18-EB26D1-34TCY4-IG-3Installer's Guide

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

Single Packaged, Cooling w/ Electric Heat,14 SEER, Convertible, 2 - 5 Ton, R-410A

4TCY4024A through 4TCY4060A

WARNING: HAZARDOUS VOLTAGE - DISCONNECT POWER and DISCHARGE CAPACITORS BEFORE SERVICING

IMPORTANT — This Document is customer property. Please return to service information pack and give this Installer's Guide to the homeownerupon completion of work.

SAFETY HAZARD!Bodily injury can result from high voltage electrical compo-nents, fast moving fans, and combustible gas. For protectionfrom these inherent hazards during installation and service,the electrical supply must be disconnected and the main gasvalve must be turned off. If operating checks must beperformed with the unit operating, it is the technician'sresponsibility to recognize these hazards and proceed safely.

▲▲ WARNING!SAFETY HAZARD!This information is for use by individuals having adequatebackgrounds of electrical and mechanical experience. Anyattempt to repair a central air conditioning product mayresult in personal injury and/or property damage. Themanufacturer or seller cannot be responsible for the inter-pretation of this information, nor can it assume any liability inconnection with its use.

▲▲ WARNING!

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Installer’s Guide

IMPORTANT: Read this entire manual before beginning installation procedures.Safety Considerations

WARNING: Indicates a potentially hazardous situa-tion which, if not avoided, could result in death orserious injury.

CAUTION: Indicates a potentially hazardous situa-tion which, if not avoided, may result in minor ormoderate injury. It may also be used to alert againstunsafe practices and where property-damage-onlyaccidents could occur.

NOTICEWarning and Cautions appear at appropriatelocations throughout this guide. Your personalsafety and the proper operation of this air condi-tioning product require that you follow themcarefully. The manufacturer assumes no liability forinstallations or servicing performed by unqualifiedpersonnel.

SAFETY HAZARD!Do not operate the unit without the evaporator fan or coilaccess panels in place. Reinstall the access panels afterperforming maintenance proceedures on the fan. Operatingthe unit without the access panels properly installed mayresult in severe personal injury or death.

▲▲ WARNING!

▲▲ CAUTION!Reconnect all grounding devices.All parts of this product that are capable of conductingelectrical current are grounded. If grounding wires, screws,straps, clips, nuts, or washers used to complete a path toground are removed for service, they must be returned totheir original position and properly fastened.

PRECAUTIONARY MEASURES

• Avoid breathing fiberglass dust

• Use a NIOSH approved dust/mist respirator

• Avoid contact with the skin or eyes. Wear long-sleeved,loose fitting clothing, gloves, and eye protection.

• Wash clothes separately from other clothing, rinse washerthoroughly.

• Operations, such as sawing, blowing, tear-out, and spray-ing may generate fiber concentrations requiring additionalrespiratory protection. Use the appropriate NIOSH ap-proved respirator in these situations.

FIRST AID MEASURES

Eye Contact: Flush eyes with water to removedust. If symptoms persist, seek medical

attention.

Skin Contact: Wash affected area gently with soap and

warm water after handling.

This product contains fiberglass wool insulation! Fiber-glass dust and ceramic fibers are believed by the state ofCalifornia to cause cancer through inhalation. Glasswoolfibers may also cause respiratory, skin, or eye irritation.

▲▲ WARNING!

EXPLOSION HAZARD!To prevent an explosion or possible injury, death, and equip-ment damage. Do not store combustible materials, gasoline,or other flammable vapors or liquids near the unit.

▲▲ WARNING!

CONTAINS REFRIGERANT!SYSTEM CONTAINS OIL AND REFRIGERANT UNDER HIGHPRESSURE. RECOVER REFRIGERANT TO RELIEVE PRES-SURE BEFORE OPENING SYSTEM. Failure to follow properprocedures can result in personal illness or injury or severeequipment damage.

Unit contains R-410A Refrigerant!R-410A operating pressure exceeds the limit of R-22. Properservice equipment is required. Failure to use proper servicetools may result in equipment damage or personal injury.

SERVICEUse only R-410A Refrigerant and approved POE com-

pressor oil.

▲▲ WARNING!

▲▲ WARNING!

▲▲ CAUTION!Hot Surface!Do Not touch top of compressor. May cause minor to severeburning.

IMPORTANT: This product has been designed and manufac-tured to meet ENERGY STAR criteria for energy efficiency.However, proper refrigerant charge and proper air flow arecritical to achieve rated capacity and efficiency. Installation ofthis product should follow the manufacturer’s refrigerantcharging and air flow instructions. Failure to confirm propercharge and airflow may reduce energy efficiency andshorten equipment life.

IMPORTANT: Wear appropriate gloves, arm sleeve protectors,and eye protection when servicing or maintaining thisequipment.

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Installer’s Guide

Read this manual carefully before attempting to install, operate,or perform maintenance on this unit. Installation and maintenanceshould be performed by qualified service technicians only. Thisunit is listed by Underwriters Laboratory.

Model 4TCY4 air conditioning units are designed for outdoormounting with a vertical condenser discharge. They can belocated either at ground level or on a roof in accordance with localcodes. Each unit contains an operating charge of refrigerant asshipped.

The indoor fan motor speed adjustment is provided in theMaintenance section.

Extreme mounting kits are available for slab (BAYEXMK003A),curb (BAYEXMK001A), and utility curb (BAYEXMK0002B)mountings.

Supplemental heaters are installed separately per the appropriateSupplemental Electric Heaters Installer's Guide.

Single power entry kits are installed separately per theappropriate Single Power Entry Kit Installer's Guide.

This guide is organized as follows:

� Step 1 - Inspect Shipment

� Step 2 - Determine Unit Clearances

� Step 3 - Review Location and Recommendation Information

� Step 4 - Unit Installation

� Step 5 - Unit Startup

� Sequence of Operation

� Maintenance

IntroductionContentsSafety Considerations 2Introduction 3Step 1-Inspect Shipment 3Step 2-Determine Unit Clearances 4Step 3-Review Location and Recommendation Information 10Step 4-Unit Installation 11 Ground Level Installation 11 Rooftop Installation -- Curb Mounting 11 Covert Horizontal Airflow to Down Airflow 11 Install Full Perimeter Roof Mounting Curb 11 Lifting and Rigging 11 Placing the Unit on the Mounting Curb 12 Rooftop Installation -- Frame Mounting 12 Ductwork Installation 15 Attaching Downflow Ductwork to Roof Curb 15 Attaching Downflow Ductwork to Roof Frame 15 Attaching Horizontal Ductwork to Unit 15 Condensate Drain Piping 15 Air Filter Installation 16 Electrical Wiring 16 Electrical Connections 16 Electrical Power 16 Disconnect Switch 16 Overcurrent Protection 16 Power Wiring 16 Field Wiring Diagram 17 Control Wiring (Class II) 18 Thermostat Heat Anticipator 18Step 5-Unit Startup 18 Pre-start Quick Checklist 18 Starting the Unit in the Cooling Mode 18 Operating Pressures 18 Voltage Check 18 Cooling Shutdown 18 Starting the Unit in Heating Mode 19 Heating Shutdown 19Sequence of Operation 19 General 19 Cooling Mode 19 Heating Mode 19Final Inspection Checklist 19Maintenance 19 Owner Maintenance 19 Service Maintenance 20 Cooling Season 20 Heating Season 20 ECM Fan Motor Adjustments 20Warranty Information 21

Step 1—Inspect Shipment1. Check for damage after the unit is unloaded. Report promptly

to the carrier any damage found to the unit. Do not drop theunit.

IMPORTANT: To prevent damage to the sides and top ofthe unit when hoisting, retain the top shipping skid on theunit or use “spreader bars” as shown on page 13.

2. Check the unit’s nameplate to determine if the unit is correctfor the intended application. The power supply must beadequate for both the unit and all accessories.

3. Check to be sure the refrigerant charge has been retainedduring shipment. Remove the Compressor access panel toaccess the 1/4" flare pressure taps.

4. If this unit is being installed on a curb, verify that the correctcurb is provided with the unit.

• 4TCY4024 through 4TCY4036 use the small cabinet,Model BAYCURB050A.

• 4TCY4042 through 4TCY4060 use the large cabinet,Model BAYCURB051A.

5. If the unit is being hoisted, accessory kit BAYLIFT002AA isrecommended. It includes a kit of four (4) lifting lugs andinstructions.

NOTE: If practical, install any internal accessories to the unitat the shop.

Page 4

Installer’s GuideStep 2—Determine Unit Clearances

Figure 1. 4TCY4024A through 4TCY4036A (1 of 3)

Figures 1 to 6 show the unit critical dimensions.

NOTE: The view labeled“Bottom Side” represents theBase as viewed looking up from

underneath the unit.

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Installer’s Guide

Figure 2. 4TCY4024A through 4TCY4036A (2 of 3)

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Figure 3. 4TCY4024A through 4TCY4036A (3 of 3)

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Figure 4. 4TCY4042A through 4TCY4060A (1 of 3)

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Figure 5. 4TCY4042A through 4TCY4060A (2 of 3)

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Installer’s Guide

Figure 6. 4TCY4042A through 4TCY4060A (3 of 3)

Page 10

Installer’s GuideStep 3—Review Location and Recom-mendation Information

1. Location of the unit must allow service clearance around it toensure adequate serviceability, maximum capacity, and peakoperating efficiency.

2. Refer to the Installation section (page 11) for instruction onconverting the supply and return airflow covers to downairflow.

3. The field assembled Roof Mounting Curb (BAYCURB050Aor BAYCURB051A) or a field fabricated curb should be inplace before the unit is hoisted to the roof top.

IMPORTANT: The Roof Mounting Curb (frame) must beinstalled on a flat, level section of the roof (maximum of1/4" per foot pitch) and provide a level mountingsurface for the unit. Also, be sure to provide sufficientheight above the roof to prevent water from entering theunit.

4. Be sure the mounting curb spans structural members(trusses) of the roof, thereby providing sufficient supportfor the weight of the unit, the curb, the duct(s), and anyfactory or field installed accessories.

5. Be sure the hole in the structure for the ducts is largeenough to accommodate the fabricated ducts and theinsulation surrounding them.

6. These units are design certified for outdoor installation.They may be installed directly on a slab, wood flooring, oron Class A, B, or C roof covering material. The dischargeair from the condenser fans must be unrestricted for aminimum of three (3) feet above the unit.

7. Exhaust vents or other sources of contaminated air shouldnot be near the unit’s air inlet if outside air is to beintroduced as make-up air or a ventilation feature is to beused. Contamination from exhaust vents or chimneys mayalso foul the condensor causing degraded performance.

8. Check the handling facilities to ensure the safety ofpersonnel and the unit(s).

Clearances

1. The recommended clearances for single-unit installations areillustrated in Figures 1 through 6, pages 4-9.

2. Any reduction of the unit clearances indicated in these figuresmay result in condenser coil starvation or the recirculation ofwarm condenser air. Actual clearances, which appear to beinadequate should be reviewed with a local engineer.

3. See the unit’s nameplate for the absolute minimum clearancebetween the unit and any combustible surfaces.

Down Airflow Units

NOTE: The unit is shipped for horizontal installation.

Horizontal Airflow Units

1. Location of the unit must allow service clearance around it toensure adequate serviceability, maximum capacity, and peakoperating efficiency.

2. These units are design certified for outdoor installation. Theymay be installed directly on a slab, wood flooring, or on ClassA, B, or C roof covering material. The discharge air from thecondenser fans must be unrestricted for a minimum of 3 feetabove the unit.

3. Check the handling facilities to ensure the safety of personneland the unit.

4. The unit must be mounted level for proper drainage of waterthrough the drain holes in the base pan.

5. The unit should not be exposed to direct roof water runoff.

6. Flexible duct connectors must be of a flame retardantmaterial. All duct work outside of the structure must beinsulated and weatherproofed in accordance with local codes.

7. Holes through exterior walls or roof must be sealed inaccordance with local codes.

8. All fabricated outdoor ducts should be as short as possible.

Clearances

1. The recommended clearances for single-unit installations areillustrated in Figures 1 through 6 pages 4-9.

2. Any reduction of the unit clearances indicated in these figuresmay result in condenser coil starvation or the recirculation ofwarm condenser air. Actual clearances, which appear to beinadequate should be reviewed with a local engineer.

3. See the unit’s nameplate for the absolute minimum clearancebetween the unit and any combustible surfaces.

▲▲ CAUTION!Caution must be taken at all times to avoid personal injuriesand/or damage to equipment.

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Installer’s GuideStep 4—Unit Installation

NOTE: The unit is shipped for horizontal installation.

Ground Level InstallationTo install the unit at ground level:

1. Place the unit on a pad the size of the unit or larger. Theunit must be mounted level for proper water drainagethrough the holes in the base pan. The pad must notcome in contact with the structure (See Figure 9, below). Besure the outdoor portion of the supply and return air ductsare as short as possible.

2. Location of the unit must allow service clearance around it.Clearance of the unit must be given careful consideration. SeeFigures 1 to 6, pages 4-9.

NOTE: Any reduction of the unit clearances indicated inthese illustrations may result in condenser coil starvation orthe recirculation of warm condenser air. Actual clearances,which appear to be inadequate should be reviewed with alocal engineer.

4. Attach the supply and return air ducts to the unit as ex-plained in the following Ductwork Installation section.

5. Flexible duct connectors must be of a flame retardantmaterial. Insulate any ductwork outside of the structure withat least 2 inches of insulation and weatherproof. There mustbe a weatherproof seal where the duct enters the structure.

6. Do not expose the unit to direct roof water runoff.

7. Seal all holes through exterior walls in accordance withlocal codes.

8. Continue with the following installation sections to completethe installation: Ductwork Installation, page 15, Air FilterInstallation, page 16, and Electrical Wiring, page 16.

Rooftop Installation -- Curb MountingConvert Horizontal Airflow to Down AirflowThe factory ships the unit for horizontal airflow. Perform thisprocedure to convert it to down airflow:

1. Remove the three sheet metal screws securing the supply aircover and the four sheet metal screws securing the return aircover from the base of the unit. Remove the covers from the base.See Figure 10, page 12.

2. Place the covers over the horizontal supply and return openings(painted side out). Align the screw holes, and secure using thesame screws removed in step 1.

Lifting and Rigging1. Before preparing the unit for lifting, check the unit dimension

drawings for center of gravity for lifting safety (Figures 1 to 6,pages 4-9). Because of placement of internal components, theunit’s weight may be unevenly distributed. Approximate unitweights are also provided in the unit drawings.

NOTE: Unit rigging and hoisting requires accessory kitBAYLIFT002AA. It includes a kit of four (4) lifting lugs. SeeFigure 11 inset B, page 13.

2. Insert the four lifting lugs in the openings provided in thedrip lip on each end of the unit. See Figure 11 Inset B, page 15.A tap or jerk to the lug will overcome the interference that arisesdue to the dimple on the lug.

Figure 9. Typical Ground Level Applications

Install Full Perimeter Roof Mounting Curb

1. Verify that the roof mounting curb is correct for the unit. There aretwo Installer's Guides depending on the cabinet sizes:• TCY4024 through TCY4036 use the small cabinet, Model BAYCURB050A.

• TCY4042 through TCY4060 use the large cabinet, Model BAYCURB051A.

2. Assemble and install the curb following the instruction in theappropriate Installer's Guide.

NOTE: Use the extrememounting kit, BAYEXMK002AA,to secure the unit to the slab.

SIDING

RETURNAIRDUCT

SUPPLYAIRDUCT

EXTERIORWALL INSULATE

WEATHERPROOFOR RAIN SHIELD

FLEXIBLE DUCTCONNECTORS ISOLATORS 1 PER

CORNER AND 1 UNDERUNIT CONTROL BOX

SUPPORT PADFOUNDATION

OUTDOOR AIRDISCHARGE

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Installer’s Guide

Rooftop Installation -- Frame MountingFor roof top applications using a field fabricated frame and ducts,use the following procedure:

1. Locate and secure the frame to the roof by bolting or welding.Add flashing as required. Flashing must conform to localbuilding codes.

2. Prepare the hole in the roof in advance of installing the unit.

3. Secure the horizontal or down airflow ducts to the roof. Referto the previous Convert from Horizontal Airflow to Down Airflowsection if conversion is needed.

4. All fabricated outdoor ducts should be as short as possible.

5. Place the unit on the frame. Refer to Figures 13 or 14.

6. The unit must be mounted level for proper water drainagethrough the holes in the base pan.

7. Secure the unit to the frame.

8. Insulate any ductwork outside of the structure with at least two(2) inches of insulation and then weatherproof. There must bea weatherproof seal where the duct enters the structure.

9. The unit should not be exposed to direct roof water runoff.

10. Flexible duct connectors must be of a flame retardant material.All duct work outside of the structure must be insulated andweatherproofed in accordance with local codes.

11. Access and service clearances for the unit must be givencareful consideration when locating the duct entrance open-ings. Figures 1 to 6 provide unit dimensions.

12. Continue with the following installation sections to completethe installation: Ductwork Installation page 15, Air Filter Instal-lation, page 16, and Electrical Wiring, page 16.

Placing the Unit on the Mounting Curb

1. The unit is designed with a perimeter drip lip that is lowerthan the unit base bar, see Figure 11, Inset A, page 15.

2. Position the unit drip lip down over and in contact with theoutside corner of the curb, as illustrated in Figure 11, insetA, page 15. Continue to lower the unit on top of the curb,with the unit drip lip astraddle and in contact with both theend and side rail of the curb. The unit should now rest ontop of the curb.

3. Continue with the following installation sections to completethe installation: Ductwork Installation page 15, Air FilterInstallation, page 16, and Electrical Wiring, page 16.

Figure 10. Converting Horizontal to Down Airflow

3. When hoisting the unit, be sure that a proper method of riggingis used. Use either the unit's top shipping skid and straps orslings and spreader bars for protection during lifting. Alwaystest-lift the unit to determine the exact unit balance and stabilitybefore hoisting it to the installation location.

IMPORTANT: Do not lift the unit without test lifting for balanceand rigging. Do not lift the unit in windy conditions or abovepersonnel. Do not lift the unit by attaching clevis, hooks, pins,or bolts to the unit casing, casing hardware, corner lugs,angles, tabs, or flanges. Failure to observe these warningsmay result in equipment damage.

4. When the curb and air ducts have been properly installed, theunit is ready to be hoisted to the roof and set in position.

IMPORTANT: To prevent damage to the sides and top ofthe unit when hoisting, retain the top shipping skid on theunit or use “spreader bars” as shown on page 13.

IMPORTANT: The unit must be lowered into position. TheP.V.C. rubber tape on the curb flange permits the unit to berepositioned if required without destroying the P.V.C. rubberseals affixed to the mounting curb.

NOTE: The ductwork is installed as part of the curb installation.Do not attach ductwork to the unit and lower the unit withductwork onto the curb.

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Installer’s Guide

Figure 11. Lifting and Rigging

IMPORTANT: To prevent damageto the sides and top of the unit whenhoisting, retain the top shipping skidon the unit or use “spreader bars” asshown in these illustrations.

Gasket Seal

Spreader Bars

Curb Corner

Base of unitrest on top ofcurb rails

Drip lip onperimeter ofunit

Unit Corner

Drip Lip

DimpleBAYLIFT002ALifting Lugs

Top shipping skidattached to unit

This drawing was prepared by the manufacturer in order to provide detail regarding job layout only. This drawing isnot intended to be used as a basis to construct, build or modify the item depicted in the drawing. The manufactureris not responsible for the unauthorized use of this drawing and expressly disclaims any liability for damagesresulting from such unauthorized use.

Figure 12. Curb Dimensions

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Installer’s Guide

Figure 14.Typical Rooftop Down Airflow Application with Frame

Figure 13. Typical Rooftop Horizontal Airflow Application with Frame

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Installer’s Guide

Attaching Horizontal Ductwork to UnitAll conditioned air ductwork should be insulated to minimizeheating and cooling duct losses. Use a minimum of two (2) inchesof insulation with a vapor barrier. The outside ductwork must beweatherproofed between the unit and the building. See Figure 16.

When attaching ductwork to a horizontal unit, provide a flexiblewatertight connection to prevent noise transmission from the unit tothe ducts. The flexible connection must be indoors and made outof heavy canvas.

NOTE: Do not draw the canvas taut between the solid ducts.

Attaching Downflow Ductwork to Roof CurbSupply and return air flanges are provided on the roof curb for easyduct installation. All ductwork must be run and attached to the curbbefore the unit is set into place. Refer to the Roof Mounting CurbInstaller's Guide for details.

Attaching Downflow Ductwork to Roof FrameFollow these guidelines for ductwork construction:

Connections to the unit should be made with three-inch canvasconnectors to minimize noise and vibration transmission.

Elbows with turning vanes or splitters are recommended to mini-mize air noise and resistance.

The first elbow in the ductwork leaving the unit should be no closerthan two (2) feet from the unit, to minimize noise and resistance.

To prevent leaking, do not attach the ductwork to the bottom of theunit base as the bottom example in Figure 15, below shows. Condensate Drain Piping

A 3/4-inch female NPT condensate drain connection is provided onthe evaporator access panel end of the unit. Provide a trap and fillit with water before starting the unit to avoid air from being drawnthrough. Follow local codes and standard piping practices whenrunning the drain line. Pitch the line downward away from the unit.Avoid long horizontal runs. See Figure 17, below.

NOTE: Do not use reducing fittings in the drain lines.

The condensate drain must be:

● Made of 3/4" pipe size.

● Pitched 1/4" per foot to provide free drainage to convenient drainsystem.

● Trapped.

● Must not be connected to a closed drain system unless the trapis properly vented.

Ductwork Installation

Figure 16. Attaching Horizontal Airflow Ductwork

FIELD DUCT

UNIT DUCTFLANGE

UNIT BASE

AIR PROOFTHIS SEAM

FIELD DUCT

UNIT DUCTFLANGE UNIT BASE

AIR PROOFTHIS SEAM

FIELDDUCT

UNIT DUCT FLANGE

UNIT BASE

AIR PROOFTHIS SEAM

FIELD DUCT

UNIT DUCTFLANGE

UNIT BASE

NOT RECOMMENDED

WATERPROOF SEAMWITH BUTYL OR

SILICONE

Figure 15. Attaching Down Airflow Ductwork to Frame

Figure 17. Typical Condensate Drain Piping

FIELD DUCT

UNIT EXTERIOR

WEATHERPROOFTHIS SEAM

FIELD DUCT

UNIT EXTERIOR

WEATHERPROOFTHIS SEAM

3/4" PVC OR COPPERTUBING AND FITTINGS

1-1/2" MIN.

1-1/2" MIN.

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Installer’s Guide

Electrical ConnectionsElectrical wiring and grounding must be installed in accordancewith local codes, or in the absence of local codes, with the NationalElectrical Code ANSI/NFPA 70, Latest Revision.

Electrical PowerIt is important that proper electrical power be available for the unit.Voltage variation should remain within the limits stamped on theunit nameplate.

Disconnect SwitchProvide an approved weatherproof disconnect within close prox-imity and within sight of the unit.

Over Current ProtectionThe branch circuit feeding the unit must be protected as shown onthe unit rating plate.

Power WiringThe power supply lines must be run in weather-tight conduit to thedisconnect and into the side of the unit control box. Provide strainrelief for all conduit with suitable connectors.

Electrical Wiring

Provide flexible conduit supports whenever vibration transmissionmay cause a noise problem within the building structure.

For units that are configured for single point entry, refer to theappropriate Single Power Entry Kit Installer's Guide to connectpower.

For units that are configured with supplemental heat, refer to theappropriate Supplemental Electric Heater Installer's Guide toconnect heater power.

NOTE: For branch circuit wiring (main power supply to unitdisconnect), determine wire size for the length of run using thecircuit ampacity found on the unit nameplate and the N.E.C.

For more than 3 conductors in a raceway or cable, see the N.E.C.for derating the ampacity of each conductor.

*Filters must be installed in the return air system. The above squarefootages are based on 300 F.P.M. face velocity. If permanent filters areused, size per mfg. Recommendation with clear resistance of 0.05"WC.

To connect the power wiring:

1. Remove the Control access panel. See Figure 18. Pass thepower wires through the appropriate Power Entry hole inthe end of the unit.

2. Connect the high voltage wires to the appropriate contactorterminals. Single phase units use a two (2) pole contactorand three phase units use a three (3) pole contactor.Connect the ground to the ground lug on the chassis. SeeFigure 19. Be sure all connections are tight.

GROUNDING: THE UNIT MUST BE ELECTRICALLYGROUNDED IN ACCORDANCE WITH LOCAL CODES ORTHE NATIONAL ELECTRIC CODE.

NOTE: Ground the unit internally as provided. See wiringdiagram for location (Figure 20).

NOTE: For units with single power entry, refer to the SinglePower Entry Installer's Guide to connect the power wiring.

Figure 19. Power Connections

Figure 18. Power Wiring

Run powersupply Linesthroughweather-tightconduit andsecure to unitwith strain relief

Power Entry

Power Entry

Single Pointy Entry(use with SinglePower Entry Kit)

24V Entry

ControlAccess Panel

NOTE: This unit is factory wired for 230V. See wiring diagramfor 208V conversion.

Contactor

Unit Ground Lug

Table 1. Filter Sizes (field supplied filter rack)

Air Filter InstallationThe 4TCY4 cooling unit requires an air filter. The unit does notcome with a factory installed filter rack in it, however, two filter frameaccessories are offered that will allow the installation of a filterwithin the unit, BAYFLTR101 & BAYFLTR201. Otherwise a fieldsupplied filter rack must be installed by the installer in the returnduct work. Refer to Table1 to determine filter sizes for field suppliedfilter racks.

NOMINAL FILTER

CFM SIZE(Sq Ft)

4*CY4024A 800 2.67 0.08

4*CY4030A 1000 3.33 0.08

4*CY4036A 1200 4 0.08

4*CY4042A 1400 4.67 0.08

4*CY4048A 1600 5.33 0.084*CY4060A 2000 6.67 0.08

UNITFILTER

RESISTANCE ("W.C.)

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Installer’s Guide

Figure 20. 4TCY4 Field Wiring Diagram

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Installer’s Guide

Starting the Unit in Cooling Mode

Control Wiring (Class II)Low voltage control wiring should not be run in conduit with powerwiring unless Class 1 wire of proper voltage rating is used. Routethe thermostat cable or equivalent single leads of No. 18 AWGcolored wire from the thermostat subbase terminals through therubber grommet on the unit. See Figures 2, 4, 6, or 8 for the controlentry (24V Entry) location. Make connections as shown on the unitwiring diagram.

Do not short thermostat wires since this will damage the controltransformer.

Refer to Table 2 for recommended wire sizes and lengths forinstalling the unit thermostat. The total resistance of these lowvoltage wires must not exceed one (1) ohm. Any resistance inexcess of 1 ohm may cause the control to malfunction because ofthe excessive voltage drop.

IMPORTANT: Upon completion of wiring, check all electricalconnections, including factory wiring within the unit.

Make sure all connections are tight. Replace and secure allelectrical box covers and access panels before leaving the unit orturning on the power to the unit.

Pre-Start Quick Checklist

� Is the unit properly located and level with the properclearance? See Figures 1 to 6. See Step 3-ReviewLocation and Recommendation Information on page 10.

� Is the duct work correctly sized, run, taped, insulated, andweatherproofed with proper unit arrangement? SeeDuctwork Installation section on page 15.

� Is the condensate line properly sized, run, trapped, andpitched? See Condensate Drain Piping section on page15.

� Is the filter of the correct size and quantity? Is it clean and inplace? See Air Filter Installation section on page 16.

� Is the wiring properly sized and run according to the unitwiring diagram? See Electrical Wiring section on page 16.

� Are all the wiring connections, including those in the unit,tight? See Electrical Wiring section on page 16.

� Has the unit been properly grounded and fused with therecommended fuse size? See Electrical Wiring section onpage 16.

� Is the thermostat well located, level, and correctly wired?See Electrical Wiring section on page 16.

� Have the air conditioning systems been checked at the serviceports for charge and leak tested if necessary?

Step 5—Unit Startup

WIRE SIZE MAXIMUM LENTGH (Ft)18 7516 12514 200

Table 2. Thermostat Wire Size and Maximum Length

� Do the condenser fan and indoor blower turn free withoutrubbing, and are they tight on the shafts?

� Has all work been done in accordance with applicable localand national codes?

� Are all covers and access panels in place to prevent air loss andsafety hazards?

Thermostat Heat AnticipatorSet the thermostat heat anticipators to equal the amperage draw ofthe W1 thermostat circuit.

▲▲ CAUTION!Before starting the system on the cooling cycle, turn the comfortcontrol to OFF and close the unit disconnect switch. This is aprecaution against foaming at startup which could damage thecompressor bearings.

Safety Hazard. Do not operate the unit without the evaporatorfan access panel or evaporator coil access panel in place.Reinstall the access panels after performing maintenanceprocedures on the fan. Operating the unit without the accesspanels properly installed may result in severe personal injuryor death.

▲▲ WARNING!

NOTE: See the section on “Sequence of Operation” for adescription of the cooling operating sequence.

To start the unit in the cooling mode, set the comfort control to COOLand to a setting below room temperature. The condenser fan motor,compressor and evaporator fan motor will operate automatically.

Operating Pressure ChecksAfter the unit has operated in the cooling mode for a short period oftime, install pressure gauges on the gauge ports of the dischargeand suction line valves (behind the Compressor access panel).Check the suction and discharge pressures and compare them tothe normal operating pressures provided in the unit’s SERVICEFACTS.

NOTE: Do not use the pressures from the unit's SERVICEFACTS to determine the unit refrigerant charge. The correctcharge is shown on the unit nameplate. To charge the systemaccurately, weigh in the charge according to the unit nameplate.

Voltage CheckWith the compressor operating, check the line voltage at the unit(contactor is located behind the Control access panel). The voltageshould be within the range shown on the unit nameplate. If lowvoltage is encountered, check the size and length of the supply linefrom the main disconnect to the unit. The line may be undersizedfor the length of the run.

Cooling Shut DownSet the comfort control to OFF or to a setting above room tempera-ture.

IMPORTANT: De-energize the main power disconnect ONLYwhen servicing the unit. Power may be required to keep the heatpump compressor warm and to boil off refrigerant in the compres-sor.

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Installer’s Guide

GeneralOperation of the system cooling (and optional heating) cycles iscontrolled by the comfort control. Once the comfort control is set toeither HEAT or COOL, unit operation is automatic. The optionalautomatic changeover control, when set to AUTO, automaticallychanges to heat or cool with sufficient room temperature change.

The fan can be set to ON, causing continuous evaporator (indoor)fan operation or set to AUTO causing fan operation to coincide withheating or cooling run cycles. Continuous fan mode during coolingoperation may not be appropriate in humid climates. If the indoorair exceeds 60% relative humidity or simply feels uncomfortablyhumid, it is recommended that the fan only be used in the AUTOmode.

Cooling ModeWith the comfort control set to COOL and the fan set to AUTO, thecompressor contactor (CC) and the indoor fan motor (IDM) areenergized.

The energized compressor contactor (CC) completes the circuit tothe compressor (CPR) and a secondary circuit to the outdoor fanmotor (ODM). If the compressor safety controls are closed, thecompressor (CPR) will operate with the outdoor fan motor (ODM).The indoor fan motor (IDM) will operate. The comfort control willcontinue to cycle the compressor and fans to maintain the desiredtemperature.

With the fan set to ON, the indoor fan motor (IDM) will continue torun regardless of compressor and condenser fan operation.

Sequence of Operation

Starting the Unit in Heating ModeNOTE: See the section on "Sequence of Operation" for adescription of the heating operating sequence.

Check that all grills and registers are open and all unit accesspanels are closed before start-up.

Set the comfort control above room temperature until achieving afirst stage call for heat and set the fan control to AUTO or ON.

Heating Shut DownSet the comfort control to OFF or to a setting below room tempera-ture.

Heating ModeHeating mode uses electric heaters, which are installed separately.Refer to the Supplemental Electric Heaters Installer's Guide for additionalinformation.

On a call for heat, power from the comfort control is received at “W1”,which energizes the “AH” contactor coil. The “AH” contactor closespowering the heater, provided all element limits are closed.

If two stages of heat are provided and additional heat is required,the comfort control’s second stage “W2” circuit is energized pow-ering the “BH” contactor coil.

Maintenance

Final Installation Checklist

Owner MaintenanceSome of the periodic maintenance functions of the unit can beperformed by the owner; this includes replacing the disposable orcleaning the permanent air filters, cleaning the unit cabinet, andconducting a general unit inspection on a regular basis.

FiltersWhen the system is in constant operation, inspect the filters atleast once each month.

If the unit has disposable-type filters, replace them with new filtersof the same type and size. Do not attempt to clean disposablefilters.

Permanent-type filters can be cleaned by washing them with a milddetergent and water. Make sure that the filters are thoroughly drybefore reinstalling them in the unit (or duct system).

NOTE: It may be necessary to replace permanent filtersannually if washing fails to clean the filter or if the filter showssigns of deterioration. Be sure to use the same type and sizeas was originally installed.

Condenser CoilBe sure to keep all vegetation and debris away from the condensercoil area.

NOTE: The indoor comfort control must be configured to provide a“G” signal to energize the indoor fan relay (F) during the heatingmode. The heater control circuit will not be energized unless theindoor fan relay (F) is energized.

� Does the unit run and operate as described in the sectionon “Sequence of Operation” in response to the roomthermostat?

� Are the condenser fan and indoor blower operatingcorrectly with proper rotation and without undue noise?

� Is the compressor operating correctly and has the systembeen checked with a charging chart?

� Has the voltage and running current been checked todetermine if it is within limits?

� Has the thermostat been checked for calibration and the airdischarge grilles adjusted to balance the system?

� Has the ductwork been checked for air leaks and conden-sation?

� Has the furnace manifold pressure been checked andadjusted if necessary?

� Has the heating air temperature rise been checked?

� Has the unit been checked for tubing and sheet metalrattles? Are there any other unusual noises to be checked?

� Are all covers and panels in place and properly fastened?

� Has the owner been instructed on proper operation andmaintenance of the unit? Be sure to leave this manual withthe owner.

Page 20

Installer’s GuideService Maintenance

Cooling SeasonTo keep the unit operating safely and efficiently, the manufac-turer recommends that a qualified service technician check theentire system at least once each year or sooner if needed. Theservice technician should examine these areas of the unit:

● filters (for cleaning or replacement)

● motors and drive system components

● economizer gaskets (for possible replacement)

● safety controls (for mechanical cleaning)

● electrical components and wiring (for possible replacementand connection tightness)

● condensate drain (for proper sealing and cleaning)

● unit duct connections (to see that they are physically soundand sealed to the unit casing)

● unit mounting support (for structural integrity)

● the unit (for obvious unit deterioration)

Heating SeasonComplete the following unit inspections and service routinesdescribed at the beginning of each heating season.

● Visually inspect the unit to ensure that the airflow requiredfor combustion and condenser coil is not obstructed from theunit.

● Inspect the control panel wiring to verify that all electricalconnections are tight and that the wire insulation is intact

ECM Fan Motor Adjustments

If the airflow needs to be increased or decreased, see theAirflow Table in the SERVICE FACTS. Information on changingthe speed of the blower motor is in the Blower PerformanceTable. Blower speed changes are made on the ECM FanControl mounted in the control box. The ECM Fan Controlcontrols the variable speed motor. There is a bank of 8 dipswitches, (See Figure 21 below), located on the board. The dipswitches work in pairs to match the cooling/heat pump airflow(CFM/TON), Fan off-delay options and electric heat airflowadjustment. The switches appear as shown in the Figure below.

CFM SELECTIONLIGHT

DIP SWITCHES

Figure 21. ECM Fan Control

Trane6200 Troup HighwayTyler, TX 75707-9010

Trane has a policy of continuous product and product data improvement. It reservesthe right to change design and specification without notice.© Trane 2007

Page 21

Installer’s Guide

6 26-1000-21

The limited warranties displayed in this publication and/or on ComfortSite™ may not accurately reflect the actual limited warranty that shipped with the product.

Limited WarrantyHigh Efficiency Air Conditioner4TCY4, 4TCX3 and TCY (Parts Only)

This limited warranty is extended by Trane U.S. Inc., to the original purchaser and to any succeeding owner of the real property to which the Air Conditioner is originally affixed, and applies to products purchased and retained for use within the U.S.A. and Canada.

If any part of your Air Conditioner fails because of a manufacturing defect within five years from the date of the origi-nal purchase, Warrantor will furnish without charge the required replacement part. Any local transportation, related service labor, diagnosis calls, refrigerant and related items are not included.

In addition, if the sealed motor-compressor fails or the outdoor coil† should become defective, either or both events occurring because of a manufacturing defect within the sixth through tenth year from the date of original purchase, Warrantor will furnish without charge the required replacement compressor and/or outdoor coil. Any local transporta-tion, related service labor, diagnosis calls, refrigerant and related items are not included.

†NOTE: If your Central Air Conditioner is installed within one mile of salt water, including but not limited to seacoasts and inland waterways, your outdoor coil warranty as stated above is limited to five years from the date of original purchase.

This limited warranty does not cover failure of your Central Air Conditioner if it is damaged while in your possession, damage caused by unreasonable use of the Central Air Conditioner and/or damage from failure to properly main-tain the Central Air Conditioner as set forth in the Use and Care manual (see Proper Maintenance section).

THE LIMITED WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WAR-RANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING BUT NOT SPECIFICALLY LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, AND IN NO EVENT SHALL WARRAN-TOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied limited warranty lasts or do not allow the exclusion or limi-tation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Parts will be provided by our factory organization through an authorized service organization in your area listed in the yellow pages. If you wish further help or information concerning this limited warranty, contact:

Trane P. O. Box 9010, Tyler, TX 75711-9010 Attention: Manager, Field Operations Excellence

Or visit our website: www.trane.com/residential

TW-1000-4707

* This limited warranty is for residential usage of this equipment and not applicable when this equipment is used for a commercial application. A commercial use is any application where the end purchaser uses the product for other than personal, family or household purposes.

Models Less Than 20 Tons for Residential Use*

Page 22

Installer’s Guide

8 26-1000-21

The limited warranties displayed in this publication and/or on ComfortSite™ may not accurately reflect the actual limited warranty that shipped with the product.

Models Less Than 20 Tons for Commercial Use*

Limited WarrantyCentral Air Conditioner4TCY4, TCY, 4TCC3, 4TCX3, TCD, TCH, TCK, THC and TSC (Parts Only)

This warranty is extended by Trane U.S. Inc., to the original purchaser and to any succeeding owner of the real prop-erty to which the Air Conditioner is originally affixed, and applies to products purchased and retained for use within the U.S.A. and Canada. There is no warranty against corrosion, erosion or deterioration.

If any part of your Air Conditioner fails because of a manufacturing defect within one year from the date of the original purchase, Warrantor will furnish without charge the required replacement part.

In addition, if the sealed motor-compressor fails because of a manufacturing defect within the second through fifth year from the date of original purchase, Warrantor will furnish without charge the required replacement compressor. Warrantor’s obligations and liabilities under this warranty are limited to furnishing F.O.B. Warrantor factory or ware-house replacement parts for Warrantor’s products covered under this warranty. Warrantor shall not be obligated to pay for the cost of lost refrigerant. No liability shall attach to Warrantor until products have been paid for and then liability shall be limited solely to the purchase price of the equipment under warranty shown to be defective.

THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING BUT NOT SPECIFICALLY LIMITED TO IMPLIED WARRANTIES OF MER-CHANTABILITY AND FITNESS FOR PARTICULAR USE, AND IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Trane P.O. Box 9010 Tyler, TX 75711-9010 Attention: Manager, Field Operations Excellence

TW-1001-4707

* This warranty is for commercial usage of said equipment and not applicable when the equipment is used for a residential application. Commercial use is any application where the end purchaser uses the product for other than personal, family or household purposes.