Trane RT-SVX10C-EN Bedienungsanleitung

T rane has a policy of continuous product and product data improvement and reserves the right to c hange design and specifications without notice. Only qualified tec hnicians should perform the installation and servicing of equipment refer red to in this publication. Installation R T -SVX10C-EN Operation Maintenance Library Service Literature Produ[...]

2 About The Manual Note: This document is customer property and must be retained by the unit's owner for use by maintenance personnel. Literature Change History RT -SVX10C-EN (No vember 2004) Re-issue of manual for minor corrections to Connection Sizes T able 3-5; provides specific installation, operation and maintenance instructions for S_HF [...]

3 T able of Contents Section One About The Man ual ............................................................... 2 Literature Change History ................................................ 2 Overview of Manual ......................................................... 2 Section T wo General Information ............................................[...]

4 General Inf ormation Model Number Description All products are identified by a multiple character model number listed on the unit nameplate. An e xplanation of the alphanumeric identification code is provided belo w . Its use can define the unit's specific components, type of applica- tion, i.e. CV or V A V , f or a par ticular unit. When or[...]

5 Sam p le M o d el N o .: S X H G - D 1 1 4 0 A H 7 C G 8 D 1 0 0 1 A T ,et c Dig it N o .: 1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21+ Di gi t 1 - Uni t Ty pe Di git 1 2 - E x haus t Ai r Fan D r iv e Di gi t 1 8 - Ac ce ss ory P a ne l S = Sel f- Co ntai ned 0 = None 0 = None 5 = 50 0 R PM A = BAYSENS0 08 * Di gi t 2 - Uni t Func ti [...]

6 General Information (Continued) Unit Nameplate One Mylar unit nameplate is located on the outside upper left cor ner of the control panel door . It includes the unit model number , serial number , electrical characteristics, weight, refrigerant charge, as well as other pertinent unit data. A small metal nameplate with the Model Number , Se- rial [...]

7 Rooftop Module (RTM - 1U48 Standard on all units) The Rooftop Module (RTM) responds to cooling, heating, and v entilation requests by energizing the proper unit com- ponents based on information received from other unit mod- ules, sensors, remote panels, and customer supplied bi- nary inputs. It initiates supply fan, exhaust fan, exhaust damper ,[...]

8 General Information (Contin ued) V entilation Control Module (VCM - Design special option only) The V entilation Control Module (VCM) is located in the filter section of the unit and is linked to the unit's UCM network. Using a "velocity pressure" sensing ring located in the fresh air section, allows the VCM to monitor and control [...]

9 General Information (Contin ued) 3S69 is a binar y input de vice used on all rooftop units equipped with an e xhaust f an. It is located in the e xhaust fan section of the unit and is connected to the R TM (1U48). During a request for f an operation, if the differential s witch is detected to be open for 40 consecutiv e seconds, the economizer is[...]

10 General Information (Continued) Low Ambient Compressor Lockout Utilizes an analog input de vice for CV & V A V applications. When the system is configured for low ambient compressor lockout, the compressors are not allowed to operate if the temperature of the outside air falls below the lockout set- point. When the temperature rises 5 F abov[...]

11 General Information (Continued) V ariable Air V olume (V A V) Units Occupied Heating - Supply Air T emperature When a V A V units is equipped with "Modulating Heat", and the system is in an occupied mode, and the field supplied changeover relay contacts (5K87) have closed, the supply air temperature will be controlled to the customer s[...]

12 General Information (Continued) Space T emperature A veraging Space temperature a v eraging for Constant V olume applica- tions is accomplished by wiring a number of remote sensors in a series/parallel circuit. The fewest number of sensors required to accomplish space temperature av eraging is f our . Figure 8 illustr ates a single sensor circui[...]

13 General Information (Contin ued) Control Module Locations f or S_HF 40, 60, 70 & 75 T on Units RTM RTM 1U48 1U48 GBAS MOD GBAS MOD 1U51 1U51 Bracke Bracke t VOM VOM 1U53 1U53 Mounting Mounting Plate Plate Heat MOD Heat MOD 1U50 1U50 LCI MOD LCI MOD 1U54 1U54 TCI MOD TCI MOD 1U54 1U54 OR OR 1PCB MOD 1PCB MOD 1U55 1U55 ECEM ECEM 1U52 1U52 1TB9[...]

T able of Contents Section One About The Man ual ............................................................... 2 Literature Change Histor y ................................................ 2 Overview of Manual ......................................................... 2 Section T w o General Infor mation ...........................................[...]

14 Installation Unit Inspection As soon as the unit arrives at the job site [ ] V e r ify that the nameplate data matches the data on the sales order and bill of lading (including electrical data). [ ] V e r ify that the p o w er supply complies with the unit name- plate specifications. [ ] V e r ify that the p o w er supply complies with the elect[...]

15 Figure 3-1 Minimum Operation and Service Clearances for Single & Multiple Unit Installation[...]

16 Figure 3-2A SAHF Cooling-Only Units (20 thru 75 T on)[...]

17 Installation (Continued) T able 3-1A Unit Dimensional Data Unit D imens ions S i z e ABCD E F G H J 20 & 25 T on 21'- 9 3/4" 5' -3 1/8" 7' -6 1/2" 5' -8 15/16" 3' -9 5/16" 12' - 6" 1" 7' 1' -3 1/2" 30 Ton 21'- 9 3/4" 5'- 8 5/8" 7'- 6 1/2&[...]

18 Figure 3-2B SEHF , SFHF , SLHF , SSHF , SXHF Units (20 thru 75 T on)[...]

19 Installation (Continued) T able 3-2A Unit Dimensional Data Unit D imens ions S i z e AB CD E F G H J 20 & 25 T on 24' -1 3/8" 5' -3 1/8" 7' -6 1/ 2" 5' - 8 15/16" 3' -9 5/ 16" 13' -3" 1" 7' 1' -3 1/2" 30 Ton 24' -1 3/ 8" 5' -8 5/8" 7' -6 [...]

20 Figure 3-2C S_HG Cooling & Heating Units (90 thr ough 130 T on)[...]

21 Un it s w it h Uni t s Un it s 100% w i t hout w it h Supply & E x h au s t F an E xhau st F an E xh au st V F D Un it Un it Di m . Di m . Di m . Dim . Di m . Di m . Mo d e l Si ze A B A B A B SA H F C20 12' 6" 3' 8" 13' 5" 3' 10" 11' 10" 3' 9" C25 12' 9" 3' 8" 1[...]

22 Installation (Continued) T able 3-3 T ypical Unit & Curb Weights Ty pic a l Uni t Ope r a ting W e ight ( 1 ) R oof C ur b Un it S E,S L , M ax. W ei g h t ( 3) Si ze SA H F SSH F SF H F SXH F SE H G SF H G SXH G SA H F S*H F /G C2 0 4360 4 690 4970 4580 490 510 C2 5 4520 4860 5130 4750 490 510 C3 0 5220 5590 5840 5460 490 510 C4 0 6890 7400[...]

23 Installation (Continued) Note: If a “built-up” curb is provided by others, keep in mind that these commercial rooftop units do not have base pans in the condenser section. Note: If this is a REPLACEMENT UNIT keep in mind that the CURRENT DESIGN commerical rooftop unitsdo not have base pans in the condenser section. Unit Rigging & Placeme[...]

24 Figure 3-4 T ypical Unit Rigging Figure 3-5 Unit Base & Roof Curb Section[...]

25 Installation (Continued) General Unit Requirements The checklist listed below is a summary of the steps re- quired to successfully install a Commercial rooftop unit. This checklist is intended to acquaint the installing person- nel with what is required in the installation process. It does not replace the detailed instructions called out in the [...]

26 Installation (Continued) Requirements f or Steam Heat (SSH_) [ ] Install an automatic air vent at the top of the return water coil header . [ ] Route properly sized steam piping through the base of the unit into the heating section. [ ] Install the factory-supplied, 2-way modulating valve [ ] Complete the valve actuator wiring. [ ] Install 1/2&q[...]

27 Installation (Continued) Condensate Drain Connections Each S_HF unit is pro vided with two or six 1" ev aporator condensate drain connections (one on each side of the unit). Each S_HG unit is provided with two or six 1-1/4" e vaporator dr ain connections (one on each side of the unit.) Due to the size of these units , all condensate dr[...]

28 Figure 3-7A Removing Scr oll Compressor Shipping Har dware f or 20 through 60 T on Units Figure 3-7B Removing Scr oll Compressor Shipping Har dware f or 70 through 105 T on Units Figure 3-7C Removing Scr oll Compressor Shipping Hard ward for 115 and 130 T on Units[...]

29 Installation (Continued) Removing Supply and Exhaust F an Shipping Channels (Motors >5Hp) Each supply fan assembly and exhaust fan assembly for S_HF units shipped with a motor larger than 5 HP is equipped with rubber isolators, (as standard), or optional spring isolators. Each supply fan assembly and exhaust fan assembly for S_HG units is equ[...]

30 Figure 3-8 Removing F an Assembly Shipping Har dware (20 through 75 T on) Note: Fan assemblies not equipped with rubber or spring isolators have mounting bolts at the same locations and must not be removed. (90 through 130 T on)[...]

31 Installation (Continued) O/A Sensor & T ubing Installation An Outside Air Pressure Sensor is shipped with all units de- signed to operate on variable air volume applications or constant volume units with 100% modulating exhaust w/ Stratitrac. On V A V systems, a duct pressure transducer (3U60) and the outside air sensor is used to control th[...]

32 Installation (Continued) Gas Heat Units (SFH_) All internal gas piping is factory-installed and pressure leak- tested before shipment. Once the unit is set into place, the gas supply line must be field-connected to the elbow lo- cated inside the gas heat control compartments. W ARNING Hazardous Gases and Flammab le V apors! Exposure to hazardous[...]

33 Installation (Continued) T able 3-4 Sizing Natural Gas Pipe Mains & Branches Si zi n g N atu ra l G as Pi p e Mai n s & B ran ch es G a s Input (C ubic F e e t /H our )* N ote s : 1. I f m or e t han one unit is s er v ed by G a s S upply 1 - 1 /4 " 1 - 1 /2 " 2 " 2 -1 /2 " 3 " 4 " t he s am e m ain gas s up[...]

34 Installation (Continued) Figure 3-10 (Continued) Unit Gas T rains (Natural Gas) 1000 MBH Modulating (500 MBH - 1000 MBH) Flue Assembly Installation 1. Locate the flue assembly and the extension (refer to Fig- ure 3-11 f or extension usage) in the shipwith section of the unit. 2. Install the flue extension onto the flue assembly as shown in Figur[...]

35 Installation (Continued) 4. Install a "Gate" type valve in the supply branch line as close as possible to the hot water main and upstream of any other de vice or takeoff . 5. Install a "Gate" type valve in the return branch line as close as possible to the return main and down stream of any other device. 6. Install a strainer[...]

36 Installation (Continued) 12. Position the outlet or discharge port of the steam trap at least 12" below the outlet connection on the coil(s). This will provide adequate hydrostatic head pressure to over- come the trap losses and assure complete condensate removal. 40 through 130 T on units; Utilizes two steam coils stac ked together . These[...]

37 Figure 3-13 Steam Coil Piping (20 through 30 T on Units) Steam Coil Piping (40 through 130 T on Units)[...]

38 Installation (Continued) Disconnect Switch External Handle (Factory Mounted Option) Units ordered with the factory mounted disconnect switch comes equipped with an externally mounted handle. This allows the operator to disconnect power from the unit with- out ha ving to open the control panel door . The handle loca- tions and its three positions[...]

39 Installation (Continued) 2. If the unit is not equipped with an optional f actory in- stalled non-fused disconnect s witch, a field supplied dis- connect s witch must be installed at or near the unit in ac- cordance with the National Electrical Code (NEC latest edition). Refer to the "P ower Wire Sizing & Protection De- vice Equations&q[...]

40 Figure 3-14 (Continued) T ypical Field P ower Wiring (90 thru 130 T on) T able 3-6 Customer Connection Wire Range[...]

41 T able 3-7 Electrical Service Sizing Data (20 through 130 T on) Unit 20 0/60/3, Nominal 230/60/3, Nominal 460/60/3, Nominal 575/60/3, Nominal Com p onent ( s ) ( 180-220V Utiliz . ) ( 207-253V Utiliz. ) ( 414-506V Utiliz. ) ( 517-633V Utiliz. ) RLA ( ea ) LRA ( ea ) RLA ( ea ) LRA ( ea ) RLA ( ea ) LRA ( ea ) RLA ( ea ) LRA ( ea ) Com p ressor: [...]

42 T able 3-7 (Continued) Electrical Service Sizing Data (20 through 130 T on) U n i t 200/ 60/ 3, N o mi n al 230/ 60/ 3, N o mi n al 460/ 60/ 3, N o mi n al 575/ 60/ 3, N o mi n al C om pone nt (s ) ( 1 8 0 - 220V U t iliz.) (2 0 7 - 253V U t iliz.) ( 4 1 4 - 506V U t iliz.) (5 1 7 -6 3 3 V Utiliz.) E lec tr i c H e at F LA (3 ) F LA (3 ) F LA (3[...]

43 Figure 3-15 P ower Wire Sizing and Protection Device Equations T o correctly size the main power wiring for the unit, use the appropriate calculation(s) listed below . Read the load definition s that f ollow and use Calculation #1 for determining the MCA (Minimum Circuit Ampacity), MOP (Maximum Over current Pro- tection), and RDE (Recommended Du[...]

44 P ower Wire Sizing and Protection Device Equations (Contin ued) RDE = (1.5 x LO AD 1) + LOAD 2 + LO AD 3 + LOAD 4 The selected RDE value will be the larger of the cooling mode RDE v alue or the heating mode RDE value calculated abo ve . Select a fuse rating equal to the RDE v alue. If the RDE value does not equal a standard fuse siz e as listed [...]

45 Installation (Continued) Field Installed Contr ol Wiring The Rooftop Module (RTM) m ust hav e a mode input in or- der to operate the rooftop unit. The fle xibility of having se v- eral system modes depends upon the type of sensor and/or remote panel selected to interface with the R TM. An o v erall la yout of the va r ious control options a vail[...]

46 Installation (Continued) The occupied cooling setpoint ranges between 40 and 80 F ahrenheit. The wa r m-up setpoint ranges between 50 and 90 degrees F ahrenheit with a 2 degrees deadband. The Un- occupied cooling setpoint ranges between 45 and 98 degrees F ahrenheit. The heating setpoint r anges between 43 and 96 degrees F ahrenheit. T wo liquid[...]

47 Installation (Continued) Remote Minimum Position Potentiometer (5U70) (B A YST A T023A) The remote minimum position potentiometer is used on units with an economizer . It allows the operator to remotely set the economizer's minim um position (which controls the amount of outside air entering the unit). Use the installation instructions that[...]

48 PURGE Supply F an - On Inlet V anes - Open (if equipped) Exhaust F an - On (if equipped) Exhaust Dampers - Open (if equipped) OA Dampers - Open Heat - All heat stages Off (staged gas and elec.), Hydronic heat & Mod Gas Heat output at 0%. Occupied/Unoccupied output - Energized V O Relay - Energiz ed (with V OM module installed) OA Preheater S[...]

49 Figure 3-16A T ypical Field Wiring Diagram for 20 thr ough 130 T on CV Control Options Refer to Wiring Notes on page 51[...]

50 Figure 3-16B T ypical V entilation Override Binary Output Wiring Diagram for 20 thr ough 130 T on CV Control Options Refer to Wiring Notes on page 51[...]

51 Field Connection Diagram Notes f or 20 through 130 T on CV or V A V Applications[...]

52 Figure 3-17A T ypical Field Wiring Diagram for 20 thr ough 130 T on V A V Control Option Refer to Wiring Notes on page 51[...]

53 Figure 3-17B T ypical V entilation Override Binary Output Wiring Diagram f or 20 through 130 T on V A V Contr ol Options Refer to Wiring Notes on page 51[...]

54 Figure 3-18 T ypical GBAS Analog Input Wiring Diagram f or 20 through 130 T on CV & V A V Control Options GB AS V oltage vs Setpoint U nit Type VA V C V SE TPO IN T Input Voltage* S etpt R ange x x Unoc cupied Zone Cooling Setpoint 0.5 to 4.5 vdc 50°F t o 90°F x Oc cupied Zone C ooling S etpoint 0.5 to 4.5 vdc 50°F to 90° F x x Occupied [...]

T able of Contents Section One About The Man ual ............................................................... 2 Literature Change Histor y ................................................ 2 Overview of Manual ......................................................... 2 Section T w o General Infor mation ...........................................[...]

55 Unit Start-Up Cooling Sequence of Operation Time dela ys are built into the controls to increase reliability and performance by protecting the compressors and maxi- mizing unit efficiency . Sequence of Operation Compressor Crankcase Heaters Each compressor is equipped with a crankcase heater and is controlled by a 600 volt auxiliary switch on th[...]

56 Unit Start-Up (Continued) Lead/Lag Operation When Lead/Lag is enabled, each time the system cycles af- ter h a ving stages 1 and 2 "On", "Stage 2" (K11 on SCM or K3 on MCM) and the corresponding condenser fan output "2A" will sta r t first. The compressor module cycles the compressors "On" and "Off&qu[...]

57 Unit Start-Up (Continued) eration. As you re view the sequence of oper ations, k eep the following in mind: 1. The fur nace will not light unless the manual gas v alves are open and the control circuit switch 4S24 is closed. 2. The control systems are wired to ensure that heating and cooling cannot occur simultaneously . 3. The unit supply fans [...]

58 Unit Start-Up (Continued) A set of relay contacts are available for external use for heat fail (Information Only). Note: The modulating gas heaters are factory adjusted for the proper air/gas ratio at minimum and nameplate rated firing MBH for most areas in the country . Electric Heat Sequence of Operation The control system for the rooftop unit[...]

59 Unit Start-Up (Continued) Use the checklist provided below in conjunction with the “General Unit Requirement" checklist” to ensure that the unit is properly installed and ready for operation. Be sure to complete all of the procedures described in this section be- fore starting the unit for the first time. [ ] T u rn the field supplied d[...]

60 Unit Start-Up (Continued) [ ] 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[...]

61 T able 4-1 Service T est Guide for Component Operation COM P ONE NT COMP ONE NT CONF I G URAT I ON Oc c B EIN G TESTED S uppl y E xha us t C ondens e r H e a t Stages C ompressor St age Econo Exhaust VF D U nocc Fan Fan Fans 1 2 3 1 2 3 4 D amper D ampe r IG V Ou tput R elay * COM P RE S S OR 20 thru 30 Ton A Off Off A -Off/B-On O ff Off Off K10[...]

62 T able 4-1 (Continued) Service T est Guide for Component Operation COM P ON E NT COM P O NE NT C ONF I G URAT I O N Oc c B EIN G TESTE D Suppl y Exhaust Condens er He at Stages Compress or Stage Econo E xha ust VFD U nocc (C ont.) Fan Fan Fans 1 2 3 1 2 3 4 D amper D amper IGV Output Relay * * CO NDE NS E R F AN S 90 T on 1A- 2B3/2B14 O ff Off 1[...]

63 Unit Start-Up (Continued) W ARNING Hazardous V oltage! Disconnect all electric power , including remote discon- nects before servicing. Follow pr oper lock out/tagout procedures to ensure the power can not be inadvert- ently energized. Failure to disconnect power before ser- vicing could result in death or serious injury . c. Interchange any two[...]

64 Figure 4-1 Condenser Fan Location with Human Interface Designator 5. Use T able 4-1 to program the Supply F an for oper ation by scrolling through the displays. 6. Once the configuration for the Fan is complete, press the NEXT key until the LCD displays the “Start test in __Sec.” screen. Press the + key to designate the delay bef ore the tes[...]

65 Unit Start-Up (Continued) Use this data to assist in calculating a new fan drive if the CFM is not at design specifications. An alternate method with less accuracy is to measure the static pressure drop across the e vapor ator coil. This can be accomplished by; a. drilling a small hole through the unit casing on each side of the coil. Note: Coil[...]

66 Unit Start-Up (Continued) Exhaust Airflow Measurement (Optional with all Units) 1. Close the disconnect switch or circuit protector switch that provides the supply power to the unit's terminal block 1TB1 or the unit mounted disconnect switch 1S14. W ARNING Hazardous V oltage! Disconnect all electric power , including remote discon- nects be[...]

67 Figure 4-2 20 & 25 T on Supply Fan P erformance without Inlet Guide V anes 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 0 2000 400 0 6000 8000 10000 12000 14000 16000 18000 20000 CFM STATIC PRESSURE, Inches w.c. 40% wocfm 50% 60% S_HFC20 & 25 To n Dual 15 X 15 Fans Ent ranc e Loss es - without Inlet Guide V anes - [...]

68 Figure 4-2 (Continued) 40, 50 & 55 T on Supply F an P erformance without Inlet Guide V anes 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 0 20 00 4000 6000 80 00 10000 12000 1 4000 16000 1800 0 20000 22000 2400 0 26000 28000 30000 CF M STATIC PRESSURE, Inches w.c . 40 H P 7.5 HP 10 H P 15 HP 20 HP 25 HP 30 HP 1200 RP M [...]

69 Figure 4-2 (Continued) 90, 105, 115, & 130 T on Suppl y Fan P erformance without Inlet Guide V anes 0 10000 20000 30000 400 00 50000 60000 0 1 2 3 4 5 6 7 8 9 4 0 % W O C F M 5 0 % W O C F M 6 0 % W O C F M 9 0 % W O C F M 8 0 % W O C F M 7 0 % W O C F M 1 0 0 HP 75 HP 6 0 HP 5 0 HP 4 0 HP 3 0 HP 25 HP 2 0 HP 1 6 0 0 R P M 1 5 0 0 R P M 1 4 [...]

70 Figure 4-3 W et Airside Pressure Dr op at 0.075 lb/cu.ft. 20 through 60 T on Standard Evaporator Coil 4000 5000 6000 7000 80 00 9000 10 000 10000 20000 3 0000 0.05 0.06 0.07 0.08 0.09 0.1 0.2 0.3 0.4 0.5 0.6 0.7 S * H F 6 0 S * H F 5 0 & 5 5 S * H F 4 0 S * H F 3 0 S * H F 2 0 - 2 5 Wet Airside Pressure Drop at 0. 075 lb/cu.ft. 20-60 Ton Sta[...]

71 Figure 4-3 (Continued) W et Airside Pressure Dr op at 0.075 lb/cu.ft. 70 through 130 T on Standar d Evaporator Coil 20000 30 000 4000 0 500 00 60000 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 S * H F 9 0 S * H F 1 0 5 S * H F 1 1 5 & 1 3 0 S * H F 7 0 S * H F 7 5 Wet A irside P ressu re Dro p at 0 .075 lb /cu.ft. 7 0-130 T on To n Standar d E vapor[...]

72 Figure 4-3 (Continued) W et Airside Pressure Dr op at 0.075 lb/cu.ft. 20 thr ough 105 T on Hi-Cap Evaporator Coil (Hi-Cap Not A vailab le on 115 & 130 T on Units) 4000 6000 8000 10000 20000 40000 60000 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 S * H F 9 0 & 1 0 5 S * H F 6 0 S * H F 5 0 & 5 5 & 7 5 S * H F 4 0 S * H F 3 0 S * H F 2[...]

73 Figure 4-4 20 & 25 T on Supply Fan P erformance with Inlet Guide V anes 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 0 20 00 4000 6000 8000 100 00 12000 14000 1 6000 18000 2000 0 CFM STATIC PRESSURE, In ches w.c . 50% 60% 70% 40%wocfm 90% woc fm 20 H P 15 0 0 R P M 15 HP 1 400 R P M 13 0 0 R P M 7. 5 HP 10 H P 1 200 R [...]

74 Figure 4-4 (Continued) 40, 50 & 55 T on Supply F an Performance with Inlet Guide V anes 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 0 2 000 40 00 6000 80 00 10 000 12000 14 000 16000 18 000 20000 22000 24000 26000 280 00 30000 CF M STATIC PRESSURE, Inches w.c . 40% wocfm 50% 60% 70% 1200 RP M 500 RP M 600 RP M 700 R P[...]

75 Figure 4-4 (Continued) 90, 105, 115, & 130 T on Supply Fan P erformance with Inlet Guide V anes 0 10000 200 00 30000 400 00 50000 6 0000 0 1 2 3 4 5 6 7 8 9 4 0 % W O C F M 5 0 % W O C F M 6 0 % W O C F M 9 0 % W O C F M 8 0 % W O C F M 7 0 % W O C F M 1 0 0 H P 7 5 H P 6 0 H P 5 0 H P 4 0 H P 3 0 H P 2 5 H P 2 0 H P 1 6 0 0 R PM 1 5 0 0 R P[...]

76 T able 4-2 20 through 75 T on Component Static Pressure Drops (Inches W .C.) Ec o n . CF M P e r m Ba g Ca r t r idge S t d W it h Or Nom S T D SE H F / G S td. H igh W ir e And A nd R oof W it hout Tons AIR W e t Dr y We t D r y Low High All KW ' s Low High Low H igh F ibe r E ff ic . M e s h Pr e f ilt e r P r e f ilt e r Cur b E xh . F a[...]

77 T able 4-2 (Continued) 90 through 130 T on Component Static Pressure Drops (Inches W .C.) E c on. CF M P e r m Ba g C a r t r idge S td W it h Or Nom S T D S E HF /G S t d. High W ir e And And Roof W it hout Tons AI R W e t Dry W e t Dr y Low High All KW ' s Low High Low H igh F ibe r Effi c . M e s h Pr e f ilte r P r e f ilt e r Cur b E x[...]

78 T able 4-3 (Continued) 20 through 75 T on 100% Modulating Exhaust Fan Performance Ne gative Stat ic Pr essure C f m 0.25" W.G. 0.50" W.G. 0.75" W.G . 1.00" W.G . 1.25" W.G. 1.50" W.G. 1.75" W.G. 2.00" W.G . Std. Ai r RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP S * H F -C20 4, 00[...]

79 T able 4-4 20 through 75 T on 50% Modulating Exhaust Fan Performance N egative St atic P ressur e C f m 0.20" W.G . 0.40" W.G . 0.60" W.G. 0.80" W.G. 1.00" W.G . 1.20 " W.G . 1.40" W.G. Std. Ai r RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP RP M BHP S* HF- C 20 2, 000 364 0. 17 487 0. 30 582 0 .45 65 8[...]

80 Unit Start-Up (Continued) Economizer Damper Adjustment Exhaust Air Dampers V erify that the exhaust dampers (if equipped) close tightly when the unit is off. Adjust the damper linkage as necessary to ensure proper closure. An access panel is provided un- der each damper assembly . Fresh Air & Return Air Damper Operation The fresh air and ret[...]

81 Unit Start-Up (Continued) T o relocate the fresh air/return air connecting rod to balance the fresh air damper pressure drop against the return static pressure, use the following steps. If no adjustment is neces- sary , proceed to step 17. 12. Remove the drive rod and swivel from the crank arm(s). If only one hole requires changing, loosen only [...]

82 Unit Start-Up (Continued) Figure 4-5 Fresh Air & Return Air Linkage Adjustment Compressor Start-Up (All Systems) 1. Ensure that the "System" selection switch at the remote panel is in the "Off" position. 2. Before closing the disconnect switch, ensure that the compressor discharge service valve and the liquid line service[...]

83 Unit Start-Up (Continued) 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. Refer to general service bulletin MSCU-SB-1 (latest edition). 7. V erify that the oil level in each compressor is correct. The oil level may be dow[...]

84 Figure 4-6 Compressor Locations[...]

85 T able 4-6 20 T on Operating Pressure Curve (All Compressors and Condenser Fans "On") COO L I NG CYCL E P RES S URE CURV E (B a s e d on I ndoor Airf l ow of 400 CFM / Ton) FU LL LOA D 160 180 200 220 240 260 280 300 320 340 360 50 55 60 65 70 75 80 85 90 95 100 S UCT I ON P RES S URE, P S I G DISCHARGE PRESSURE, PSIG 105 F OD A m bi e[...]

86 T able 4-6 (Continued) 30 T on Operating Pressure Curve (All Compressors and Condenser Fans "On") COO L I NG CYCL E P RES S URE CURV E (B a s e d on I ndoor Airf l ow of 400 CFM / Ton) FU LL LOA D 180 200 220 240 260 280 300 320 340 360 380 50 55 60 65 70 75 80 85 90 95 100 S UCT I ON P RES S URE, P S I G DISCHARGE PRESSURE, PSIG 105 F[...]

87 T able 4-6 (Continued) 50 T on Operating Pressure Curve (All Compressors and Condenser Fans, per ckt; "On") COO L I NG CYCL E P RES S URE CURV E (B a s e d on I ndoor Airf l ow of 400 CFM / Ton) FU LL LOA D 180 200 220 240 260 280 300 320 340 360 380 50 55 60 65 70 75 80 85 90 95 100 S UCT I ON P RES S URE, P S I G DISCHARGE PRESSURE, [...]

88 T able 4-6 (Continued) 55 T on Hi Operating Pressure Curve (All Compressors and Condenser Fans, per ckt, "On") 50 55 60 65 70 75 80 85 90 95 100 180 200 220 240 260 280 300 320 340 360 55 To n Hi Ope rati ng Pressur e Curve (All Compresso rs and Condenser Fans, per ckt, "On") Full Load (Based on I ndoor Airfow of 400 CF M / T[...]

89 T able 4-6 (Continued) 60 T on Hi Operating Pressure Curve (All Compressors and Condenser Fans, per ckt; "On") 50 55 60 65 70 7 5 80 85 90 95 100 180 200 220 240 260 280 300 320 60 Ton Hi O perating Pressure Curve (All Compressor s and Conden ser Fans, per ckt , "On") Full Load (Based on I ndoor Air fow of 400 CFM / Ton) Cool[...]

90 T able 4-6 (Continued) 75 T on Standard Operating Pressure Curve (All Compressors and Condenser Fans, per ckt, "On") 50 55 60 65 7 0 75 80 85 90 95 100 180 200 220 240 260 280 300 320 340 360 380 75 Ton Std Operat ing Pressure Curve ( A ll Compressor s and Condenser Fans, per ckt , "On") Full Load (Bas ed o n Indo or Air f ow[...]

91 T able 4-6 (Continued) 90 T on Operating Pressure Curve (All Compressors and Condenser Fans, per ckt; "On") COO L I NG CYCL E P RES S URE CURV E (B a s e d on I ndoor Airf l ow of 400 CFM / Ton) FU LL LOA D 180 200 220 240 260 280 300 320 340 360 380 50 55 60 65 70 75 80 85 90 95 100 S UCT I ON P RES S URE, P S I G DISCHARGE PRESSURE, [...]

92 T able 4-6 (Continued) 1 15 T on Operating Pressure Curve (All Compressors and Condenser Fans, per ckt; "On") COO L I NG CYCL E P RES S URE CURV E (B a s e d on I ndoor Airf l ow of 400 CFM / Ton) FU LL LOA D 180 200 220 240 260 280 300 320 340 360 380 50 55 60 65 70 75 80 85 90 95 100 S UCT I ON P RES S URE, P S I G DISCHARGE PRESSURE[...]

93 Unit Start-Up (Continued) With the unit operating at "Full Circuit Capacity", acceptable subcooling ranges between 14 F to 22 F . Measuring Subcooling 1. At the liquid line service valve, measure the liquid line pressure. Using a Refrigerant 22 pressure/temperature chart, convert the pressure reading into the correspond- ing saturated [...]

94 Unit Start-Up (Continued) Damper Installation When a unit is ordered with the low ambient option (i.e., Digit 19 is a “1” in the model number), a damper is factory installed over the condenser fans 2B1, 2B4, 2B13 & 2B14 (depending on unit size). Refer to the illustration in Figure 4-1 for the damper locations. For field installation, mou[...]

95 Unit Start-Up (Continued) The volume of air supplied by the combustion blower deter- mines the amount of oxygen available for combustion, while the manifold gas pressure establishes fuel input. By mea- suring the percentage of carbon dioxide produced as a by- product of combustion, the operator can estimate the amount of oxygen used and modify t[...]

96 T able 4-8 Natural Gas Combustion Curve (Ratio of Oxygen to Carbon Dioxide in percent) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 012345 6789 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 P er c en t O x y g en Percent Carbon Dioxide Curve Fue l A = 1,000 B TU per c u. ft. of N atural G as . A Figure 4-8 Gas V alve Adjustment Screw Locatio[...]

97 Unit Start-Up (Continued) Full Modulating Gas Furnace Full Modulating gas heaters are available for the 500, 850 and 1000 MBH heater sizes. These heaters are available in the same cabinet sizes as the current heaters. The firing rate of the unit can vary from the pilot rate of 125 MBH up to the nameplate rating of the unit. The turn down ratios,[...]

98 Unit Start-Up (Continued) 10. If the measured carbon dioxide level is below the rec- ommended values for low heat, return the burner to 90% fire rate and repeat steps 6 and 7, to achieve optimum combustion. 1 1. Program the burner for 100% operation and recheck the CO 2 or O 2 value. 12. Check the flue gas values at several intermediate out- put[...]

99 Unit Start-Up (Continued) Figure 4-10 T ypical Gas Furnace Final Unit Checkout After completing all of the checkout 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 and heating), perform these final checks before leaving the unit: [ ] Close the discon[...]

100 Service & Maintenance T able 5-1 Control Settings and Time Delays C ontr o l D escri pti on E lec. Des igna tion Contac ts O pen C ontac ts C losed C om p res so r C irc u it Bre a k ers S* HF 20 - 60 1C B8 thr u 1C B11 S ee Table 5-2 See T able 5-2 S* HG 90 - 130 1CB14 thr u 1C B17 See Table 5- 2 S ee Table 5- 2 C om bus tion Air flow Sw i[...]

101 Service & Maintenance (Continued) T able 5-3 Unit Internal Fuse Replacement Data & VFD Factory Settings[...]

102 T able 5-4 Filter Data Panel-Type Filters Bag-Type Filters Car tridge Filter s Panel-Type Prefilter s Unit M ode l ( Note 1) (N ote 2) (box-t ype ) (Not e 2 ) ( Not e 3 ) Q t y S iz e o f each Q t y. S iz e of each Q t y. Si z e of each Q t y. S iz e of each S_H F -C 20 & 12 20 X 20 X 2 4 12 X 24 X 19 4 12 X 24 X 12 4 12 X 24 X 2 C 25 3 24 [...]

103 Service & Maintenance (Continued) T able 5-6 Grease Recommendations R ecommen ded R ecommended Gr ease Oper at ing Ra nge Exxon U nirex #2 Mobil 532 -20 F to 250 F Mobil SHC #220 Te xaco P r emiu m R B T able 5-7 Refrigerant Coil Fin Data C oil F ins Co il F a c e C oil F in Tube Coil pe r Ar e a Tube M ode l Ty p e Config. Dia. Row s F oot[...]

104 Service & Maintenance (Continued) Fan Belt Adjustment The supply fan belts and optional exhaust 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 t[...]

105 Service & Maintenance (Continued) Figure 5-1 Belt T ension Measurement and Deflection Ranges D eflection Force (Lbs.) Super Steel C able B elts G r ipbelts Gripnotch Gripbelts C ross S mall P.D Section R ange M in. Max . Min. M ax. Min. Ma x 3.0 - 3.6 3 4 1/2 3 7/8 5 1/ 2 3 1/4 4 A 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[...]

106 Service & Maintenance (Continued) W ARNING Hazardous V oltage! Disconnect all electric power , including remote discon- nects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvert- ently energized. Failure to disconnect power before ser- vicing could result in death or serious injury . VFD Program[...]

107 Service & Maintenance (Continued) (q) Press the Up Arrow button to scroll to the Active Setup menu. (r) Press the Change Data button. (s) Press the Up Arrow button to scroll to the Setup 1 setting. (t ) Press the OK button. (v) Press the Change Data button. (w) Press the Up Arrow button to scroll to the Down load All Parameters setting. (x)[...]

108 Service & Maintenance (Continued) [ ] Check the condition of the gasket around the control panel doors. These gaskets must fit correctly and be in good condition to prevent water leakage. [ ] V er ify that all wire ter minal connections are tight. [ ] Remove any corrosion present on the exterior surfaces of the unit and repaint these areas.[...]

109 Service & Maintenance (Continued) CA UTION Coil Cleaners! Coil cleaners can damage roofs, surrounding buildings, vehicles, etc. Cleaning substances should be checked to ensure that they will not cause damage to surround- ings. Coils and roof (if applicable) should berinsed thor- oughly . Do not spra y coil cleaners in wind y conditions. Ref[...]

110 R ef ri ger ant C ir cui t #1 R ef ri ger ant C ir cui t #2 C urre nt A mbient C ompr . Suct. D isch. Liquid Super- Sub- C ompr. Suct. D isch. Liquid Super- Sub- Temp. Oil Pr ess. Pr ess. P r ess. heat coo l. Oil Pr ess. P r ess. P r ess. h eat cool. D at e (F) Level (P sig ) ( Psi g) (P sig ) (F) ( F) L evel ( Psi g) (P sig ) ( Psi g) (F ) ( F[...]

111 Index A AC Conductors ................................................................. 4 5 See T able 3-8 Adjusting the F resh Air Damper ...................................... 8 0 Airflow Measurements ..................................................... 6 3 B BA YSENS008B ................................................................ 4 9 S[...]

112 See Figure 3-11 Flue Gas Carbon Dioxide & Oxygen Measurements ..... 9 6 See Figure 4-7 Freeze Protection .............................................................. 58 Freezestat .......................................................................... 10 F resh Air & Retur n Air Damper ................................... 80-81 See [...]

113 Return Air Humidity Sensor (3U64) .................................. 8 return air temperature reaches 135 F ............................. 1 0 Rooftop Module ................................................................... 7 R TM Resistance Input vs Set point T emper atures ............. 7 R TM Resistance V alue vs System Operating Mode .....[...]

114 W ARRANTY AND LIABILITY CLA USE COMMERCIAL EQUIPMENT RA TED 20 T ONS AND LARGER AND RELA TED A CCESSORIES PRODUCTS COVERED - This warranty* is extended by American Standard Inc. and applies only to commercial equipment rated 20 Tons and larger and related accesso- ries. The Company warrants for a period of 12 months from ini- tial start-up or 1[...]

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