TCA SERIES WARNING
Contents
1. 15 TO MULLION Remove unit top panel and condenser section access panel Remove screws securing coil end plate to mullion Remove clips connecting coils slabs and separate AME colt slabs 3 4 76 102 d BLOWER Clean coils with detergent or commercial coil cleaner Rinse thoroughly with water and reassemble CONDENSER COILS CONDENSER ACCESS PANEL FIGURE 15 ASSEMBLED ROOF MOUNTING FRAME The accessories section describes the application of most of TCA090 150 the optional accessories which can be factory or field installed to the TCA units A LARMF and LARMFH Mounting Frames TCA090 150 When installing either the TCA units on a combustible surface for downflow discharge applications the Lennox LARMF 10 15 14 inch or 24 inch 356 mm or 610mm height roof mounting frame is used The roof mounting frames are recommended in all other applications but not required If the TCA units are not mounted on a flat roof surface they MUST be supported un der all edges and under the middle of the unit to prevent sag ging The units MUST be mounted level within 1 16 per linear foot or 5mm per meter in any direction SUPPLY AIR CROSS SUPPORT The assembled LARMF mounting frame is shown in figure 16 Refer to the roof mounting frame installation instr2. Al 1814 R BBHBBBHBHBHHHBHHHBHHHHBH C aaaeeeaei TEST E 549 KIO KI 550 K2 C L 1 HB BHHH HH 0 CMCI 0 CMC2 HP 53 K68 14 95 KI46 TI8 C 118 C A 8 HB E E E S E AEA E E FIGURE 5 Page 1 3 2 5 oe E se LR hem TABLE 3 TB14 24VAC TERMINAL DESIGNATIONS rw TABLE 4 Page 14 TABLE 6 P88 TERMINAL DESIGNATIONS ma Heat Stage 1 to A3 PLUMBING COMPRESSOR AND REFRIGERANT CIRCUITS DETAIL CONDENSER COIL EVAPORATOR COIL FREEZESTAT S50 Sail NH OPTIONAL LOW AMBIENT SWITCHES 584 S11 BOTH FANS ARE ENERGIZED DRIERS WITH A Y1 DEMAND CONDENSER COIL STAGE CONDENSER FAN 1 CONDENSER COIL CONDENSER STAGE 1 FAN 2 OPTIONAL HIGH PRESSURE SWITCH S7 COMPRESSOR B1 B2 STG1 OPTIONAL PRESSURE SWITCH S4 FIGURE 6 Page 15 B Cooling Components All units use independent cooling circuits consisting of sep arate compressors condenser coils and evaporator coils See fig
3. 24 III Start Up Operation 24 IV Charging ses ive GR sae pee 24 V Maintenance 26 VI ACCESSOMIES xx 27 VII Wiring and Operating Sequence 33 2004 Lennox Industries Inc itho U S A SPECIFICATIONS General Nominal Tonnage 7 5 Ton 8 5 Ton 10 Ton 12 5 Ton Data Model No TCA090S2B TCA102S2B TCA120S2B TCA150S2B Efficiency Type Standard Standard Standard Standard Cooling Gross Cooling Capacity Btuh kW 93 000 27 2 104 000 30 5 126 000 36 6 145 000 42 5 Performance 1Net Cooling Capacity Btuh kW 90 000 26 4 100 000 29 3 120 000 35 2 138 000 40 4 ARI Rated Airflow cfm L s 3000 1415 3400 1605 3800 1795 4250 2005 Total Unit Power kW 1 EER Btuh Watt 2 Integrated Part Load Value Btuh Watt Refrigerant Charge Circuit 1 7 lbs 0 oz 3 18 kg 7 lbs 8 oz 3 140 kg 10 Ibs 0 oz 4 53 kg 13 Ibs 0 oz 5 90 kg Furnished Circuit 2 6 Ibs 8 oz 22 kg 7 lbs 0 oz kg 10 Ibs 0 oz Eum kg 12 Ibs 0 oz 168 3 Sound Rating Number dB Condenser Net face area sq ft m2 x3 total 29 3 2 72 total x 2 72 total 26 6 total Tube diameter mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 1 1 2 3 Fins per inch m 20 787 20 787 20 787 20 787 Condenser Motor horsepower W 2 1 3 249 2 1 3 249 2 1 3 249 2 1
4. LENNOX UT INFORMATION Corp 0411 L3 Revised 06 2005 Service Literature TCA SERIES 7 5 to 12 5 ton 26 3 kW to 44 kW 090 150 SERIES The 7 5 8 5 and 10 ton cooling package units are avail able in standard efficiency 0905 1025 1205 and high effi ciency 090H 102H 120H The TCA 12 5 ton unit is avail able in standard efficiency only 1505 The TCA 090 150 series uses one cabinet size with cooling capacities of 93 000 to 140 000 Btuh 27 2 to 41 kW Optional electric heat is factory or field installed in TCA units Electric heat operates in single or multiple stages depending on the kW input size 7 5 KW to 45 kW heat sections are avail able for the 090 and 102 and 15 kW to 60 kW heat sec tions are available for the TCA120 and 150 All units utilize two scroll compressors and are designed to accept any of several different energy management thermo stat control systems with minimum field wiring Factory or field provided control options connect to the unit with jack plugs When plugged in the controls become an integral part of the unit wiring Information contained in this manual is intended for use by qualified service technicians only All specifications are sub ject to change Procedures outlined in this manual are pre sented as a recommendation only and do not supersede or replace local or state codes If the unit must be lifted for service rig unit by attaching four cab
5. seem 575V 20 Amp 600 208 230V 50 Amp 250V EHA150 45 EHA150 60 Page 20 EHA 7 5 15 22 5 30 45 60KW ELECTRIC HEAT SECTION PARTS ARRANGEMENT HEATING ELEMENTS HE1 HE7 SECONDARY ELECTRIC HEAT LIMIT S20 ELECTRIC HEAT VESTIBULE CONTROL WIRE HARNESS PRIMARY ELECTRIC HEAT LIMIT FIGURE 11 ELECTRIC HEAT VESTIBULE PARTS ARRANGEMENT TERMINAL STRIP TB3 FUSE F3 FUSE F3 FIRST STAGE ELECTRIC SECOND STAGE ELECTRIC FUSE F3 F3 1 F3 2 HEAT CONTACTOR K15 HEAT CONTACTOR K16 F3 4 FIGURE 12 Page 21 9 7 5 TON STANDARD HIGH EFFICIENCY TCA090 8 5 TON STANDARD HIGH EFFICIENCY TCA102 REQUIRES UNIT FUSE BLOCK TERMINAL BLOCK AND HEATER CONTROL MODULE Minimum Circuit Ampacity 3 Maximum Overcurrent Protection 1 Volts Btuh Total Unit E
6. RPM RPM RPM RPM RPM RPM RPM RPM BHP kW kW kW 2250 455 0 30 555 0 45 640 0 601720 0 80 790 1 00 855 1 20 915 1060 0 22 0 34 0 45 0 60 0 75 0 90 4 04 5 16 7 27 8 975 1 60 1030 1 85 1080 2 05 1130 2 30 1175 2 55 1220 2 80 1 19 1 38 1 53 172 1 90 2 09 2500 475 0 40 575 0 55 660 0 70 735 0 90 805 1 10 870 1 30 985 1 75 1040 2 00 1090 2 25 1140 2 50 1185 2 75 1230 3 00 1180 0 30 0 41 0 52 0 67 0 82 0 97 1 31 1 49 1 68 1 87 2 05 2 24 2750 495 0 45 595 0 65 675 0 85 750 1 05 820 1 25 885 1 45 940 995 1 90 1050 2 20 1100 245 1145 2 65 1195 2 95 1240 3 25 1300 0 34 0 48 0 63 0 93 1 08 1 42 1 64 1 83 1 98 2 20 2 42 i 1 20 835 1 40 895 1 60 955 1010 2 10 1060 2 35 1110 2 65 1160 2 90 1205 3 20 1250 3 45 1 04 1 19 1 38 1 57 1 75 1 98 2 16 2 39 2 57 3250 550 0 65 640 0 90 715 1 10 790 1 35 855 160 915 1 80 970 2 05 1025 2 35 1075 2 60 1125 2 85 1170 3 15 1215 3 40 1260 3 70 1535 0 48 0 67 0 82 1 1 19 1 34 1 53 1 75 1 94 2 13 2 35 2 54 2 76 3500 580 0 80 665 1 05 740 1 25810 1 75 930 2 00 985 2 25 1040 2 55 1090 2 85 1135 3 10 1185 3 40 1230 3 70 1270 4 00 1650 0 78 0 93 2 31 2 54 2 76 3750 605 0 95 690 1 20 760 1 45 830 1770 0 90 1 08 12 145 1 68 1 87 2 09 2 31
7. 2 50 2 72 2 95 1 7 4000 635 1 10 715 1 40 785 1 65 850 1 90 910 2 200965 2 45 1020 275 1070 3 05 1120 3 35 1165 3 65 1210 3 95 1255 4 30 1295 4 60 1890 0 82 1 04 1 23 1 42 1 64 1 83 2 05 2 28 2 50 2 72 2 95 3 21 3 43 4250 665 1 30 740 1 60810 1 85 870 2 15 930 2 45 985 2 75 1040 3 05 1090 3 35 1135 3 65 1185 4 00 1225 4 301270 4 65 1310 4 95 2005 0 97 1 19 1 38 1 60 1 83 2 05 2 28 2 50 2 72 2 98 3 21 3 47 3 69 4500 695 1 50 770 1 80 835 2 10 895 240 955 2 70 1005 3 00 1060 3 35 1105 3 65 1155 4 00 1200 4 30 1245 4 65 1285 5 00 1325 5 30 2125 1 12 1 34 1 57 1 79 2 01 2 24 2 72 2 98 0 5 0 5 1 1 1 1 0 3000 525 0 55 615 0 75 695 0 95 770 1415 041 0 56 07 0 05 78 20 90 35 01 4750 725 2240 1 31 1 53 1 79 2 01 2 24 2 50 2 95 3 25 5000 760 205 825 2 35 885 2 65 945 3 00 1000 3 35 1050 3 65 1100 4 00 1145 4 35 1190 4 70 1235 5 05 1280 5 45 2360 1 53 1 75 1 98 2 24 2 50 2 72 2 98 3 25 3 51 3 77 4 07 5250 790 2 301855 2651910 2 95 970 3 35 1020 3 65 1070 4 00 1120 4 35 1165 4 70 1210 5 10 1255 5 45 2475 1 72 1 98 2 20 2 50 2 72 2 98 3 25 3 51 3 80 4 07 820 2 601880 2 95 940 3 30 995 3 70 1045 4 05 1095 4 40 1145 4 80 1190 5 15 1230 5 50 E Page 8 BLOWER DATA DRIVE KIT SPECIFICATIONS Motor Ou
8. IDELAY ELECIRIC HEAT FS JIFUSE ELECTRIC HEAT F4 ELEMENT ELECT HEAT 2 HES ELEMENT ELECTRIC HEAT 3 22 5 amp 30KW HE HE2 7 5 NOT USED 7 5 15 AND 30KW UNITS TB3 IS USED ON SOME UNITS 548 OR CBIO MAY BE USED WIRING DIAGRAM HEATING ELECTRIC EHA 7 5 15 22 5 30 45 60 1 2 6 FOR USE WITH UNITS HEATIN ON A4 BBA 472 534 20 Lithe U S A Page 36 Sequence of Operation 7 5 15 22 5 30 45 60 kW G J M NOTE This sequence of operation is for all Electric Heat kW ratings Y through J voltages Each step of op eration is numbered and can be followed in sequence on the diagrams Operation for G J and M voltages will be the same HEATING ELEMENTS 1 Terminal Strip TB3 is energized when the unit discon nect closes TB3 supplies line voltage to electric heat elements HE1 through HE7 Each element is protected by fuse F3 FIRST STAGE HEAT 2 Heating demand initiates at W1 in thermostat 3 24 is routed through from main control module A45 After A45 proves primary limit 515 and sec ondary limit S20 the electric heat contactor K15 is en ergized 4 contacts K15 1 close allowing the first bank of elements to be energized SECOND STAGE HEAT 5 With the first stage heat operating an additional heat ing demand initiates at W2 in the thermostat 6 Relay K9 is energized N O c
9. See unit rating plate for correct amount of charge 5 Refer to IV Charging for proper method to check refriger ant charge Three Phase Scroll Compressor Voltage Phasing Three phase power supplied to the unit disconnect switch must be phased sequentially to ensure the scroll compressor and indoor blower rotate in the correct direc tion Compressor and blower are wired in phase at the factory Power wires are color coded as follows line 1 red line 2 yellow line 3 blue 1 Observe suction and discharge pressures and blower rotation on unit start up 2 Suction pressure must drop discharge pressure must rise and blower rotation must match rotation marking If pressure differential is not observed or blower rotation is not correct 3 Disconnect all remote electrical power supplies 4 Reverse any two field installed wires connected to the line side of K2 contactor Do not reverse wires at blow er contactor 5 Make sure the connections are tight Discharge and suction pressures should operate at their normal start up ranges IV Charging WARNING Do not exceed nameplate charge under any condition This unit is factory charged and should require no further adjustment If the system requires charge reclaim the charge evacuate the system and add required nameplate charge NOTE System charging is not recommended below 60 F 15 C In temperatures below 60 F 15 C the charge must be weighed into the sys
10. Units may be equipped with motors manufactured by various manufacturers therefore electrical FLA and LRA specifications will vary See unit rating plate for information specific to your unit OPERATION ADJUSTMENT Blower Operation Initiate blower demand at thermostat according to instruc tions provided with thermostat Unit will cycle on thermostat demand The following steps apply to applications using a typical electro mechanical thermostat 1 Blower operation is manually set at the thermostat sub base fan switch With fan switch in ON position blow ers will operate continuously 2 With fan switch in AUTO position the blowers will cycle with demand Blowers and entire unit will be off when system switch is in OFF position Blower Access The blower assembly is secured to a sliding base which al lows the entire assembly to be pulled out of the unit See figure 8 1 Turn off power from unit Remove the clamp which se cures the blower wiring to the blower motor base 2 Remove and retain screws on either side of sliding base Pull base toward outside of unit 3 Slide base back into original position when finished servicing Replace the clamp and blower wiring in the previous location on the blower motor base Determining Unit CFM 1 The following measurements must be made with a dry indoor coil Run blower without a cooling demand Measure the indoor blower shaft RPM Air filters must be in place when measureme
11. 60 Hz 3 phase 208 230 460 575V 208 230 460 575V Compressors Rated load amps each total 12 8 25 6 6 4 12 8 5 1 10 2 12 4 24 9 6 4 12 8 4 8 9 6 2 Locked rotor amps each total 91 182 46 92 37 74 88 176 44 88 34 68 Condenser Number of motors 2 2 2 2 2 2 Fan Motor Full load amps each total 2 4 4 8 1 3 2 6 1 0 2 0 2 4 4 8 1 3 2 6 1 0 2 0 Locked rotor amps each total 4 7 9 4 2 4 4 8 1 9 3 8 4 7 9 4 2 4 4 8 1 9 3 8 Evaporator Motor Output hp 2 3 2 3 2 3 2 3 2 3 2 3 power kW 15 22 15 22 15 22 15 22 15 22 15 22 amps 75 106 34 48 27 39 75 106 34 48 27 39 Locked rotor amps 469 66 204 268 162 234 469 66 204 268 162 234 1 Maximum Overcurrent With Exhaust Fan 50 50 25 25 20 20 50 50 25 25 20 20 Protection amps Less Exhaust Fan 50 50 25 25 20 20 50 50 25 25 20 20 2 Minimum Circuit With Exhaust Fan 44 47 22 24 18 19 43 46 22 24 17 18 Ampacity Less Exhaust Fan 42 45 21 22 17 18 41 44 21 22 16 17 Optional Power Number Horsepower W 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 Exhaust Fan Full load amps 24 1 3 1 0 2 4 1 3 1 0 Locked rotor amps 4 7 24 1 9 4 7 24 1 9 Service Outlet 2 115 volt GFCI amp rating 15 15 15 15 15 15 NOTE Extremes of operating range plus and minus 10 of line voltage 1 HACR type breaker or fuse 2 Referto Nati
12. 8 The 208 230 Y voltage transformers use two 208 230V TRANSFORMER Primary voltage taps BLUE YELLOW as shown in figure 3 SECONDARY while 460 G and 575 J voltage transform 208 VOLTS ers use a single prima RED ry voltage tap PRIMARY ORANGE BLACK 3 Terminal Strip TB1 All indoor thermostat connections will be to TB1 located on the MCC board A45 For thermostats without occupied and unoccupied modes a factory installed jumper across terminals A1 and A2 found on the MCC board should be in place 4 Terminal Strip TB14 Terminal strip TB14 located on the MCC board distributes 24V power from the indoor thermostat to the control box Units not equipped with smoke detectors A17 or A64 will have a factory installed jumper across terminals 24 and R 5 Condenser Fan Capacitors C1 amp C2 Fan capacitors C1 and C2 are 370V 10 MFD capacitors used to assist in the start up of condenser fans B4 and B5 Ratings are on side of capacitor or condenser fan motor nameplate 6 Compressor Contactor K1 amp K2 All compressor contactors are three pole double break contactors with 24VAC coils In TCA090 150 units K1 and K2 energized by MCC board A45 energize compres sors B1 and B2 in response to thermostat demand K2 also serves as the line voltage terminal block for L1 L2 and L3 7 Blower Contactor K3 all units Blower contactor K3 used in all units is a three pole double break contactor wi
13. Ends amp Sides Open Diffuser cfm L s in w g Pa in w g Pa in w g Pa in w g Pa 2400 1135 0 21 52 0 18 45 0 15 37 0 14 35 2600 1225 0 24 60 0 21 52 0 18 45 0 17 42 2800 1320 0 27 67 0 24 60 0 21 52 0 20 50 3000 1415 0 32 80 0 29 72 0 25 62 0 25 62 3200 1510 0 41 0 37 92 0 32 0 31 3400 1605 0 50 0 45 0 39 0 37 3600 1700 0 61 0 54 0 48 0 44 3800 1795 0 73 0 63 0 57 0 51 1700 0 36 90 0 28 70 1890 0 44 109 0 36 90 2170 0 60 149 0 49 122 0 42 2265 0 65 132 0 46 2360 0 69 144 0 50 2455 0 75 154 0 54 1980 0 22 55 47 0 16 2170 0 34 85 72 0 24 150 Models 2360 0 46 114 97 0 34 2550 0 58 122 0 43 2645 0 64 134 0 47 2735 0 70 147 0 51 Unit Air Volume Size Page 10 ECONOMIZER OPTIONAL FILTER DRIERS CONDENSATE DRAIN TCA PARTS ARRANGEMENT FILTERS EVAPORATOR FOUR 18 X 24 X 2 CONDENSER FANS N N 59 q m N CONDENSER L BLOWER ELECTRIC HEAT MOTOR F4 FUSE BLOCK Optional COMPRESSORS OPTIONAL FIGURE 1 TCA CONTROL BOX MCC Control Module Electric Heat Hat A45 Section Relay E Time Delay e DL12 Se 0 Blower Transformer 5 Contactor Compressor Contactors CAPACITOR CAPACITOR 1 T1 Power Exhaust Relay K65 s K3 K1 a
14. K2 1 closes energizing compressor B2 14 Optional N O low ambient switch S84 closes energizing contacts K10 2 K10 2 close energiz ing condenser fan B5 Page 34 7 5 15 22 5 30 45 60kW IKEY COMPONENT _______________ 22 FS HEAT C ELEMENT ELECT HEAT 2 LEMENT ELECT HEAT 2 HES ___ HEAT 8 HES IELEMENT ELECTIRIC HEAT 6 CLEMENT ELECIRIC HEAT 7 2 lJACK ELECTRIC HEAT 7 JACK ELECT HT SUD BASE KIT WAR PTOR DACK CONTROL MODULE J 9 RELAY HEAT KTS T CONTACTO R ELECTRIC HT _____ IKI6 1 CONTACTOR ELECTRIC HT 2 _ JPLUG ELECTRIC HEAT 22 5 amp 30KW NS n OS 2 HE4 m pg 1 HE6 Q cM 21520 44520 HE 2 HE4 HE5 HE6 HE7 5 1 3 O O HE4 1 Xis 1 5 520 FAN 6 520 deo MMC HE7 0 145 NOT USED 7 5 15 AND 30KW UNITS TB3 IS USED ON SOME UNITS AX TB2 548 OR CBIO MAY BE USED WIRING DIAGRAM 2 04 HEATING ELECTRIC 7 5 15 22 5 30 45 60 1 2 FOR USE WITH TCA UNITS N ON ENT Litho U S A Page 35 7 5 15 22 5 30 45 60kW DESCRIPTION KEY COMPONENT
15. kW 2 hp 1 5 kW 3 hp 2 2 kW 3 hp 2 2 kW 5 hp 3 7 kW Electric Heat Model No EHA see Electric Heat Data tables for additional information kW Input Range 7 5 15 22 5 30 45 15 22 5 30 45 60 Unit With 208 230V Fuse Power Block Exhaust 460V 3phase Fans 575V Without 208 230V 56K93 56K93 56K94 56K94 56K94 56K95 56K96 Power Exhaust 460V 56K52 56K52 56K52 56K52 25K08 25K09 25 09 575 56 51 56 51 56K51 56K51 56K52 56K52 25K08 LTB2 ELECTRIC HEAT TERMINAL BLOCK LTB2 175 30K75 175 amps LTB2 335 30 76 335 amps Required For Units Without Disconnect Circuit Breaker But With Single Point Power Source LTB2 All hp 208 230V 30 75 30K75 30K75 30K75 30K75 30K75 30K75 Terminal Block All hp 208 230V 30 75 30K75 30K75 30K75 30K75 30K75 30K75 All hp 208 230 30 75 30 75 30 75 30K75 30K75 30K75 30 75 All hp 208 230 30 75 30 75 30 75 30K75 30K75 30K75 30 75 All hp 208 230V m 30K76 30K76 30 76 NOTE 460V and 575V models use 30K75 terminal block NOTE Terminal Block is factory installed in units with factory installed electric heat without disconnect circuit breaker but with single point power source All hp 208 230V 30 75 30K75 30K75 30K75 30K75 30K75 30K75 Page 5 ELECTRICAL DATA 7 5 TON STANDARD HIGH EFFICIENCY Model No TCA090S 090 Line voltage data
16. kg 600 102 400 45 kW 208 115 300 220 129 000 150 45 255 152 160 175 175 2 240 153 600 440 37 8 129 000 180 460 41 3 141 000 76 79 80 80 575V 480 45 0 153 600 129 000 99J12 141 000 61 63 70 70 42 lbs 19 kg 153 600 60 kW 153 600 172 000 EHA150 60 188 000 161 169 175 175 208 230 204 800 22013 22 440 50 4 172 000 460V 22 460 55 1 188 000 84 80 90 99214 22 480 600 204 800 575V 22 550 50 4 172 000 99 15 22 575 55 1 188 000 64 67 70 70 49 Ibs 22 kg 22 600 60 0 204 800 1 Fuse block must be ordered extra Factory installed heaters will have the fuse block factory installed Fuse block must be installed in field installed heaters Also requires LTB2 Terminal Block See Optional Electric Heat Accessories tables 2 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Use wires suitable for at least 167 F 75 3 HACR type breaker or fuse 4 be used with two stage control Page 23 AND INSTALLATION Make sure the unit is installed in accordance with the installation instructions and all applicable codes See accessories section for conditions requiring use of the optional roof mounting frame LARMF18 36 or LARMFH18 24 lll Start Up Operation A Preliminary and Seasonal Checks 1 Make sure the unit is installed in accordance with the installation instructions and applicable codes 2 Inspect all elect
17. table 18 Setting A is recommended See figure 20 At set ting A free cooling will be energized when outdoor air is approximately 73 F 23 C and 50 relative humidity If in door air is too warm or humid lower the setpoint to B At setting B free cooling will be energized at 70 F 21 C and 50 relative humidity When an optional A62 differential sensor is installed turn A6 enthalpy control free cooling setpoint potentiometer completely clockwise to position TABLE 18 ENTHALPY CONTROL SETPOINTS 8 rero srarg Damper Minimum Position NOTE A jumper is factory installed between TB1 A1 and A2 terminals to maintain occupied status allowing minimum fresh air When using an electronic thermostat or energy management system with an occupied unoc cupied feature remove jumper Page 29 1 Set thermostat occupied mode if the feature is avail able Make sure jumper is in place between A45 con trol board TB1 terminals A1 and A2 if using a thermo stat which does not have the feature 2 Rotate MIN POS SET potentiometer to approximate desired fresh air percentage Note Damper minimum position can be set lower than traditional minimum air requirements when an AQ sensor is specified Dampers will open to DCV MAX setting if CO2 is above setpoint to meet traditional ventilation require ments 3 Measure outdoor air temperature Mark the point on the bottom line of chart 1 and label the po
18. to move the motor outward and tighten the belt 3 Tighten two bolts on motor pulley side IMPORTANT Align top edges of blower motor base and mounting frame base parallel before tightening two bolts on the other side of base Motor shaft and blower shaft must be parallel 4 Tighten two bolts on other side of base TO INCREASE CFM LOOSEN ALLEN SCREW amp TURN PULLEY CLOCKWISE TO DECREASE CFM TURN PULLEY COUNTERCLOCKWISE BELT TENSION ADJUSTING BOLT TURN SIDE VIEW ALLEN SCREW PULLEY BLOWER ASSEMBLY CLOCKWISE TO TIGHTEN BELT MOTOR BASE ADJUSTMENT SCREWS P 2 EACH SIDE BLOWER MOTOR MOUNTING FRAME BLOWER MOTOR BASE REMOVE 2 SCREWS FROM BOTH SIDES BEFORE SLIDING BLOWER ASSEMBLY OUT OF UNIT FIGURE 8 1 Loosen four bolts securing motor base to mounting frame See figure 8 1 To increase belt tension Turn adjusting bolt to the right or clockwise to move the motor outward and tighten the belt This increases the distance between the blower motor and the blower housing To loosen belt tension Turn the adjusting bolt to the left or counterclockwise to loosen belt tension 3 Tighten two bolts on motor pulley side IMPORTANT Align top edges of blower motor base and mounting frame base parallel before tightening two bolts on the other side of base Motor shaft and blower shaft must be parallel 4 Tighten two bolts on other side of base Check Belt Tension Overtens
19. x 15 381 x 381 1 15 x 15 381 x 381 Filters Type of filter Disposable pleated MERV 7 standard or MERV 11 optional Number and size in mm 4 18 x 22x 2 4 18x 24x 2 4 18x 24x 2 457 x 610 x 51 457 x 610 x 51 457 x 610 x 51 Electrical characteristics 208 230V 460V or 575V 60 hertz 3 phase NOTE Net capacity includes evaporator blower motor heat deduction Gross capacity does not include evaporator blower motor heat deduction 1 Certified in accordance with the ULE certification program which is based on ARI Standard 340 360 95 F 35 C outdoor air temperature and 80 F 27 C db 67 F 19 C wb entering evaporator air minimum external duct static pressure 2 Integrated Part Load Value rated at 80 F 27 C outdoor air temperature 80 F 27 C db 67 F 19 C wb indoor air temperature 3 Sound Rating Number rated in accordance with test conditions included in ARI Standard 270 Maximum usable output of motors furnished by Lennox are shown In Canada nominal motor output is also maximum usable motor output If motors of comparable output are used be sure to keep within the service factor limitations outlined on the motor nameplate Page 3 Cabinet Accessories Ceiling Diffusers Controls Cooling Accessories Economizer Barometric Relief OPTIONAL FIELD INSTAL Coil Guards Hail Guards Horizontal Discharge Conversion Kit Step Down Net Weight Flush Net Weight Transitions Sup
20. 2 372 Fans Motor rpm 1075 1075 1075 1075 Total Motor watts 700 700 700 1150 Diameter in mm no of blades 2 24 610 3 2 24 610 3 2 24 610 3 2 24 610 3 Total air volume cfm L s 8 000 3775 8 000 3775 8 000 3775 9 000 4245 Evaporator Net face area sq ft m2 10 5 0 98 total 10 5 0 98 total 10 5 0 98 total 10 5 0 98 total Coll Tube diameter in mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 3 3 4 4 Fins per inch m 14 551 14 551 14 551 14 551 Drain Connection no amp size 1 1 in NPT coupling 1 1 in NPT coupling 1 1 in NPT coupling 1 1 in NPT coupling Expansion device type Balanced Port Thermostatic Expansion Valve removable power head Standard Belt Drive Nominal motor output 2 hp 1 5 2 hp 1 5 kW 3 hp 2 2 kW 5 hp 3 7 kW Maximum usable output US Only 2 3 hp 1 7 kW 2 3 hp 1 7 kW 3 45 hp 2 6 kW 5 75 hp 4 3 kW Drive Drive kit kit 1 680 925 rpm kit 1 680 925 rpm kit 3 895 1120 kit 6 1100 1395 rpm Wheel nominal diameter x width in mm 1 15 15 381 x 381 1 15 x 15 381 x 381 1 15 x 15 381 x 381 1 15 x 15 381 x 381 Filters Type of filter Disposable pleated MERV 7 standard or MERV 11 optional Number and size 4 18x 24 x2 4 18x 24 x 2 4 18x 24x 2 4 18x 24x 2 457 x 610 x 51 457 x 610 x 51 457 x 610 x 51 457 x 610 x 51 Electrica
21. 3 1 through F3 4 contactors are equipped with a 24VAC coil The coils in 9 Fuse F4 the K15 and K16 contactors are energized by the main panel A45 Contactor K15 energizes the first stage heating elements while K16 energizes the second stage heating elements 4 High Temperature Limits 515 Primary 15 is a SPST N C auto reset thermostat located on the back panel of the electric heat section below the heating elements 515 is the high temperature limit for the electric heat section When 515 opens indicating a problem in Page 19 Fuse F4 is used only with single point power along with TB2 F4 gives over amperage protection to the compres sor and other cooling components while F3 protects the electrical heat component The F 4 fuse block is located inside sheetmetal enclosure figure 1 8 TCA ELECTRIC HEAT SECTION FUSE RATING Ce was _ sw _ _ wem sa 100 7 5 Ce kea Emm Gem Dew pea w Dmm Co pra een a ee e 20 Am u a me rem inno mm ww wmew mew sar 60 22 5 460 575V 20 Amp 600V a 208 230V 50 Amp 250V ELA 208 230V 50 Amp 250V ES 150 30 460 25 600 NELLE poet C e e
22. 36 6 Maximum Overcurrent With Exhaust Fan 60 60 70 30 30 35 20 25 25 70 70 80 35 35 40 25 30 30 Protection amps Less Exhaust Fan 60 60 70 30 30 30 20 25 25 60 70 70 35 35 35 25 25 30 Minimum Circuit With Exhaust Fan 50 53 59 24 26 29 19 21 23 54 57 63 28 29 32 22 23 26 Ampacity Less Exhaust Fan 47 51 57 23 25 27 18 20 22 52 55 61 27 28 31 21 22 25 Optional Power Number Horsepower W 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 1 1 3 249 Exhaust Fan Full load amps 24 13 10 24 13 10 Locked rotor amps 4 7 24 1 9 4 7 24 1 9 Service Outlet 2 115 volt GFCI amp rating 15 15 15 15 15 15 NOTE Extremes of operating range are plus and minus 10 of line voltage 1 HACR type breaker or fuse 2 Referto National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 12 5 TON STANDARD EFFICIENCY Model No TCA150S Line voltage data 60 Hz 3 phase 208 230 460 575 Compressors Rated load amps each total 18 6 37 2 9 18 7 4 14 8 Q Locked rotor amps each total 156 312 75 150 54 108 Condenser Full load amps each total 3 0 6 0 1 5 3 0 1 2 24 Fan Motors 2 Locked rotor amps each total 6 0 12 0 3 0 6 0 2 9 5 8 Evaporator Motor Output hp 3 5 3 5 3 5 22 37 22 37 22 37 otor Full load amps 10
23. 6 16 7 4 8 7 6 3 9 6 1 Locked rotor amps 66 105 26 8 45 6 234 36 6 Maximum Overcurrent With Exhaust Fan 70 80 35 40 30 30 Protection amps Less Exhaust Fan 70 80 35 35 30 30 Minimum Circuit With Exhaust Fan 61 67 30 33 24 27 Ampacity Less Exhaust Fan 59 65 29 31 23 26 Optional Power Number Horsepower W 1 1 3 249 1 1 3 249 1 1 8 249 Exhaust Fan Full load amps 24 13 1 0 Locked rotor amps 4 7 24 1 9 Service Outlet 2 115 volt GFCI amp rating 15 15 15 NOTE Extremes of operating range are plus and minus 10 of line voltage 1 HACR type breaker or fuse 2 Referto National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Page 7 BLOWER DATA 090 102 120 150 BELT DRIVE BLOWER BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY NO HEAT SECTION WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE FOR ALL UNITS ADD 1 Wet indoor coil air resistance of selected unit 2 Any factory installed options air resistance heat section economizer etc 3 Any field installed accessories air resistance duct resistance diffuser etc Then determine from blower table blower motor output and drive required BOLD INDICATES FIELD FURNISHED DRIVE Total Static Pressure in w g Pa 20 50 40 100 60 150 80 200 1 00 250 1 20 300 1 40 350 4 60 400 1 80 450 2 00 495 2 20 545 2 40 595 2 60 645 RPM RPM RPM
24. B2 Terminal Block See Optional Electric Heat Accessories tables 2 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Use wires suitable for at least 167 F 75 type breaker or fuse 4 be used with two stage control Page 22 10 10 TON STANDARD HIGH EFFICIENCY 120 12 5 TON STANDARD EFFICIENCY TCA150 REQUIRES UNIT FUSE BLOCK TERMINAL BLOCK AND HEATER CONTROL MODULE 2 Minimum Circuit Ampacity 3 Maximum Overcurrent Protection 1 prae Heat Volts kW Btuh Total Unit Electric Heat Total Unit Electric Heat amp Not Weight Steps Input Input Output with Power Exhaust Fan with Power Exhaust Fans TCA120 150 120 150 15 kW 1 208 11 3 38 600 1 220 12 6 43 000 150 15 120H 70 1 230 13 8 47 100 e 1205 60 208 230V 39322 1 240 15 0 51 200 1 440 12 6 43 000 460 120 35 s 1 460 13 8 47 100 31 34 1205 30 40 1 480 15 0 51 200 n 1 550 12 6 1 575 13 8 25 27 25 30 31 Ibs 14 kg 1 600 15 0 22 5 kW 22 208 220 EHA360 22 5 250 84 92 90 100 208 230 240 9928 240 460V 460 42 45 45 45 575 550 99 30 575 34 36 35 40 38 Ibs 17 kg 600 30 kW 208 76 800 EHA150 30 220 86 000 t 25 i25 208 230V 230 93 900 59307 240 102 400 440 86 000 460V 4515 460 93 900 53 57 60 60 480 102 400 550 86 000 575 93 900 43 45 45 45 38 Ibs 17
25. Ibs 8 oz 3 86 kg 10 Ibs 0 oz 4 54 Fumish d HCFC 22 Circuit2 8 Ibs 8 oz 3 86 kg 8 Ibs 8 oz 3 86 kg 10 Ibs 0 oz 4 54 kg 3 Sound Rating Number dB 88 88 88 Condenser Net face area sq ft m2 29 3 2 72 total 29 3 2 72 total 29 3 2 72 total Sell Tube diameter in mm 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 2 2 2 Fins per inch m 20 787 20 787 20 787 Condenser Motor horsepower W 2 1 3 249 2 1 3 249 2 1 3 249 Fans Motor rpm 1075 1075 1075 Total Motor watts 700 700 700 Diameter in mm no of blades 2 24 610 3 2 24 610 3 2 24 610 3 Total air volume cfm L s 8 000 3775 8 000 3775 8 000 3775 Evaporator Net face area sq ft m2 10 5 0 98 total 10 5 0 98 total 10 5 0 98 total Coll Tube diameter in mm 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 3 3 4 Fins per inch m 14 551 14 551 14 551 Drain Connection no amp size 1 1 in NPT coupling 1 1 in NPT coupling 1 1 in NPT coupling Expansion device type Balanced Port Thermostatic Expansion Valve removable power head Standard Belt Drive Nominal motor output 2 hp 1 5 kW 2 hp 1 5 kW 3 hp 2 2 kW Indoor Maximum usable output US Only 2 8 hp 1 7 kW 2 8 hp 1 7 kW 3 45 hp 2 6 kW Blower and Drive Motor Drive kit kit 1 680 925 rpm kit 1 680 925 rpm kit 3 895 1120 rpm Wheel nominal diameter x width in mm 1 15 x 15 381 x 381 1 15
26. ON CI Supersedes Form No New Form No wem n Litho U S A POWER 1 Terminal strip TB1 found on the main control module A45energize thermostat components with 24VAC OPERATION 2 The main control module A45 receives data from the electronic thermostat A2 Y1 Y2 W1 W2 G OCP A45 energizes the appropriate components for heat cool demand Page 38 SERIES ECONOMIZER WIRING DIAGRAM 11 05 RIPTI N Ae CONTROL SOLID STATE ENTHALEY ENTHALPY ACCESSORIES IAA SENSOR SOLID STATE ENTHALPY ECONOMIZER ineo ENSOR ENTHALPY INDOOR OTOR DAMPER ECONOMIZER FOR TCA TGA UNITS ACK SENSOR OUTDOOR ENTHALPY ACK SENSOR RETURN AIR ENTHALP ECONOMIZER SECTION DI LUG SENSOR OUTDOOR ENTHALPY New Form No LUG SENSOR RETURN AIR ENTHALPY 534 485W 2003 Litho U S A Flos DU pru i lt SEQUENCE OF OPERATION POWER 1 Terminal strip TB1 found on main control module A45 energizes the economizer components with 24VAC OPERATION 2 Enthalpy sensor A7 and A62 if differential enthalpy is used communicates to the economizer control module A6 when to power the damper motor B7 3 control module supplies B7 with 0 10 VDC to control the positioning of economizer 4 The damper actuator provides 2 to 10 position feedback Page 39
27. P CLASS IT VOLTAGE 5 zo tithe 0757 33 090 150 SEQUENCE OF OPERATION Power 1 Line voltage from unit disconnect energizes transformer T1 T1 provides 24VAC power to terminal strip TB1 TB1 provides 24VAC to the unit cooling heating and blower controls Blower Operation 2 The main control module receives a demand from thermostat terminal G A45 energizes blower contactor with 24VAC 3 N O 1 closes energizing blower Economizer Operation 4 The economizer control module receives a demand and energizes exhaust fan relay K65 with 24 at 50 outside air damper open adjustable 5 N O K65 1 and N O K65 2 both close energizing exhaust fan motor B10 1st Stage Cooling compressor B1 First stage cooling demand Y1 and G is energized by the thermostat G energizes blower 24 is routed through TB1 on main control module A45 A45 proves freezestat S49 and optional N C high pressure switch S4 Compressor contactor K1 is energized N O contacts K1 1 close energizing compressor B1 9 Optional N O low ambient switch S11 closes to energize condenser fan relay K10 10 N O contacts K10 1 close energizing condenser fan B4 2nd Stage Cooling compressor B2 is energized 11 Second stage cooling demand energizes Y2 12 24VAC is routed through TB1on module A45 A45 proves N C freezestat S50 and optional N C high pressure switch S7 Compressor contactor K2 is energized 13 N O
28. TCA090S NORMAL OPERATING PRESSURES Doe ee ee Outdoor CIRCUIT 1 CIRCUIT 2 TABLE 16 Entenng Dis 10 eT TCA120H NORMAL OPERATING PRESSURES Air Temp psig ig psig psig CIRCUIT 1 CIRCUIT 2 180 e Entering Dis 10 Suct 5 Dis 10 Suc 5 206 13 psig psig psig psig ccn 65 F 75 F ar 78 22 9 Svr 244 22 8 12 10552 275 81 28 83 TCA090H NORMAL OPERATING PRESSURES 115 309 83 322 84 CIRCUIT 1 CIRCUIT 2 ol Entering Dis 10 Suct 5 Dis 10 Suc 5 TABLE 17 Air Temp psig psig psig psig TCA150S NORMAL OPERATING PRESSURES 156 76 Outdoor CIRCUIT 1 CIRCUIT 2 181 18 Entering 015 10 Suct 5 Dis 10 209 80 Air Temp psig psig psig 29 65 F 70 274 83 S m eee 21 72 27 13 95 74 1025 NORMAL OPERATING PRESSURES 105 F 76 Outdoor CIRCUIT 1 CIRCUIT 2 115 F 77 Coil Entering Dis 10 Suc 5 Air Temp psig psig Charge Verification Approach Method 178 73 204 73 1 Using the same thermometer compare liquid temper 237 74 ature to outdoor ambient temperature 272 76 313 77 Sh 78 Approach Temperature Liquid temperature minus ambient temperature TABLE 14 EA MH NORMAL OPERATING PRESSURES 2 Approach temperature should be 7 F 1 3 8 C 0 5 Coil CIRCUITI An approach temperature greater than this valu
29. air when an R1 mixed air sensor is installed Page 31 F LAGED H Gravity Exhaust Dampers LAGED H 10 15 dampers figure 23 available for 090 150 units are used in downflow and LAGEDH are used in horizontal air discharge applications LAGED H gravity exhaust dampers are installed in the re tum air plenum The dampers must be used any time an economizer or power exhaust fans are applied to TCA series units Gravity exhaust dampers allow exhaust air to be discharged from the system when an economizer and or power exhaust is operating Gravity exhaust dampers also prevent outdoor air infiltration during unit off cycle See installation instructions for more detail LAGED AND LAPEF INSTALLATION ECONOMIZER FRESH AIR HOOD GRAVITY EXHAUST p LAPEF POWER EXHAUST FAN ASSEMBLY LAGED GRAVITY EXHAUST DAMPERS FIGURE 23 G LAPEF Power Exhaust Fans all units LAPEF10 15 available 90 150 units haust fans used in downflow applications only TAPEF fans requires optional down flow gravity exhaust dampers and LA REMD economizers Power exhaust fans provide exhaust air pressure relief and also run when return air dampers are closed and supply air blowers are operating Figure 23 shows location of the LAPEF See installation instructions for more detail H Control Systems Three different types of control systems may be used with the series units A
30. e indi Entering Dis 10 Dis 10 Suc 5 cates an undercharge An approach temperature less Air Temp psig psig psig nin 160 75 than this value indicates an overcharge 186 77 213 79 3 Do not use the approach method if system pressures 243 81 do not match pressures in tables 11 through 17 The 277 82 approach method is not valid for grossly over or under 313 84 charged systems Page 25 The unit should be inspected once a year by qualified vice technician AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation Verify proper operation after ser vicing AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cal ifornia to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown on unit nameplate or contact your supervisor A Filt
31. ers Units are equipped with four 18 X 24 X 2 filters Filters should be checked and replaced when necessary with fil ters of like kind and size Take note of air flow direction marking on filter frame when reinstalling filters See figure 14 B Lubrication All motors are lubricated at the factory No further lubrica tion is required REMOVE FILTERS PULL TO REMOVE FILTERS FIGURE 14 NOTE Filters must U L C certified or equivalent for use in Canada C Evaporator Coil Inspect and clean coil at beginning of each cooling season Clean using mild detergent or commercial coil cleanser Flush coil and condensate drain with water taking care not to get insulation filters and return air ducts wet D Condenser Coil Clean condenser coil annually with detergent or commer cial coil cleaner and inspect monthly during the cooling season Condenser coils are made of one two and three formed slabs Dirt and debris may become trapped between the slabs To clean between slabs carefully separate coil slabs and wash them thoroughly See figure 15 Flush coils with water following cleaning Note Remove all screws and gaskets prior to cleaning procedure and replace upon completion E Supply Blower Wheel Annually inspect supply air blower wheel for accumulated dirt or dust Turn off power before attempting to remove ac cess panel or to clean blower wheel Page 26
32. ferential sensor A62 may be used with the A7 outdoor sensor to compare outdoor air temperature to return air temperature When the outdoor air temperature is below the return air temperature outdoor air is used for free cooling An optional mixed air sensor R1 may be used to modulate dampers to 55 F 13 C discharge air An optional IAQ sensor A63 may be used to lower operat ing costs by controlling outdoor air based on CO level or room occupancy also called demand control ventilation or DCV Damper minimum position can be set lower than traditional minimum air requirements dampers open to traditional ventilation requirements when CO level reach es DCV IAQ setpoint Refer to instructions provided with sensors for installation A6 Enthalpy Control LED s A steady green Free Cool LED indicates that outdoor air is suitable for free cooling When an optional IAQ sensor is installed a steady green DCV LED indicates that the IAQ reading is higher than set point requiring more fresh air See figure 20 A6 ENTHALPY CONTROLLER DAMPER MINI MUM POSITION IAQ MAXIMUM POSITION set higher than minimum position IAQ READING IS ABOVE SETPOINT IAQ SETPOINT OUTDOOR AIR SUITABLE LED FREE COOLING SETPOINT A Completely counterclockwise D Completely clockwise FIGURE 20 Free Cooling Setpoint Outdoor air is considered suitable when temperature and humidity are less than the free cooling setpoints shown in
33. figure 20 Note DCV Max must be set higher than economizer mini mum position setting for proper demand control ventilation CHART 1 CALCULATE MINIMUM FRESH AIR PERCENTAGE MIXED AND RETURN AIR TEMPERATURE F 20 10 0 10 20 30 40 E 23 18 12 7 1 4 60 70 80 90 100 F 16 1 27 32 38 C B 10 20 30 30 40 40 50 50 60 lt 05 ra LL z ui 60 PERCENT FRESH AIR 70 70 80 80 90 100 F 20 10 0 10 20 30 40 C 29 23 18 12 7 1 4 90 100 60 70 80 90 100 F 16 21 27 32 38 C OUTDOOR AIR TEMPERATURE Economizer Operation The occupied time period is determined by the thermostat or energy management system Outdoor Air Not Suitable During the unoccupied time period dampers are closed During the occupied time period a cooling demand will open dampers to minimum position and mechanical cool ing functions normally Page 30 During occupied time period dampers will open to MAX when IAQ reading is above setpoint regardless of MANUAL OUTDOOR AIR DAMPER thermostat demand or outdoor air suitability SIDE VIEW Outdoor Air Suitable Loosen sheet metal screws See table 19 for economizer operation with a standard two to adjust damper position stage thermostat tighten screws when damp er is in correct position During the occupied pe
34. gure 18 Either air damper can be installed in TCA units Washable filter supplied with the outdoor air dampers can be cleaned with water and a mild detergent It should be sprayed with Filter Handicoater when dry prior to reinstallation Filter Handicoater is R P Products coating no 418 and is available as Lennox Part No P 8 5069 D Supply and Return Diffusers all units Optional flush mount diffuser retum FD11 and extended mount diffuser return RTD11 are available for use with all TCA units Refer to manufacturers instructions included with transition for detailed installation procedures LAOAD M OUTDOOR AIR DAMPER DAMPER ASSEMBLY UNIT DIVISION PANEL SIDE VIEW e SHEET METAL SCREWS DAMPER BLADES FIGURE 18 E TAREMD Economizer Field or Factory Installed Unit may contain an optional factory installed three posi tion economizer equipped with an A6 enthalpy control and an A7 outdoor enthalpy sensor The three position econo mizer opens fully to use outdoor air for free cooling when temperature is suitable and opens to minimum position during the occupied time period The enthalpy control is located in the economizer ac cess area See figure 19 The A7 enthalpy sensor is located on the division panel between horizontal supply and return air sections Page 28 ECONOMIZER CONTROLS A6 AT ENTHALPY ENTHALPY SENSOR FIGURE 19 Optional Sensors An optional dif
35. iagram section for specific unit operation 2 Freezestats S49 and S50 Each unit is equipped with a low temperature switch freezes tat located on a return bend of each evaporator coil S49 first circuit and S50 second circuit are located on the corresponding evaporator coils Each freezestat is wired to the main control module A45 Each freezestat is a SPST N C auto reset switch which opens at 29 F 3 F 1 7 1 7 C on a temperature drop and closes at 58 4 14 4 C 2 2 C on atempera ture rise To prevent coil icing freezestats open during compressor operation to temporarily disable the re spective compressor until the coil temperature rises If the freezestats are tripping frequently due to coil icing check the air flow filters economizer position and unit charge before allowing unit back in operation Make sure to eliminate conditions which might promote evaporator ice buildup 3 High Pressure Switches S4 and S7 optional The high pressure switch is a manual reset SPST N C switch which opens on a pressure rise Each switch is located in the compressor discharge line and is wired in series with the com pressor contactor coil When discharge pressure rises to 450 10 psig 3103 69 kPa indicating a problem in the system the switch opens and the respective compressor is de energized the economizer can continue to operate 4 Low Ambient Switches S11 amp S84 optional The low ambient switch is an a
36. int A 40 F 4 C shown Measure return air temperature Mark that point on the top line of chart 1 and label the point B 74 F 23 shown 1 5 Measure mixed air outdoor and return air tempera ture Mark that point on the top line of chart 1 and label point C 70 F 21 C shown 6 Draw a straight line between points A and B 7 Draw a vertical line through point C 8 Draw a horizontal line where the two lines meet Read the percent of fresh air intake on the side 9 If fresh air percentage is less than desired adjust MIN POS SET potentiometer higher If fresh air percentage is more than desired adjust MIN POS SET potentiom eter lower Repeat steps 3 through 8 until calculation reads desired fresh air percentage DCV Set and Max Settings Adjust settings when an optional IAQ sensor is installed The DCV SET potentiometer is factory set at approxi mately 5096 of the potentiometer range Using a standard 1 2000ppm sensor dampers will start to open when the IAQ sensor reads approximately 1000ppm Adjust the DCV SET potentiometer to the approximate setting specified by the controls contractor Refer to figure 20 The DCV MAX potentiometer is factory set at approxi mately 50 of the potentiometer range or 6VDC Damp ers will open approximately half way when CO rises above setpoint Adjust the DCV MAX potentiometer to the approximate setting specified by the controls con tractor Refer to
37. ioning belts shortens belt and bearing life Check belt tension as follows 1 Measure span length X See figure 9 2 Apply perpendicular force to center of span X with enough pressure to deflect belt 1 64 for every inch of span length or 1 5mm per 100mm of span length Example Deflection distance of a 40 span would be 40 64 or 5 8 Example Deflection distance of a 400mm span would be 6mm Measure belt deflection force For a used belt the deflection force should be 5 Ibs 35kPa A new belt deflection force should be 7 Ibs 48kPa A force below these values indicates an underten sioned belt A force above these values indicates an overtensioned belt MEASURE BELT TENSION CD 1 DEFLECTION 1 64 PER INCH OF SPAN OR 1 5mm PER 100mm OF SPAN FIGURE 9 Page 18 D Optional Electric Heat Components Tables 9 and 10 show all possible TCA to EHA matchups and electrical ratings All electric heat sections consist of electric heating ele ments exposed directly to the airstream See figure 10 EHA parts arrangement is shown in figures 11 and 12 Multiple stage elements are sequenced on and off in re sponse to thermostat demand HEAT SECTION PLACEMENT CE Exc ELECTRIC HEAT SECTION behind hinged panel FIGURE 10 1 Electric Heat Relay K9 Electric heat relay K9 is a N O SPST pilot relay located on the main control panel figure 2 K9 electrically isolates the
38. l characteristics 208 230V 460V or 575V 60 hertz 3 phase NOTE Net capacity includes evaporator blower motor heat deduction Gross capacity does not include evaporator blower motor heat deduction 1 Certified in accordance with the ULE certification program which is based on ARI Standard 340 360 95 F 35 C outdoor air temperature and 80 F 27 C db 67 F 19 C wb entering evaporator air minimum external duct static pressure 2 Integrated Part Load Value rated at 80 F 27 C outdoor air temperature 80 F 27 C db 67 F 19 C wb indoor air temperature 3 Sound Rating Number rated in accordance with test conditions included in ARI Standard 270 Maximum usable output of motors furnished by Lennox are shown In Canada nominal motor output is also maximum usable motor output If motors of comparable output are used be sure to keep within the service factor limitations outlined on the motor nameplate Page 2 SPECIFICATIONS General Nominal Tonnage 7 5 Ton 8 5 Ton 10 Ton Data Model No TCA090H2B TCA102H2B Cooling Gross Cooling Capacity Btuh kW 93 000 27 2 106 000 31 0 126 000 36 9 Performance 1Net Cooling Capacity kW 90 000 26 4 103 000 30 2 120 000 35 2 ARI Rated Airflow cfm L s 3000 1415 3400 1605 3800 1795 Total Unit Power kW 8 0 9 2 10 9 1 EER Btuh Watt 11 0 11 0 11 0 2 Integrated Part Load Value Btuh Watt 11 4 11 4 11 4 Refrigerant Charge Circuit 1 8 Ibs 8 oz 3 86 8
39. lectric Heat Total Unit Electric Heat odel No with Power Exhaust Fan with Power Exhaust Fans amp Net Weight Steps Input Input Output TCA090 TCA102 TCA090 TCA102 7 5 kW 1 208 I 1 220 090H 43 EHA102 7 5 27 Conse an 50 60 208 230V 99J01 1 240 1 440 460V 1 460 59702 22 25 30 1 480 575V 1 550 99J03 090H 17 102H 18 1 575 090S 18 1025 19 20 20 31 Ibs 14 kg 1 600 15 1 208 1 220 150 15 58 58 208 230 99704 2 1 440 460 1 460 Sosis 29 29 30 30 1 480 575V 1 550 99J06 1 575 23 23 25 25 31 Ibs 14 kg 1 600 22 5 kW 22 208 2 EHA360 22 5 2 220 22 230 208 230V 2 99J28 2 2 22 440 460 22 460 9926 40 40 40 40 22 480 575V 22 550 99J30 22 575 32 32 35 35 38 Ibs 17 kg 22 600 30 kW 22 208 76 800 22 220 86 000 EHA150 30 22 530 93 900 103 103 110 110 208 230 2 3907 2 240 102 400 22 440 86 000 460V 22 460 93 900 51 51 60 60 22 480 102 400 225 22 550 86 000 22 575 93 900 41 41 45 45 38 Ibs 17 kg 22 600 102 400 45 kW 22 208 115 300 22 220 129 000 EHA150 45 22 m 141 000 148 148 150 150 208 230 2 39910 2 240 153 600 22 440 37 8 129 000 460V 2 2 460 41 3 141 000 74 74 22 480 45 0 153 600 REN 22 550 37 8 129 000 22 575 41 3 141 000 59 59 60 60 42 Ibs 19 kg 22 600 45 0 153 600 1 Fuse block must be ordered extra Factory installed heaters will have the fuse block factory installed Fuse block must be installed in field installed heaters Also requires LT
40. les to the holes located in the unit base rail two holes at each comer Refer to the installation instructions for the prop er rigging technique AWARNING Improper installation adjustment alteration service maintenance can cause property damage person al injury or loss of life Installation and service must be performed by a qualified installer or service agency WARNING Refrigerant can harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in person al injury or death Technical Publications Page 1 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electro static charge by touching hand and all tools on an unpainted unit surface before performing any service procedure Table of Contents Specifications 2 2 0 usuy usss chee vee 4 Electrical Data 6 Blower Data 8 I Unit Components 12 Placement and Installation
41. ll thermostat wiring is connected to terminal block TB1 located in the control box of the unit Each thermostat has additional control options available See thermostat installation instructions for more detail 1 Electro mechanical thermostat 13F06 The electro mechanical thermostat is a two stage heat two stage cool thermostat with dual temperature levers A non switching or manual system switch subbase may be used 2 Electronic thermostat see price book Any two stage heat two stage cool electronic ther mostat may be used 3 Honeywell T7300 thermostat 60L59 The Honeywell T7300 thermostat is a programmable in ternal or optional remote temperature sensing thermo stat The T7300 provides occupied and unoccupied changeover control Il Smoke Detectors A17 and A64 Photoelectric smoke detectors are a factory installed op tion The smoke detectors can be installed in the supply air section A64 return air section A17 or in both the supply and return air section J Blower Proving Switch 552 The blower proving switch monitors blower operation and locks out the unit in case of blower failure The switch is N O and closes at 14 W C 34 9 Pa The switch is mounted on the upper left hand corner of the blower deck K Dirty Filter Switch S27 The dirty filter switch senses static pressure increase indi cating a dirty filter condition The switch is N O and closes at 1 W C 248 6 Pa The switch is mounted on the top filte
42. nd K2 IE ET cx D olol 2 S oloo S FIGURE 2 Page 11 I UNIT COMPONENTS AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies The TCA unit components are shown in figure 1 All units come standard with removable panels All L1 L2 and L3 wiring is color coded L1 is red L2 is yellow and L3 is blue A Control Box Components TCA control box components are shown in figure 2 The control box is located in the upper left portion of the com pressor compartment 1 Disconnect Switch S48 Optional all units All units may be equipped with an optional disconnect switch S48 or circuit breaker CB10 S48 and CB10 are toggle switches which can be used by the service technician to dis connect power to the unit 2 Control Transformer T1 all units All use a single line voltage to 24VAC transformer mounted in the control box Transformer supplies power to control circuits in the unit The transformer is rated at and is protected by a 3 5 amp circuit breaker
43. nts are taken 2 With all access panels in place measure static pres sure external to unit from supply to return Measure static in duct below roof curb if roof curb is used 3 Refer to blower tables in BLOWER DATA table of con tents in the front of this manual Use static pressure and RPM readings to determine unit air volume 4 The blower RPM can be adjusted at the motor pulley Loosen Allen screw and turn adjustable pulley clock wise to increase CFM Turn counterclockwise to de crease CFM See figure 8 Do not exceed minimum and maximum number of pulley turns as shown in table 7 TABLE 7 MINIMUM AND MAXIMUM PULLEY ADJUSTMENT Minimum Maximum Turns Open Turns Open 8 amp dm 9 No minimum number of turns open when B belt is used on pulleys 6 O D or larger Blower Belt Adjustment Maximum life and wear can be obtained from belts only if proper pulley alignment and belt tension are main tained Tension new belts after a 24 48 hour period of operation This will allow belt to stretch and seat grooves Make sure blower and motor pulley are aligned as shown in figure 7 PULLEY ALIGNMENT ALIGNED pud em BLOWER PULLEY BELT MOTOR PULLEY NOT ALIGNED FIGURE 7 Page 17 TO INCREASE BELT TENSION 1 Loosen four bolts securing motor base to mounting frame ALIGN TOP EDGES PARALLEL BEFORE TIGHTENING MOTOR IN PLACE gt lt 2 Turn adjusting bolt to the right or clockwise
44. onal or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 8 5 TON STANDARD HIGH EFFICIENCY Model No TCA102S TCA102H Line voltage data 60 Hz 3 phase 208 230 460 575V 208 230V 460V 575V Compressors 2 Rated load amps each total 14 7 29 4 91 182 7 1 14 2 50 100 5 8 11 6 37 74 14 7 29 4 91 182 7 1 14 2 46 92 5 1 10 2 37 74 Locked rotor amps each total Full load amps each total 24 4 8 Locked rotor amps each total 47 94 Condenser Fan Motors 2 13 2 6 24 4 8 1 0 2 0 1 9 3 8 2 4 4 8 4 7 9 4 1 8 2 6 2 4 4 8 1 0 2 0 1 9 3 8 Evaporator Blower Motor Motor Output hp 2 3 kW 15 22 Fullload amps 7 5 10 6 Locked rotor amps 46 9 66 2 3 1 5 22 34 4 8 204 268 2 3 1 5 22 2 7 3 9 162 234 2 3 1 5 22 7 5 10 6 46 9 66 2 3 1 5 22 34 4 8 204 268 2 3 1 5 22 2 7 3 9 162 234 With Exhaust Fan 60 60 Less Exhaust Fan 60 60 1 Maximum Overcurrent Protection amps 30 30 25 30 20 25 20 20 60 60 60 60 30 30 25 30 20 20 20 20 With Exhaust Fan 48 51 Less Exhaust Fan 46 49 2 Minimum Circuit Ampacity 24 25 22 27 19 20 18 19 48 51 46 49 24 25 22 24 18 19 17 18 Optional Power Exhaust Fan Number Horsepower W 1 1 3 249 Full load amps Locked r
45. ontactor coil K16 When S20 opens contactors K15 K16 are de energized When the contactors are de energized first stage and all subsequent stages of heat are de energized The limit is factory set to open at 220 F 6 F 104 C 3 3 C on a temperature rise and can be manually reset when temperature falls below 160 F 71 0 C 6 Terminal Strip TB3 Electric heat line voltage connections are made to termi nal strip TB3 or a fuse block on some models located in the upper left corner of the electric heat vestibule 7 Elements HE2 HE6 HE7 Heating elements are composed of helix wound bare nichrome wire exposed directly to the airstream Three elements are connected in a three phase arrange ment The elements in 208 230V units are connected in a Delta arrangement Elements in 460 and 575V units are connected in Wye arrangement Each stage is energized independently by the corresponding contac tors located on the electric heat vestibule panel Once energized heat transfer is instantaneous High temper ature protection is provided by primary and redundant high temperature limits and overcurrent protection is provided by fuses 8 Fuse F3 Fuse F3 are housed in a fuse block which holds three fuses Each F3 fuse is connected in series with each leg of electric heat Figure 11 and table 8 show the fuses used with each electric heat section For simplicity the ser vice manual labels the fuses F
46. ontacts K9 1 close ener gizing timer DL2 7 After a 30 second delay DL2 closes energizing contac tor K16 8 N O contacts K16 1 close allowing the second bank of elements to be energized END OF SECOND STAGE HEAT 9 Heating demand is satisfied Terminal W2 in the ther mostat is de energized 10 Electric heat contactor K16 is de energized 11 The second set of electric heat elements are de ener gized END OF FIRST STAGE HEAT 12 Heating demand is satisfied Terminal W1 in the ther mostat is de energized 13 Electric heat contactor K15 is de energized 14 The first set of electric heat elements are de energized Page 37 ELECTRONIC ELECTROMECHANICAL THERMOSTAT dS E 5 ins 25 COMMON COMMON N RI IS USED WITH OPTIONAL MODULATING ECONOMIZER FIELD KIT D RIPTI N COMPONENT SENSOR ELECTRONIC Y CONTROL MODULE REMOVE JUMPER WHEN RI IS USED 65 SENSOR CO2 1 ICMC3 I CLOCK TIME JACK UNIT ECONOMIZER THERMOSTAT HEAT ANTICIPATION SETTING 0 1 AMP INDICATES MICRO PROCESSER K65 RELAY EXHAUST FAN lt DESIGNATES OPTIONAL WIRING P3 PLUG LESS ECONOMIZER CLASS II FIELD WIRING 76 PLUG SENSOR ECONOMIZER WIRING DIAGRAM 12703 ONTRO BLOWER 4 ONTR ACCESSORIES SUPPLT AIR ELECTROMECHANICAL OR ELECTRONIC TBI TERMINAL STRIP 24V CLASS II THERMOSTAT FOR TCA TGA UNITS TEMPERATURE CONTROL SECTI
47. otor amps 24 4 7 1 1 3 249 13 24 1 1 3 249 10 19 1 1 3 249 24 4 7 1 1 8 249 1 3 2 4 1 1 3 249 1 0 1 9 Service Outlet 2 115 volt GFCI amp rating 15 15 15 15 15 15 NOTE Extremes of operating range are plus and minus 10 of line voltage 1 HACR type breaker or fuse 2 Referto National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Page 6 10 TON STANDARD HIGH EFFICIENCY ELECTRICAL DATA Model No TCA120S TCA120H Line voltage data 60 Hz 3 phase 208 230V 460 575V 208 230V 460V 575V Compressors Rated load amps each total 15 4 30 8 7 4 14 8 5 9 11 8 17 3 34 6 9 0 18 0 7 1 14 2 Q Locked rotor amps each total 124 248 59 6 119 2 49 4 98 8 123 246 62 124 50 100 Condenser Full load amps each total 24 4 8 1 3 2 6 1 0 2 0 2 4 4 8 1 3 2 6 1 0 2 0 Fan Motors 2 Locked rotor amps each total 4 7 9 4 24 4 8 1 9 3 8 4 9 9 4 24 4 8 1 9 3 8 Evaporator Motor Output hp 2 3 5 2 3 5 2 3 5 2 3 5 2 3 5 2 3 5 mower kW 1 5 22 37 15 22 37 15 22 37 15 22 37 1 5 2 2 37 1 5 2 2 3 7 Full load amps 7 5 10 6 16 7 34 4 8 7 6 27 3 9 6 1 7 5 10 6 16 7 3 4 4 8 7 6 2 7 39 6 1 Locked rotor amps 46 9 66 105 20 4 26 8 456 16 2 23 4 36 6 46 9 66 105 20 4 26 8 45 6 16 2 23 4 1
48. plicable the board will energize Y1 Y2 and Y3 in successive order In the same manner a Y2 will be interpreted as a Y1 Y2 The MCC control also incorporates a minimum run time of 4 minutes for up to 2 independent cooling stages This 4 minute run time can be interrupted by pushing SW1 located on the board If pressed for 3 seconds or more the control goes into TEST mode disabling AUTO STAGING The MCC control board is used for all T series units A dip switch factory set is provided to configure to unit type TGA gas TCA cooling electric heat THA heat pump See fig ure 4 Page 12 1 No power to Check field wiring If problem per board sists refer to service manual Press MCC pushbutton and Processor error hold for three seconds to reset processor Flashes Flashes Invalid unit DIP Make sure switches are set Rapidly switch selected correctly Refer to figure 4 Simultaneous heat and cool Rapidly demands Flashes Check thermostat and wiring Press pushbutton and immediately release to override the 4 minute compressor minimum run time UNIT TYPE DIP SWITCH FACTORY SET TGA UNITS THA UNITS UNUSED HEARTBEAT LED WILL FLASH RAPIDLY IN ERROR FIGURE 4 MCC CONTROL BOARD A45 HHHHHHH RW1 Y1 C G BL W2 OUT YI Ye Y3 Y4 WI W2
49. ply and Return Net Weight Blower Proving Switch Dirty Filter Switch L Connection Network Smoke Detector Supply Smoke Detector Return PVC Condensate Drain Trap Copper Condensate Drain Trap High Pressure Switch Compressor Crankcase Heater Low Ambient Kit Economizer Net Weight Economizer Outdoor Air Hood Net Weight Number and Size of Filters Economizer Enthalpy Control Differential Economizer Enthalpy Control Outdoor Down Flow Barometric Relief Dampers Net Weight Hood for Down Flow LAGED Horizontal Barometric Relief Dampers Net Weight LED ACCESSORIES TACGKGC10 15 TAHGKGC10 15 LTHSDKGC10 15 RTD11 135 205 Ibs 93 kg FD11 135 174 1 79 kg LASRT10 12 32 Ibs 15 kg LTABPSK LTADFSK See Engineering Handbook LTASASDK10 36 LTRASDK 10 30 LTACDKP03 36 LTACDKC03 36 TAHPK10 15 TACCHK10 15 TALAK10 15 TAREMD10 15 47 Ibs 21 kg LAOAH10 15 11 Ibs 5 kg 2 16 x 25 x 1 in 406 x 635 x 25 mm LTADEK03 36 LTASEKO03 36 LAGED10 15 8 lbs 4 kg LAGEHO09 15 15 8 Ibs 4 kg RTD11 95 88 1 5 40 kg FD11 95 75 Ibs 34 kg LASRT08 10 30 Ibs 14 kg RTD11 185 392 Ibs 178 kg FD11 185 289 Ibs 131 kg LASRT15 36 Ibs 16 kg Outdoor Air Dampers Damper Section down flow Automatic Net Weight Damper Section down flow Manual Net Weight Outdoor Air Hood down flow Net Weight Number and Size of Filters Power Exhaust Powe
50. r channel corner Page 32 Vil Wiring Diagrams and Sequence of Operation 090 150 UNIT DIAGRAM From TBI R lt 0 e NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE USED ON M VOLTAGE UNITS AND UNITS WITH HIGH EFFICIENCY MOTORS AI7 AND A64 ARE FIELD INSTALLED OPTIONS DH400 REMOVE WIRE WHEN USING OPTIONAL SMOKE DETECTOR HRI HR2 ARE OPTIONAL WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES 4132 ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH 52 WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION DISCONNECT ALL POWER BEFORE SERVICING DESIGNATES OPTIONAL WIRING CLASS II FIELD WIRING WIRING DIAGRAM ae T G ECONOM HAR COMBINATION PACKAGEDZROOF IOP H R COI TCA TGA 090 102 120 150 6 101 JACK SMOKE D AIR B JACK SMOKE DETECTOR SUPPLY AIR SWITCH FREEZESTAT COMPRESSOR n JTS AGED JL OV WER amp COOL _____ISWITCH FREEZESTAT COMPRESSOR 2 A 00 584 ISWIICH LOW PRESS LOW COMP 2 N New Form No HEA E TIRANSFORMER CONTROL 4 554 476W tes TJACK ECONOMTZER HARNESS TET TERMINAL STRI
51. r Exhaust Fan Net Weight Electrical Accessories HACR Circuit Breaker Disconnect Switch GFI Service Outlets TAOADM10 15 31 Ibs 14 kg LAOAD10 15 26 Ibs 12 kg LAOAH10 15 11 Ibs 5 kg 2 16 x 25 x 1 in 406 x 635 x 25 mm LAPEF 10 15 28 Ibs 13 kg TAHBK10 15 indicate size TADK10 15 80 80A TADK10 15 150 150A LTAGFIK10 15 Filters MERV 11 High Efficiency AFK 11 18 x 24 x 2 specify four per unit Indoor Air Quality CO2 Sensors Standard Roof Curbs Cliplock 1000 Roof Curbs CO Sensor Duct Mounting Kit Sensor white case CO display Sensor white case no display Sensor black case display Sensor duct mount black no display Aspiration Box for duct mounting Handheld Monitor 14 in 356 mm height Net Weight 24 in 610 mm height Net Weight 14 in 356 mm height Net Weight 18 in 457 mm height 24 in 610 mm height Net Weight Page 4 LTIAQSDMKO03 36 LTAIAQSWDKO03 36 LTAIAQSWNO3 36 LTAIAQSNDO03 36 LTAIAQSDMBNO03 36 LTIAQABD03 36 LTAIAQSHM03 36 0 15 14 126 Ibs 57 kg LARMF10 15 24 174 Ibs 79 kg 0 158 14 126 Ibs 57 kg 0 158 18 0 158 24 174 Ibs 79 kg OPTIONAL ELECTRIC HEAT ACCESSORIES UNIT FUSE BLOCKS WITH ELECTRIC HEAT Unit Model No 0905 090 1025 102 1205 120 1505 Blower Motor Size 2 hp 1 5 kW 2 hp 1 5 kW 2 hp 1 5
52. rical wiring both field and factory installed for loose connections Tighten as required Refer to unit diagram located on inside of compressor access panel 3 Check to ensure that refrigerant lines are in good condition and do not rub against the cabinet or other refrigerant lines 4 Check voltage at the disconnect switch Voltage must be within the range listed on the nameplate If not consult the power company and have the voltage cor rected before starting the unit 5 Recheck voltage and amp draw with unit running If voltage is not within range listed on unit nameplate stop unit and consult power company Refer to unit nameplate for maximum rated load amps 6 Inspect and adjust blower belt see section on Blower Compartment Blower Belt Adjustment B Operation 1 Initiate first and second stage cooling demands ac cording to instructions provided with thermostat 2 First stage thermostat demand will energize compres sor 1 Second stage thermostat demand will energize compressor 2 On units with an economizer when out door air is acceptable a first stage demand will ener gize the economizer a second stage demand will en ergize compressor 1 3 Units contain two refrigerant circuits or stages See fig ure 13 REFRIGERANT STAGES CONDENSER FAN 1 CONDENSER COIL STAGE 2 BOTH FANS ARE ENERGIZED WITH A Y1 DEMAND FIGURE 13 4 Each refrigerant circuit is separately charged with HCFC 22 refrigerant
53. riod dampers will open to DCV MAX when reading is above setpoint regardless of DAMPER thermostat demand or outdoor air suitability DCV MAX BLADES will NOT override damper full open position When an R1 mixed air sensor for modulating dampers is installed DCV MAX may override damper free cooling position when oc cupancy is high and outdoor air temperatures are low If R1 senses discharge air temperature below 45 F 7 C FIGURE 21 dampers will move to minimum position until discharge air temperature rises to 48 F 9 C DAMPER MOTOR B Outdoor Air Dampers THUMBWHEEL Optional manual and motorized outdoor air dampers pro vide fresh outdoor air The motorized damper assembly opens to minimum position during the occupied time peri od and remains closed during the unoccupied period Manual damper assembly is set at installation and re mains in that position See figure 21 Set damper minimum position in the same manner as economizer minimum position Adjust motorized damper position using the thumbwheel on the damper motor See figure 22 Manual damper fresh air intake percentage can be determined in the same manner FIGURE 22 TABLE 19 ECONOMIZER OPERATION OUTDOOR AIR IS SUITABLE FOR FREE COOLING FREE COOL LED DAMPER POSITION THERMOSTAT DEMAND MECHANICAL COOLING UNOCCUPIED OCCUPIED OFF NO CLOSED CLOSED G CLOSED MINIMUM NO OPEN OPEN N Y1 Dampers will modulate to maintain 55 F 13 supply
54. tem If weighing facilities are not available or to check the charge use the following procedure 1 Attach gauge manifolds and operate unit in cooling mode until system stabilizes approximately five min utes Make sure outdoor air dampers are closed 2 Check each system separately with all stages operat ing 3 Use a thermometer to accurately measure the outdoor ambient temperature 4 Apply the outdoor temperature to tables 11 through 17 to determine normal operating pressures 5 Compare the normal operating pressures to the pres sures obtained from the gauges Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system Correct any system problems before proceeding Page 24 6 If discharge pressure is high remove refrigerant from TABLE 15 the system If discharge pressure is low add refriger 1205 NORMAL OPERATING PRESSURES ant to the system e d CIRCUIT 1 CIRCUIT 2 in i Entering Dls 10 Suct 5 Dis 10 Suc 5 Add or remove charge in increments Air Temp Allow the system to stabilize each time refrigerant 65 169 74 176 77 is added or removed 75 195 77 203 79 7 Use the following approach method along with the nor 85 F mal operating pressures to confirm readings 95 F 81 105 F 283 11 115 319 84 340 84
55. th a 24 coil used to energize the indoor blower motor B3 in response to blower demand K3 is ener gized by the MCC board A45 8 Condenser Fan Relay K10 Condenser fan relay K10 is a DPDT relay with a 24VAC coil K10 energizes condenser fans B4 and B5 9 Power Exhaust Relay K65 PED units Power exhaust relay K65 is a relay with 24 coil K65 is used in all TCA units equipped with the op tional power exhaust dampers K65 is energized by the economizer enthalpy control A6 after the economizer dampers reach 5096 open adjustable When K65 closes exhaust fan B10 is energized 10 MCC Control A45 The main control module A45 figure 5 controls all cool ing operation and serves as a staging point for all internal inputs to the appropriate components of the TCA unit The MCC control receives and sends out 24 volts to the com ponents located in the TCA control box economizer and supply return compartments The control communicates to compressors contactors K1 K2 condenser fan relay K10 and indoor blower contactor K3 Thermostat hook ups TB1 and accessory low voltage hook ups TB14 are located on the board See tables 2 and 3 for terminal designations Tables 4 5 and 6 show pin terminal designations Features The MCC A45 is equipped with a green LED for board sta tus See table 1 for LED flash codes While in the cooling mode the board will incorporate AUTO STAGING If the board receives a Y3 demand if ap
56. tputs RPM Range Drive 4 kW kW 2 3 680 925 895 1120 WEE 680 925 895 1120 1110 1395 Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor output required Maximum usable output of motors furnished by Lennox are shown In Canada nominal motor output is also maximum usable motor output If motors of comparable output are used be sure to keep within the service factor limitations outlined on the motor nameplate CEILING DIFFUSER AIR THROW DATA POWER EXHAUST FANS PERFORMANCE Effective Throw Range Return Air System Air Volume Model No RTD11 Step Down FD11 Flush Static Pressure in w g Air Volume Exhausted 0 05 0 10 0 15 0 20 0 25 0 30 0 35 6000 2830 44 54 13 17 40 50 12 15 6200 2925 45 55 14 17 42 51 13 16 6400 3020 46 55 14 17 43 52 13 16 6600 3115 47 56 14 17 45 56 14 17 150 Throw is the horizontal or vertical distance an air stream travels on leaving the outlet or diffuser before the maximum velocity is reduced to 50 ft 15 m per miute Four sides open Page 9 BLOWER DATA ACCESSORY AIR RESISTANCE Wet Indoor Coil MERV 11 Air Volume 090 102 1205 120 1505 Electric Heat Economizer Filter in w g AIR RESISTANCE CEILING DIFFUSERS RTD11 Step Down Diffuser FD11 Flush 2 Ends Open 1 Side 2 Ends Open All
57. uctions for details of proper assembly and mounting The roof mounting FIGURE 16 frame MUST be squared to the roof and level before mount ing Plenum system MUST be installed before the unit is set on the mounting frame Typical roof curbing and flashing is shown in figure 17 Refer to the roof mounting frame installation in structions for proper plenum construction and attachment Page 27 TYPICAL FLASHING DETAIL UNIT BASE BOTTOM UNIT BASE RAIL FIBERGLASS INSULATION Furnished COUNTER FLASHING NAILER STRIP Field Supplied Furnished CANT STRIP Field Supplied RIGID INSULATION Field Supplied MOUNTING FRAME Extends around entire perimeter of unit ROOFING MATERIAL FIGURE 17 B Transitions Optional supply return transitions LASRT08 10 is avail able for use with the TCA 7 5 ton units and LASRT10 12 is available for the 7 5 and 10 ton units utilizing optional LARMF 10 15 roof mounting frames TCA 12 5 ton units will use LASRT15 with LARMF10 15 roof mounting frame Transition must be installed in the LARMF mounting frame before mounting the unit to the frame Refer to the manufacturer s instructions included with the transition for detailed installation procedures C LAOAD M Outdoor Air Dampers LAOAD M 10 15 used TCA090S 150 units consists of a set of dampers which may be manually or motor M oper ated to allow up to 25 percent outside air into the system at all times see fi
58. unit s 24V circuit from the electric heat 24V circuit 9 is energized by main control A45 which in turn energizes timer DL2 2 Time Delay DL2 DL2 is a factory installed solid state timer used in 22 5 to 60 kW electric heat units DL2 is located on the main control panel figure 2 DL2 allows staging by providing a timed interval between the first and sec ond heating elements When the timer is energized the contacts are delayed for 30 seconds before clos ing When the timer is de energized the contacts are delayed 1 second before opening 3 Contactors K15 K16 Contactors K15 and K16 are three pole double break contactors located on the electric heat vestibule All the system contactor K15 is de energized When K15 is de energized first stage and all subsequent stages of heat are de energized For EHA102 150 units the high temperature limit is factory set to open at 170 F 5 F 76 C 2 8 on a temperature rise and automatical ly reset at 130 F 6 F 54 4 C 3 3 C on a tempera ture fall For EHA100 units the limit is factory set to open 160 F 5 F 71 0 C 2 890 a tempera ture rise and automatically reset at 120 F 6 F 49 0 C 3 3 on a temperature fall The limit is not adjustable 5 High Temperature Limit S20 Secondary 520 is a SPST manual reset thermostat Like the primary temperature limit S20 is wired in series with the first stage contactor coil K15 and second stage c
59. ure 6 Two draw through type condenser fans are used in TCA090 150 units All units are equipped with belt drive blowers which draw air across the evaporator during unit operation Cooling may be supplemented by a factory or field installed economizer The evaporators are slab type and are stacked Each evaporator uses a thermostatic ex pansion valve as the refrigerant metering device Each evaporator is also equipped with enhanced fins and rifled tub ing In all units each compressor is protected by a freezestats on each evaporator Low ambient switches S11 S84 and high pressure switches S4 S7 are available as an op tion for additional compressor protection 1 Compressors B1 and B2 090 150 units use two scroll compressors Com pressor capacity may vary from stage to stage In all cases the capacity of each compressor is added to reach the total capacity of the unit See SPECIFICATIONS and ELEC TRICAL DATA table of contents or compressor name plate for compressor specifications WARNING Electrical shock hazard Compressor must be grounded Do not operate without protective cover over terminals Disconnect power before removing protective cover Discharge before vicing unit Failure to follow these precautions could cause electrical shock resulting in injury or death Each compressor is energized by a corresponding com pressor contactor NOTE Refer to the wiring d
60. uto reset SPST N O pres sure switch which allows for mechanical cooling opera tion atlow outdoor temperatures In all models a switch is located in each liquid line prior to the indoor coil sec tion In the TCA090 150 511 and S84 are wired in parallel with outdoor fan relay K10 compressor one When liquid pressure rises to 275 10 psig 1896 69 kPa the switch closes and the condenser fans are en ergized When discharge pressure in both refrigerant cir cuits drops to 150 10 psig 1034 69 kPa the switches open and the condenser fans are de energized This inter mittent fan operation results in higher evaporating temper ature allowing the system to operate without icing the evap orator coil and losing capacity Page 16 C Blower Compartment The blower compartment all TCA090 1508 units is lo cated between the evaporator coil and the condenser coil sec tion The blower assembly is accessed by disconnecting the blower motor See Blower Access in the Operation Adjust ment section The blower pulls out as shown in figure 8 1 Blower Wheels All TCA090 150 units have one 15 in x 15 in 381 mm x 381 mm blower wheel 2 Indoor Blower Motor B3 All units use three phase single speed blower motors CFM adjustments are made by adjusting the motor pulley sheave Motors are equipped with sealed ball bearings All motor spec ifications are listed in the SPECIFICATIONS table of con tents in the front of this manual
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