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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)

_______________________________________________________________________

_______________________________________________________________________

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Содержание WC*150B***G Series

Страница 1: ...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 ...

Страница 2: ...pment 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 orderi...

Страница 3: ...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 ...

Страница 4: ...llation 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 A...

Страница 5: ...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 Commerc...

Страница 6: ...t 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 Digi...

Страница 7: ...ir 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 satis...

Страница 8: ...int 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 pro...

Страница 9: ...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 Contro...

Страница 10: ... 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 ...

Страница 11: ...elded 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 she...

Страница 12: ...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 ...

Страница 13: ...ion 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 Was...

Страница 14: ... 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 ...

Страница 15: ...WC IOM 7 Packaged Heat Pump 15 Unit Dimensions Figure 1 Typical Installation Clearances for Single Multiple Unit Applications ...

Страница 16: ...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 ...

Страница 17: ...WC IOM 7 Packaged Heat Pump 17 Unit Dimensions Figure 4 Unit Dimensional Data 20 Ton Figure 5 Roofcurb Dimensional Data 20 Ton ...

Страница 18: ...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 ...

Страница 19: ...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 150...

Страница 20: ...il 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 un...

Страница 21: ...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...

Страница 22: ...orator 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 C...

Страница 23: ...eet 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 ...

Страница 24: ...n 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 ...

Страница 25: ... 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 servi...

Страница 26: ...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 i...

Страница 27: ...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 ...

Страница 28: ... 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...

Страница 29: ...WC IOM 7 Packaged Heat Pump 29 Installation Figure 13 Typical field wiring diagrams for optional controls ReliaTel only ...

Страница 30: ...e 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 Table 4 lists...

Страница 31: ...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...

Страница 32: ... 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 readi...

Страница 33: ... 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 electrocutio...

Страница 34: ...roperly 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 ...

Страница 35: ...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 Table 5 Pre Start Table 5 Service test guide for component operati...

Страница 36: ...ow 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 requi...

Страница 37: ...ring 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 table...

Страница 38: ...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...

Страница 39: ... 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 Serv...

Страница 40: ...hat 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...

Страница 41: ...e 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 correspon...

Страница 42: ...nnect 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 St...

Страница 43: ...ckages 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 m...

Страница 44: ...nce 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 s...

Страница 45: ...e 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 compone...

Страница 46: ..._________________________________________________ _______________________________________________________________________ _______________________________________________________________________ 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 C Co...

Страница 47: ...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 burni...

Страница 48: ... 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 BAYSE...

Страница 49: ...oils 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 c...

Страница 50: ... 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 Coolin...

Страница 51: ... 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...

Страница 52: ...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 ...

Страница 53: ...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 res...

Страница 54: ...ode 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 Conn...

Страница 55: ...e 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 R...

Страница 56: ...lectrical 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 plu...

Страница 57: ...e 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 L...

Страница 58: ...placement 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...

Страница 59: ......

Страница 60: ...Order Number WC IOM 7 Date 12 04 Supersedes WC IOM 7 04 03 The manufacturer has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice ...

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