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Trane BCVC User Manual

Trane BCVC
72 pages
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BCXC-SVX01A-EN
Installation, Operation,
and Maintenance
September 2002
Blower Coil Air Handler
Air Terminal Devices
400 to 3000 cfm
Models BCHC and BCVC
“AO” and later design sequence

Table of Contents

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Trane BCVC Specifications

General IconGeneral
MountingDirect Drive
ModelBCVC
BrandTrane
Voltage115/208-230V
ApplicationResidential/Commercial HVAC Systems

Summary

General Information and Safety

About This Manual and Literature History

Provides context for the manual and lists previous versions.

Warnings and Cautions

Highlights safety precautions and potential hazards.

Special Note on Refrigeration Emissions

Emphasizes environmental responsibility regarding refrigerant use.

Common HVAC Acronyms

Defines frequently used HVAC acronyms and abbreviations.

Installation Procedures

Blower Coil Unit General Information

Describes the design and components of blower coil units.

Blower Coil Model Number Description

Explains how to interpret model numbers for unit options.

Receiving and Handling Procedures

Guidelines for inspecting and handling delivered unit components.

Jobsite Storage Recommendations

Advice on storing units properly at the jobsite to prevent damage.

Rigging and Handling Unit Safely

Instructions for safely lifting and positioning the unit.

Unit Location Recommendations

Guidelines for selecting an appropriate installation location.

Horizontal Blower Coil Dimensions and Weights

Detailed dimensions and weight data for horizontal blower coil units.

Vertical Blower Coil Dimensions and Weights

Detailed dimensions and weight data for vertical blower coil units.

Angle Filter & Mixing Box Dimensions and Weights

Dimensions and weights for angle filter and mixing box accessories.

Bottom or Top Access Filter Box Dimensions and Weights

Dimensions and weights for bottom or top access filter box options.

Electric Heat Dimensions and Weights

Dimensions and weights for electric heat components.

Steam Coil Dimensions and Weights

Dimensions and weights for steam coil boxes and connections.

Hydronic and DX Coil Connection Sizes

Specifications for hydronic and DX coil connection sizes.

Piping Packages Dimensions and Details

Dimensions and details for basic and deluxe piping packages.

Duct Connections Requirements

Guidelines for proper ductwork connection to the unit.

Condensate Drain Connections

Instructions for installing condensate drain piping and traps.

Water Coil Connections

Details on sweat connections for water coils and piping practices.

Piping Packages Brazing Guidelines

Guidelines for brazing piping components to prevent damage.

Refrigerant Coil Piping

Instructions for DX coil piping, including liquid and suction lines.

Field-Installing Evaporator Piping

Detailed steps for field installation of evaporator piping.

Unit Wiring Diagrams and Information

Locating and using unit wiring diagrams for connections.

Supply Power Wiring

Installer's responsibility for providing unit power supply wiring.

Electrical Connections

Describes unit connection points based on control options.

Electrical Grounding Restrictions

Guidelines for proper electrical grounding to avoid noise issues.

MCA and MFS Calculations for Electric Heat

Formulas and tables for calculating electrical circuit requirements.

Motor Electrical Data

Table detailing motor specifications, including FLA and IRA.

Installing the Unit: Horizontal Units

Step-by-step instructions for installing horizontal blower coil units.

BCHC Installation Procedure Details

Specific steps for hanging horizontal units with threaded rods.

Installing the Unit: Vertical Units

Instructions for installing vertical blower coil units on the floor.

Heating Coil Option Adjustment

Procedure for rotating hydronic heating coils for connection changes.

Mixing Box Option Installation

Installation steps for the mixing box accessory.

Mixing Box Installation Procedure

Detailed steps for attaching the mixing box and installing linkage.

Mixing Box Linkage Installation

Procedure for attaching linkage components to the mixing box.

Installing Wall Mounted Controls and Zone Sensors

Guidelines for installing controllers and zone sensors on walls.

Zone Sensor Installation Procedure

Step-by-step instructions for installing zone sensor modules.

Communication Wiring for Tracer ZN Controllers

Guidelines for wiring Tracer ZN controllers for communication.

Zone Sensors Wiring Without Interconnecting

Wiring Tracer ZN controllers directly to the board for service communication.

Unit Startup Procedures

Steps to follow for starting up the unit after installation.

Tracer Controller Communication

Overview of Tracer ZN controller communication capabilities.

Tracer Summit Communication Wiring

Wiring Tracer ZN units for Tracer Summit building management systems.

Pre-Startup Checklist

A comprehensive checklist before initiating unit startup.

Unit Location Considerations

Checks for unit location adequacy and clearances.

Unit Mounting Checks

Verifying unit placement, skid removal, and isolator mounting.

Component Overview Checks

Verifying fan, motor, sheaves, belt tension, and rotation.

Ductwork Pre-Startup Checks

Ensuring ductwork is complete, secure, and conforms to codes.

Unit Piping Pre-Startup Checks

Verifying drain piping, water connections, and leak checks.

Electrical Pre-Startup Checks

Checking electrical connections for tightness and verifying voltage/amperage.

Unit Panel Checks

Ensuring all unit access panels are in place and secured.

Unit Operation

Control Options Overview

Describes available control options for blower coil units.

Control Interface Operation

Details the control interface and its components for thermostat control.

Tracer Controller Options

Information on Tracer ZN010, ZN510, and ZN520 controllers.

Tracer ZN010 Controller

Description of the Tracer ZN010 as a stand-alone controller.

Tracer ZN510 and ZN520 Controllers

Details on ZN510/ZN520 for stand-alone or ICS operation.

Rover Service Software

Overview of Rover service software for configuring Tracer controllers.

Tracer Controller Input/Output Summary

Summary of inputs and outputs for Tracer ZN controllers.

Tracer Controller Function Summary

Summary of control functions available for Tracer ZN controllers.

End Device Option Availability

Shows which end devices are available with each controller type.

Tracer ZN Controller Sequence of Operation

Describes the operational sequence of Tracer ZN controllers.

Tracer ZN Controller Power-Up Sequence

Steps followed when 24 VAC power is initially applied to the controller.

Tracer ZN Controller Modes of Operation

Details the different operating modes for Tracer ZN controllers.

Occupancy Sources for Tracer ZN

Identifies the four ways to control controller occupancy.

Occupied Mode Operation

How the unit operates when in occupied mode.

Unoccupied Mode Operation

How the unit operates when in unoccupied mode.

Occupied Standby Mode Operation

Operation for ZN510/ZN520 in occupied standby mode.

Occupied Bypass Mode Operation

How to place the controller into occupied bypass mode.

Tracer Summit Supply Fan Control

Operation of Tracer ZN controllers with supply fan control via Tracer Summit.

Cooling Operation

How the controller manages cooling capacity based on setpoints.

Economizer Cooling (Tracer ZN520 Only)

How the economizer provides cooling when outdoor conditions are favorable.

DX Cooling Operation (Tracer ZN520 Only)

Controller behavior with DX cooling, avoiding simultaneous economizer use.

Discharge Air Tempering (Tracer ZN520 Only)

Function to raise discharge air temperature when it falls below a limit.

Heating Operation

How the controller manages heating capacity based on setpoints.

Economizer Damper Operation (Tracer ZN520 Only)

How the economizer damper is used for ventilation and cooling.

Dehumidification Operation (Tracer ZN520 Only)

How the controller manages dehumidification using cooling and reheat.

Fan Mode Operation

Describes fan speed selections and configurations.

Fan Speed Switch Operation

How the fan speed switch controls fan operation.

Fan Mode Operation for ZN010 and ZN510

Fan mode sequences for Tracer ZN010 and ZN510 controllers.

Fan Mode Operation for Tracer ZN520

Fan mode sequences for Tracer ZN520 controllers.

Tracer ZN520 Fan Configuration Summary

Summary of fan configurations for ZN520 in heating and cooling.

2-Speed Fan Operation

How 2-speed fans operate with selected speeds and valve cycling.

Continuous Fan Operation

Fan operation during occupied and standby modes.

Fan Cycling Operation

How Tracer ZN520 cycles the fan in unoccupied mode.

Fan Off Delay Function

The 30-second delay after heating output turns off to dissipate residual heat.

Fan Start on High Speed

How fan motors start on high speed for torque.

Fan Operation During Occupied Heating Modes

Describes fan behavior in occupied heating modes for ZN520.

Fan Mode Operation Summary (ZN010/ZN510)

Summary of fan modes for ZN010 and ZN510 in heating and cooling.

Operating Range and Default Setpoints (ZN010/ZN510)

Lists valid operating ranges and default setpoints for ZN010/ZN510.

Local Fan Switch Enable Configuration

Configuration options for enabling or disabling the local fan switch.

Fan Operation in Heating and Cooling Modes

Summary of fan operation based on mode and speed settings.

Two and Four-Pipe Changeover Operation

How Tracer ZN controllers manage changeover using EWT sampling.

Entering Water Temperature Sampling Function

How the controller samples EWT to verify correct water temperature for modes.

Unit Mode vs. Water Temperature

Table relating unit modes to required water temperatures for changeover.

Electric Heat Operation

How Tracer ZN controllers manage electric heat stages.

Economizer Damper Operation (Tracer ZN520 Only)

How the economizer damper is used as a cooling source.

Economizer Damper Position vs. Outdoor Temperature

Table showing economizer damper position based on outdoor temperature.

Tracer Dehumidification (Tracer ZN520 Only)

How the controller manages dehumidification using cooling and reheat.

Data Sharing (Tracer ZN510/ZN520)

Using LonWorks technology for controller data sharing.

Tracer ZN Controller Binary Inputs

Describes the functions of binary inputs on Tracer ZN controllers.

BIP1: Low Temperature Detection

Configuration and effect of the low temperature detection input.

BIP2: Condensate Overflow Detection

Configuration and effect of the condensate overflow detection input.

BIP3: Occupancy Sensor Input

Using occupancy sensors with Tracer ZN controllers.

BIP4: Fan Status Input (ZN520 Only)

Using fan status input with ZN520 controllers.

Binary Input Configurations Summary

Summary of binary input configurations and controller responses.

Tracer ZN Controller Analog Inputs

Describes the functions of analog inputs on Tracer ZN controllers.

Tracer ZN Controller Binary Outputs

Describes the functions of binary outputs on Tracer ZN controllers.

Analog Input Details

Details the function, range, and availability of analog inputs.

Binary Output Configuration Details

Details the configuration of binary outputs for various functions.

Zone Sensor Functionality

Describes zone sensor inputs: temperature, setpoint, fan mode, and buttons.

Space Temperature Measurement

How zone sensors measure space temperature using thermistors.

Local Setpoint Adjustment

Using thumbwheels for setpoint adjustment on zone sensors.

Fan Mode Switch Operation

Selections available on the fan mode switch.

External Setpoint Adjustment

Providing a local setpoint using a 1kW adjustment.

Zone Sensor Fan Switch

How the zone sensor fan switch provides fan request signals.

Zone Sensor On/Cancel Buttons

Using buttons for occupied bypass mode and canceling overrides.

Zone Sensor Communication Jack

Using the RJ-11 jack for communication via Rover service tool.

Zone Sensor Wiring Connections Summary

Summary of zone sensor wiring connections to TB1.

Sensor Resistance Temperature Curve

Graph showing resistance vs. temperature for common sensors.

Maintenance and Troubleshooting

Maintenance Procedures

Routine tasks for maintaining unit performance and longevity.

Air Filter Maintenance

Instructions for inspecting, cleaning, or replacing air filters.

Fan Bearing Maintenance

Information on fan bearing lubrication and maintenance.

Fan Motor Inspection

Guidelines for inspecting fan motors for vibration or temperature.

Sheave Alignment Procedure

Steps for aligning fan and motor sheaves for proper operation.

Fan Assembly Set Screw Checks

Checking and adjusting fan wheel, bearing, and sheave set screws.

Fan Belt Tension Adjustment

How to check and adjust fan belt tension for optimal life.

Coil Maintenance Procedures

Procedures for cleaning and inspecting coils.

Fan, Filter, and Mixing Box General Data

General data for fans, filters, and mixing boxes.

Piping Package Waterflow Limits

Recommended maximum gpm for piping packages to prevent erosion/noise.

Coil General Data

General data for hydronic, DX, and steam coils.

Drive Data for Unit Components

Data related to motor and sheave selections for unit drives.

Steam, Hot Water, and Cooling Coil Cleaning

Step-by-step procedure for cleaning various types of coils.

Winterizing the Coil

Procedure for draining coils to prevent freeze-up.

Periodic Maintenance Checklists

Recommended maintenance schedules for monthly, semi-annual, and annual tasks.

Monthly Maintenance Checklist

Tasks to perform monthly to keep the unit running efficiently.

Semi-Annual Maintenance Checklist

Tasks to perform semi-annually for unit maintenance.

Annual Maintenance Checklist

Tasks to perform annually for unit maintenance and checks.

LED Activity Indicators

Explains the meaning of red, green, and yellow LEDs on the controller.

Red Service LED Meaning

Indicates controller operation status or failure.

Green Status LED Meaning

Indicates if the controller is powered on.

Yellow Comm LED Meaning

Indicates controller communication status.

Manual Output Test Procedure

Procedure to verify output and end device operation.

Resetting Unit Diagnostics

Six methods to reset unit diagnostics.

ZN010/ZN510 Test Sequence Summary

Sequence for testing outputs on ZN010/ZN510 controllers.

ZN520 Test Sequence Summary

Sequence for testing outputs on ZN520 controllers.

Understanding Multiple Diagnostics

How the controller senses, records, and reports diagnostics.

Automatic Diagnostic Reset

Controller's automatic function to restore unit after low temp diagnostic.

BAS Diagnostic Reset (ZN510/ZN520)

Using BAS to reset diagnostics in Tracer ZN controllers.

Rover Service Tool Diagnostic Reset

Using Rover service tool to reset diagnostics in Tracer ZN520.

Diagnostic Reset (ZN510/ZN520)

Devices that can communicate alarm reset to clear diagnostics.

Cycling Fan Switch Reset (ZN520 Only)

How cycling the fan switch resets diagnostics.

Alarm Reset Procedures

Resetting diagnostics via devices that communicate alarm reset.

ZN010/ZN510 Controller Diagnostics Summary

Table summarizing diagnostics and their effects on unit components.

ZN520 Controller Diagnostics Summary

Table summarizing diagnostics and their effects on unit components.

Troubleshooting: Fan Outputs Not Energizing

Probable causes and explanations for fan outputs not energizing.

Troubleshooting: Valves Stay Closed

Probable causes and explanations for valves remaining closed.

Troubleshooting: Valves Stay Open

Probable causes and explanations for valves remaining open.

Troubleshooting: Electric Heat Not Operating

Probable causes and explanations for electric heat failure.

Troubleshooting: Fresh Air Damper Stays Closed

Probable causes and explanations for fresh air damper remaining closed.

Troubleshooting: Fresh Air Damper Stays Open

Probable causes and explanations for fresh air damper remaining open.

Troubleshooting: Valves Stay Closed (Continued)

More causes and explanations for valves remaining closed.

Troubleshooting: DX or Electric Outputs Do Not Energize

Causes for DX or electric outputs failing to energize.

Typical Wiring Diagrams: Two-Pipe BCXB with Tracer ZN510

Wiring diagram for a two-pipe BCXB unit with a Tracer ZN510 controller.

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN510

Wiring diagram for a four-pipe BCXB unit with Tracer ZN510.

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN510 (cont.)

Wiring diagram for a four-pipe BCXB unit with Tracer ZN510 (cont.).

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN520

Wiring diagram for a four-pipe BCXB unit with Tracer ZN520.

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN520 (cont.)

Wiring diagram for a four-pipe BCXB unit with Tracer ZN520 (cont.).

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN520 (cont. 2)

Wiring diagram for a four-pipe BCXB unit with Tracer ZN520 (cont. 2).

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN520 (cont. 3)

Wiring diagram for a four-pipe BCXB unit with Tracer ZN520 (cont. 3).

Typical Wiring Diagrams: Four-Pipe BCXB with Tracer ZN520 (cont. 4)

Wiring diagram for a four-pipe BCXB unit with Tracer ZN520 (cont. 4).

Typical Wiring Diagrams: Four-Pipe BCXB with Control Interface

Wiring diagram for a four-pipe BCXB unit with a Control Interface.

Typical Wiring Diagrams: Four-Pipe BCXB with Control Interface (cont.)

Wiring diagram for a four-pipe BCXB unit with Control Interface (cont.).

Typical Wiring Diagrams: BCXB with DX Coil & Tracer ZN520

Wiring diagram for BCXB with DX coil and Tracer ZN520 controller.

Typical Wiring Diagrams: BCXB with DX Coil & Tracer ZN520 (cont.)

Wiring diagram for BCXB with DX coil and Tracer ZN520 controller (cont.).

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