Trane EBC036 - User Manual

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Summary

Installation, Operation, and Maintenance

Safety Warnings

Critical safety information regarding installation and servicing.

Introduction

Warnings, Cautions, and Notices

Defines safety advisory types and their meanings for user safety.

Personal Protective Equipment (PPE) Required!

Mandates proper PPE for technicians to prevent injury.

General Information

Unit Inspection

Procedures for inspecting the unit upon arrival for damage and correctness.

Precautionary Measures

Essential safety precautions, including handling fiberglass insulation.

System Input Devices & Functions

Sensors

Details high temperature sensors and their applications.

Installation

Unit Foundation

Requirements for proper unit support and foundation, including warnings.

General Unit Requirements

Checklist for successful installation, including wiring and grounding.

Main Electrical Power Requirements

Electrical Phasing (Three Phase Motors)

Pre Start

Electromechanical Controls Test Procedure

Steps for testing electromechanical controls and wiring connections.

Start Up

Compressor Start-Up

Steps for safely starting and verifying compressor operation.

Maintenance

Fan Belt Adjustment-Belt Drive Units

Instructions for inspecting, adjusting, and replacing fan belts.

Monthly Maintenance

Cooling Season

Specific maintenance tasks relevant during the cooling season.

Troubleshooting

Resetting Cooling and Heating Lockouts

Methods for resetting system lockouts after addressing issues.

This document describes the installation, operation, and maintenance of Packaged Rooftop Air Conditioners, specifically the Foundation™ Electric/Electric models, ranging from 3 to 5 tons and operating at 50Hz.

Function Description

These units are designed to provide cooling and electric heating for commercial applications. They are pre-shipped leak-tested, dehydrated, charged with refrigerant and compressor oil, and run-tested for proper control operation. The units utilize direct-drive, vertical discharge condenser fans with built-in thermal overload protection. Capacity control is achieved by starting the Economizer Control Actuator (ECA). The system requires a thermostat input for operation and includes various input devices and sensors to manage its functions.

Important Technical Specifications

Models: EBC036-060 (3 to 5 tons)
Efficiency: ASHRAE 90.1 - 2016
Airflow Configuration: Convertible
Nominal Gross Cooling Capacity (MBh): 036 (3 Tons), 048 (4 Tons), 060 (5 Tons)
Voltage Selection: 380-415/50/3
Unit Controls: Electromechanical
Heating Capacity: Available in 0 (No Heat), A (4.7 kW Electric Heat), B (6.3 kW Electric Heat), C (9 kW Electric Heat), D (12.5 kW Electric Heat), E (15.7 kW Electric Heat).
Fresh Air Selection: 0 (No Fresh Air), A (Manual Outside Air Damper 0-50%)
Supply Fan/Drive Type/Motor: 0 (Standard Motor), 1 (Oversized Motor)
Condenser Coil Protection: 0 (Standard Coil), 4 (CompleteCoat™ Condenser Coil)
Through The Base Provisions: 0 (No Through The Base Provisions)
Disconnect Switch: 0 (No Disconnect)
Refrigerant: R-410A (for Copeland SXA scroll compressors).
Compressor Oil: Trane OIL00094.
Filters: Units ship with 2-inch filters.
Voltage Imbalance: Maximum allowable voltage imbalance is 2 percent. Exceeding this can lead to motor overheating and reduced motor life.

Usage Features

Condensate Overflow Switch (Optional): Mounted on the drain pan, it energizes a relay and opens the 24VAC control circuit, disabling the unit if the condensate level reaches the trip point. A 3-minute delay timer prevents immediate restart.
Phase Monitor: A three-phase line monitor module that protects against phase loss, phase reversal, and phase unbalance. It operates within 190-600 Vac and automatically resets from a fault condition.
Discharge Line Thermostat Control: Wired in series with high-pressure controls to the safety input of the Locking Safety Device (LSD), disabling the compressor contactor coil if activated. It has an automatic lockout.
Locking Safety Device with Anti-Short Cycle Timer: Monitors compressor safety switch trips to prevent short cycling. A manual reset is required after a fourth safety switch trip within a 6-hour period.
High Temperature Sensor (BAYFRST003*): Connects to the Emergency Stop Input on the LTB, providing high-limit shutdown due to fire or high temperatures in air conditioning/ventilation ducts. Return air duct sensor (X1310004001) opens at 135°F; supply air duct sensor (X1310004002) opens at 240°F.
Thermostats:
- TCONT402AN32DA: Multi-stage 3 heat/2 cool, auto-changeover digital display, non-programmable, wall-mounted, suitable for economizer operation.
- TCONT802AS32DA: Multi-stage 3 heat/2 cool, auto-changeover digital display, programmable, 7-day programmable with night setback, wall-mounted.
Occupancy Sensor (Customer-supplied): Can be added for damper control based on occupied/unoccupied conditions.
Crankcase Heaters: Each compressor can be equipped with a crankcase heater to maintain elevated compressor oil temperature during the "Off" cycle, reducing oil foaming during starts and preventing damage. Units must be powered and crankcase heaters energized for at least 8 hours before compressors are started.

Maintenance Features

Periodic Maintenance: Essential for trouble-free operation. A maintenance schedule is provided.
Unit Inspection: Upon arrival, verify nameplate data, power supply compliance, and visually inspect for shipping damage (exterior and internal components). Concealed damage must be reported within 15 days.
Precautionary Measures:
- Fiberglass Wool: Requires wearing all necessary Personal Protective Equipment (PPE) including gloves, eye protection, NIOSH approved dust/mist respirator, long sleeves, and pants during installation, maintenance, or repair to avoid exposure to glass wool fibers.
- Proper Field Wiring and Grounding: All field wiring must be performed by qualified personnel, adhering to NEC and local/state electrical codes to prevent fire and electrocution hazards.
- Personal Protective Equipment (PPE): Technicians must wear appropriate PPE (cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE, arc flash clothing) when working on the equipment.
- EHS Policies: All Trane personnel must follow company EHS policies; non-Trane personnel should follow local regulations.
Storage: Take precautions to prevent condensate formation in electrical compartments and motors if stored before installation or if temporary heat is provided in the building.
Ductwork: Elbows with turning vanes or splitters are recommended. Water-tight flexible connectors should be used at the unit. Outdoor ductwork must be weather-proofed.
Main Electrical Power Requirements: Verify power supply compliance, inspect control panel components, tighten connections, and install proper grounding. Use copper conductors only.
Electric Heat Requirements: Verify power supply compliance, inspect heater junction box and control panel, check electric heat circuits for continuity.
Low Voltage Wiring: Install zone thermostat and connect control wiring. Ensure AC control wiring resistance does not exceed 3 ohms/conductor.
Condensate Drain Configuration: Install a condensate trap and pitch drain lines at least 1/2-inch for every 10 feet of horizontal run to assure proper condensate flow. Do not use PVC glue.
Filter Installation: Units ship with 2-inch filters. Inspect and clean/replace as necessary. Do not operate without filters.
Pre Start Checklist: Verify proper installation, check for shipping damage, correct model/options/voltage, required clearances, roof curb installation, ductwork, rigging, unit levelness, unit-to-curb seal, condensate drain line, filters, and clear interior.
Verifying Proper Air Flow (Belt Drive Indoor Fan): Adjust indoor fan speed by opening or closing the adjustable motor sheave. Set economizer minimum position setpoint to 0% before service test.
Electromechanical Controls Test Procedure: Includes tests for fan, minimum ventilation, economizer cooling, cool 1, cool 2, heat 1, and heat 2.
Compressor Start-Up: Attach service gauges, verify correct rotation (suction pressure drops, discharge pressure rises), and check system subcooling. Do not operate compressor backwards for more than 5 seconds.
Heating Start-Up: Clamp amp meter around heater power wires and verify proper operation of heater stages.
Final System Set Up: Program NSB panel (if applicable), verify remote panel settings, inspect for misplaced tools/debris, and secure all exterior panels.
Monthly Maintenance:
- Filters: Inspect and clean/replace.
- Condensate Overflow Switch: Check float for free movement.
- Cooling Season: Check drain pans for blockages, inspect/clean evaporator and condenser coils, manually rotate condenser fan(s) and check motor bearings, inspect F/A-R/A damper hinges/pins, lubricate damper linkages, check supply fan motor/shaft bearings, check supply belt, verify wire terminal connections, remove/repaint corrosion, and generally inspect for unusual conditions.
- Heating Season: Inspect air filters, supply fan motor bearings, main unit control panel, heat section control box, and verify electric heat system operation.
Condenser Coil Cleaning (Microchannel (MCHE) Coils): Annual cleaning is recommended. Use pressurized water or air ONLY (no greater than 600psi) with a non-pinpoint nozzle. Do NOT use detergents. Approach cleaning perpendicular to the coil face, with optimum clearance of 1"-3".
Troubleshooting: Includes procedures for cooling failure, simultaneous heat and cool failure, and resetting cooling/heating lockouts. Always disconnect electric power before servicing.
Wiring Diagrams: Available via e-Library or technical support.