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

User Manual: Trane WC-IOM-7 to the manual

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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.