Table of Contents
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Service Literature
The TCA 7.5, 8.5 and 10 ton cooling package units are avail-
able in standard efficiency (090S, 102S, 120S) and high effi-
ciency (090H, 102H, 120H). The TCA 12.5 ton unit is avail-
able in standard efficiency only (150S). The TCA 090/150
series uses one cabinet size with cooling capacities of
93,000 to 140,000 Btuh (27.2 to 41 kW).
Optional electric heat is factory−or field−installed in TCA units.
Electric heat operates in single or multiple stages depending
on the kW input size. 7.5 kW to 45 kW heat sections are avail-
able for the TCA090 and 102 and 15 kW to 60 kW heat sec-
tions are available for the TCA120 and 150.
All units utilize two scroll compressors and are designed to
accept any of several different energy management thermo-
stat control systems with minimum field wiring. Factory or
field provided control options connect to the unit with jack
plugs. When "plugged in" the controls become an integral
part of the unit wiring.
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are sub-
ject to change. Procedures outlined in this manual are pre-
sented as a recommendation only and do not supersede or
replace local or state codes.
If the unit must be lifted for service, rig unit by attaching four
cables to the holes located in the unit base rail (two holes at
each corner). Refer to the installation instructions for the prop-
er rigging technique.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a licensed professional installer or
service agency.
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant
must be used and recovered responsibly.
Failure to follow this warning may result in person-
al injury or death.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
Electrostatic discharge can affect electronic
components. Take precautions during unit instal-
lation and service to protect the unit's electronic
controls. Precautions will help to avoid control
exposure to electrostatic discharge by putting
the unit, the control and the technician at the
same electrostatic potential. Neutralize electro-
static charge by touching hand and all tools on an
unpainted unit surface before performing any
service procedure.
Table of Contents
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Blower Data
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II Placement and Installation
III Start Up Operation
IV Charging
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V Maintenance
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VI Accessories
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VII Wiring and Operating Sequence
©2008 Allied Air Enterprises Inc., a Lennox International Inc. Company
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TCA
ROOFTOP UNITS
TCA−090−102−120−150 (10−08)
CAUTION
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Phone: (803) 738−4000
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Table of Contents
Related Manuals for ALLIED COMMERCIAL TCA Series
Summary of Contents for ALLIED COMMERCIAL TCA Series
- Page 1 ROOFTOP UNITS Service Literature TCA−090−102−120−150 (10−08) The TCA 7.5, 8.5 and 10 ton cooling package units are avail- able in standard efficiency (090S, 102S, 120S) and high effi- ciency (090H, 102H, 120H). The TCA 12.5 ton unit is avail- able in standard efficiency only (150S). The TCA 090/150 series uses one cabinet size with cooling capacities of 93,000 to 140,000 Btuh (27.2 to 41 kW).
- Page 2 SPECIFICATIONS General Nominal Tonnage 7.5 Ton 8.5 Ton 10 Ton 12.5 Ton Data Model No. TCA090S2B TCA102S2B TCA120S2B TCA150S2B Efficiency Type Standard Standard Standard Standard Cooling Gross Cooling Capacity − Btuh (kW) 93,000 (27.2) 104,000 (30.5) 126,000 (36.6) 145,000 (42.5) Performance Net Cooling Capacity −...
- Page 3 SPECIFICATIONS General Nominal Tonnage 7.5 Ton 8.5 Ton 10 Ton Data Model No. TCA090H2B TCA102H2B TCA120H2B Cooling Gross Cooling Capacity − Btuh (kW) 93,000 (27.2) 106,000 (31.0) 126,000 (36.9) Performance Net Cooling Capacity − Btuh (kW) 90,000 (26.4) 103,000 (30.2) 120,000 (35.2) ARI Rated Airflow −...
- Page 4 OPTIONAL FIELD INSTALLED ACCESSORIES 7.5 ton 8.5 ton 10 ton 12.5 ton Item Cabinet Coil Guards TACGKGC10/15 Accessories Hail Guards TAHGKGC10/15 Horizontal Discharge Conversion Kit LTHSDKGC10/15 Ceiling Step−Down − Net Weight RTD11-95 RTD11-135 RTD11-185 Diffusers 88 lbs. (40 kg) 205 lbs. (93 kg) 392 lbs.
- Page 5 OPTIONAL ELECTRIC HEAT ACCESSORIES UNIT FUSE BLOCKS WITH ELECTRIC HEAT Unit Model No. TCA090S TCA090H TCA102S TCA102H TCA120S TCA120H TCA150S Blower Motor Size 2 hp (1.5 kW) 2 hp (1.5 kW) 2 hp (1.5 kW) 2 hp (1.5 kW) 3 hp (2.2 kW) 3 hp (2.2 kW) 5 hp (3.7 kW) Electric Heat Model No.
- Page 6 ELECTRICAL DATA 7.5 TON STANDARD / HIGH EFFICIENCY Model No. TCA090S TCA090H Line voltage data − 60 Hz − 3 phase 208/230V 460V 575V 208/230V 460V 575V Rated load amps − each (total) 12.8 (25.6) 6.4 (12.8) 5.1 (10.2) 12.4 (24.9) 6.4 (12.8) 4.8 (9.6) Compressors...
- Page 7 ELECTRICAL DATA 10 TON STANDARD / HIGH EFFICIENCY Model No. TCA120S TCA120H Line voltage data − 60 Hz − 3 phase 208/230V 460V 575V 208/230V 460V 575V Rated load amps − each (total) Compressors 15.4 (30.8) 7.4 (14.8) 5.9 (11.8) 17.3 (34.6) 9.0 (18.0) 7.1 (14.2)
- Page 8 BLOWER DATA 090, 102, 120, 150 BELT DRIVE BLOWER − BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY (NO HEAT SECTION) WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 − Wet indoor coil air resistance of selected unit. 2 −...
- Page 9 BLOWER DATA DRIVE KIT SPECIFICATIONS Motor Outputs RPM Range Nominal Maximum Nominal Maximum Drive 1 Drive 3 Drive 4 Drive 5 Drive 6 680 − 925 895 − 1120 − − − − − − − − − 3.45 680 − 925 895 −...
- Page 10 BLOWER DATA ACCESSORY AIR RESISTANCE Wet Indoor Coil MERV 11 Air Volume Electric Heat Economizer Filter 090, 102 120S, 120H,150S in. w.g. in. w.g. in. w.g. in. w.g. in. w.g. 2250 1060 .035 2500 1180 2750 1325 .045 3000 1420 3250 1535 3500...
- Page 11 TCA PARTS ARRANGEMENT FILTERS EVAPORATOR ECONOMIZER CONDENSER (FOUR − 18 X 24 X 2") COIL (OPTIONAL) FANS BLOWER FILTER DRIERS CONDENSER CONDENSATE COIL BLOWER DRAIN MOTOR ELECTRIC HEAT F4 FUSE BLOCK (Optional) (OPTIONAL) COMPRESSORS FIGURE 1 TCA CONTROL BOX MCC Control Module Electric Heat Hat (A45) Section...
- Page 12 I−UNIT COMPONENTS 6−Compressor Contactor K1 & K2 All compressor contactors are three-pole-double-break WARNING contactors with 24VAC coils. In all TCA090/150 units, K1 and K2 (energized by MCC board A45) energize compres- Electric shock hazard. Can cause injury sors B1 and B2 in response to thermostat demand. K2 also or death.
- Page 13 TABLE 1 UNIT TYPE DIP SWITCH (FACTORY−SET) Indicates Action Status No power to Check field wiring. If problem per- board. sists refer to service manual. Press MCC pushbutton and Processor error. hold for three seconds to reset TGA UNITS processor.* TCA UNITS Flashes Normal.
- Page 14 TABLE 2 TABLE 5 TB1 TERMINAL DESIGNATIONS P113 TERMINAL DESIGNATIONS Cool Stage 1 Terminal Function Cool Stage 2 Relay KA To Freeze Stat Cool Stage 3 (N/A) From Freeze Stat Cool Stage 4 (N/A) Heat Stage 1 Relay KA To Outdoor Fan Contactor Heat Stage 2 Freeze Stat to Compressor Contactor Occupied Loop...
- Page 15 TCA PLUMBING, COMPRESSOR AND REFRIGERANT CIRCUITS DETAIL CONDENSER COIL EVAPORATOR COIL FREEZESTAT FREEZESTAT OPTIONAL LOW AMBIENT SWITCHES (S84), (S11) (BOTH FANS ARE ENERGIZED WITH A Y1 DEMAND) DRIERS OPTIONAL HIGH PRESSURE SWITCH (S7) COMPRESSOR (B2) COMPRESSOR (B1) STG 2 OPTIONAL HIGH STG 1 PRESSURE SWITCH (S4)
- Page 16 B−Cooling Components 2−Freezestats S49 and S50 Each unit is equipped with a low temperature switch (freezes- All units use independent cooling circuits consisting of sep- arate compressors, condenser coils and evaporator coils. tat) located on a return bend of each evaporator coil. S49 See figure 6.
- Page 17 C−Blower Compartment Determining Unit CFM The blower compartment in all TCA090/150S units is lo- 1− The following measurements must be made with a dry cated between the evaporator coil and the condenser coil sec- indoor coil. Run blower without a cooling demand. tion.
- Page 18 BLOWER ASSEMBLY TO INCREASE BELT TENSION MOTOR BASE ADJUSTMENT SCREWS 1−Loosen four bolts securing motor base to mounting − 2 EACH SIDE frame. ALIGN TOP EDGES 2−Turn adjusting bolt to the right, or clockwise, to PARALLEL BEFORE BLOWER MOTOR move the motor outward and tighten the belt. TIGHTENING MOTOR MOUNTING FRAME IN PLACE...
- Page 19 D−Optional Electric Heat Components the system, contactor K15 is de-energized. When K15 is de-energized, first stage and all subsequent stages of Tables 9 and 10 show all possible TCA to EHA matchups and heat are de-energized. For EHA102/150 units, the high electrical ratings.
- Page 20 TABLE 8 TCA ELECTRIC HEAT SECTION FUSE RATING FUSE (3 each) EHA QUANTITY VOLTAGES & SIZE F3 − 1 F3 − 2 F3 − 3 F3 − 4 208/230V 25 Amp 250V −−−−− −−−−− −−−−− 460V 15 Amp 600V −−−−− −−−−−...
- Page 21 EHA 7.5, 15, 22.5, 30, 45, 60KW ELECTRIC HEAT SECTION PARTS ARRANGEMENT HEATING ELEMENTS HE1 − HE7 SECONDARY ELECTRIC HEAT LIMIT S20 ELECTRIC HEAT VESTIBULE CONTROL WIRE HARNESS PRIMARY ELECTRIC HEAT LIMIT FIGURE 11 ELECTRIC HEAT VESTIBULE PARTS ARRANGEMENT TERMINAL STRIP (TB3) FUSE F3 FIRST STAGE ELECTRIC...
- Page 22 TABLE 9 7.5 TON STANDARD / HIGH EFFICIENCY − TCA090 8.5 TON STANDARD / HIGH EFFICIENCY − TCA102 REQUIRES UNIT FUSE BLOCK, TERMINAL BLOCK AND HEATER CONTROL MODULE Minimum Circuit Ampacity Maximum Overcurrent Protection Electric Heat Total Unit + Electric Heat Total Unit + Electric Heat Volts Btuh...
- Page 23 TABLE 10 10 TON STANDARD / HIGH EFFICIENCY − TCA120 12.5 TON STANDARD EFFICIENCY − TCA150 REQUIRES UNIT FUSE BLOCK, TERMINAL BLOCK AND HEATER CONTROL MODULE Minimum Circuit Ampacity Maximum Overcurrent Protection Electric Heat Total Unit + Electric Heat Total Unit + Electric Heat Volts Btuh Model No.
- Page 24 II−PLACEMENT AND INSTALLATION 4− Each refrigerant circuit is separately charged with HCFC−22 refrigerant. See unit rating plate for correct Make sure the unit is installed in accordance with the amount of charge. installation instructions and all applicable codes. See accessories section for conditions requiring use of the 5−...
- Page 25 6− If discharge pressure is high, remove refrigerant from TABLE 15 TCA120S NORMAL OPERATING PRESSURES the system. If discharge pressure is low, add refriger- Outdoor CIRCUIT 1 CIRCUIT 2 ant to the system. Coil DIs. +10 Suct. +5 Dis. +10 Suc.
- Page 26 V−MAINTENANCE REMOVE FILTERS The unit should be inspected once a year by a qualified ser- vice technician. WARNING Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at discon- nect switch(es).
- Page 27 CLEAN CONDENSER COIL ENDPLATE IS SECURED TO MULLION TOP VIEW 1− Remove unit top panel and condenser section access panel. 2− Remove screws securing coil end plate to mullion. 3− Remove clips connecting coils slabs and separate slabs 3−4" (76−102mm). EVAPORATOR COIL BLOWER 4−...
- Page 28 TYPICAL FLASHING DETAIL LAOAD(M) OUTDOOR AIR DAMPER UNIT BASE BOTTOM DAMPER ASSEMBLY UNIT BASE RAIL FIBERGLASS INSULATION (Furnished) COUNTER FLASHING (Field Supplied) NAILER STRIP (Furnished) UNIT DIVISION CANT STRIP PANEL (Field Supplied) SIDE VIEW RIGID INSULATION (Field Supplied) ROOF MOUNTING FRAME ROOFING (Extends around entire MATERIAL...
- Page 29 ECONOMIZER CONTROLS A6 ENTHALPY CONTROLLER ENTHALPY OUTDOOR AIR CONTROL DAMPER MINI- ENTHALPY MUM POSITION SENSOR IAQ MAXIMUM DIVISION POSITION Open PANEL (set higher than minimum position) IAQ READING IS ABOVE SETPOINT IAQ SETPOINT Free FIGURE 19 Cool OUTDOOR AIR Optional Sensors SUITABLE LED An optional differential sensor (A62) may be used with the A7 outdoor sensor to compare outdoor air temperature to...
- Page 30 1− Set thermostat to occupied mode if the feature is avail- 8− Draw a horizontal line where the two lines meet. Read able. Make sure jumper is in place between A45 con- the percent of fresh air intake on the side. trol board TB1 terminals A1 and A2 if using a thermo- 9−...
- Page 31 During the occupied time period dampers will open to DCV MANUAL OUTDOOR AIR DAMPER MAX when IAQ reading is above setpoint (regardless of thermostat demand or outdoor air suitability). SIDE VIEW Outdoor Air Suitable: Loosen sheet metal screws See table 19 for economizer operation with a standard two− to adjust damper position;...
- Page 32 Three different types of control systems may be used with LAGED(H)10/15 dampers (figure 23) available for the TCA series units. All thermostat wiring is connected to TCA090/150 units are used in downflow and LAGEDH terminal block TB1 located in the control box of the unit.
- Page 33 VII−Wiring Diagrams and Sequence of Operation TCA090/150 UNIT DIAGRAM Page 33...
- Page 34 TCA090/150 SEQUENCE OF OPERATION Power: 1. Line voltage from unit disconnect energizes transformer T1. T1 provides 24VAC power to terminal strip TB1. TB1 provides 24VAC to the unit cooling, heating and blower controls. Blower Operation: 2. The main control module receives a demand from thermostat terminal G. A45 energizes blower contactor K3 with 24VAC.
- Page 35 EHA−7.5, 15, 22.5, 30, 45 60kW Y VOLTAGE Page 35...
- Page 36 EHA−7.5, 15, 22.5, 30, 45 60kW G, J, M VOLTAGE Page 36...
- Page 37 Sequence of Operation −EHA 7.5, 15, 22.5, 30, 45, 60 kW − Y and G, J, M NOTE: This sequence of operation is for all Electric SECOND STAGE HEAT: Heat kW ratings Y through J voltages. Each step of op- 5 −...
- Page 38 ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT POWER: Terminal strip TB1 found on the main control module A45energize thermostat components with 24VAC. OPERATION: The main control module A45 receives data from the electronic thermostat A2 (Y1, Y2, W1, W2, G, OCP) A45 energizes the appropriate components for heat or cool demand. Page 38...
- Page 39 T" SERIES ECONOMIZER SEQUENCE OF OPERATION POWER: Terminal strip TB1 found on main control module A45 energizes the economizer components with 24VAC. OPERATION: Enthalpy sensor A7 and A62 (if differential enthalpy is used) communicates to the economizer control module A6 when to power the damper motor B7. Economizer control module A6 supplies B7 with 0 −...
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