Total Comfort TC Series Air Handler

Transcription

1 INSTALLATION & OPERATING INSTRUCTIONS Total Comfort TC Series Air Handler NOTICE TO HOMEOWNER THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A QUALIFIED INSTALLER AND WHERE REQUIRED BY LAW, A LICENSED TECHNICIAN. READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING AND/OR OPERATING YOUR SUMMERAIRE TC SERIES AIR HANDLER FOR YOUR SAFETY THIS PRODUCT SHOULD BE INSTALLED AND SERVICED BY TRAINED AND REGISTERED TECHNICIANS ONLY. IF THIS APPLIANCE IS INSTALLED WITH A CENTRAL AIR CONDITIONING UNIT, THE A/C SYSTEM REFRIGERANT CHARGE AND SYSTEM OPERATION MUST BE VERIFIED BY A CERTIFIED/LICENSED MECHANIC. SUMMERAIRE MFG. PETERBOROUGH, ONTARIO Canada, K9J 6X6

2 Table of Contents Important Notes For Installer Introduction Product Description Equipment Selection and Sizing Installation Domestic Water Piping Start-up Procedures Service and Maintenance Troubleshooting Electrical Control Design Detail Horizontal Installation Illustration Temperature Sensor Illustration Upflow Installation Illustration Trouble Shooting Remote Return Air Sensor Installation ECM Fan Motor Connections Wiring Diagram Parts Diagram Parts List Specifications Warranty

3 WARNING This appliance is not intended for installation in a non conditioned space where the potential may exist for the water and or drain lines to freeze. 1.0 IMPORTANT NOTES FOR THE INSTALLER 1.1 A Quick Check List 1. Are the water connections to the water heater oriented in a way to avoid trapping air in the heating circuit? 2. Is the purge valve installed on the return line from the air handler upstream from the isolation valve? 3. Is the air handler hung and isolated to avoid transmitting vibration through framing and duct work? 4. Full port isolation valves MUST be provided. Restrictive valves will limit performance. 5. Is outdoor cooling unit contactor wired to screw terminals on controller to provide hard-start protection? 6. Are thermostat connections correct, including cooling and continuous run connections? 7. Have the packing materials been removed from the blower and the pump? 8. Is there an installation manual for the home owner? 9. Is the unit accessible? Are there clearances for service and component replacement? 10. Is the discharge air stream sensor mounted downstream of the cooling coil? 11. Is the remote return sensor installed upstream of the A/C coil if the A/C coil is in the return air duct? 12. Are the supply plenum and return duct/drop acoustically lined? (at least 6 of the return duct/drop must be lined in addition to the supply plenum). This option ONLY applies to REV5 and higher control designs. Refer to the identifying silk screen on the control board. Also confirm the presence of a connector on the control identified as RETURN AIR. 13. Is the filter cover in place? Is a clean filter in place? Is the supplied filter rack installed? 14. If this appliance is installed with air conditioning, the A/C refrigerant charge and system operation must be verified by a certified/ licensed mechanic prior to commissioning. 3

4 2.0 INTRODUCTION Some of the features described in this manual apply to specific control designs, i.e. A,B,C etc. Refer to the model identifying label on your the control. 2.1 The Total Comfort Series line of air handlers are designed for use with hydronic (boiler) systems, tank-less or on demand water heaters, or in combination space and domestic water heating systems (combo systems or aqua air systems). Combo heating systems use the home s water heater to provide both the space heating and domestic hot water, eliminating the need for a furnace. The Total Comfort Series line of high efficient warm water air handler furnaces are designed to automatically adjust their output size based on the ever changing load of the structure. The automatic adjustments are made in heating as well as cooling. This minimizes selecting an oversized heating appliance just to accommodate the cooling load. The Total Comfort Series is always the right size. 3.0 PRODUCT DESCRIPTION 3.1 Cabinet All cabinets have a tough, durable polyester powder coat pebble finish on satin coat 20 ga. steel 3.2 Heating Coils All heating coils are potable water grade copper suitable for use in plumbing systems. No lead solder is used in any component construction. All coils and internal piping conform to ASTM B-68, B-88 and/or B-743 standards. High density aluminum fins provide maximum heat transfer for small coil surface. 4

5 3.3 Fan and Motor All fans are wide body dynamically balanced for extra quiet operation. Multi-directional sleeve bearing motors allow mounting in any direction for maximum installation flexibility. 3.4 Circulating Pump The circulating pump is matched for maximum performance. Air handlers come with internally mounted pumps for ease of installation. Externally mounted pumps can be added for long runs from the hot water source to the air handler. 3.5 Check Valve A check valve is built into the water pump to protect against backflow of water to avoid short circulating around water heater during domestic water use and protect against thermal siphoning. Check valves (½ ), can have a maximum elevation of 25 (8 metres) above the water heater. Check valves (¾ ) can have a maximum elevation of 50 (15 metres) above the water heater. 3.6 Connecting to a Water Heater Any properly sized gas, propane or oil fired water heater will work in a combo heating system. Make sure the water heater being used is approved for combo applications. Tank-less water heater may reduce the capacity of air handlers due to the higher internal pressure drop. Use only approved and tested air handlers when using any tank-less water heater. Make sure the Tank-less water heater is approved for combo heating. 3.7 Condenser Freeze Protection If the evaporator coil temperature is too low or operating outside of normal conditions, the control will shut off the outdoor condenser for 5 minutes. Evaporator coil freezing can cause slugging at the compressor. Dirty air filters, oversizing of A/C equipment, improper 5

6 A/C installation and commissioning and/or poor duct design may also contribute to evaporator coil freezing. 3.8 Water Refresher If the circulating pump has not run in the previous 24 hours, the control will turn the pump on for 1 minute to flush the lines and heat exchanger. This will help ensure that the water lubricated pumps do not stick during long periods of inactivity. 3.9 Home freeze Protection The TC series air handlers have a built in sensor which will help prevent the home from freezing due to a faulty thermostat. Should the temperature get too low, the control will turn the air handler on automatically and maintain the home at approximately 40 degrees F. Note: this feature will only work if the hot water source is turned on and the air handler has power. While in Home Freeze Protect mode the alarm relay and red light will be on. Refer to page # Alarms Should service problems arise the TC Series will notify the user with an audible alarm and/or, red light that is visible through the front door sight glass, if so equipped. Dry contacts are provided on the controller which can be connected to a warning a light. or home security system. These are identified on the controller as ALM RLY. To temporarily disable the audible alarm for 24 hours, turn the power to the air handler OFF then ON. Refer to page #40. Pause in the OFF position for 5 seconds Set Back Recovery If a setback thermostat is used or incidental increase in temperature is required, the control will ramp the air handler quickly to maximum output to recover, then the next cycle will run at normal size. 6

7 3.12 Indicators A bicolor LED indicator is included and is used to indicate alarm, test mode, and normal operation. The indicator will display temperature readings of the sensors during normal operation. Refer to Trouble Shooting & Operation Guide located at the back of this manual Test Mode A push button will allow the installer a 20 minute window to set up the TC Series air handler for cooling and heating mode. After 20 minutes the unit will return to normal operation. Pushing the test button before the 20 minutes is completed, will return the unit to normal operation. For this sequence to be operational, the door safety switch will have to be bypassed before activating the test switch. Once activated, the front covers need to be installed. Be certain to restore the door safety switch to a functional state prior to commissioning this appliance Main Control Beeper Alarm In the event of a temperature sensor failure, page 16, too low of an ambient temperature, page 35 or if cooling lockout, page 17, has been initiated, the alarm beeper will sound. Beeper can be silenced for 24 hrs only by turning power OFF and back ON. Beeper will continue to sound after 24 hrs of power on until fault condition is corrected with the exception of cooling lockout where the beeper will always be active. Provide minimum of 5 seconds during power off time for the controller to reset Dehumidifying / Cooling The Total Comfort TC Series air handlers use a modulating blower fan to regulate the amount of humidity. When humidity is high the blower fan runs slower to provide rapid removal of moisture. When conditions are normal the fan speeds up to provide optimal cooling. The balance between 7

8 dehumidifying and cooling is always met. By maintaining optimal humidity levels the home owner can set cooling temperatures higher, thus saving on electrical costs as well as improved comfort. This also helps to prevent mould growth by targeting a 50-55% relative humidity Heating The strategy in heating is to allow the TC Series air handler to change output to match the loss. By automatically changing fan and pump speeds, the output of the air handler can be increased or decreased to match the loss of the home. This provides better comfort for the occupants as the longer run times provide less stratification and improved air filtration Customizing The cooling and heating features can be field customized to provide maximum comfort for almost any home or location. Refer to page 29 and EQUIPMENT SELECTION AND SIZING Proper sizing of systems components is crucial for proper operation. 1. Obtain room by room heat loss and/or heat gain 2. Determine heating water temperature 3. Determine duct layout Make sure a proper room-by-room heat loss and heat gain for the dwelling is calculated using Manual J, HRAI, ASHRAE or other approved sizing method. 5.0 Installation 5.1 The installer shall adhere to all local, state and national code requirements pertaining to the installation of this equipment. 5.2 The TC Series air handler can be mounted in most directions. Upflow, horizontal left and horizontal right. You cannot install the air 8

9 handler on it s back or suspended with front cover facing down. Adequately sized drain pan and drain connection must be installed under this appliance. This appliance shall not be installed in a non conditioned space where the potential may exist for the appliance and or water lines and drain line to freeze. 5.3 The return air can ONLY be installed in the bottom of the cabinet in horizontal installations. DO NOT install the return air in the bottom of the cabinet in vertical installations. To do so will not permit the installation of the required drain pan and drain. 5.4 The air handler can be suspended by securing straps to the corner ¼ - 20 machine screws provided. Do not install your own screws as damage to the heating coil may occur. Install the air handler with the door screwed in place to avoid racking of the cabinet. The Installing contractor must ensure that suspension materials are sized and installed to provide sufficient support to the air handler and connected accessory fittings and materials. 5.5 Provide at least 2 feet ( 0.75 meters) of clearance from the front of the cabinet for service and maintenance. Zero clearance is acceptable on the other sides. 6.0 Domestic Water Piping 6.01 A webstone ball valve with drain/purge valve must be installed. The drain valve must be located downstream of the pump and check valve, and upstream of the isolation valve (if isolation valve is present). With this arrangement, any air trapped in the system can easily be flushed out following the instructions in the Start-up & Troubleshooting sections Isolation valves are recommended. Installing isolation valves facilitates easy servicing and ensures positive purging of the system during startup. 9

10 6.03 For combo systems all joints in copper pipe must be lead-free solder. All piping must be suitable for potable water use Maximum pipe lengths for all TC series air handlers should be 24 feet for 1/2 piping or 120 ft for 3/4 piping. Pipe lengths indicated are actual lengths. Allowance has been made for a reasonable number of valves and fittings. For distances that are greater, a second circulator may be added or pipe size may be increased in diameter When both top and side connections are provided on the water heater, the side connections should be used for the space heating loop When the space heating loop connections are made to the domestic water connections. The heating loop connections should be positioned horizontally in a vertical section of the domestic water line for both inlet and outlet. Refer to the piping schematic for details. Connect the heating loop to the domestic water connections as close to the water heater as possible Avoid sections of pipe in the heating loop that can trap air where possible. It is usually impossible to install a system, without having at least one part of the system or heating coil able to trap air. This will not be a problem if the connection to the domestic water lines is made properly, and the system is properly purged on setup: The circulating pump is capable of removing small amounts of entrained air from the heating loop. Following the flushing procedures in the Start-up section will ensure that there is no air in the system after initial set-up. Proper connections between the domestic water lines and the heating loop will ensure that any air that collects in the water tank, does not make its way into the heating loop If connected to a water heater, air bleed valves at high points of the heating system are not required and NOT recommended. 10

11 6.1 Anti-Scald Valve Anti-scald valves are not required for normal operation, but may be used for installations where the local, state, or national code demands it or the home owner wishes a lower domestic water temperature than 140F (60C). It is not recommended that anti-scald valves be installed unless required. If an anti-scald device is to be installed, it must comply with ASSE standards no and Boiler Piping Use a primary, secondary piping arrangement to de-couple the flow through the boiler from the flow through the air handler. Make certain the supply and return connections for the air handler heating loop are not more than 4 pipe diameters apart. Make certain the supply connection is upstream of the return connection for boilers operating at or below 160F (71C). Maximum length of piping to and from the Air Handler shall be as per paragraph Water Heater or Boiler Follow the manufacturer s instructions for installation and start-up of the water heater or boiler. Make sure the heating device is turned off during air handler installation and service. Ensure system has been refilled, and all air is purged from the system before turning on the heating device. 6.4 Duct Work All duct designs must be designed to conform with ARI Manuals J and D or local codes and requirements. To minimize fan noise in the living space, it is recommended that the first six feet of supply and return air duct be lined with acoustic insulation. Return and supply air duct work should be the same size as the air handler openings up to the first branch, fitting or transition. 11

12 7.0 START-UP PROCEDURES Refer to Installation Notes page 3 and Prestart checklist page 37. Do not start the air handler or water heater until ALL Air has been purged from water lines and air handler pump! 1. Fill the boiler loop or water heater with water, but do not start it. 2. Purge all air from the heating boiler or domestic hot water system. 3. Purge all air from the space-heating loop by closing the isolation valve on the return leg of the loop and open the drain to purge air. Open the return leg isolation valve and then close the drain valve. 4. Start the boiler or water heater according to the manufacturer s instructions. Set the design water temperature and wait for the system to shut off. You can check that the water heater is set properly by running hot water from a faucet into a glass. Using a thermometer measure the temperature of the water as soon as the water heater burner shuts off. If the set-point temperature is too low or is above 140F, reset the tank control, run water until the burner starts again and repeat the measurement. 5. Turn on the power to the air handler and set the room thermostat for heat to energize the fan and pump. If a gurgling sound is present, it should subside within one minute. If noise is still present after one minute, repeat step 3 to purge air as necessary. 6. Check supply and return pipes for temperature differences to make sure there is flow. There should be a noticeable difference in temperature between supply and return lines. Warning, use caution when supply water temperature is above 120 degrees F. 12

13 8.0 SERVICE AND MAINTENANCE 8.1 Filter The TC Series of air handlers are provided with a disposable filter media. This filter should be inspected monthly and removed and replaced as required. 8.2 Coils Air conditioning and heating coils should not require cleaning if the filter maintenance schedule is adhered to. If a filter is damaged or collapses from plugging, dust may foul the coils. If this happens, replace the filter and carefully vacuum the heating coil. 8.3 Pump The circulating pump is water lubricated and should require no regular maintenance. The system control has a cycle timer to exercise the pump even during prolonged periods of no heat to avoid seizing from long idle periods. 9.0 TROUBLESHOOTING 9.1 Pump does not run In areas where hard water is present the pump may stick and fail to run. Often, closing the isolation valve on the return leg and opening the drain port so that water flows through the pump can free this. For Grundfos pumps, remove the screw-on cover from the face of the pump, and rotate the shaft one turn with a slotted screwdriver. If either method fails to free the pump, removal for cleaning or replacement is necessary. The daily pump exercise will help prevent pump sticking. 13

14 9.2 Pump is noisy at start-up Air is present in heating loop. If sound has not diminished within 1 minute, purge air in accordance with the Start-Up procedures. If heat source is a water heater, check to make sure branch connections for heating loop are horizontal to prevent the collecting of air in the heating loop. 9.3 Water heater T&P is weeping A check valve or back-flow preventer may have been installed in the system. Some form of pressure relief may be required. Options are: - Install expansion tank ( potable water safe ) - Install pressure relief valve; locate outlet over laundry tub or floor drain. - Install combination toilet tank/pressure relief valve. 9.4 Cold water at hot faucet When heat source is a water heater, the most probable cause is reverse flow through the heating loop from the stuck check valve; repair or replace valve. 9.5 Insufficient or no heat Plugged air filter or coil. Refer to Maintenance section for filter care and coil cleaning Tank-less water heater inlet filter plugged. See manufacturers instructions Air in heating loop; purge system Inlet and outlet connections to air handler backwards; reverse connections Water heater supply tube (dip tube) is restricted or damaged; check and/or replace. Tank style water heaters only. 14

15 9.5.6 Supply water temperature set too low or not calibrated properly; check water temperature. In the case of water heater; If the temperature has been set too low because of homeowner preference, it may be necessary to install and anti-scald valve to control the faucet temperature and raise the operating temperature of the water heater Restriction in heating loop; remove restrictions, check valves stick, valves too restrictive, left partially closed after purging or closed valve Water heater supply temperature is unstable. Check water heater setting and temperature sensors for good contact on coil headers. 9.6 Fan runs for cooling but not for heating - Room thermostat may be connected improperly. 9.7 Heating during Standby mode Probable cause is thermal Siphoning. See check valve description for details; repair or replace check valve. Check elevation of the air handler above water heater to see if motorized valve required for positive shut-off Electrical 10.1 Warning! Make sure unit is properly grounded. Locate air handler on a separate circuit. All TC Series Air Handlers that use PSC (permanent split capacitor) motors operate on 230v / 1 ph / 60hz 3 wire plus ground line voltage. All controls are 24 volt. The TC series of air handlers that use DC (ECM) motors are 120/1/ Thermostat Most standard heat/cool, setback, or electronic thermostats are compatible with the TC Series Air Handlers. Thermostat wire from the thermostat is connected to the screw terminals located on the control board inside the air handler. They should be connected as follows: 15

16 RH, RC power ( 24vac ) W heating Y cooling ( if present ) G continuous run fan ( if present on thermostat ) NOTICE: A/C condensor must be connected to position AC relay -Y-C only Electrical Information Air handler wiring diagrams are located on the inside of the access panel for reference during installation and servicing. Name plate data is located on the front access panel Cooling Sensor When the cooling evaporator coil is installed above (downstream) the air handler, the cooling sensor must be installed downstream of the coil approximately inches and located in the main part of the air stream. The sensor can be attached to a heavy gauge wire or metal coat hanger to support it. When then cooling coil is located upstream on the return air side of the air handler, an optional remote return air sensor must be installed in the return air stream, upstream of the A/C coil. Refer to page 25 and CONTROL DESIGN DETAIL 1.1 TEMPERATURE SENSORS: The Air Handler Control includes five temperature sensors. Temperature sensors are 3-wire devices that are connected to the control board with a three pin connector allowing field replacement of individual sensors. In the event of a sensor failure for longer than 2 minutes, the alarm beeper will sound 2 beeps every 8 minutes after 24 hours of continuous power on. Refer to page # FAN SPEED CONTROL: The fan speed control is designed to support up to 3/4HP 230VAC fan 16

17 motors. Fan speed will be automatically controlled if moduation is selected. The fan will optionally be a two-speed fan with a high-speed winding and a low-speed winding. 1.3 PUMP SPEED CONTROL: The pump speed control will be designed to support up to 5 amp 115VAC pump motors. Pump speed will be controlled to one of 3 Speeds. 1.4 RELAY CONTROLS: Air Conditioning Relay (24VAC) The Air Conditioning relay is on when the A/C cooling function should be active. It is a 24VAC signal that will energize the A/C power contactor Fan Relay (115VAC 5A Max dry contact) The fan relay is on at any time the fan is running. The relay presents a contact closure that may be used to activate external air cleaners, humidifiers, etc that should be active while the fan is running Heat Relay (115VAC 5A Max dry contact) The heat relay is on when the thermostat calls for heat Alarm Relay (115VAC 5A Max dry contact) The alarm relay provides a dry contact closure that is used to indicate an alarm condition. The contacts are closed during an alarm condition. The alarm relay contacts may be used to activate an external device to alert the user that an alarm condition exists. Alarm conditions include: Heat exchanger freeze protection limit exceeded Return air temperature is too low Exhaust air temperature is too cold Control in cooling lockout Refer to page # 40, Illuminated Alarm indicator. Should your unit be equipped with two sight glasses in the front fan door, the left hand 17

18 sight glass provides visual observation of the RED alarm indicator Cooling Lockout If a freeze protect cycle (Section 1, 5, 6) is initiated 3 times within a single cooling cycle, the system goes into cooling lockout mode. The cooling cycle in stopped and new cooling cycles are inhibited. The alarm relay is turned on. Refer to page # 40. This condition can be terminated by cycling the power OFF then ON. While in cooling lockout mode, the control LED will flash RED,RED,RED. The alarm beeper will beep 4 beeps every 8 minutes 1.46 High A/C Coil Delta (applies to control designs CM68E and higher) During a cooling sequence the air temperatures before and after the A/C coil are monitored. Should this temperature exceed 20 degrees F the fan speed will be increased until the delta is reduced to 20 F. Should the fan speed reach maximum speed and the delta continue to be too high, the A/C will be turned off and the fan will continue to run until the delta is reduced. Cooling sequence will then be restarted. If the A/C delta is exceeded 3 times within a single cooling cycle, the alarm relay red light will be turned on. Refer to page # 40. The control LED will flash GREEN, RED,RED. 1.5 CONTROL INPUTS: Heating Control A 24VAC input is provided to control the heating function. When the thermostat calls for heat 24VAC is applied to the W contact and a heating cycle will be initiated. NOTE: the heating cycle control will be ignored while a cooling cycle is in progress. If the heating control is turned off during the initial heat exchanger warmup or during the fan cycle up to speed period the heat mode will be terminated without an end of cycle fan period Cooling Control A 24VAC input is provided to control the cooling function. When the thermostat calls for cooling 24VAC is applied to the Y contact and a 18

19 cooling cycle will be initiated. NOTE: the heating cycle control will be ignored while a cooling cycle is in progress. If the cooling control is turned off during the fan cycle up to speed period the cool mode will be terminated without an end of cycle fan period Thermostat Fan On/Auto Control The 24VAC Thermostat Fan On/Auto input will select the fan operation. When the control is in the Auto state the fan will be off while not heating/cooling. In the Fan On state the fan will run at the lowest speed while not heating/cooling. During a heating cycle the fan is always off during the initial heat exchanger warmup period Supply Water Temperature The sensor is mounted at the supply end of the water heat exchanger Return Water Temperature The sensor is mounted at the discharge end of the water heat exchanger Freeze Protection Temperature The sensor is mounted above the water heat exchanger to detect freezing temperatures from the A/C evaporator coil that could damage the water heat exchanger. The exhaust air is also monitored during cooling mode. If the freeze protection sensor, or the discharge air temperature sensor record readings below the values stated in the Variable Table on page # 22, the unit will go into freeze protect mode. In this mode the pump and fan will be running either at low speed or at the current speed if heating/cooling is in progress. The A/C relay will be turned off. After 5 minutes the freeze mode will end and the unit will resume normal operation. If the conditions reoccur freeze mode will resume. The control LED will flash RED,RED,GREEN. The alarm relay and red light is turned on. Refer to page # A/C Discharge Air Temperature The sensor must be installed in the discharge air path of the Air Handler, downstream of the Air Handler and/or Air Conditioning assembly. Refer to page

20 1.5.8 Return Air Temperature A return air temperature sensor is required. The factory supplied sensor is mounted on the board. It is approximately 3 long. An optional remote return air sensor is required when the A/C coil is installed upstream of the Air Handler in the return air duct. This is approximately 10 Ft. long. When the remote sensor is used the board mounted sensor must replaced with the longer sensor. And installed in the duct air stream, up stream of the Evap coil Ambient Temperature This sensor is provided as an option. Note that this sensor is ONLY compatible with control design part number CM68D and higher. Refer to the label on the control to identify your control. Refer to page # System select dipswitch The control board dipswitch will allow the selection of models and customer setup options. Refer to page 33. Max heat temperature The return air temperature will be monitored for unreasonably high values. When the upper limit is reached the unit will override the thermostat and maintain the temperature at the set value. The value may be selected as 75,80,85,90. Refer to Table 1 (page #29) for switch positions. Min cooling temperature - The return air temperature will be monitored for unreasonably low values. When the lower limit is reached the unit will override the thermostat and maintain the temperature at the set value. The value may be selected as 72,70,68,65. Refer to Table 2 (page #29) for switch positions. The switch may also be set to select 6 different system configurations. Refer to page

21 1.6 INDICATORS: A bicolor LED is included used as a system status indicator to indicate alarm, test mode, normal operation, etc. The indicator will display the temperature sensor values during normal operation. When abnormal behavior is noted the LED will display an indication to indicate the condition. Refer to Trouble Shooting & Operation located at the back of this manual. During normal mode the LED will blink to indicate the temperature reading of the five sensors. The LED will blink red to indicate the sensor number, then will blink the temperature in green. Example, while sensor number 3 is reading 24degC the LED will blink red 3X then green 2X then green 4X then red 4X followed by the reading for the next sensor. If a sensor has a bad read, or is not functioning the LED will blink red 8X 8X rather than the green temperature reading. One should cycle through the sensors cycle at least 3 times to confirm whether or not a sensor is bad. 1.7 CONNECTORS: Thermostat connections there are four connections to go between the thermostat and the control board. The connections are for the W,Y,G, and RH connections. NOTE: the RH and RC connections must be connected together on the thermostat. Refer to wiring diagram page 34 Relay connection- The A/C relay connector is two connectors that are connected to the AC relay contactor. When the A/C relay is on 24VAC is supplied to turn the contactor on. The Heat Relay is on when the thermostat calls for heat. The connector is a two terminal connector that provides a contact closure when the Heat Relay is on. The contacts will support up to 24VAC at 2 Amps. The Fan relay is on when the fan is running at any speed. When the fan is off the relay is off. The connector is a two terminal connector that provides a contact closure when the fan is on. The contacts will support up to 24VAC at 2 Amps. 21

22 Alarm Relay is on when an unusual condition is detected. The connector is a two terminal connector that provides a contact closure when the Alarm Relay is on. The contacts will support up to 24VAC at 2 Amps. TO BE USED WHEN THE A/C COIL IS UPSTREAM (IN THE RETURN AIR DUCT) OF THE AIR HANDLER The board mounted return air sensor may be replaced by a sensor that is remotely mounted. When the remotely mounted sensor is used, the board-mounted sensor is removed from the board and replaced with the optional 10 Ft. sensor. The replacement remote sensor is connected to the board terminal provided, labeled as RETURN AIR. Sensor must be inserted into the return duct upstream of the A/C coil. Refer to Page SOFTWARE DESIGN DETAILS Variable Table System M4 M5 T2 T3 T5 T6 T9 T10 T11 T12 T Temperatures shown above are in Degrees Celsius System M4 M5 T2 T3 T5 T6 T9 T10 T11 T12 T Temperatures shown above are in Degrees Fahrenheit Heading Description 22 M4 - M5 - T2 - T3 - T5 - T6 - T9 - T10 - T11 - T12 - T15 - Maximum Heat Cycle Time in Minutes Minimum Heat Cycle Time in Minutes Maximum Discharge Air Temperature During Cooling Minimum Water Out Temperature to Start Heat Cycle Maximum Water Delta T Minimum Water Delta T Minimum Discharge Air Temperature During Cooling Minimum Water In Temperature Minimum Discharge Air Temperature During Heating Water Coil Freeze Protection Low Limit Temperature Discharge Air Freeze Protection Low Limit Temperature

23 2.1 FAN STARTUP At the start of a heating/cooling cycle the fan will step from the off speed to the initial speed with one step every 15 seconds. The off speed is set by the Fan On/Auto setting. When switching from off a brief period of full speed will be used to start the fan. 2.2 WATER REFRESHER If the water circulating pump has not run for 24 Hrs, the pump will run at low speed for one minute to flush the water in the heat exchanger. 2.3 HEATING MODE CONTROL: When thermostat changes off to on: Initially Pump Speed is high, Fan Speed is off. Wait for heating coil to warm up. If water out is less than T3 value in the variable table after 3 minutes, turn pump off and wait 5 minutes, then restart heating cycle. When water out temperature is greater than T3, then Fan Speed = Low, and Pump Speed = Low. Start heating when coil warm using previous settings. If thermostat is off before reaching the run mode the heating cycle is canceled. If the hot water input temperature drops below a minimum value for heating during the heating cycle, assume the the hot water has been used up by another appliance. Discontinue the heating cycle, wait five minutes and then restart the heating cycle. Every minute, if water in temperature is less than T10 value in variable table, discontinue the heating cycle. Wait 5 minutes and restart the heating cycle. After 2 minutes turn fan off. If the thermostat goes back on before this timeout, the heating cycle is resumed. 23

24 NOTICE: A FIELD FABRICATED AUXILARY DRAIN PAN WITH DRAIN PIPE IS REQUIRED IN ALL CONFIGURATIONS. Horizontal Installation NOTE: Field selected suspension materials must be sized by installing contractor so as to be of sufficient strength to support Air Handler weight of 100lbs. and connected accessory fittings and materials. Minimum 1 X 1 X 1/8 angle Return air opening shall not be installed in the back panel. NOTE: Return air opening must be cut out to knockouts provided. Minimum return air opening size, 18 X 18. Suspend Air Handler via factory installed 1/4-20 hanging screws. Both screws at each corner must be secured to suspension angle. Four places. 24

25 NOTICE: A FIELD FABRICATED AUXILARY DRAIN PAN WITH DRAIN PIPE IS REQUIRED IN ALL CONFIGURATIONS. Temperature Sensor and Low Voltage Lead Routing A/C Coil installed downstream of Air Handler in return plenum Drill 3/8 dia. hole in warm air duct a minimum of 15 downstream of plenum. Discharge and return sensor lead shall be routed out of air handler casing through knock-out provided in either side of casing and secured to plenum using nylon clips provided. Snap round bushing into hole and insert sensor lead approximately 2 and secure to duct using nylon strap included. Discharge sensor lead and low voltage lead wires shall be isolated from high voltage leads and routed through knockouts provided. FOR HORIZONTAL INSTALLATION OVER A FINISHED SPACE, A FIELD FABRICATED AUXILARY DRAIN PAN WITH DRAIN PIPE IS REQUIRED TO PREVENT DAMAGE BY OVERFLOW DUE TO BLOCKED CONDENSATE DRAIN. Temperature Sensor and Low Voltage Lead Routing A/C Coil installed upstream of Air Handler in return plenum Refer to Remote Return Air Sensor Installation at the back of this manual for sensor removal information Remove 3 In. temperature sensor from control and install optional 10 ft. sensor on control board Drill 3/8 dia. hole in wa air duct a minimum of 15 upstream of plenum. Snap round bushing into hole and insert sensor lea approximately 2 and secure to duct using nylo strap included. Air Filter A/C Coil Discharge sensor lead shall be routed out of air handler casing through knockout provided in either side of casing and secured to plenum using nylon clips provided. Discharge sensor lead and low voltage lead wires shall be isolated from high voltage leads and routed through knockouts provided. 25

26 NOTICE: A FIELD FABRICATED AUXILARY DRAIN PAN WITH DRAIN PIPE IS REQUIRED IN ALL CONFIGURATIONS. Upflow Installation Caution: Return air openings shall not be installed in black panel. Return air openings must be cut out to knockouts provided. Minimum return air opening shall be 18 X

27 Trouble Shooting & Operation Flashing LED: During normal operating mode the LED will blink to indicate the temperature reading of the five sensors. The LED will blink RED to indicate the sensor number. It will then blink the temperature in GREEN. All temperature readings are in Celsius. (See chart to convert Celsius to Fahrenheit). Example, while sensor number 3 is reading 24degC the LED will blink RED 3X then GREEN 2X then GREEN 4X then RED 4X followed by the reading for the next sensor. If a sensor has a bad read, or is malfunctioning, the LED will blink RED 8X-8X rather than the green temperature reading. This 8X blink may repeat. Be sure to cycle through all sensors at least three times to determine is a sensor is faulty. LED flash code will indicate the sensor location in RED and temperature in GREEN. Eg. 2RED then 2GREEN, pause, 4GREEN = Sensor # 2 is 24degC or 75F An 8RED then 8RED flash indicates a bad reading or defective sensor, this may repeat several cycles. Sensor 5 = Remote/ Integral Return Air Sensor 1 = Supply Water In Sensor 2 = Return Water Out Sensor 3 = Freeze Protection Sensor 4 = Discharge Air Note: If a defective sensor is present, the audible alarm will sound. F = C (9/5) + 32or F = C x eg. 24 x 1.8 = = 75.2 F Sensor 1 should see GREEN flashes of 4GREEN 3GREEN (43C = 110F) to 8GREEN 2GREEN (82C = 180F) depending on the temperature of the hot water source. 27

28 Sensor #2 should see the same as sensor #1 on start-up. As soon as the fan starts, sensor 2 should see readings of about 25F less than sensor 1. With 120F (49C) to 180F (82 C) entering water the reading would be 3GREEN 6GREEN (36 C) to 7GREEN 1GREEN (71 C), after the correct number of red flashes to indicate the sensor #. Control LED flash Codes (applies to control designs CM68E and higher) A visual display is provided by the control mounted LED. During normal operation this LED will display temperature sensor identification and readings in degrees C, refer to page # 27. This display also advises of the current status of the air handler behavior and its environment should unusual conditions exist. Refer to the chart below. When multiple flash codes are being displayed, they will be displayed in the following order. Flash Code Explanation Cause RRR Cooling Lockout Page # 18 RRG Freeze protect cycle in process Page # 19 GRR A/C Delta exceeded 3 times Page # 18 RGR High A/C coil delta Page # 18 RGG Low ambient temperature Page # 20 R = Red G = Green Alarm: Alarm Relay is on when an unusual condition is detected. The connector is a two terminal connector that provides a contact closure when the Alarm Relay is on. The contacts will support up to 24VAC at 2 Amps. The alarm beeper may be silenced for 24 hours by turning power to the unit off and then on. If the condition still exists after 24 hours the alarm will be activated again. It can be silenced again by turning power to the unit off and on. An alarm condition does not mean the unit is not working, it just means the information the control 28

29 is receiving does not meet specifications. These conditions could be cool supply water, discharge air temperature too cold, room air too cold, etc. The alarm will shut off when the condition is corrected. Note: There must be 1 sensor on all 4 inputs in the proper locations. If A/C coil is in the return air plenum then the return air sensor identified as U5 on the control board must be removed from the control by snipping its three leads and a new OPTIONAL return air sensor MUST be installed on the board at the RETURN AIR receptacle with the sensor lead end located 15 upstream of the A/C coil in the return air duct. Refer to page # 34. The discharge air sensor (supplied) shall be installed downstream of the heating coil in the supply air ductwork and attached to the DISCHARGE AIR receptacle location on the control. The following beeper/alarm sequences apply to control models CM68E and newer. Alarm Buzzer is active every 8 minutes under the following conditions: Number of beeps 1 beep Surrounding Ambient temperature too low page # 35 2 beeps Failed temperature sensor page # 27 4 beeps Cooling Lockout enabled page # 18 Alarm relay and red indicator light (if so equipped) are on under the following conditions: 1) Coil freeze protect cycle in process page # 19 2) Cooling Lockout cycle is active page # 18 3) Installed environment ambient temperature too low page # 20 4) Home freeze protect cycle active page # 6 5) High A.C delta, exceeds 20 F 3 times in a single cooling cycle. page # 18 Dip Switch Settings The dipswitch will allow the selection of custom setup options. Refer to Variable Table for system options. NOTE, this feature is only available on control with identifying labels bearing part number X- BOARDCM68A or have a higher letter designation. 29

30 Max Heat Override Table 1 The return air temperature will be monitored for unreasonably high values. When the upper limit is reached the unit will override the thermostat and maintain the temperature at the set value. The value may be selected as 75, 80, 85, 90. Min Cooling Override Table 2 The return air temperature will be monitored for unreasonably low values. When the lower limit is reached the unit will override the thermostat and maintain the temperature at the set value. The value may be selected as 72, 70, 68, 65. Relays: When the A/C relay is on, 24VAC is supplied to turn the contactor on. The Heat Relay is on when the thermostat calls for heat. The contacts will support up to 24VAC at 2 Amps. The heat relay is active only on a call for heat. The Fan relay is on when the fan is running at any speed. When the fan is off the relay is off. The connector is a two terminal connector that provides a contact closure when the fan is on. The contacts will support up to 24VAC at 2 Amps. 30 Table 1 S1 S2 Max heating override Off Off 90F(32C) On Off 85F(29.5C) Off On 80F(26.5C) On On 75F(24C) Table 2 S3 S4 Min cooling override Off Off 65F(15.5C) On Off 68(20C) Off On 70F(21C) On On 72F(22C)

31 Start-up: Do not power the unit until the water supply has been connected and the system purged of air. (See instruction manual). The circulating pump may come on at anytime. No water = damaged circulating pump and NO WARRANTY. A water refresher cycle is built-in on power-up. If the circulating pump has not run in the last 24 hours, the pump will run for 1 minute to purge the coils of stagnant water. This will happen even during the cooling cycle. Normal Operation: Heating Mode: On a call for heat from the thermostat, if fan is on it will turn off, and the circulating pump will turn on to high speed. The water inlet and outlet sensors are looking for a minimum temperature of 111F or 44C (1RED 4GREEN- 4GREEN). Once temperature is reached then the fan will turn on and the fan relay will be energized. The unit will run at the last parameter set until a) the call for heat exceeds 14 minutes, or b) is satisfied in less than 10 minutes. If longer than 14 minutes then circulating pump and blower will increase speed until they reach high speed. They will remain at high speed until the call is satisfied. Once the thermostat is satisfied, the circulating pump will shut down and fan will continue to run for 2 minutes. During the run cycle the sensors are making multiple adjustments to the pump and blower fan speeds to maintain high delta T and delivered air temperature above 95F or 35C (4RED- 3GREEN- 5GREEN) minimum. Cooling Mode: Applies to control designs CM68E and higher letter designations. On a call for cooling from the thermostat, if the fan is on, it will turn off and the A/C relay will be energized. The outdoor condenser will turn on and flood the evaporator coil with refrigerant. The fan will turn on and deliver cool air to the system. After approximately 5 minutes (this gives the condenser and coil time to normalize pressures), the microprocessor control will cause multiple fan speed adjustments in order to target the latent load first (humidity) before speeding up to 31

32 capture the sensible load. Sensor feedback allows this enhanced blower fan feature to protect the outdoor unit from refrigerant slugging caused by lower fan speeds, dirty filters, poor duct design or poor installations. By targeting humidity levels of 50% to 55 maximum comfort can be obtained for the structure while protecting the A/C system from freezing. Should coil temperatures drop outside of safe design parameters, fan speed will be increased to correct the coil temperature. Should the coil temperature delta continue to rise, the A/C will be turned off and the fan will continue to run to correct the delta. Once the delta is within a reasonable range, the cooling sequence will be enabled. The outdoor unit will be interrupted for 5 minutes while the fan continues to run and the pump turns on to circulate hot water to defrost the evaporator coil. Fan speeds may run as low as 300 cfm per ton to as high as 500 cfm per ton. This enhanced blower operation is continuous and automatic as long as the sensors have been installed correctly. Once the thermostat has been satisfied, the outdoor unit will turn off and the blower will continue for 2 minutes, to purge the ductwork. If the fan is set to on, it will now go back to the low fan on speed. This target point of 50% - 55% humidity is the perfect setting for human enthalpy. It is the state at which the human body is most comfortable. Automatic changes are made continuously and adjusted every 30 seconds if required. Once the system is stabilized, the blinking LED should be: Sensor 4 Supply Air 1GREEN- 2GREEN and Sensor 5 Return Air should be 2GREEN- 3GREEN or 2GREEN- 4GREEN. In Summary: In heating mode, most error codes and/or improper unit operation are caused by too low of supply water temperature or sensors not installed correctly. Cooling mode errors are caused by too low or too high of refrigerant charge or gross over sizing of equipment. 32

33 NOTICE Refer to variable table on page 22 When an Air Handler control is replaced the dip switches on the control must be set to suit the specific application. Refer to the control being removed to determine the correct switch positions. Failure to set the switches correctly will result in improper unit operation. Controls with the label 2.BOARDCM68A support systems 1 to 3 Controls with the label 2.BOARDCM68B or with higher letter designation, support systems 1 to 6 Minimum Hot Water Supply Temperature Switch Positions System F D D D D D D D U U System 2 95 F D D D D D D U D U System 3 75 F D D D D D D U U U System 4, 5 and 6 only apply when a remote return air sensor is used. System F D D D D D U D D U System 5 95 F D D D D D U D U U System 6 75 F D D D D D U U D U Switch Positions when control is positioned as below D= DOWN (OFF) U = Up (ON)

34 FAN MODULATION SELECTION and REMOTE RETURN AIR SENSOR INSTALLATION Fan Modulation - Applies to control model #BOARDCM68C and newer To select fan modulation during heating and cooling cycles, set switch # 9 at the dip switch on the controller to the OFF position. Factory supplied positions shown below, System # 1. To turn off fan modulation, turn switch # 9 ON. This will provide full speed fan and pump during the heating cycle and full speed fan during cooling. Remote Sensor Installation, Systems 4,5,6 only. Note: If the A/C coil is installed in the return air plenum. A new (optional) REMOTE RETURN AIR SENSOR must be installed onto the control at the receptacle labeled RETURN AIR. Remove factory installed sensor.. This sensor end is then inserted into the return air duct at a location approximately 15 upstream of the A/C coil. (Page 25) Remote DISCHARGE AIR SENSOR to be installed as per installation manual. Set dip switches as per the system preference. Note, systems 4,5 and 6 are only applicable when the remote return air sensor is used. Failure to observe this may result in possible water coil damage. Minimum Hot Water Supply Temperature Switch Positions System 1 110F D D D D D D D U U System 2 95F D D D D D D U D U System 3 75F D D D D D D U U U System F D D D D D U D D U System 5 95 F D D D D D U D U U System 6 75 F D D D D D U U D U Switch Positions when control is positioned as below D= DOWN (OFF) U = Up (ON) 34

35 Notice: In ECM fan motor applications, the fan motor operates independent of the Controller temperature control logic. Externally installed temperature sensors operate as system safeties only, not as inputs for fan modulation etc. In all ECM fan motor sytems, switch # 9 should be turned to the ON position to disable fan modulation. It is also suggested that only either system 3 or 6 on page 34 be selected. The selection of either system 3 or 6 will be determined by the placement of the evap coil. If it should be found that the entering water temperature is less than the minimum system requirements as per the table on page 34, the ECM fan will operate continuously until the thermostat is satisfied. Also, the Hydronic pump may cycle on and off (section 2.3) until the entering temperature meets the minimum requirements. 35

36 TC1530E Air Handler 1/3 H.P. ECM - Air Flow Selectable Options To ensure suitable heating cycle operation, modulation must be turned off at the board mounted switch. Switch #9 on the RED controller mounted dip switch must be turned OFF. Heat Fan Speed Switches 1 & 2 OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF OFF 1050 ON OFF 825 OFF ON 675 ON ON 550 Adjust Fan Speed Switches 3 & 4 Cool Fan Speed Switches 5 & 6 PreRun Time Min. OFF OFF 1175 ON OFF 925 OFF ON 750 ON ON 600 Cool Fan Speed Profiles Switches 7 & 8 Motor % ShortRun Time Min. Motor % MotorOFF Time Min. Motor % OFF OFF ON OFF OFF ON ON ON PreRun Time Min. Heating Fan Speed Profile Motor % ShortRun Time Min. OFF/OFF ON/OFF OFF/ON Motor % MotorOFF Time Min. Motor % NOTE: Power to the Air Handler must be turned off before changing switch settings. Above values are approximations only, actual results may vary. NOTICE: The following operational features are disabled when the ECM motor is used. 1) Home freeze protect 2) Blower fan and pump modulation 3) Latent/Sensible cooling feature is disabled NOTE: Factory set switch positions are indicated in bold Air flow shown above are approximate at.20 ESP. CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling

37 TC2540E Air Handler 1/2 H.P. ECM - Air Flow Selectable Options To ensure suitable heating cycle operation, modulation must be turned off at the board mounted switch. Switch #9 on the RED controller mounted dip switch must be turned OFF. Heat Fan Speed Switches 1 & 2 OFF OFF 1300 ON OFF 980 OFF ON 760 OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling Adjust Fan Speed Switches 3 & 4 Cool Fan Speed Switches 5 & 6 PreRun Time Min. OFF OFF 1640 ON OFF 1270 OFF ON 980 ON ON 740 Cool Fan Speed Profiles Switches 7 & 8 Motor % ShortRun Time Min. OFF/OFF ON/OFF OFF/ON Motor % MotorOFF Time Min. Motor % OFF OFF ON OFF OFF ON ON ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling NOTE: Power to the Air Handler must be turned off before changing switch settings. Above values are approximations only, actual results may vary. NOTICE: The following operational features are disabled when the ECM motor is used. 1) Home freeze protect 2) Blower fan and pump modulation 3) Latent/Sensible cooling feature is disabled NOTE: Factory set switch positions are indicated in bold Air flow shown above are approximate at.20 ESP. 37

38 TC3550E Air Handler 3/4 H.P. ECM - Air Flow Selectable Options To ensure suitable heating cycle operation, modulation must be turned off at the board mounted switch. Switch #9 on the RED controller mounted dip switch must be turned OFF. Heat Fan Speed Switches 1 & 2 OFF OFF 1650 ON OFF 1590 OFF ON 1470 ON ON 1320 Adjust Fan Speed Switches 3 & 4 OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling OFF/OFF ON/OFF OFF/ON CFM Heating Cooling Cool Fan Speed Switches 5 & 6 OFF OFF 1875 ON OFF 1730 OFF ON 1620 ON ON 1500 Cool Fan Speed Profiles Switches 7 & 8 PreRun Time Min. Motor % ShortRun Time Min. Motor % MotorOFF Time Min. Motor % OFF OFF ON OFF OFF ON ON ON NOTE: Power to the Air Handler must be turned off before changing switch settings. Above values are approximations only, actual results may vary. NOTICE: The following operational features are disabled when the ECM motor is used. 1) Home freeze protect 2) Blower fan and pump modulation 3) Latent/Sensible cooling feature is disabled NOTE: Factory set switch positions are indicated in bold Air flow shown above are approximate at.20 ESP. 38

39 Installation of Optional Remote Ambient Sensor Recommended for installations where ambient temperatures may be as low as 40 degrees F. It should be noted that this is a precautionary measure and is not designed to preventwater line freezing in situations where the ambient temperatures may get too low. Final determination of the suitability of the installed location shall be that of theinstalling contractor. The following ONLY applies to board model # CM68D programmed with software version5.05 and higher. Refer to the label on the control to determine model and software version. The optional ambient sensor provides water pump operation when ambient temperatures outside of the air handler cabinet are less than 40 degrees F. The pump will continue to run until the ambient temperature rises above 45 degrees F. During this pump on cycle, the alarm relay and red indicator light (if equipped) will remain on and the alarm beeper will sound one beep every 8 minutes. The buzzer can be silenced for 24 hours by turning the power OFF then ON. Provide a 5 second delay before turning the power back on. The control mounted LED light will display a flash code of RED,GREEN,GREEN. The sensor connector is plugged onto position J45 at the top of the control board and routed through the cabinet fan tray openings up to the top panel. The fan tray opening may need to be provided. If so, drill a 3/8 diameter through the tray at the left side of the air handler. Pass the sensor through the opening and install the split bushing provided. Be sure to position the hole so that it does not interfere with the removal of the fan assembly. Drill a 3/8 diameter hole in the panel above the water inlet pipe approximately 4 to the right of the water line. Insert the rubber plug and sensor end through this opening. Be sure that sensor is exposed at least 1/4 beyond the rubber plug. 39

40 40

41 February 16, 2012 Y1 BLUE Y2 See Note 1 See Note 1 GREEN/YELLOW YELLOW GREEN RED WHITE VIOLET BROWN PINK RED Y2 BLUE * If so equipped * Note 1 - For 2 stage cooling disconnect motor 'Y2' lead at control and connect to 'Y2' lead from the thermostat. 'Y' from motor remains connected to 'Y' terminal on control board. Connect 'Y1' from thermostat to 'Y' terminal on control board. 41

42 11.0 Parts Diagram

43 11.1 Parts List Item # REPLACEMENT PART DESCRIPTION TC 1530 TC 2540 TC 3550 TC 1530E TC 2540E 1 2.GROMMET720 Water line grommet X X 1 2.GROMMET825 Water line grommet X X X X 2 2.COILTC1530 Coil assy c/w copper fittings & pump X X 2 2.COILTC2540 Coil assy c/w copper fittings & pump X X 2 2.COILTC3550 Coil assy c/w copper fittings & pump X X 3 2.PUMP15427 Grundfos Water Pump X X X X X X 4 2.TRANS40VA24 Transformer 40va 24v X X X X X X 5 2.BOARDCM68WOA Board without ambient sensor X X X X X X 6 2.NUTXN8S Nylon Expansion Nut #8 XN8S X X X X X X 7 2.BLWRG10DD2450 Delhi blower X X 7 2.BLWRG10DD3550 Delhi blower X X 7 2.BLWRG108DD Delhi blower X X 8 2.FILTSCREWAH Filter cover plate screw knob X X X X X X 9 2.FILTPULLAH Filter pull c/w screw and nut X X X X X X 10 8.CAP370V5MF Capacitor 370V 5MF X X 10 8.CAP370V75MF Capacitor 370V 7.5 MF X X 11 2.MTR1973 Emerson motor 1/2hp v 3sp X 11 2.MTR1971 Emerson motor 1/4hp v 3sp X 11 2.MTR5846 Emerson motor 3/4hp v 4sp X 11 2.MTR1530ECM GE ECM motor 1/3hp #5460 X 11 2.MTR2540ECM GE ECM motor 1/2hp #5462 X 11 2.MTR3550ECM GE ECM motor 3/4hp #5464 X 12 2.SWITCH220V Fan door safety switch X X X X X X Not Shown In Diagram Item # REPLACEMENT PART DESCRIPTION TC 1530 TC 2540 TC 3550 TC 1530E TC 2540E TC 3550E TC 3550E 2.BLWRASSYTC1530 Blower assy c/w motor,cap,blower PSC X X 2.BLWRASSYTC2540 Blower assy c/w motor,cap,blower PSC X X 2.BLWRASSYTC3550 Blower assy c/w motor,cap,blower PSC X X 2.BLWRASSYTC1530E Blower assy c/w motor, cap, blower ECM X 2.BLWRASSYTC2540E Blower assy c/w motor, cap, blower ECM X 2.BLWRASSYTC3550E Blower assy c/w motor, cap, blower ECM X 2.BOARDTAP Tap select board for ECM motors X X X 2.COILTC1530NP Coil assy without pump X 2.COILTC2540NP Coil assy without pump X X 2.COILTC3550NP Coil assy without pump X X 2.SENSORCF Coil Freeze Sensor 42" X X X X X X 2.SENSORDA Discharge Air Sensor 120" X X X X X X 2.SENSORRR Remote Return Sensor 120" optional X X X X X X 2.SENSORWI Water In Sensor 54" X X X X X X 2.SENSORWO Water Out Sensor 54" X X X X X X 2.TERMBLOCKAH 3pt power distribution block X X X X X X 2.CHOKE Power factor correction choke DE X 43 A-TC-INSMAN-EN-REV37

44 PRESTART CHECKLIST 1) q REMOVE PACKING MATERIALS FROM LEFT SIDE OF BLOWER 2) q REMOVE PACKING MATERIALS FROM UNDER WATER PUMP 3) q BLEED ALL AIR FROM WATER LINES 4) q BLEED AIR FROM END OF WATER PUMP AT SLOTTED BLEED SCREW GENTLY OPEN BLEED SCREW ABOUT 1/2 TURN UNTIL AIR BLEEDS OUT ENSURE WATER DOES NOT LEAK ONTO CONTROL BOARD IN FAN COMPARTMENT 5) q DISHARGE AIR SENSOR INSTALLED DOWNSTREAM OF A/C COIL WHEN A/C COIL INSTALLED IN SUPPLY DUCT DOWNSTREAM OF AIR HANDLER. REFER TO INSTALLATION INSTRUCTIONS. 6) q REMOTE RETURN AIR SENSOR INSTALLED UPSTREAM OF A/C COIL IF COIL IS INSTALLED IN RETURN AIR DUCT, UPSTREAM OF AIR HANDLER. 7) q IF A/C COIL IS INSTALLED IN RETURN AIR DUCT UPSTREAM OF AIR HANDLER, AIR FILTER IS INSTALLED UPSTREAM OF A/C COIL 8) q CONFIRM HOT WATER SUPPLY TEMPERATURE MINIMUM TEMPERATURE AS SELECTED, SEE MANUAL FOR DIP SWITCH SETTINGS 9) q INITIATE CALL FOR HEAT, q PUMP TURNS ON q FAN TURNS ON 10) q CANCEL CALL FOR HEAT PUMP TURNS OFF APPROXIMATELY 1 MINUTE LATER, FAN TURNS OFF 11) q DISCONNECT POWER TO OUTDOOR CONDENSOR. INITIATE CALL FOR COOLING, ONCE FURNACE FAN IS RUNNING, CONFIRM 24 VOLT OUTPUT AT Y AND C AT COMP RELAY ON MAIN CONTROL. RECONNECT POWER IF TEST SUCCESSFUL 12) q CANCEL CALL FOR COOLING APPROXIMATELY 1 MINUTE LATER, FAN TURNS OFF 44

45 Announcement: Illuminated Alarm Indicator Effective January 21, 2009 and serial number FN31649, All TC Series Air Handlers will be equipped with acontrol mounted Illuminated Alarm indicator This indicator light illuminates any time the control mounted alarm relay is activated. The control mounted alarm relay is turned on under the following circumstances. 1) Ambient Temperature too Low (Home Freeze Protect)Automatic Home Freeze Protection is initiated when the return air temperature is lower than 4 deg C (39deg F). During this time the alarm relay and heat cycle are turned on until the ambient temperature risesabove 7 deg C (45 deg F) 2) Water Coil Freeze ProtectThe Water Coil Freeze Protect cycle is initiated when the water coil temperature sensor is exposed totemperatures that are too low or when the discharge air temperature is lower than 5 deg C ( 41 deg F). If thecooling cycle is active when these low temperatures are present, the cooling cycle is terminated. The coolingcycle is suspended for 5 minutes while the fan and pump are run at high speed. At the end of this heat cycle thealarm relay and indictor light turn off. Should these extreme low temperatures return, this cycle of the alarmrelay, indicator light and heat cycle repeat. 3) Cooling LockoutIf the Freeze Protect Cycle (2 above) is initiated three times within the same cooling cycle, the systemgoes into Cooling Lockout Mode. During this time the cooling cycle is disabled and new cooling cyclesare inhibited. The cooling cycle can only be reintroduced by cycling the power to the air handler, off andon. During this Lockout Mode the air handler control audible alarm will also sound. The Red Alarm indicator can be viewed through the left-hand sight glass on the lower front panel. Alarm light is shown below, bottom left hand corner of control. is shown below, bottom left hand corner of control. 45