Electrical Code
(NEC latest edition).
2. Location of the applicable electrical service entrance is illustrated in Unit
Dimensions. Complete the unit’s power wiring connections onto either; the
main terminal block HTB1 inside the unit control panel, the factory mounted
nonfused disconnect switch (UCD) or circuit breaker (UCB), or the electric
heat terminal block. Refer to the customer connection diagram that shipped
with the unit for specific termination points.
3. Provide proper grounding for the unit in accordance with local and national
codes.
Optional TBUE Wiring
(Through the Base Electrical Option)
1. Location of the applicable electrical service is illustrated in the following
illustration. Refer to the customer connection diagram that is shipped with
the unit for specific termination points. The termination points, depending on
the customer option selected would be a factory mounted nonfused
disconnect switch (UDC) or circuit breaker (UCB).
WC-IOM-7 • Packaged Heat Pump 25
Installation
2. Provide proper grounding for the unit in accordance with local and national
codes.
Field Installed Control Wiring
An overall layout of the various control options available with the required
number of conductors for each control device is illustrated in Figure 8.
Note: All field wiring must conform to NEC guidelines as well as state and local
codes.
Control Power Transformer
The 24 volt control power transformers are to be used only with the accessories
called out in this manual. Transformers rated greater than 50 VA are equipped
with internal circuit breakers. If a circuit breaker trips, turn “Off” all power to the
unit before attempting to reset it.
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.
Figure 10.
26 Packaged Heat Pump • WC-IOM-7
Installation
The transformer is located in the control panel. The circuit breaker is located on
the left side of the transformer and can be reset by pressing in on the black reset
button.
Controls using 24 VAC
Before installing any connecting wiring, refer to Unit Dimensions for the
electrical access locations provided on the unit and Tab l e 2 for AC conductor
sizing guidelines, and;
1. Use copper conductors unless otherwise specified.
2. Ensure that the AC control wiring between the controls and the unit’s
termination point does not exceed three (3) ohms/conductor for the length of
the run.
Note: Resistance in excess of 3 ohms per conductor may cause component
failure due to insufficient AC voltage supply.
3. Be sure to check all loads and conductors for grounds, shorts, and mis-
wiring.
4. Do not run the AC low voltage wiring in the same conduit with the high
voltage power wiring.
5. Route low voltage wiring per illustrations on Figure 11.
Controls using DC Analog Input/Outputs (Standard Low Voltage
Multiconductor Wire)
Before installing any connecting wiring between the unit and components
utilizing a DC analog input\output signal, refer to Unit Dimensions for the
electrical access locations provided on the unit.
1. Table 3 lists the conductor sizing guidelines that must be followed when
interconnecting the DC binary output devices and the system components
utilizing a DC analog input\output signal to the unit.
Table 2. Electromechanical Thermostat 24V AC conductors with ReliaTel™
Distance from Unit to Control Recommended Wire Size
000 - 460 feet 18 gauge
000 - 140 m .75 mm2
461 - 732 feet 16 gauge
141 - 223 m 1.3 mm2
733 - 1000 feet 14 gauge
224 - 305 m 2.0 mm2
WC-IOM-7 • Packaged Heat Pump 27
Installation
Note: Resistance in excess of 2.5 ohms per conductor can cause deviations in
the accuracy of the controls.
2. Ensure that the wiring between controls and the unit’s termination point does
not exceed two and a half (2.5) ohms/conductor for the length of the run.
3. Do not run the electrical wires transporting DC signals in or around conduit
housing high voltage wires.
Table 3. DC Conductors Zone Sensor Module wiring
Distance from Unit to Control Recommended Wire Size
0 - 150 feet 22 gauge
0 - 45.7 m .33 mm2
151 - 240 feet 20 gauge
46 - 73.1 m .50 mm2
241 -385 feet 18 gauge
73.5 - 117.3 m .75 mm2
386 - 610 feet 16 gauge
117.7 - 185.9 m 1.3 mm2
611 - 970 feet 14 gauge
186.2 - 295.7 m 2.0 mm2
Figure 11. Reliatel conventional thermostat field wiring diagram
RTRM
28 Packaged Heat Pump • WC-IOM-7
Installation
Smoke Detector Customer Low Voltage Wiring
When interlocking System Sensor smoke detectors together, all of the detectors
must be powered from the same power supply. If multiple smoke detectors are
required, all detectors must be disconnected from the HVAC unit power supply
and connected together from another single source supply.
Note: Do not interconnect smoke detectors together that have separate power
supplies. Do not exceed ten smoke detectors on one power supply.
Note: Multiple System Sensor smoke detectors are connected together using
terminals 1 and 12 on each detector.
If you have supply and return smoke detectors in all HVAC units, you can connect
a maximum of 5 HVAC units (10 detectors) up to one power supply. See the
following field wiring example.
If you have more than 5 HVAC units, you can connect all the supply detectors
together on one power supply (up to 10 HVAC units), and all the return detectors
together (up to 10 HVAC units) on another power supply. See the following field
wiring example.
Figure 12. Smoke detector wiring
More than 5 HVAC units
Up to 5 HVAC units
WC-IOM-7 • Packaged Heat Pump 29
Installation
Figure 13. Typical field wiring diagrams for optional controls (ReliaTel™ only)
30 Packaged Heat Pump • WC-IOM-7
Installation
Space Temperature Averaging
Space temperature averaging is accomplished by wiring a number of remote
sensors in a series/parallel circuit.
Using the BAYSENS016* or BAYSENS017*, at least four sensors are required to
accomplish space temperature averaging. Example #1 illustrates two series
circuits with two sensors in each circiut wired in parallel. The square of any
number of remote sensors is required. Example #2 illustrates three sensors
squared in a series/parallel circuit. Using BAYSENS032*, two sensors are
required to accomplish space temperature averaging. Example #3 illustrates the
circuit required for this senor. Tab l e 4 lists the temperature versus resistance
coefficient for all sensing.
Figure 14.
WC-IOM-7 • Packaged Heat Pump 31
Installation
Use the checklist provided below in conjunction with the “General Unit
Requirements” checklist to ensure that the unit is properly installed and ready for
operation.
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.
• Check all electrical connections for tightness and “point of termination”
accuracy.
• Verify that the condenser airflow will be unobstructed.
• Verify that the condenser fan and indoor blower turn freely without rubbing
and are properly tightened on the shafts.
Table 4. Temperature vs. Resistance
Temperature
Degrees F° Degrees C° Nominal Resistance
-20° -28.9° 170.1 K - Ohms
-15° -26.1° 143.5 K - Ohms
-10° -23.3° 121.4 K - Ohms
-5° -20.6° 103.0 K - Ohms
0° -17.8° 87.56 K - Ohms
5° -15.0° 74.65 K - Ohms
10° -12.2° 63.80 K - Ohms
15° -9.4° 54.66 K - Ohms
20° -6.7° 46.94 K - Ohms
25° -3.8° 40.40 K - Ohms
30° -1.1° 34.85 K - Ohms
35° 1.7° 30.18 K - Ohms
40° 4.4° 26.22 K - Ohms
45° 7.2° 22.85 K - Ohms
50° 10.0° 19.96 K - Ohms
55° 12.8° 17.47 K - Ohms
60° 15.6° 15.33 K - Ohms
65° 18.3° 13.49 K - Ohms
70° 21.1° 11.89 K - Ohms
75° 23.9° 10.50 K - Ohms
80° 26.7° 9.297 K - Ohms
85° 29.4° 8.247 K - Ohms
90° 32.2° 7.330 K - Ohms
95° 35.0° 6.528 K - Ohms
100° 37.8° 5.824 K - Ohms
32 Packaged Heat Pump • WC-IOM-7
Installation
• Check the supply fan belts for proper tension and the fan bearings for
sufficient lubrication. If the belts require adjustment, or if the bearings need
lubricating, refer to the maintenance section of this manual for instructions.
• Verify that a condensate trap is installed and the piping is properly sized and
pitched.
• Verify that the correct size and number of filters are in place.
• Inspect the interior of the unit for tools and debris and install all panels in
preparation for starting the unit.
Voltage Imbalance
Three phase electrical power to the unit must meet stringent requirements for
the unit to operate properly. Measure each leg (phase-to-phase) of the power
supply. Each reading must fall within the utilization range stamped on the unit
nameplate. If any of the readings do not fall within the proper tolerances, notify
the power company to correct this situation before operating the unit.
Excessive three phase voltage imbalance between phases will cause motors to
overheat and eventually fail. The maximum allowable voltage imbalance is 2%.
Measure and record the voltage between phases 1, 2, and 3 and calculate the
amount of imbalance as follows:
% Voltage Imbalance =
where Average Voltage (AV);
V1, V2, V3 = Line Voltage Readings
VD = Line Voltage reading that deviates the farthest from the average voltage.
Example: If the voltage readings of the supply power measured 221, 230, and 227,
the average volts would be:
VD (reading farthest from average) = 221
The percentage of Imbalance equals:
The 2.2% imbalance in this example exceeds the maximum allowable imbalance
of 2.0%. This much imbalance between phases can equal as much as a 20%
current imbalance with a resulting increase in motor winding temperatures that
will decrease motor life. If the voltage imbalance is over 2%, notify the proper
agencies to correct the voltage problem before operating this equipment.
100 AV VD–
AV
-----------------------
⎝⎠
⎛⎞
AV Volt1 Volt2 Volt3++
3
-----------------------------------------------------------------
⎝⎠
⎛⎞
=
221 230 227++
3
-----------------------------------------------2.2percent=
100 226 221–
226
----------------------------
⎝⎠
⎛⎞
2.2percent=
WC-IOM-7 • Packaged Heat Pump 33
Installation
Electrical Phasing
(Three Phase Motors)
The compressor motor(s) and the supply fan motor are internally connected for
the proper rotation when the incoming power supply is phased as A, B, C.
Proper electrical supply phasing can be quickly determined and corrected before
starting the unit by using an instrument such as an Associated Research Model
45 Phase Sequence Indicator and following the steps below:
• Turn the field supplied disconnect switch that provides power to the main
power terminal block or to the “Line” side of the optional factory mounted
disconnect switch to the “Off” position.
• Connect the phase sequence indicator leads to the terminal block or to the
“Line” side of the optional factory mounted disconnect switch as follows;
Black (phase A) to L1
Red (phase B) to L2
Yellow (phase C) toL3
• Close the field supplied main power disconnect switch or circuit protector
switch that provides the supply power to the unit.
WARNING
Live Electrical Components!
During installation, testing, servicing and troubleshooting of this product, it may
be necessary to work with live electrical components. Have a qualified licensed
electrician or other individual who has been properly trained in handling live
electrical components perform these tasks. Failure to follow all electrical safety
precautions when exposed to live electrical components could result in death or
serious injury.
To prevent injury or death from electrocution, it is the responsibility of the
technician to recognize this hazard and use extreme care when performing
service procedures with the electrical power energized.
• Observe the ABC and CBA phase indicator lights on the face of the
sequencer. The ABC indicator light will glow if the phase is ABC. If the CBA
indicator light glows, open the disconnect switch or circuit protection switch
and reverse any two power wires.
• Restore the main electrical power and recheck the phasing. If the phasing is
correct, open the disconnect switch or circuit protection switch and remove
the phase sequence indicator.
Compressor Crankcase Heaters (Optional)
Each compressor can be equipped with a crankcase heater. The proper operation
of the crankcase heater is important to maintain an elevated compressor oil
temperature during the “Off” cycle to reduce oil foaming during compressor
34 Packaged Heat Pump • WC-IOM-7
Installation
starts. Oil foaming occurs when refrigerant condenses in the compressor and
mixes with the oil. In lower ambient conditions, refrigerant migration to the
compressor could increase.
When the compressor starts, the sudden reduction in crankcase pressure causes
the liquid refrigerant to boil rapidly causing the oil to foam. This condition could
damage compressor bearings due to reduced lubrication and could cause
compressor mechanical failures.
Before starting the unit in the “Cooling” mode, set the system switch to the “Off”
position and turn the main power disconnect to the “On” position and allow the
crankcase heater to operate a minimum of 8 hours.
Before closing the main power disconnect switch, insure that the “System”
selection switch is in the “Off” position and the “Fan” selection switch is in the
“Auto” position.
Close the main power disconnect switch and the unit mounted disconnect switch,
if applicable.
WARNING
Live Electrical Components!
During installation, testing, servicing and troubleshooting of this product, it may
be necessary to work with live electrical components. Have a qualified licensed
electrician or other individual who has been properly trained in handling live
electrical components perform these tasks. Failure to follow all electrical safety
precautions when exposed to live electrical components could result in death or
serious injury.
To prevent injury or death from electrocution, it is the responsibility of the
technician to recognize this hazard and use extreme care when performing
service procedures with the electrical power energized.
ReliaTel Controls
Upon power initialization, the RTRM performs self-diagnostic checks to insure
that all internal controls are functional. It also checks the configuration
parameters against the components connected to the system. The Liteport LED
located on the RTRM module is turned “On” within one second of power-up if
internal operation is okay.
Use one of the following “Test” procedure to bypass some time delays and to
start the unit at the control panel. Each step of unit operation can be activated
individually by temporarily shorting across the “Test” terminals for two to three
seconds. The Liteport LED located on the RTRM module will blink when the test
mode has been initiated. The unit can be left in any “Test” step for up to one hour
before it will automatically terminate, or it can be terminated by opening the
main power disconnect switch. Once the test mode has been terminated, the
Liteport LED will glow continuously and the unit will revert to the “System”
control.
WC-IOM-7 • Packaged Heat Pump 35
Test Modes
There are three methods in which the “Test” mode can be cycled at LTB-Test 1
and LTB-Test 2.
1. Step Test Mode - This method initiates the different components of the unit,
one at a time, by temporarily shorting across the two test terminals for two to
three seconds.
For the initial start-up of the unit, this method allows the technician to cycle a
component “On” and have up to one hour to complete the check.
2. Resistance Test Mode - This method can be used for start-up providing a
decade box for variable resistance outputs is available. This method initiates
the different components of the unit, one at a time, when a specific resistance
value is placed across the two test terminals. The unit will remain in the
specific test mode for approximately one hour even though the resistance is
left on the test terminals.
3. Auto Test Mode - This method is not recommended for start-up due to the
short timing between individual component steps. This method initiates the
different components of the unit, one at a time, when a jumper is installed
across the test terminals. The unit will start the first test step and change to
the next step every 30 seconds. At the end of the test mode, control of the
unit will automatically revert to the applied "System" control method.
For unit test steps, test modes, and step resistance values to cycle the various
components, refer to Ta b l e 5 .
Pre-Start
Table 5. Service test guide for component operation
TEST
STEP MODE Fan Econ
(Note 2) Comp 1 Comp 2 Heat 1 Heat 2 Ohms
1 Fan On Minimum
Position Off
Setpoint 0%
Off Off Off 2.2K
Minimum
Ventilation On Selectable Off Off Off Off
2Economizer
Test Open On Open Off Off Off Off 3.3K
3 Cool Stage 1 On Minimum
Position (Note 1)
On Off Off Off 4.7K
4 (Note 3) Cool Stage 2 On Minimum
Position (Note 1)
On (Note 1)
On Off Off 6.8K
5 (Note 3) Reheat On Minimum On On Off Off 33K
6 (Note 3) Heat Stage 1 On Minimum Off Off On Off 10K
7 (Note 3) Heat Stage 2 On Minimum Off Off On On 15K
Notes:
1 - The condenser fans will operate any time a compressor is "On" providing the outdoor air temperatures are within the operating values.
2 - The exhaust fan will turn on anytime the economizer damper position is equal to or greater than the exhaust fan setpoint.
3 - Steps for optional accessories and non-applicable modes in unit will be skipped.
36 Packaged Heat Pump • WC-IOM-7
Pre-Start
Verifying Proper Air Flow
(Units with Belt Drive Indoor Fan)
Much of the systems performance and reliability is closely associated with, and
dependent upon having the proper airflow supplied both to the space that is
being conditioned and across the evaporator coil.
The indoor fan speed is changed by opening or closing the adjustable motor
sheave.
Before starting the SERVICE TEST, set the minimum position setpoint for the
economizer to 0 percent using the setpoint potentiometer located on the
Economizer Control (ECA), if applicable.
ReliaTel Control
Using the Service Test Guide in Ta b l e 5 , momentarily jump across the Test 1 &
Test 2 terminals on LTB1 one time to start the Minimum Ventilation Test.
Once the supply fan has started, check for proper rotation. The direction of
rotation is indicated by an arrow on the fan housing.
With the fan operating properly, determine the total system airflow (CFM) by;
1. Measuring the actual RPM,
2. Measure the amperage at the supply fan contactor and compare it with the
full load amp (FLA) rating stamped on the motor nameplate.
a. Calculate the theoretical BHP
Actual Motor Amps X Motor HP
Motor Nameplate Amps
b. Using the fan performance tables in the unit Service Facts, plot the actual
RPM (step 1) and the BHP (step 2a) to obtain the operating CFM.
3. If the required CFM is too low, (external static pressure is high causing motor
HP output to be below table value),
a. Relieve supply and/or return duct static.
b. Change indoor fan speed and repeat steps 1 and 2.
• To Increase Fan RPM; Loosen the pulley adjustment set screw and turn
sheave clockwise.
• To Decrease Fan RPM; Loosen the pulley adjustment set screw and turn
sheave counterclockwise.
• If the required CFM is too high, (external static pressure is low causing motor
HP output to be above table value), change indoor fan speed and repeat steps
1 and 2.
• To stop the SERVICE TEST, turn the main power disconnect switch to the
“Off” position or proceed to the next component start-up procedure. Remove
electro mechanical test mode connections (if applicable).
WC-IOM-7 • Packaged Heat Pump 37
Pre-Start
Return Air Smoke Detector
The return air smoke detector is designed to shut off the unit if smoke is sensed
in the return air stream. Sampling the airflow entering the unit at the return air
opening performs this function.
In order for the smoke detector to properly sense smoke in the return air stream,
the air velocity entering the unit must be between 500 and 4000 feet per minute.
Equipment covered in this manual will develop an airflow velocity that falls
within these limits over the entire airflow range specified in the evaporator fan
performance tables.
WC-IOM-7 • Packaged Heat Pump 38
Economizer Start-Up
ReliaTel Control
Using the Service Test Guide in Table 5, p. 35, momentarily jump across the Test
1 & Test 2 terminals on LTB1 one time to start the Minimum Ventilation Test.
1. Set the minimum position setpoint for the economizer to the required
percentage of minimum ventilation using the setpoint potentiometer located
on the Economizer Control (ECA).
The economizer will drive to its minimum position setpoint, exhaust fans (if
applicable) may start at random, and the supply fan will start when the
SERVICE TEST is initiated.
WARNING
Rotating Components!
During installation, testing, servicing and troubleshooting of this product it may
be necessary to measure the speed of rotating components. Have a qualified or
licensed service individual who has been properly trained in handling exposed
rotating components, perform these tasks. Failure to follow all safety
precautions when exposed to rotating components could result in death or
serious injury.
The Exhaust Fan will start anytime the economizer damper position is equal to or
greater than the exhaust fan setpoint.
2. Verify that the dampers stroked to the minimum position.
3. Momentarily jump across the Test 1 & Test 2 terminals on LTB one additional
time if continuing from previous component start-up or until the desired
start-up component Test is started.
4. Verify that the dampers stroked to the full open position.
5. To stop the SERVICE TEST, turn the main power disconnect switch to the
“Off” position or proceed to the next component start-up procedure. Remove
electro mechanical test mode connections (if applicable).
Compressor Start-Up
1. Attach a set of service gauges onto the suction and discharge gauge ports for
each circuit. Refer to the refrigerant circuit illustration in the Service Facts.
Using the Service Test Guide in Table 5, p. 35, continue the SERVICE TEST
start-up procedure for each compressor circuit.
Momentarily jump across the Test 1 & Test 2 terminals on LTB1 one
additional time if continuing from previous component start-up or until the
desired start-up component Test is started.
Start Up
WC-IOM-7 • Packaged Heat Pump 39
Start Up
Scroll Compressors
a. Once each compressor has started, verify that the rotation is correct. If a
scroll compressor is rotating backwards, it will not pump and a loud
rattling sound can be observed.
b. If the electrical phasing is correct, before condemning a compressor,
interchange any two leads (at the compressor Terminal block) to check the
internal phasing. Refer to the following illustration for the compressor
terminal/phase identification. If the compressor runs backward for an
extended period (15 to 30 minutes), the motor winding can overheat and
cause the motor winding thermostat to open.
c. Check the compressor oil levels. The oil level in each compressor sight
glass should be 1/2 to 3/4 full when they are “Off”.
Note: The scroll compressor uses Trane OIL-42 without substitution. The
appropriate oil charge for a 9 and 10 Ton scroll compressor is 8 pints. For a
14 and 15 Ton scroll compressor, use 14 pints.
2. After the compressor and condenser fan have started and operated for
approximately 30 minutes, observe the operating pressures. Compare the
operating pressures to the operating pressure curve in the Service Facts.
3. Check system superheat. Follow the instruction listed on the superheat
charging curve in the Service Facts.
Superheat should be within ±5 F of the superheat chart value.
4. Repeat steps 1 through 4 for each refrigerant circuit.
5. To stop the SERVICE TEST, turn the main power disconnect switch to the
“Off” position or proceed to the next component start-up procedure. Remove
electro mechanical test mode connections (if applicable).
Heating Start-Up
1. Clamp an amp meter around one of 1st stage heater power wires at the
heater contactor.
Figure 15.
40 Packaged Heat Pump • WC-IOM-7
Start Up
2. ReliaTel Control
Using the Service Test Guide in Table 5, p. 35, continue the SERVICE TEST
start-up procedure for each compressor circuit.
Momentarily jump across the Test 1 & Test 2 terminals on LTB one additional
time if continuing from previous component start-up or until the desired
start-up component Test is started.
3. Verify that the heater stage is operating properly.
4. Clamp an amp meter around one of 2nd stage heater power wires at the
heater contactor (if applicable).
5. ReliaTel Control
Using the Service Test Guide in Table 5, p. 35, continue the SERVICE TEST
start-up procedure for each compressor circuit. Momentarily jump across the
Test 1 & Test 2 terminals on LTB one additional time if continuing from
previous component start-up or until the desired start-up component Test is
started.
6. Verify that the heater stage is operating properly
7. To stop the SERVICE TEST, turn the main power disconnect switch to the
“Off” position or proceed to the next component start-up procedure.
Final System Setup
After completing all of the pre-start and start-up procedures outlined in the
previous sections (i.e., operating the unit in each of its Modes through all
available stages of cooling & heating), perform these final checks before leaving
the unit:
• Program the Night Setback (NSB) panel (if applicable) for proper unoccupied
operation. Refer to the programming instructions for the specific panel.
• Verify that the Remote panel “System” selection switch, “Fan” selection
switch, and “Zone Temperature” settings for automatic operation are correct.
• Inspect the unit for misplaced tools, hardware, and debris.
• Verify that all exterior panels including the control panel doors and
condenser grilles are secured in place.
• Close the main disconnect switch or circuit protector switch that provides the
supply power to the unit’s terminal block or the unit mounted disconnect
switch.
WC-IOM-7 • Packaged Heat Pump 41
WARNING
Rotating Components!
During installation, testing, servicing and troubleshooting of this product it may
be necessary to measure the speed of rotating components. Have a qualified or
licensed service individual who has been properly trained in handling exposed
rotating components, perform these tasks. Failure to follow all safety
precautions when exposed to rotating components could result in death or
serious injury.
Make sure all personnel are standing clear of the unit before proceeding. The
system components will start when the power is applied.
Fan Belt Adjustment - Belt Drive Units
The fan belts must be inspected periodically to assure proper unit operation.
Replacement is necessary if the belts appear frayed or worn. Units with dual belts
require a matched set of belts to ensure equal belt length.
When removing or installing the new belts, do not stretch them over the sheaves.
Loosen the belts using the belt tension adjustment bolts on the motor mounting
base.
Once the new belts are installed, using a Browning or Gates tension gauge (or
equivalent) illustrated in Figure 16; adjust the belt tension as follows;
1. To determine the appropriate belt deflection;
a. Measure the center-to-center shaft distance (in inches) between the fan
and motor sheaves.
b. Divide the distance measured in Step 1a by 64; the resulting value
represents the amount of belt deflection that corresponds to the proper
belt tension.
2. Set the large O-ring on the belt tension gauge at the deflection value
determined in Step 1b.
3. Set the small O-ring at zero on the force scale of the gauge plunger.
4. Place the large end of the gauge at the center of the belt span; then depress
the gauge plunger until the large O-ring is even with the top of the next belt
or even with a straightedge placed across the fan and motor sheaves. Refer
to Figure 16.
5. Remove the belt tension gauge. The small O-ring now indicates a number
other than zero on the plunger’s force scale. This number represents the force
(in pounds) required to give the needed deflection.
6. Compare the “force” scale reading (Step 5) with the appropriate “force”
value listed in Tab l e 6 . If the “force” reading is outside the range, readjust the
belt tension.
Maintenance
42 Packaged Heat Pump • WC-IOM-7
Maintenance
Note: Actual belt deflection “force” must not exceed the maximum “force”
value shown in Table 6.
7. Recheck the belt tension at least twice during the first 2 to 3 days of
operation. Belt tension may decrease until the new belts are “run in”.
Monthly Maintenance
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.
Before completing the following checks, turn the unit OFF and lock the main
power disconnect switch open. Failure to disconnect power before servicing can
cause severe personal injury or death.
Table 6. Belt tension measurement and deflection ranges
Deflection Force (Lbs.)
Belts
Cross
Section
Small
P.D
Range
Super Gripbelts Gripnotch Steel Cable
Gripbelts
Min. Max. Min. Max. Min. Max
A3.0 - 3.6 3 4 1/2 3 7/8 5 1/2 3 1/4 4
3.8 - 4.8 3 1/2 5 4 1/2 6 1/4 3 3/4 4 3/4
5.0 - 7.0 4 5 1/2 5 6 7/8 4 1/4 5 1/4
B3.4 - 4.2 4 5 1/2 5 3/4 8 4 1/2 5 1/2
4.4 - 5.6 5 1/8 7 1/8 6 1/2 9 1/8 5 3/4 7 1/4
5.8 - 8.8 6 3/8 8 3/4 7 3/8 10 1/8 7 8 3/4
Figure 16. Belt tension gauge
WC-IOM-7 • Packaged Heat Pump 43
Maintenance
Filters
• Inspect the return air filters. Clean or replace them if necessary. Refer to the
unit Service Facts for filter information.
Return Air Smoke Detector Maintenance
Airflow through the unit is affected by the amount of dirt and debris accumulated
on the indoor coil and filters. To insure that airflow through the unit is adequate
for proper sampling by the return air smoke detector, complete adherence to the
maintenance procedures, including recommended intervals between filter
changes, and coil cleaning is required.
Periodic checks and maintenance procedures must be performed on the smoke
detector to insure that it will function properly. For detailed instructions
concerning these checks and procedures, refer to the appropriate section(s) of
the smoke detector Installation and Maintenance Instructions provided with the
literature package for this unit.
Cooling Season
• Check the unit’s drain pans and condensate piping to ensure that there are no
blockages.
• Inspect the evaporator and condenser coils for dirt, bent fins, etc. If the coils
appear dirty, clean them according to the instructions described in “Coil
Cleaning” later in this section.
• Manually rotate the condenser fan(s) to ensure free movement and check
motor bearings for wear. Verify that all of the fan mounting hardware is tight.
• Inspect the F/A-R/A damper hinges and pins to ensure that all moving parts
are securely mounted. Keep the blades clean as necessary.
• Verify that all damper linkages move freely; lubricate with white grease, if
necessary.
• Check supply fan motor bearings; repair or replace the motor as necessary.
• Check the fan shaft bearings for wear. Replace the bearings as necessary.
• Check the supply fan belt. If the belt is frayed or worn, replace it. Refer to the
“Fan Belt Adjustment” section for belt replacement and adjustments.
• Verify that all wire terminal connections are tight.
• Remove any corrosion present on the exterior surfaces of the unit and repaint
these areas.
• Generally inspect the unit for unusual conditions (e.g., loose access panels,
leaking piping connections, etc.)
• Make sure that all retaining screws are reinstalled in the unit access panels
once these checks are complete.
44 Packaged Heat Pump • WC-IOM-7
Maintenance
• With the unit running, check and record the: ambient temperature;
compressor suction and discharge pressures (each circuit); superheat (each
circuit);
Record this data on an “operator’s maintenance log” like the one shown in
Table 7 on page 46. If the operating pressures indicate a refrigerant shortage,
measure the system superheat. For guidelines, refer to the “Compressor Start-
Up” section.
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.
Heating Season
• Inspect the unit’s air filters. If necessary, clean or replace them.
• Check supply fan motor bearings; repair or replace the motor as necessary.
• Inspect both the main unit control panel and heat section control box for
loose electrical components and terminal connections, as well as damaged
wire insulation. Make any necessary repairs.
• Verify that the electric heat system operates properly.
Coil Cleaning
Regular coil maintenance, including annual cleaning, enhances the unit’s
operating efficiency by minimizing: compressor head pressure and amperage
draw; evaporator water carryover; fan brake horsepower, due to increase static
pressure losses; airflow reduction.
At least once each year, or more often if the unit is located in a “dirty”
environment, clean the evaporator and condenser coils using the instructions
outlined below. Be sure to follow these instructions as closely as possible to
avoid damaging the coils.
To clean refrigerant coils, use a soft brush and a sprayer (either a garden pump-
up type or a high-pressure sprayer). A high-quality detergent is also required;
suggested brands include “SPREX A.C.”, “OAKITE 161”, “OAKITE 166” and
“COILOX”. If the detergent selected is strongly alkaline (ph value exceeds 8.5),
add an inhibitor.
1. Remove enough panels from the unit to gain access to the coil. Remove the
access panel from the roof located next to the rear condenser fan.
2. Protect all electrical devices such as motors and controllers from any over
spray.
3. Straighten any bent coil fins with a fin comb.
4. Mix the detergent with water according to the manufacturer’s instructions. If
desired, heat the solution to 150° F maximum to improve its cleansing
capability.
WC-IOM-7 • Packaged Heat Pump 45
Maintenance
WARNING
Hazardous Pressures!
Coils contain refrigerant under pressure. When cleaning coils, maintain coil
cleaning solution temperature under 150°F to avoid excessive pressure in the
coil. Failure to follow these safety precautions could result in coil bursting, which
could result in death or serious injury.
Do not heat the detergent-and-water solution above 150° F. Hot liquids sprayed
on the exterior of the coil will raise the coil’s internal pressure and may cause it to
burst. Failure to follow proper procedures can result in personal illness or injury
or severe equipment damage.
5. 5. Pour the cleaning solution into the sprayer. If a high-pressure sprayer is
used:
a. do not allow sprayer pressure to exceed 600 psi.
b. the minimum nozzle spray angle is 15 degrees.
c. maintain a minimum clearance of 6" between the sprayer nozzle and the
coil.
d. spray the solution perpendicular (at 90 degrees) to the coil face.
6. Spray the leaving-airflow side of the coil first; then spray the opposite side of
the coil. Allow the cleaning solution to stand on the coil for five minutes.
7. Rinse both sides of the coil with cool, clean water.
8. Inspect both sides of the coil; if it still appears to be dirty, repeat Steps 6 and
7.
9. Reinstall all of the components and panels removed in Step 1 and any
protective covers installed in step 2.
10. Restore the unit to it’s operational status and check system operation.
Final Process
For future reference, you may find it helpful to record the unit data requested
below in the blanks provided.
(1) Complete Unit Model Number:
_______________________________________________________________________
(2) Unit Serial Number:
_______________________________________________________________________
(3) Wiring Diagram Numbers (from unit control panel):
— schematic(s)
_______________________________________________________________________
_______________________________________________________________________
46 Packaged Heat Pump • WC-IOM-7
Maintenance
_______________________________________________________________________
_______________________________________________________________________
— connection(s)
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Table 7. Sample maintenance log
Refrigerant Circuit #1 Refrigerant Circuit #2
Date Current
Ambient
temp F/C
Compr. Oil
Level Suction
Pressure
Psig/kPa
Dischcharge
Pressure
Psig/kpa
Super heat
F/C Sub coolF/
CCompr. Oil
Level Suction
Pressure
Psig/kPa
Dischcharge
Pressure
Psig/kpa
Super heat
F/C Sub coolF/
C
WC-IOM-7 • Packaged Heat Pump 47
ReliaTel Control
The RTRM has the ability to provide the service personnel with some unit
diagnostics and system status information.
WARNING
Hazardous Service Procedures!
The maintenance and troubleshooting procedures recommended in this section
of the manual could result in exposure to electrical, mechanical or other
potential safety hazards. Always refer to the safety warnings provided
throughout this manual concerning these procedures. When possible,
disconnect all electrical power including remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. When necessary to work with live electrical
components, have a qualified licensed electrician or other individual who has
been trained in handling live electrical components perform these tasks. Failure
to follow all of the recommended safety warnings provided, could result in death
or serious injury.
Before turning the main power disconnect switch “Off”, follow the steps below to
check the ReliaTel Refrigeration Module (RTRM). All diagnostics & system status
information stored in the RTRM will be lost when the main power is turned “Off”.
To prevent injury or death from electrocution, it is the responsibility of the
technician to recognize this hazard and use extreme care when performing
service procedures with the electrical power energized.
1. Verify that the Liteport LED on the RTRM is burning continuously. If the LED is
lit, go to Step 3.
2. If the LED is not lit, verify that 24 VAC is presence between J1-1 and J1-2. If 24
VAC is present, proceed to Step 3. If 24 VAC is not present, check the unit
main power supply, check transformer (TNS1). Proceed to Step 3 if necessary.
3. Utilizing “Method 1” or “Method 2” in the “System Status Checkout
Procedure ” section, check the following:
System status
Heating status
Cooling status
If a System failure is indicated, proceed to Step 4. If no failures are indicated,
proceed to Step 5.
4. If a System failure is indicated, recheck Steps 1 and 2. If the LED is not lit in
Step 1, and 24 VAC is present in Step 2, the RTRM has failed. Replace the
RTRM.
5. If no failures are indicated, use one of the TEST mode procedures described
in the “Unit Start-Up” section to start the unit. This procedure will allow you
Troubleshooting
48 Packaged Heat Pump • WC-IOM-7
Troubleshooting
to check all of the RTRM outputs, and all of the external controls (relays,
contactors, etc.) that the RTRM outputs energize, for each respective mode.
Proceed to Step 6.
6. Step the system through all of the available modes, and verify operation of
all outputs, controls, and modes. If a problem in operation is noted in any
mode, you may leave the system in that mode for up to one hour while
troubleshooting. Refer to the sequence of operations for each mode, to assist
in verifying proper operation. Make the necessary repairs and proceed to
Steps 7 and 8.
7. If no abnormal operating conditions appear in the test mode, exit the test
mode by turning the power “Off” at the main power disconnect switch.
8. Refer to the individual component test procedures if other microelectronic
components are suspect.
System Status Checkout Procedure
“System Status” is checked by using one of the following two methods:
Method 1
If the Zone Sensor Module (ZSM) is equipped with a remote panel with LED
status indication, you can check the unit within the space. If the ZSM does not
have LED’s, use Method 2. BAYSENS010B, BAYSENS011B, BAYSENS019B,
BAYSENS020B, BAYSENS021A & BAYSENS023A all have the remote panel
indication feature. The LED descriptions are listed below.
LED 1 (System)
“On” during normal operation.
“Off” if a system failure occurs or the LED fails.
“Flashing” indicates test mode.
LED 2 (Heat)
“On” when the heat cycle is operating.
“Off” when the heat cycle terminates or the LED fails.
“Flashing” indicates a heating failure.
LED 3 (Cool)
“On” when the cooling cycle is operating.
“Off” when the cooling cycle terminates or the LED fails.
“Flashing” indicates a cooling failure.
WC-IOM-7 • Packaged Heat Pump 49
Troubleshooting
LED 4 (Service)
“On” indicates a clogged filter.
“Off” during normal operation.
“Flashing” indicates an evaporator fan failure
Below is the complete listing of failure indication causes.
System Failure
Check the voltage between terminals 6 and 9 on J6, it should read approximately
32 VDC. If no voltage is present, a System failure has occurred. Refer to Step 4 in
the previous section for the recommended troubleshooting procedure.
Cooling Failure
1. Cooling and heating set point (slide pot) on the zone sensor has failed. Refer
to the “Zone Sensor Test Procedure” section.
2. Zone temperature thermistor ZTEMP on ZTS failed. Refer to the “Zone
Sensor Test Procedure” section.
3. CC1 or CC2 24 VAC control circuit has opened, check CC1 & CC2 coils, and
any of the controls below that apply to the unit (HPC1, HPC2).
4. LPC1 has opened during the 3 minute minimum “on time” during 4
consecutive compressor starts, check LPC1 or LPC2 by testing voltage
between the J1-8 & J3-2 terminals on the RTRM and ground. If 24 VAC is
present, the LPC’s has not tripped. If no voltage is present, LPC’s has tripped.
Service Failure
5. If the supply fan proving switch has closed, the unit will not operate (when
connected to RTOM), check the fan motor, belts, and proving switch.
6. Clogged filter switch has closed, check the filters.
Simultaneous Heat and Cool Failure
1. Emergency Stop is activated.
Method 2
The second method for determining system status is done by checking voltage
readings at the RTRM (J6). The system indication descriptions and the
approximate voltages are listed below.
System Failure
Measure the voltage between terminals J6-9 & J6-6.
Normal Operation = approximately 32 VDC
System Failure = less than 1 VDC, approximately 0.75 VDC
50 Packaged Heat Pump • WC-IOM-7
Troubleshooting
Test Mode = voltage alternates between 32 VDC & 0.75 VDC
Heat Failure
Measure the voltage between terminals J6-7 & J6-6.
Heat Operating = approximately 32 VDC
Heat Off = less than 1 VDC, approximately 0.75 VDC
Heating Failure = voltage alternates between 32 VDC & 0.75 VDC
Cool Failure
Measure the voltage between terminals J6-8 & J6-6.
Cool Operating = approximately 32 VDC
Cool Off = less than 1 VDC, approximately 0.75 VDC
Cooling Failure = voltage alternates between 32 VDC & 0.75 VDC
Service Failure
Measure the voltage between terminals J6-10 & J6-6.
Clogged Filter = Approximately 32 VDC.
Normal = Less than 1 VDC, approximately 0.75 VDC
Fan Failure = voltage alternates between 32 VDC & 0.75 VDC.
To use LED’s for quick status information at the unit, purchase a BAYSENS010B
ZSM and connect wires with alligator clamps to terminals 6 through 10. Connect
each respective terminal wire (6 through 10) from the Zone Sensor to the unit J6
terminals 6 through 10.
Note: If the system is equipped with a programmable zone sensor,
(BAYSENS019A, BAYSENS020A or BAYSENS023A), the LED indicators
will not function while the BAYSENS010A is connected.
Resetting Cooling and Heating Lockouts
Cooling Failures and Heating Lockouts are reset in an identical manner. Method 1
explains resetting the system from the space; Method 2 explains resetting the
system at the unit.
Note: Before resetting Cooling Failures and Heating Lockouts check the Failure
Status Diagnostics by the methods previously explained. Diagnostics will
be lost when the power to the unit is disconnected.
Method 1
To reset the system from the space, turn the “Mode” selection switch at the zone
sensor to the “Off” position. After approximately 30 seconds, turn the “Mode”
selection switch to the desired mode, i.e. Heat, Cool or Auto.
WC-IOM-7 • Packaged Heat Pump 51
Troubleshooting
Method 2
To reset the system at the unit, cycle the unit power by turning the disconnect
switch “Off” and then “On”.
Lockouts can be cleared through the building management system. Refer to the
building management system instructions for more information.
Zone Temperature Sensor (ZTS) Service Indicator
The ZSM SERVICE LED is a generic indicator, that will signal the closing of a
Normally Open switch at any time, providing the Indoor Motor (IDM) is
operating. This indicator is usually used to indicate a clogged filter, or an air side
fan failure.
The RTRM will ignore the closing of this Normally Open switch for 2 (±1) minutes.
This helps prevent nuisance SERVICE LED indications. The exception is the LED
will flash 40 seconds after the fan is turned “On” if the Fan Proving Switch is not
made.
Clogged Filter Switch
This LED will remain lit the entire time that the Normally Open switch is closed.
The LED will be turned off immediately after resetting the switch (to the Normally
Open position), or any time that the IDM is turned “Off”.
If the switch remains closed, and the IDM is turned “On”, the SERVICE LED will be
turned “On” again after the 2 (±1) minute ignore delay.
This LED being turned “On”, will have no other affect on unit operation. It is an
indicator only.
Fan Failure Switch
When the “Fan Failure” switch is wired to the RTOM, the LED will remain flashing
the entire time the fan proving switch is closed, indicating a fan failure, and it will
shut the unit operations down.
52 Packaged Heat Pump • WC-IOM-7
Troubleshooting
Zone Temperature Sensor (ZTS) Test
Note: These procedures are not for programmable or digital models and are
conducted with the Zone Sensor Module electrically removed from the
system.
Te s t 1
Zone Temperature Thermistor (ZTEMP)
This component is tested by measuring the resistance between terminals 1 and 2
on the Zone Temperature Sensor. Below are some typical indoor temperatures,
and corresponding resistive values.
Te s t 2
Cooling Set Point (CSP) and Heating Set Point (HSP)
The resistance of these potentiometers are measured between the following
ZSM terminals. Refer to the chart above for approximate resistances at the given
setpoints.
Cool SP = Terminals 2 and 3
Range = 100 to 900 Ohms approximate
Heat SP = Terminals 2 and 5
Range = 100 to 900 Ohms approximate
Table 8.
Zone Temperature
Nominal
ZTEMP
Resistance
Nominal CSP
or HSP
Resistance
50 F° 10.0 C° 19.9 K-Ohms 889 Ohms
55 F° 12.8 C° 17.47 K-Ohms 812 Ohms
60 F° 15.6 C° 15.3 K-Ohms 695 Ohms
65 F° 18.3 C° 13.49 K-Ohms 597 Ohms
70 F° 21.1 C° 11.9 K-Ohms 500 Ohms
75 F° 23.9 C° 10.50 K-Ohms 403 Ohms
80 F° 26.7 C° 9.3 K-Ohms 305 Ohms
85 F° 29.4 C° 8.25 K-Ohms 208 Ohms
90 F° 32.2 C° 7.3 K-Ohms 110 Ohms
WC-IOM-7 • Packaged Heat Pump 53
Troubleshooting
Te s t 3
System Mode and Fan Selection
The combined resistance of the Mode selection switch and the Fan selection
switch can be measured between terminals 2 and 4 on the Zone Sensor. The
possible switch combinations are listed on the following page with their
corresponding resistance values.
Te s t 4
LED Indicator Test, (SYS ON, HEAT, COOL & SERVICE)
Method 1
Testing the LED using a meter with diode test function. Test both forward and
reverse bias. Forward bias should measure a voltage drop of 1.5 to 2.5 volts,
depending on your meter. Reverse bias will show an Over Load, or open circuit
indication if LED is functional.
Method 2
Testing the LED with an analog Ohmmeter. Connect Ohmmeter across LED in one
direction, then reverse the leads for the opposite direction. The LED should have
at least 100 times more resistance in reverse direction, as compared with the
forward direction. If high resistance in both directions, LED is open. If low in both
directions, LED is shorted.
Method 3
To test LED’s with ZSM connected to unit, test voltages at LED terminals on ZSM.
A measurement of 32 VDC, across an unlit LED, means the LED has failed.
Note: Measurements should be made from LED common (ZSM terminal 6 to
respective LED terminal). Refer to the Zone Sensor Module (ZSM) Terminal
Identification table at the beginning of this section.
Programmable & Digital Zone Sensor Test
Testing serial communication voltage
1. Verify 24 VAC is present between terminals J6-14 & J6-11.
2. Disconnect wires from J6-11 and J6-12. Measure the voltage between J6-11
and J6-12, should be about 32 VDC.
3. Reconnect wires to terminals J6-11 and J6-12. Measure voltage again
between J6-11 and J6-12, voltage should flash high and low every 0.5
seconds. The voltage on the low end will measure about 19 VDC, while the
voltage on the high end will measure from approximately 24 to 38 VDC.
54 Packaged Heat Pump • WC-IOM-7
Troubleshooting
4. Verify all modes of operation, by running the unit through all of the steps in
the “Test Modes” section discussed in “Unit Start-Up”.
5. After verifying proper unit operation, exit the test mode. Turn the fan on
continuously at the ZSM, by pressing the button with the fan symbol. If the
fan comes on and runs continuously, the ZSM is good. If you are not able to
turn the fan on, the ZSM is defective.\
ReliaTel Refrigeration Module (RTRM) Default Chart
If the RTCI loses input from the building management system, the RTRM will
control in the default mode after approximately 15 minutes. If the RTRM loses the
Heating and Cooling setpoint input, the RTRM will control in the default mode
instantaneously. The temperature sensing thermistor in the Zone Sensor Module
is the only component required for the “Default Mode” to operate.
Unit Operation without a Zone Sensor
This procedure is for temporary operation only. The economizer and condenser
fan cycling functions are disabled.
1. Open and Lock the unit disconnect switch.
2. Remove the Outside Air Sensor (OAS) from the condenser section of unit.
3. Use two (2) wire nuts, to individually cap the wires.
4. Locate the RTRM (J6). Connect two (2) wires to terminals J6-1 and 2.
5. Connect the sensor (OAS) using two wire nuts to the two (2) field supplied
wires that were connected to terminals 1 and 2 on J6.
Table 9. System mode and fan selection chart
Resistance Valves
(Ohms) Zone Sensor
Unit/Fan Mode Local Unit Mode Local Fan
Mode
2.32K Off/ Auto Off Auto
4.87K Cool/Auto Cool Auto
7.68K Auto/Auto Auto Auto
10.77K Off/On Off On
13.32K Cool/On Cool On
16.13K Auto/On Auto On
19.48K Heat/Auto Heat Auto
27.93K Heat/On Heat On
35.0K Emergency Heat/Auto Emergency Heat Auto
43.45K Emergency Heat/On Emergency Heat On
Out of Range (Short) INVALID/Short Invalid (CV), Auto (VAV) Invalid
Out of Range (Open) INVALID/Open Invalid (CV), Off (VAV) Invalid
WC-IOM-7 • Packaged Heat Pump 55
Troubleshooting
Unit Economizer Control (ECA) Troubleshooting
ReliaTel Control
Table 10. Verify economizer status by economizer actuator (ECA) LED indicator:
OFF: No Power or Failure
ON: Normal, OK to Economize
Slow Flash: Normal, Not OK to Economize
Fast Flash - 1/2 Second On / 2 Seconds Off:
Error Code:
Communications Failure
Pulse Flash: 2 Second On / 1/2 Second Off:
Error Code:
1 Flash: Actuator Fault
2 Flashes: CO2 Sensor
3 Flashes: RA Humidity Sensor
4 Flashes: RA Temp Sensor
5 Flashes: OA Quality Sensor
6 Flashes: OA Humidity Sensor
7 Flashes: OA Temp Sensor
8 Flashes: MA Temp Sensor
9 Flashes: RAM Fault
10 Flashes: ROM Fault
11 Flashes: EEPROM Fault
WC-IOM-7 • Packaged Heat Pump 56
For easier access, after 2007, published unit wiring diagrams (individual, separate
diagrams for unitary product lines) will become available via e-Library instead of
through wiring manuals. Diagrams prior to 2008 will be located in wiring
diagram books RT-SVE03A-EN and RT-SVE06A-EN.
Wiring Diagrams
Drawing
Number Description
2309-3105 Diagram; Novar ETM-3051 (Home Depot)
2309-3108 Diagram; CONTROL WC_150 WC_240 400-575/60/3
2309-3115 Diagram; Power Electrical WC 150-240
2309-3116 Diagram; Power Electrical WC 240
2309-3140 Diagram; Master Stacked Layer Model
2309-3149 Diagram; Connection Electrical WC 180
2309-3170 Diagram; Connection Electrical WC 240
2309-3171 Diagram; Connection Electrical WC 240
2309-3172 Diagram; Connection Electrical WC 150
2309-3173 Diagram; Connection Electrical WC 150
2309-3174 Diagram; Connection Electrical WC 180
2309-3194 INSTRUCTIONAL DIAGRAM FOR CONVETNIONAL THERMOSTAT
23093195 Diagram;Novar 3051
2309-3352 MICRO INTERCONNECTION DIAGRAM
2309-3358 Diagram; Crankcase Heater Kits for Voyager 2
2309-3360 SCHEMATICS; CONNECTION DIAGRAM--VOY2 208-230V WC180
2309-3361 SCHEMATICS; CONNECTION DIAGRAM--VOY2 460/575V WC 180
2309-3364 Diagram 14 position plug
2309-3377 MASTER DRAWING; CONNECTION DIAGRAMS--VOY2
2309-3382 Schematic; Power 200-230V WC 150-240
2309-3383 Schematic; Power 400-575V WC 150-240
2309-3392 Schematic, Control 200-575V WC 150-240
2309-3393 Diagram, Connection 208-230V WC 150
2309-3394 Diagram, Connection 400-575V WC 150
2309-3183 Diagram; Electric Heat
2309-3184 Diagram; Electric Heat
2309-3185 Diagram; Electric Heat
2309-3186 Diagram; Electric Heat
2309-3187 Diagram; Electric Heat
2309-3188 Diagram; Electric Heat
2309-3189 Diagram; Electric Heat
2309-3190 Diagram; Electric Heat
2309-3191 Diagram; Electric Heat
2309-3192 Diagram; Electric Heat
WC-IOM-7 • Packaged Heat Pump 57
Heat Pump
WCZ, WCY, WCX, WCC, WCD, WCH, WCM, WCP and WSC (Parts Only)
Models Less Than 20 Tons for Commercial Use*
This warranty is extended by Trane, to the original purchaser and to any
succeeding owner of the real property to which the Heat Pump is originally
affixed, and applies to products purchased and retained for use within the U.S.A.
and Canada. There is no warranty against corrosion, erosion or deterioration. If
any part of your Heat Pump fails because of a manufacturing defect within one
year from the date of the original purchase, Warrantor will furnish without charge
the required replacement part.
In addition, if the sealed motor-compressor fails because of a manufacturing
defect within the second through fifth year from the date of original purchase,
Warrantor will furnish without charge the required replacement compressor.
Warrantor’s obligations and liabilities under this warranty are limited to
furnishing F.O.B. Warrantor factory or warehouse replacement parts for
Warrantor’s products covered under this warranty. Warrantor shall not be
obligated to pay for the cost of lost refrigerant. No liability shall attach to
Warrantor until products have been paid for and then liability shall be limited
solely to the purchase price of the equipment under warranty shown to be
defective.
THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL
OTHER WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN
NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE,
AND IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
Some states do not allow limitations on how long an implied warranty lasts or do
not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from state to
state.
Trane
2701 Wilma Rudolph Blvd.
Clarksville, TN 37040-1008
Attention: Manager, Product Service
GW-604-4800
* This warranty is for commercial usage of said equipment and not applicable
when the equipment is used for a residential application. Commercial use is any
application where the end purchaser uses the product for other than personal,
family or household purposes.
Warranty
58 Packaged Heat Pump • WC-IOM-7
Warranty
Heat Pump
Standard Equipment Warranty Terms and Conditions
Commercial Equipment Warranty and Liability
Models Larger that 20 Tons for Commercial Use*
The Company warrants for a period of 12 months from initial start-up or 18
months from date of shipment, whichever is less, that the Company products
covered by this order (1) are free from defects in material and workmanship and
(2) have the capacities and ratings set forth in the Company’s catalogs and
bulletins, provided that no warranty is made against corrosion, erosion or
deterioration.
The Company’s obligations and liabilities under this warranty are limited to
furnishing f.o.b. factory or warehouse at Company designated shipping point,
freight allowed to Buyer’s city (or port of export for shipment outside the
conterminous United States) replacement equipment (or at the option of the
Company parts therefore) for all Company products not conforming to this
warranty and which have been returned to the manufacturer.
The Company shall not be obligated to pay for the cost of lost refrigerant. No
liability whatever shall attach to the Company until said products have been paid
for and then said liability shall be limited to the purchase price of the equipment
shown to be defective.
The Company makes certain further warranty protection available on an optional
extra-cost basis. Any further warranty must be in writing, signed by an officer of
the Company.
The warranty and liability set forth herein are in lieu of all other warranties and
liabilities, whether in contract or in negligence, express or implied, in law or in
fact, including implied warranties of merchantability and fitness for particular
use. In no event shall the Company be liable for any incidental or consequential
damages.
Trane
2701 Wilma Rudolph Blvd.
Clarksville, TN 37040-1008
Attention: Manager,Product Service
Literature Order Number WC-IOM-7
Date 12/04
Supersedes WC-IOM-7 (04/03)
The manufacturer has a policy of continuous product and product data improvement and reserves
the right to change design and specifications without notice.

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