ALLIED COMMERCIAL TCA Series Service manual

Page 1 ©2008 Allied Air Enterprises Inc., a Lennox International Inc. Company
Phone: (803) 738−4000
Service Literature
TCA
ROOFTOP UNITS
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).
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
CAUTION
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
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Data 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Data 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
II Placement and Installation 24. . . . . . . . . . . . . . . . . . . .
III Start Up Operation 24. . . . . . . . . . . . . . . . . . . . . . . . . .
IV Charging 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VI Accessories 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Operating Sequence 33. . . . . . . . . . . . .

Page 2
SPECIFICATIONS
General
Data
Nominal Tonnage 7.5 Ton 8.5 Ton 10 Ton 12.5 Ton
Model No. TCA090S2B TCA102S2B TCA120S2B TCA150S2B
Efficiency Type Standard Standard Standard Standard
Cooling
Performance
Gross Cooling Capacity − Btuh (kW) 93,000 (27.2) 104,000 (30.5) 126,000 (36.6) 145,000 (42.5)
1Net Cooling Capacity − Btuh (kW) 90,000 (26.4) 100,000 (29.3) 120,000 (35.2) 138,000 (40.4)
ARI Rated Airflow − cfm (L/s) 3000 (1415) 3400 (1605) 3800 (1795) 4250 (2005)
Total Unit Power (kW) 8.9 9.9 11.8 14.5
1EER (Btuh/Watt) 10.1 10.1 10.1 9.5
2Integrated Part Load Value (Btuh/Watt) 10.5 10.5 10.5 9.2
Refrigerant Charge
Furnished (HCFC-22)
Circuit 1 7 lbs. 0 oz. (3.18 kg) 7 lbs. 8 oz. (3.140 kg) 10 lbs. 0 oz. (4.53 kg) 13 lbs. 0 oz. (5.90 kg)
Circuit 2 6 lbs. 8 oz. (2.95 kg) 7 lbs. 0 oz. (3.18 kg) 10 lbs. 0 oz. (4.53 kg) 12 lbs. 0 oz. (5.44 kg)
3Sound Rating Number (dB) 88 88 88 88
Compressor − Number & Type (2) Scroll (2) Scroll (2) Scroll (2) Scroll
Condenser
Coil
Net face area − sq. ft. (m2)29.3 (2.72) total 29.3 (2.72) total 29.3 (2.72) total 26.6 (2.47) total
Tube diameter − in. (mm) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5)
Number of rows 1 1 2 3
Fins per inch (m) 20 (787) 20 (787) 20 (787) 20 (787)
Condenser
Fans
Motor horsepower (W) (2) 1/3 (249) (2) 1/3 (249) (2) 1/3 (249) (2) 1/2 (372)
Motor rpm 1075 1075 1075 1075
Total Motor watts 700 700 700 1150
Diameter − in. (mm) − no. of blades (2) 24 (610) − 3 (2) 24 (610) − 3 (2) 24 (610) − 3 (2) 24 (610) − 3
Total air volume − cfm (L/s) 8,000 (3775) 8,000 (3775) 8,000 (3775) 9,000 (4245)
Evaporator
Coil
Net face area − sq. ft. (m2)10.5 (0.98) total 10.5 (0.98) total 10.5 (0.98) total 10.5 (0.98) total
Tube diameter − in. (mm) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5)
Number of rows 3 3 4 4
Fins per inch (m) 14 (551) 14 (551) 14 (551) 14 (551)
Drain Connection − no. & size (1) 1 in. NPT coupling (1) 1 in. NPT coupling (1) 1 in. NPT coupling (1) 1 in. NPT coupling
Expansion device type Balanced Port Thermostatic Expansion Valve, removable power head
Standard
Indoor
Blower and
Drive
4Belt Drive − Nominal motor output 2 hp (1.5 kW) 2 hp (1.5 kW) 3 hp (2.2 kW) 5 hp (3.7 kW)
Maximum usable output (US Only) 2.3 hp (1.7 kW) 2.3 hp (1.7 kW) 3.45 hp (2.6 kW) 5.75 hp (4.3 kW)
Drive kit kit #1 − 680 − 925 rpm kit #1 − 680 − 925 rpm kit #3 − 895 − 1120 rpm kit #6 − 1100− 1395
rpm
Wheelnominaldiameterxwidth−in.(mm) (1) 15 x 15 (381 x 381) (1) 15 x 15 (381 x 381) (1) 15 x 15 (381 x 381) (1) 15 x 15 (381 x
381)
Filters Type of filter Disposable, pleated MERV 7 (standard) or MERV 11 (optional)
Number and size − in. (mm) (4) 18 x 24 x 2
(457 x 610 x 51)
(4) 18 x 24 x 2
(457 x 610 x 51)
(4) 18 x 24 x 2
(457 x 610 x 51)
(4) 18 x 24 x 2
(457 x 610 x 51)
Electrical characteristics 208/230V, 460V or 575V − 60 hertz − 3 phase
NOTE − Net capacity includes evaporator blower motor heat deduction. Gross capacity does not include evaporator blower motor heat deduction.
1Certified in accordance with the ULE certification program, which is based on ARI Standard 340/360, 95F (35C) outdoor air temperature and 80F (27C) db/67F (19C)
wb entering evaporator air; minimum external duct static pressure.
2Integrated Part Load Value rated at 80F (27C) outdoor air temperature, 80F (27C) db/67°F (19°C) wb indoor air temperature.
3Sound Rating Number rated in accordance with test conditions included in ARI Standard 270.
4Maximum usable output of motors are shown. In Canada, nominal motor output is also maximum usable motor output. If motors of comparable output are used, be sure to
keep within the service factor limitations outlined on the motor nameplate.

Page 3
SPECIFICATIONS
General
Data
Nominal Tonnage 7.5 Ton 8.5 Ton 10 Ton
Model No. TCA090H2B TCA102H2B TCA120H2B
Cooling
Performance
Gross Cooling Capacity − Btuh (kW) 93,000 (27.2) 106,000 (31.0) 126,000 (36.9)
1Net Cooling Capacity − Btuh (kW) 90,000 (26.4) 103,000 (30.2) 120,000 (35.2)
ARI Rated Airflow − cfm (L/s) 3000 (1415) 3400 (1605) 3800 (1795)
Total Unit Power (kW) 8.0 9.2 10.9
1EER (Btuh/Watt) 11.0 11.0 11.0
2Integrated Part Load Value (Btuh/Watt) 11.4 11.4 11.4
Refrigerant Charge
Furnished (HCFC-22)
Circuit 1 8 lbs. 8 oz. (3.86 kg) 8 lbs. 8 oz. (3.86 kg) 10 lbs. 0 oz. (4.54 kg)
Circuit 2 8 lbs. 8 oz. (3.86 kg) 8 lbs. 8 oz. (3.86 kg) 10 lbs. 0 oz. (4.54 kg)
3Sound Rating Number (dB) 88 88 88
Compressor − Number and Type (2) Scroll (2) Scroll (2) Scroll
Condenser
Coil
Net face area − sq. ft. (m2)29.3 (2.72) total 29.3 (2.72) total 29.3 (2.72) total
Tube diameter − in. (mm) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5)
Number of rows 2 2 2
Fins per inch (m) 20 (787) 20 (787) 20 (787)
Condenser
Fans
Motor horsepower (W) (2) 1/3 (249) (2) 1/3 (249) (2) 1/3 (249)
Motor rpm 1075 1075 1075
Total Motor watts 700 700 700
Diameter − in. (mm) − no. of blades (2) 24 (610) − 3 (2) 24 (610) − 3 (2) 24 (610) − 3
Total air volume − cfm (L/s) 8,000 (3775) 8,000 (3775) 8,000 (3775)
Evaporator
Coil
Net face area − sq. ft. (m2)10.5 (0.98) total 10.5 (0.98) total 10.5 (0.98) total
Tube diameter − in. (mm) 3/8 (9.5) 3/8 (9.5) 3/8 (9.5)
Number of rows 3 3 4
Fins per inch (m) 14 (551) 14 (551) 14 (551)
Drain Connection − no. & size (1) 1 in. NPT coupling (1) 1 in. NPT coupling (1) 1 in. NPT coupling
Expansion device type Balanced Port Thermostatic Expansion Valve, removable power head
Standard
Indoor
Blower and
Drive
4Belt Drive − Nominal motor output 2 hp (1.5 kW) 2 hp (1.5 kW) 3 hp (2.2 kW)
Maximum usable output (US Only) 2.3 hp (1.7 kW) 2.3 hp (1.7 kW) 3.45 hp (2.6 kW)
Motor − Drive kit kit #1 − 680 − 925 rpm kit #1 − 680 − 925 rpm kit #3 − 895 − 1120 rpm
Wheelnominaldiameterxwidth−in.(mm) (1) 15 x 15 (381 x 381) (1) 15 x 15 (381 x 381) (1) 15 x 15 (381 x 381)
Filters Type of filter Disposable, pleated MERV 7 (standard) or MERV 11 (optional)
Number and size − in. (mm) (4) 18 x 24 x 2
(457 x 610 x 51)
(4) 18 x 24 x 2
(457 x 610 x 51)
(4) 18 x 24 x 2
(457 x 610 x 51)
Electrical characteristics 208/230V, 460V or 575V − 60 hertz − 3 phase
NOTE − Net capacity includes evaporator blower motor heat deduction. Gross capacity does not include evaporator blower motor heat deduction.
1Certified in accordance with the ULE certification program, which is based on ARI Standard 340/360, 95F (35C) outdoor air temperature and 80F (27C) db/67F (19C)
wb entering evaporator air; minimum external duct static pressure.
2Integrated Part Load Value rated at 80F (27C) outdoor air temperature, 80F (27C) db/67°F (19°C) wb indoor air temperature.
3Sound Rating Number rated in accordance with test conditions included in ARI Standard 270.
4Maximum usable output of motors shown. In Canada, nominal motor output is also maximum usable motor output. If motors of comparable output are used, be sure to keep
within the service factor limitations outlined on the motor nameplate.

Page 4
OPTIONAL FIELD INSTALLED ACCESSORIES
Item 7.5 ton 8.5 ton 10 ton 12.5 ton
090 102 120 150
Cabinet
Accessories
Coil Guards TACGKGC10/15
Hail Guards TAHGKGC10/15
Horizontal Discharge Conversion Kit LTHSDKGC10/15
Ceiling
Diffusers
Step−Down − Net Weight RTD11-95
88 lbs. (40 kg)
RTD11-135
205 lbs. (93 kg)
RTD11-185
392 lbs. (178 kg)
Flush − Net Weight FD11-95
75 lbs. (34 kg)
FD11-135
174 lbs. (79 kg)
FD11-185
289 lbs. (131 kg)
Transitions (Supply and Return) − Net Weight LASRT08/10
30 lbs (14 kg)
LASRT10/12
32 lbs (15 kg)
LASRT15
36 lbs. (16 kg)
Controls Blower Proving Switch LTABPSK
Dirty Filter Switch LTADFSK
L Connection®Network See Engineering Handbook
Smoke Detector − Supply LTASASDK10/36
Smoke Detector − Return LTRASDK−10/30
Cooling
Accessories
PVC Condensate Drain Trap LTACDKP03/36
Copper Condensate Drain Trap LTACDKC03/36
High Pressure Switch TAHPK10/15
Compressor Crankcase Heater TACCHK10/15
Low Ambient Kit TALAK10/15
Economizer Economizer − Net Weight TAREMD10/15 − 47 lbs. (21 kg)
Economizer Outdoor Air Hood − Net Weight
Number and Size of Filters
LAOAH10/15 − 11 lbs. (5 kg)
(2) 16 x 25 x 1 in. (406 x 635 x 25 mm)
Economizer Enthalpy Control − Differential LTADEK03/36
Economizer Enthalpy Control − Outdoor LTASEK03/36
Barometric
Relief
Down−Flow Barometric Relief Dampers − Net Weight LAGED10/15 − 8 lbs. (4 kg)
Hood for Down−Flow LAGED LAGEH09/15
Horizontal Barometric Relief Dampers − Net Weight LAGEDH03/15 − 8 lbs. (4 kg)
Outdoor
Air
Dampers
Damper Section (down−flow) − Automatic − Net Weight TAOADM10/15 − 31 lbs. (14 kg)
Damper Section (down−flow) − Manual − Net Weight LAOAD10/15 − 26 lbs. (12 kg)
Outdoor Air Hood (down−flow) Net Weight
Number and Size of Filters
LAOAH10/15 − 11 lbs. (5 kg)
(2) 16 x 25 x 1 in. (406 x 635 x 25 mm)
Power Exhaust Power Exhaust Fan − Net Weight LAPEF10/15 − 28 lbs. (13 kg)
Electrical
Accessories
HACR Circuit Breaker TAHBK10/15−* (indicate size)
Disconnect Switch TADK10/15−80 (80A) TADK10/15−150 (150A)
GFI Service Outlets LTAGFIK10/15
Filters MERV 11 High Efficiency AFK−11 (18 x 24 x 2 specify four per unit)
Indoor Air
Quality (CO2)
Sensors
CO2Sensor Duct Mounting Kit LTIAQSDMK03/36
Sensor − white case CO2display LTAIAQSWDK03/36
Sensor − white case no display LTAIAQSWN03/36
Sensor − black case CO2display LTAIAQSND03/36
Sensor − duct mount, black, no display LTAIAQSDMBN03/36
Aspiration Box for duct mounting LTIAQABD03/36
Handheld CO2Monitor LTAIAQSHM03/36
Standard
Roof Curbs
14 in. (356 mm) height − Net Weight LARMF10/15-14 − 126 lbs. (57 kg)
24 in. (610 mm) height − Net Weight LARMF10/15-24 − 174 lbs. (79 kg)
Cliplock 1000
Roof Curbs
14 in. (356 mm) height − Net Weight LARMF10/15S-14 − 126 lbs. (57 kg)
18 in. (457 mm) height LARMF10/15S-18
24 in. (610 mm) height − Net Weight LARMF10/15S-24 − 174 lbs. (79 kg)

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. EHA (see Electric Heat Data tables for additional information)
kW Input
Range 7.5−15−22.5−30−45 15−22.5−30−45−60
Unit
Fuse
Block
(3 phase)
With
Power
Exhaust
Fans
208/230V 56K93 56K93 56K94 56K94 56K94 56K95 56K96
460V 56K52 56K52 25K08 25K08 25K08 25K09 25K10
575V 56K51 56K51 56K51 56K51 56K52 56K52 25K08
Without
Power
Exhaust
Fans
208/230V 56K93 56K93 56K94 56K94 56K94 56K95 56K96
460V 56K52 56K52 56K52 56K52 25K08 25K09 25K09
575V 56K51 56K51 56K51 56K51 56K52 56K52 25K08
LTB2 ELECTRIC HEAT TERMINAL BLOCK − LTB2−175 (30K75) 175 amps, LTB2−335 (30K76) 335 amps
(Required For Units Without Disconnect/Circuit Breaker But With Single Point Power Source)
LTB2
Terminal
Block
7.5 kW All hp 208/230V 30K75 30K75 30K75 30K75 30K75 30K75 30K75 30K75
15 kW All hp 208/230V 30K75 30K75 30K75 30K75 30K75 30K75 30K75 30K75
22.5 kW All hp 208/230V 30K75 30K75 30K75 30K75 30K75 30K75 30K75 30K75
30 kW All hp 208/230V 30K75 30K75 30K75 30K75 30K75 30K75 30K75 30K75
45 kW All hp 208/230V 30K75 30K75 30K75 30K75 30K75 30K75 30K75 30K75
60 kW All hp 208/230V − − − − − − − − − − − − 30K76 30K76 30K76 30K76
NOTE − All 460V and 575V models use 30K75 terminal block.
NOTE − Terminal Block is factory installed in units with factory installed electric heat without disconnect/circuit breaker but with single point power source.

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
Compressors
(2)
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)
Locked rotor amps − each (total) 91 (182) 46 (92) 37 (74) 88 (176) 44 (88) 34 (68)
Condenser
FanMotor
Number of motors 222222
Full load amps − each (total) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0)
Locked rotor amps − each (total) 4.7 (9.4) 2.4 (4.8) 1.9 (3.8) 4.7 (9.4) 2.4 (4.8) 1.9 (3.8)
Evaporator
Blower
Motor
Motor Output − hp 232323232323
kW 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2
Fullloadamps 7.5 10.6 3.4 4.8 2.7 3.9 7.5 10.6 3.4 4.8 2.7 3.9
Lockedrotoramps 46.9 66 20.4 26.8 16.2 23.4 46.9 66 20.4 26.8 16.2 23.4
1Maximum Overcurrent
Protection (amps)
With Exhaust Fan 50 50 25 25 20 20 50 50 25 25 20 20
Less Exhaust Fan 50 50 25 25 20 20 50 50 25 25 20 20
2Minimum Circuit
Ampacity
With Exhaust Fan 44 47 22 24 18 19 43 46 22 24 17 18
Less Exhaust Fan 42 45 21 22 17 18 41 44 21 22 16 17
Optional Power
Exhaust Fan
(Number)Horsepower (W) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249)
Fullloadamps 2.4 1.3 1.0 2.4 1.3 1.0
Lockedrotoramps 4.7 2.4 1.9 4.7 2.4 1.9
Service Outlet (2) 115 volt GFCI (amp rating) 15 15 15 15 15 15
NOTE−Extremesofoperatingrangeareplusandminus10%oflinevoltage.
1 HACR type breaker or fuse.
2 RefertoNational or CanadianElectricalCodemanualtodeterminewire,fuseanddisconnectsizerequirements.
8.5 TON STANDARD / HIGH EFFICIENCY
ModelNo. TCA102S TCA102H
Linevoltagedata−60Hz−3phase 208/230V 460V 575V 208/230V 460V 575V
Compressors
(2)
Rated load amps − each (total) 14.7 (29.4) 7.1 (14.2) 5.8 (11.6) 14.7 (29.4) 7.1 (14.2) 5.1 (10.2)
Locked rotor amps − each (total) 91 (182) 50 (100) 37 (74) 91 (182) 46 (92) 37 (74)
Condenser
FanMotors (2)
Full load amps − each (total) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0)
Locked rotor amps − each (total) 4.7 (9.4) 2.4 (4.8) 1.9 (3.8) 4.7 (9.4) 2.4 (4.8) 1.9 (3.8)
Evaporator
Blower
Motor
Motor Output − hp 2323232 3 2 3 2 3
kW 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2 1.5 2.2
Fullloadamps 7.5 10.6 3.4 4.8 2.7 3.9 7.5 10.6 3.4 4.8 2.7 3.9
Lockedrotoramps 46.9 66 20.4 26.8 16.2 23.4 46.9 66 20.4 26.8 16.2 23.4
1Maximum Overcurrent
Protection (amps)
With Exhaust Fan 60 60 30 30 20 25 60 60 30 30 20 20
Less Exhaust Fan 60 60 25 30 20 20 60 60 25 30 20 20
2Minimum Circuit
Ampacity
With Exhaust Fan 48 51 24 25 19 20 48 51 24 25 18 19
Less Exhaust Fan 46 49 22 27 18 19 46 49 22 24 17 18
Optional Power
Exhaust Fan
(Number)Horsepower (W) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249)
Fullloadamps 2.4 1.3 1.0 2.4 1.3 1.0
Lockedrotoramps 4.7 2.4 1.9 4.7 2.4 1.9
Service Outlet (2) 115 volt GFCI (amp rating) 15 15 15 15 15 15
NOTE−Extremesofoperatingrangeareplusandminus10%oflinevoltage.
1 HACR type breaker or fuse.
2 RefertoNational or CanadianElectricalCodemanualtodeterminewire,fuseanddisconnectsizerequirements.

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
Compressors
(2)
Rated load amps − each (total) 15.4 (30.8) 7.4 (14.8) 5.9 (11.8) 17.3 (34.6) 9.0 (18.0) 7.1 (14.2)
Locked rotor amps − each (total) 124 (248) 59.6 (119.2) 49.4 (98.8) 123 (246) 62 (124) 50 (100)
Condenser
FanMotors (2)
Full load amps − each (total) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0) 2.4 (4.8) 1.3 (2.6) 1.0 (2.0)
Locked rotor amps − each (total) 4.7 (9.4) 2.4 (4.8) 1.9 (3.8) 4.9 (9.4) 2.4 (4.8) 1.9 (3.8)
Evaporator
Blower
Motor
Motor Output − hp 2 3 5 2 3 5 2 3 5 2 3 5 2 3 5 2 3 5
kW 1.5 2.2 3.7 1.5 2.2 3.7 1.5 2.2 3.7 1.5 2.2 3.7 1.5 2.2 3.7 1.5 2.2 3.7
Fullloadamps 7.5 10.6 16.7 3.4 4.8 7.6 2.7 3.9 6.1 7.5 10.6 16.7 3.4 4.8 7.6 2.7 3.9 6.1
Lockedrotoramps 46.9 66 105 20.4 26.8 45.6 16.2 23.4 36.6 46.9 66 105 20.4 26.8 45.6 16.2 23.4 36.6
1Maximum Overcurrent
Protection (amps)
With Exhaust Fan 60 60 70 30 30 35 20 25 25 70 70 80 35 35 40 25 30 30
Less Exhaust Fan 60 60 70 30 30 30 20 25 25 60 70 70 35 35 35 25 25 30
2Minimum Circuit
Ampacity
With Exhaust Fan 50 53 59 24 26 29 19 21 23 54 57 63 28 29 32 22 23 26
Less Exhaust Fan 47 51 57 23 25 27 18 20 22 52 55 61 27 28 31 21 22 25
Optional Power
Exhaust Fan
(Number)Horsepower (W) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249)
Fullloadamps 2.4 1.3 1.0 2.4 1.3 1.0
Lockedrotoramps 4.7 2.4 1.9 4.7 2.4 1.9
Service Outlet (2) 115 volt GFCI (amp rating) 15 15 15 15 15 15
NOTE−Extremesofoperatingrangeareplusandminus10%oflinevoltage.
1 HACR type breaker or fuse.
2 RefertoNational or CanadianElectricalCodemanualtodeterminewire,fuseanddisconnectsizerequirements.
12.5 TON STANDARD EFFICIENCY
ModelNo. TCA150S
Linevoltagedata−60Hz−3phase 208/230V 460V 575V
Compressors
(2)
Rated load amps − each (total) 18.6 (37.2) 9 (18) 7.4 (14.8)
Locked rotor amps − each (total) 156 (312) 75 (150) 54 (108)
Condenser
FanMotors (2)
Full load amps − each (total) 3.0 (6.0) 1.5 (3.0) 1.2 (2.4)
Locked rotor amps − each (total) 6.0 (12.0) 3.0 (6.0) 2.9 (5.8)
Evaporator
Blower
Motor
Motor Output − hp 353535
kW 2.2 3.7 2.2 3.7 2.2 3.7
Fullloadamps 10.6 16.7 4.8 7.6 3.9 6.1
Lockedrotoramps 66 105 26.8 45.6 23.4 36.6
1Maximum Overcurrent
Protection (amps)
With Exhaust Fan 70 80 35 40 30 30
Less Exhaust Fan 70 80 35 35 30 30
2Minimum Circuit
Ampacity
With Exhaust Fan 61 67 30 33 24 27
Less Exhaust Fan 59 65 29 31 23 26
Optional Power
Exhaust Fan
(Number)Horsepower (W) (1) 1/3 (249) (1) 1/3 (249) (1) 1/3 (249)
Fullloadamps 2.4 1.3 1.0
Lockedrotoramps 4.7 2.4 1.9
Service Outlet (2) 115 volt GFCI (amp rating) 15 15 15
NOTE−Extremesofoperatingrangeareplusandminus10%oflinevoltage.
1 HACR type breaker or fuse.
2 RefertoNational or CanadianElectricalCodemanualtodeterminewire,fuseanddisconnectsizerequirements.

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 − Any factory installed options air resistance (heat section, economizer, etc.)
3 − Any field installed accessories air resistance (duct resistance, diffuser, etc.)
Then determine from blower table blower motor output and drive required.
BOLD INDICATES FIELD FURNISHED DRIVE.
Air
Volume
cfm
(L/s)
Total Static Pressure − in. w.g. (Pa)
.20 (50) .40 (100) .60 (150) .80 (200) 1.00 (250) 1.20 (300) 1.40 (350) 1.60 (400) 1.80 (450) 2.00 (495) 2.20 (545) 2.40 (595) 2.60 (645)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
RPM BHP
(kW)
2250
(1060)
455 0.30
(0.22)
555 0.45
(0.34)
640 0.60
(0.45)
720 0.80
(0.60)
790 1.00
(0.75)
855 1.20
(0.90)
915 1.40
(1.04)
975 1.60
(1.19)
1030 1.85
(1.38)
1080 2.05
(1.53)
1130 2.30
(1.72)
1175 2.55
(1.90)
1220 2.80
(2.09)
2500
(1180)
475 0.40
(0.30)
575 0.55
(0.41)
660 0.70
(0.52)
735 0.90
(0.67)
805 1.10
(0.82)
870 1.30
(0.97)
930 1.55
(1.16)
985 1.75
(1.31)
1040 2.00
(1.49)
1090 2.25
(1.68)
1140 2.50
(1.87)
1185 2.75
(2.05)
1230 3.00
(2.24)
2750
(1300)
495 0.45
(0.34)
595 0.65
(0.48)
675 0.85
(0.63)
750 1.05
(0.78)
820 1.25
(0.93)
885 1.45
(1.08)
940 1.70
(1.27)
995 1.90
(1.42)
1050 2.20
(1.64)
1100 2.45
(1.83)
1145 2.65
(1.98)
1195 2.95
(2.20)
1240 3.25
(2.42)
3000
(1415)
525 0.55
(0.41)
615 0.75
(0.56)
695 0.95
(0.71)
770 1.20
(0.90)
835 1.40
(1.04)
895 1.60
(1.19)
955 1.85
(1.38)
1010 2.10
(1.57)
1060 2.35
(1.75)
1110 2.65
(1.98)
1160 2.90
(2.16)
1205 3.20
(2.39)
1250 3.45
(2.57)
3250
(1535)
550 0.65
(0.48)
640 0.90
(0.67)
715 1.10
(0.82)
790 1.35
(1.01)
855 1.60
(1.19)
915 1.80
(1.34)
970 2.05
(1.53)
1025 2.35
(1.75)
1075 2.60
(1.94)
1125 2.85
(2.13)
1170 3.15
(2.35)
1215 3.40
(2.54)
1260 3.70
(2.76)
3500
(1650)
580 0.80
(0.60)
665 1.05
(0.78)
740 1.25
(0.93)
810 1.50
(1.12)
870 1.75
(1.31)
930 2.00
(1.49)
985 2.25
(1.68)
1040 2.55
(1.90)
1090 2.85
(2.13)
1135 3.10
(2.31)
1185 3.40
(2.54)
1230 3.70
(2.76)
1270 4.00
(2.98)
3750
(1770)
605 0.95
(0.71)
690 1.20
(0.90)
760 1.45
(1.08)
830 1.70
(1.27)
890 1.95
(1.45)
950 2.25
(1.68)
1005 2.50
(1.87)
1055 2.80
(2.09)
1105 3.10
(2.31)
1150 3.35
(2.50)
1195 3.65
(2.72)
1240 3.95
(2.95)
1285 4.30
(3.21)
4000
(1890)
635 1.10
(0.82)
715 1.40
(1.04)
785 1.65
(1.23)
850 1.90
(1.42)
910 2.20
(1.64)
965 2.45
(1.83)
1020 2.75
(2.05)
1070 3.05
(2.28)
1120 3.35
(2.50)
1165 3.65
(2.72)
1210 3.95
(2.95)
1255 4.30
(3.21)
1295 4.60
(3.43)
4250
(2005)
665 1.30
(0.97)
740 1.60
(1.19)
810 1.85
(1.38)
870 2.15
(1.60)
930 2.45
(1.83)
985 2.75
(2.05)
1040 3.05
(2.28)
1090 3.35
(2.50)
1135 3.65
(2.72)
1185 4.00
(2.98)
1225 4.30
(3.21)
1270 4.65
(3.47)
1310 4.95
(3.69)
4500
(2125)
695 1.50
(1.12)
770 1.80
(1.34)
835 2.10
(1.57)
895 2.40
(1.79)
955 2.70
(2.01)
1005 3.00
(2.24)
1060 3.35
(2.50)
1105 3.65
(2.72)
1155 4.00
(2.98)
1200 4.30
(3.21)
1245 4.65
(3.47)
1285 5.00
(3.73)
1325 5.30
(3.95)
4750
(2240)
725 1.75
(1.31)
795 2.05
(1.53)
860 2.40
(1.79)
920 2.70
(2.01)
975 3.00
(2.24)
1030 3.35
(2.50)
1080 3.65
(2.72)
1125 3.95
(2.95)
1175 4.35
(3.25)
1215 4.65
(3.47)
1260 5.00
(3.73)
1300 5.35
(3.99)
1340 5.70
(4.25)
5000
(2360)
760 2.05
(1.53)
825 2.35
(1.75)
885 2.65
(1.98)
945 3.00
(2.24)
1000 3.35
(2.50)
1050 3.65
(2.72)
1100 4.00
(2.98)
1145 4.35
(3.25)
1190 4.70
(3.51)
1235 5.05
(3.77)
1280 5.45
(4.07) − − − − − −
5250
(2475)
790 2.30
(1.72)
855 2.65
(1.98)
910 2.95
(2.20)
970 3.35
(2.50)
1020 3.65
(2.72)
1070 4.00
(2.98)
1120 4.35
(3.25)
1165 4.70
(3.51)
1210 5.10
(3.80)
1255 5.45
(4.07) − − − − − − − − −
5500
(2595)
820 2.60
(1.94)
880 2.95
(2.20)
940 3.30
(2.46)
995 3.70
(2.76)
1045 4.05
(3.02)
1095 4.40
(3.28)
1145 4.80
(3.58)
1190 5.15
(3.84)
1230 5.50
(4.10) − − − − − − − − − − − −
5750
(2715)
850 2.95
(2.20)
910 3.30
(2.46)
965 3.70
(2.76)
1020 4.05
(3.02)
1070 4.45
(3.32)
1120 4.80
(3.58)
1165 5.20
(3.88)
1210 5.60
(4.18) − − − − − − − − − − − − − − −
6000
(2830)
885 3.35
(2.50)
940 3.70
(2.76)
995 4.10
(3.06)
1045 4.45
(3.32)
1095 4.85
(3.62)
1145 5.25
(3.92)
1190 5.65
(4.21) − − − − − − − − − − − − − − − − − −

Page 9
BLOWER DATA
DRIVE KIT SPECIFICATIONS
Motor Outputs RPM Range
Nominal
hp Maximum hp Nominal kW Maximum kW Drive 1 Drive 3 Drive 4 Drive 5 Drive 6
22.3 1.5 1.7 680 − 925 895 − 1120 − − − − − − − − −
33.45 2.2 2.6 680 − 925 895 − 1120 − − − 1110 − 1395 − − −
55.75 3.7 4.3 − − − − − − 895 − 1120 − − − 1110 − 1395
NOTE − Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor output required. Maximum usable output
of motors shown. In Canada, nominal motor output is also maximum usable motor output. If motors of comparable output are used, be sure to keep within the service factor
limitations outlined on the motor nameplate.
CEILING DIFFUSER AIR THROW DATA
Model No. Air Volume
1Effective Throw Range
RTD11 Step-Down FD11 Flush
cfm L/s ft. mft. m
090
2600 1225 24 − 29 7 − 9 19 − 24 6 − 7
2800 1320 25 − 30 8 − 9 20 − 28 6 − 9
3000 1415 27 − 33 8 − 10 21 − 29 6 − 9
3200 1510 28 − 35 9 − 11 22 − 29 7 − 9
3400 1605 30 − 37 9 − 11 22 − 30 7 − 9
102
120
3600 1700 25 − 33 8 − 10 22 − 29 7 − 9
3800 1795 27 − 35 8 − 11 22 − 30 7 − 9
4000 1885 29− 37 9 − 11 24 − 33 7 − 10
4200 1980 32 − 40 10 − 12 26 − 35 8 − 11
4400 2075 34 − 42 10 − 13 28 − 37 9 − 11
150
5600 2645 39 − 49 12 − 15 28 − 37 9 − 11
5800 2740 42 − 51 13 − 16 29 − 38 9 − 12
6000 2830 44 − 54 13 − 17 40 − 50 12 − 15
6200 2925 45 − 55 14 − 17 42 − 51 13 − 16
6400 3020 46 − 55 14 − 17 43 − 52 13 − 16
6600 3115 47 − 56 14 − 17 45 − 56 14 − 17
1Throw is the horizontal or vertical distance an air stream travels on leaving the
outletor diffuser before the maximum velocity is reduced to 50 ft. (15 m) per miute.
Four sides open.
POWER EXHAUST FANS PERFORMANCE
Return Air System
Static Pressure Air Volume Exhausted
in. w.g. Pa cfm L/s
0 0 4200 1980
0.05 12 3970 1875
0.10 25 3750 1770
0.15 37 3520 1660
0.20 50 3300 1560
0.25 62 3080 1455
0.30 75 2860 1350
0.35 87 2640 1245

Page 10
BLOWER DATA
ACCESSORY AIR RESISTANCE
Air Volume Wet Indoor Coil Electric Heat Economizer MERV 11
Filter
090, 102 120S, 120H,150S
cfm L/s in. w.g. Pa in. w.g. Pa in. w.g. Pa in. w.g. Pa in. w.g. Pa
2250 1060 .06 15 .10 25 .01 2 .035 9 .01 2
2500 1180 .08 20 .12 30 .01 2 .04 10 .01 2
2750 1325 .09 22 .14 35 .01 2 .045 11 .02 5
3000 1420 .10 25 .16 40 .02 5 .05 12 .02 5
3250 1535 .11 27 .19 47 .02 5 .06 15 .02 5
3500 1650 .13 32 .21 52 .03 7 .07 17 .03 7
3750 1770 .14 35 .23 57 .03 7 .075 19 .03 7
4000 1890 .16 40 .26 65 .04 10 .08 20 .04 10
4250 2005 .17 42 .28 70 .04 10 .09 22 .04 10
4500 2125 .18 45 .31 77 .05 12 .10 25 .04 10
4750 2240 .20 50 .33 82 .05 12 .11 27 .05 12
5000 2360 .22 55 .36 90 .06 15 .12 30 .06 15
5250 2475 .24 60 .39 97 .06 15 .13 32 .06 15
5500 2595 .26 65 .42 104 .07 17 .14 35 .07 17
5750 2715 .28 70 .45 112 .07 17 .15 37 .07 17
6000 2830 .30 75 .48 119 .08 20 .16 40 .08 20
AIR RESISTANCE − CEILING DIFFUSERS
Unit
Size
Air Volume RTD11 Step-Down Diffuser FD11 Flush
Diffuser
2 Ends Open 1 Side, 2 Ends Open All Ends & Sides Open
cfm L/s in. w.g. Pa in. w.g. Pa in. w.g. Pa in. w.g. Pa
090
Models
2400 1135 0.21 52 0.18 45 0.15 37 0.14 35
2600 1225 0.24 60 0.21 52 0.18 45 0.17 42
2800 1320 0.27 67 0.24 60 0.21 52 0.20 50
3000 1415 0.32 80 0.29 72 0.25 62 0.25 62
3200 1510 0.41 102 0.37 92 0.32 80 0.31 77
3400 1605 0.50 124 0.45 112 0.39 97 0.37 92
3600 1700 0.61 152 0.54 134 0.48 119 0.44 109
3800 1795 0.73 182 0.63 157 0.57 142 0.51 127
102 & 120
Models
3600 1700 0.36 90 0.28 70 0.23 57 0.15 37
3800 1795 0.40 99 0.32 80 0.26 65 0.18 45
4000 1890 0.44 109 0.36 90 0.29 72 0.21 52
4200 1980 0.49 122 0.40 99 0.33 82 0.24 60
4400 2075 0.54 134 0.44 109 0.37 92 0.27 67
4600 2170 0.60 149 0.49 122 0.42 104 0.31 77
4800 2265 0.65 162 0.53 132 0.46 114 0.35 87
5000 2360 0.69 172 0.58 144 0.50 124 0.39 97
5200 2455 0.75 186 0.62 154 0.54 134 0.43 107
150 Models
4200 1980 0.22 55 0.19 47 0.16 40 0.10 25
4400 2075 0.28 70 0.24 60 0.20 50 0.12 30
4600 2170 0.34 85 0.29 72 0.24 60 0.15 37
4800 2265 0.40 99 0.34 85 0.29 72 0.19 47
5000 2360 0.46 114 0.39 97 0.34 85 0.23 57
5200 2455 0.52 129 0.44 109 0.39 97 0.27 67
5400 2550 0.58 144 0.49 122 0.43 107 0.31 77
5600 2645 0.64 159 0.54 134 0.47 117 0.35 87
5800 2735 0.70 174 0.59 147 0.51 127 0.39 97

Page 11
TCA PARTS ARRANGEMENT
FIGURE 1
ELECTRIC HEAT
(Optional)
EVAPORATOR
COIL CONDENSER
FANS
CONDENSER
COIL
COMPRESSORS
CONDENSATE
DRAIN
FILTERS
(FOUR − 18 X 24 X 2")
ECONOMIZER
(OPTIONAL)
BLOWER
BLOWER
MOTOR
FILTER DRIERS
F4 FUSE BLOCK
(OPTIONAL)
TCA CONTROL BOX
FIGURE 2
MCC Control Module
(A45)
Transformer
(T1)
Fan Relay (K10)
Power Exhaust Relay
(K65)
Blower
Contactor
(K3)
Compressor Contactors
(K1) and (K2)
CAPACITOR
C1
CAPACITOR
C2
Electric Heat Hat
Section
DDC CONTROLS Relay (K9) Time
Delay
DL12

Page 12
I−UNIT COMPONENTS
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). Unit may have multiple
power supplies.
The TCA unit components are shown in figure 1. All units
come standard with removable panels. All L1, L2, and L3
wiring is color coded; L1 is red, L2 is yellow, and L3 is blue.
A−Control Box Components
TCA control box components are shown in figure 2. The
control box is located in the upper left portion of the com-
pressor compartment.
1−Disconnect Switch S48 (Optional all units)
All units may be equipped with an optional disconnect switch
S48 or circuit breaker CB10. S48 and CB10 are toggle
switches, which can be used by the service technician to dis-
connect power to the unit.
2−Control Transformer T1 (all units)
All use a single line voltage to 24VAC transformer
mounted in the control box. Transformer supplies power
to control circuits in the unit. The transformer is rated at
70VA and is protected by a 3.5 amp circuit breaker
(CB8). The 208/230 (Y) voltage transformers use two
primary voltage taps
as shown in figure 3,
while 460 (G) and 575
(J) voltage transform-
ers use a single prima-
ry voltage tap.
3−Terminal Strip TB1
All indoor thermostat connections will be to TB1 located on
the MCC board A45. For thermostats without occupied"
and unoccupied" modes, a factory installed jumper across
terminals A1 and A2 found on the MCC board should be in
place.
4−Terminal Strip TB14
Terminal strip TB14 located on the MCC board distributes
24V power from the indoor thermostat to the control box.
Units not equipped with smoke detectors A17 or A64, will
have a factory installed jumper across terminals 24VAC
and R.
5−Condenser Fan Capacitors C1 & C2
Fan capacitors C1 and C2 are 370V / 10 MFD capacitors
used to assist in the start up of condenser fans B4 and B5.
Ratings are on side of capacitor or condenser fan motor
nameplate.
6−Compressor Contactor K1 & K2
All compressor contactors are three-pole-double-break
contactors with 24VAC coils. In all TCA090/150 units, K1
and K2 (energized by MCC board A45) energize compres-
sors B1 and B2 in response to thermostat demand. K2 also
serves as the line voltage terminal block for L1, L2 and L3.
7−Blower Contactor K3 (all units)
Blower contactor K3, used in all units, is a three-pole-double-
break contactor with a 24VAC coil used to energize the indoor
blower motor B3 in response to blower demand. K3 is ener-
gized by the MCC board A45.
8−Condenser Fan Relay K10
Condenser fan relay K10 is a DPDT relay with a 24VAC coil.
K10 energizes condenser fans B4 and B5.
9−Power Exhaust Relay K65 (PED units)
Power exhaust relay K65 is a DPDT relay with a 24VAC
coil. K65 is used in all TCA units equipped with the op-
tional power exhaust dampers. K65 is energized by the
economizer enthalpy control A6, after the economizer
dampers reach 50% open (adjustable) When K65
closes, exhaust fan B10 is energized.
10−MCC Control A45
The main control module A45 (figure 5) controls all cool-
ing operation and serves as a staging point for all internal
inputs to the appropriate components of the TCA unit. The
MCC control receives and sends out 24 volts to the com-
ponents located in the TCA control box, economizer and
supply/return compartments. The control communicates to
compressors contactors K1, K2 , condenser fan relay K10 and
indoor blower contactor K3. Thermostat hook ups (TB1) and
accessory low voltage hook ups (TB14) are located on the
board. See tables 2 and 3 for terminal designations. Tables 4,
5 and 6 show pin terminal designations.
Features
The MCC A45 is equipped with a green LED for board sta-
tus. See table 1 for LED flash codes. While in the cooling
mode the board will incorporate AUTO−STAGING. If the
board receives a Y3 demand (if applicable) the board will
energize Y1, Y2 and Y3 in successive order. In the same
manner a Y2, will be interpreted as a Y1/Y2. The MCC
control also incorporates a minimum run time of 4 minutes
for up to 2 independent cooling stages. This 4 minute run
time can be interrupted by pushing SW1 located on the
board. If pressed for 3 seconds or more, the control goes
into TEST mode disabling AUTO−STAGING. The MCC
control board is used for all T series units. A dip switch,
factory set, is provided to configure to unit type (TGA
gas, TCA cooling/electric heat, THA heat pump) See fig-
ure 4.
FIGURE 3
BLUE YELLOW
ORANGE
RED
BLACK
230 VOLTS
208 VOLTS
PRIMARY
SECONDARY
208/230V TRANSFORMER

Page 13
TABLE 1
LED
Status Indicates Action
Off No power to
board.
Check field wiring. If problem per-
sists refer to service manual.
On Processor error.
Press MCC pushbutton and
hold for three seconds to reset
processor.*
Flashes
Slowly Normal. None.
Flashes
Rapidly
Invalid unit DIP
switch selected.
Make sure switches are set
correctly. Refer to figure 4.
Flashes
Rapidly
Simultaneous
heat and cool
demands.
Check thermostat and wiring.
*Press pushbutton and immediately release to override the
4−minute compressor minimum run time.
UNIT TYPE DIP SWITCH (FACTORY−SET)
TGA UNITS TCA UNITS
THA UNITS UNUSED
(HEARTBEAT LED WILL FLASH
RAPIDLY IN ERROR)
FIGURE 4
MCC CONTROL BOARD (A45)
FIGURE 5
RW1 Y1 C GBL
OUT
W2
LED

Page 14
TABLE 2
TB1 TERMINAL DESIGNATIONS
Y1 Cool Stage 1
Y2 Cool Stage 2
Y3 Cool Stage 3 (N/A)
Y4 Cool Stage 4 (N/A)
W1 Heat Stage 1
W2 Heat Stage 2
A1 Occupied Loop
A2 Occupied Loop
GIndoor Blower
R24V To Thermostat
CGround
TEST Test Terminal (Disable Min Run Time)
TABLE 3
TB14 24VAC TERMINAL DESIGNATIONS
24VAC Uninterrupted 24 Volt Power
R24 Volt Accessories (from T1 transformer)
T18 24 Volts (from T18 transformer)
CGround
TABLE 4
P142 TERMINAL DESIGNATIONS
Terminal Function
Y2 From Economizer (cool2)
Y2E To Processor (micro chip)
Y1 From Economizer
Y1E To Processor (micro chip)
24V To Smoke Detector
24V From T1 Transformer
A1 Occupied Loop from Thermostat
24V To Economizer
GND Ground to Economizer
24V From Transformer T1
GND Ground
24V From Transformer T18
Y3 To Processor (micro chip)
TABLE 5
P113 TERMINAL DESIGNATIONS
Terminal Function
S49 Relay KA To Freeze Stat
S49 From Freeze Stat
K10 Relay KA To Outdoor Fan Contactor
K1 Freeze Stat to Compressor Contactor
S50 Relay KB To Freeze Stat
S50 From Freeze Stat
K2 Freeze Stat To Compressor Contactor
K3 KD To Fan Relay
CGround To Cooling Component
TABLE 6
P88 TERMINAL DESIGNATIONS
Terminal Function
R24V To A3
W1 Heat Stage 1 to A3
Y1 Cooling Stage to A3
CGround to A3
GBlower Demand to A3
BL OUT Blower Out from A3
W2 Heat Stage 2 to A3

Page 15
TCA PLUMBING, COMPRESSOR AND
REFRIGERANT CIRCUITS DETAIL
FIGURE 6
DRIERS
COMPRESSOR (B1)
STG 1
COMPRESSOR (B2)
STG 2
OPTIONAL HIGH
PRESSURE
SWITCH (S4)
OPTIONAL HIGH
PRESSURE
SWITCH (S7)
OPTIONAL LOW AMBIENT
SWITCHES (S84), (S11)
1
2
(BOTH FANS ARE ENERGIZED
WITH A Y1 DEMAND)
EVAPORATOR COIL
CONDENSER COIL
FREEZESTAT
S50
FREEZESTAT
S49

Page 16
B−Cooling Components
All units use independent cooling circuits consisting of sep-
arate compressors, condenser coils and evaporator coils.
See figure 6. Two draw−through type condenser fans are
used in TCA090/150 units. All units are equipped with belt-
drive blowers which draw air across the evaporator during
unit operation.
Cooling may be supplemented by a factory- or field-
installed economizer. The evaporators are slab type
and are stacked. Each evaporator uses a thermostatic ex-
pansion valve as the refrigerant metering device. Each
evaporator is also equipped with enhanced fins and rifled tub-
ing. In all units each compressor is protected by a freezestats
(on each evaporator). Low ambient switches (S11, S84)
and high pressure switches (S4, S7) are available as an op-
tion for additional compressor protection.
1−Compressors B1 and B2
All TCA090/150 units use two scroll compressors. Com-
pressor capacity may vary from stage to stage. In all cases,
the capacity of each compressor is added to reach the total
capacity of the unit. See SPECIFICATIONS" and ELEC-
TRICAL DATA" (table of contents) or compressor name-
plate for compressor specifications.
WARNING
Electrical shock hazard. Compressor must be
grounded. Do not operate without protective cover
over terminals. Disconnect power before removing
protective cover. Discharge capacitors before ser-
vicing unit. Failure to follow these precautions could
cause electrical shock resulting in injury or death.
Each compressor is energized by a corresponding com-
pressor contactor.
NOTE−Refer to the wiring diagram section for specific unit
operation.
2−Freezestats S49 and S50
Each unit is equipped with a low temperature switch (freezes-
tat) located on a return bend of each evaporator coil. S49
(first circuit) and S50 (second circuit) are located on the
corresponding evaporator coils.
Each freezestat is wired to the main control module A45.
Each freezestat is a SPST N.C. auto−reset switch which
opens at 29°F + 3°F (-1.7°C + 1.7°C) on a temperature drop
and closes at 58°F + 4°F (14.4°C + 2.2°C) on a tempera-
ture rise. To prevent coil icing, freezestats open during
compressor operation to temporarily disable the re-
spective compressor until the coil temperature rises.
If the freezestats are tripping frequently due to coil icing,
check the air flow / filters, economizer position and unit
charge before allowing unit back in operation. Make sure to
eliminate conditions which might promote evaporator ice
buildup.
3−High Pressure Switches S4 and S7
(optional)
The high pressure switch is a manual-reset SPST N.C. switch
which opens on a pressure rise. Each switch is located in the
compressor discharge line and is wired in series with the com-
pressor contactor coil.
When discharge pressure rises to 450 ± 10 psig (3103 ±
69 kPa) (indicating a problem in the system) the switch
opens and the respective compressor is de−energized
(the economizer can continue to operate).
4−Low Ambient Switches S11 & S84
(optional)
The low ambient switch is an auto-reset SPST N.O. pres-
sure switch which allows for mechanical cooling opera-
tion at low outdoor temperatures. In all models a switch
is located in each liquid line prior to the indoor coil sec-
tion.
In the TCA090/150, S11 and S84 are wired in parallel with
outdoor fan relay K10 (compressor one).
When liquid pressure rises to 275 ± 10 psig (1896 ± 69
kPa), the switch closes and the condenser fans are en-
ergized. When discharge pressure in both refrigerant cir-
cuits drops to 150 ± 10 psig (1034 ± 69 kPa), the switches
open and the condenser fans are de−energized. This inter-
mittent fan operation results in higher evaporating temper-
ature allowing the system to operate without icing the evap-
orator coil and losing capacity.

Page 17
C−Blower Compartment
The blower compartment in all TCA090/150S units is lo-
cated between the evaporator coil and the condenser coil sec-
tion. The blower assembly is accessed by disconnecting the
blower motor. See Blower Access in the Operation / Adjust-
ment section. The blower pulls out as shown in figure 8.
1−Blower Wheels
All TCA090/150 units have one 15 in. x 15 in. (381 mm x 381
mm) blower wheel.
2−Indoor Blower Motor B3
All units use three-phase single-speed blower motors. CFM
adjustments are made by adjusting the motor pulley (sheave).
Motors are equipped with sealed ball bearings. All motor spec-
ifications are listed in the SPECIFICATIONS (table of con-
tents) in the front of this manual. Units may be equipped with
motors manufactured by various manufacturers, therefore
electrical FLA and LRA specifications will vary. See unit rating
plate for information specific to your unit.
OPERATION / ADJUSTMENT
Blower Operation
Initiate blower demand at thermostat according to instruc-
tions provided with thermostat. Unit will cycle on thermostat
demand. The following steps apply to applications using a
typical electro−mechanical thermostat.
1− Blower operation is manually set at the thermostat sub-
base fan switch. With fan switch in ON position, blow-
ers will operate continuously.
2− With fan switch in AUTO position, the blowers will cycle
with demand. Blowers and entire unit will be off when
system switch is in OFF position.
Blower Access
The blower assembly is secured to a sliding base which al-
lows the entire assembly to be pulled out of the unit. See
figure 8.
1− Turn off power from unit. Remove the clamp which se-
cures the blower wiring to the blower motor base.
2− Remove and retain screws on either side of sliding
base. Pull base toward outside of unit.
3− Slide base back into original position when finished
servicing. Replace the clamp and blower wiring in the
previous location on the blower motor base.
Determining Unit CFM
1− The following measurements must be made with a dry
indoor coil. Run blower without a cooling demand.
Measure the indoor blower shaft RPM. Air filters must
be in place when measurements are taken.
2− With all access panels in place, measure static pres-
sure external to unit (from supply to return). Measure
static in duct below roof curb if roof curb is used.
3− Refer to blower tables in BLOWER DATA (table of con-
tents) in the front of this manual. Use static pressure and
RPM readings to determine unit air volume.
4− The blower RPM can be adjusted at the motor pulley.
Loosen Allen screw and turn adjustable pulley clock-
wise to increase CFM. Turn counterclockwise to de-
crease CFM. See figure 8. Do not exceed minimum and
maximum number of pulley turns as shown in table 7.
TABLE 7
MINIMUM AND MAXIMUM PULLEY ADJUSTMENT
Belt Minimum
Turns Open
Maximum
Turns Open
A Section No minimum 5
B Section 1* 6
*No minimum number of turns open when B belt is used on
pulleys 6" O.D. or larger.
Blower Belt Adjustment
Maximum life and wear can be obtained from belts only if
proper pulley alignment and belt tension are main-
tained. Tension new belts after a 24−48 hour period of
operation. This will allow belt to stretch and seat
grooves. Make sure blower and motor pulley are aligned as
shown in figure 7.
FIGURE 7
PULLEY ALIGNMENT
BELT
BLOWER
PULLEY
MOTOR
PULLEY
NOT ALIGNED
ALIGNED

Page 18
BLOWER ASSEMBLY
TO INCREASE BELT TENSION
1−Loosen four bolts securing motor base to mounting
frame.
2−Turn adjusting bolt to the right, or clockwise, to
move the motor outward and tighten the belt.
3−Tighten two bolts on motor pulley side.
IMPORTANT − Align top edges of blower motor base
and mounting frame base parallel before tightening
two bolts on the other side of base. Motor shaft and
blower shaft must be parallel.
4−Tighten two bolts on other side of base.
TO INCREASE CFM
LOOSEN ALLEN SCREW &
TURN PULLEY CLOCKWISE
TO DECREASE CFM
TURN PULLEY
COUNTERCLOCKWISE
FIGURE 8
BELT TENSION
ADJUSTING BOLT − TURN
CLOCKWISE TO TIGHTEN BELT
REMOVE 2 SCREWS FROM BOTH
SIDES BEFORE SLIDING BLOWER
ASSEMBLY OUT OF UNIT
ALIGN TOP EDGES
PARALLEL BEFORE
TIGHTENING MOTOR
IN PLACE
BLOWER
MOTOR BASE
BLOWER MOTOR
MOUNTING FRAME
MOTOR BASE
ADJUSTMENT SCREWS
− 2 EACH SIDE
PULLEY
MOTOR
SIDE VIEW
ALLEN
SCREW
1− Loosen four bolts securing motor base to mounting
frame. See figure 8.
2− To increase belt tension −
Turn adjusting bolt to the right, or clockwise, to move
the motor outward and tighten the belt. This increases
the distance between the blower motor and the blower
housing.
To loosen belt tension −
Turn the adjusting bolt to the left, or counterclockwise
to loosen belt tension.
3− Tighten two bolts on motor pulley side.
IMPORTANT − Align top edges of blower motor base and
mounting frame base parallel before tightening two bolts on
the other side of base. Motor shaft and blower shaft must
be parallel.
4− Tighten two bolts on other side of base.
Check Belt Tension
Overtensioning belts shortens belt and bearing life. Check
belt tension as follows:
1− Measure span length X. See figure 9.
2− Apply perpendicular force to center of span (X) with
enough pressure to deflect belt 1/64" for every inch of
span length or 1.5mm per 100mm of span length.
Example: Deflection distance of a 40" span would be
40/64" or 5/8".
Example: Deflection distance of a 400mm span would
be 6mm.
3− Measure belt deflection force. For a used belt, the
deflection force should be 5 lbs. (35kPa). A new belt
deflection force should be 7 lbs. (48kPa).
A force below these values indicates an underten-
sioned belt. A force above these values indicates an
overtensioned belt.
MEASURE BELT TENSION
FIGURE 9
DEFLECTION 1/64" PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
FORCE

Page 19
D−Optional Electric Heat Components
Tables 9 and 10 show all possible TCA to EHA matchups and
electrical ratings.
All electric heat sections consist of electric heating ele-
ments exposed directly to the airstream. See figure 10.
EHA parts arrangement is shown in figures 11 and 12.
Multiple-stage elements are sequenced on and off in re-
sponse to thermostat demand.
FIGURE 10
HEAT SECTION PLACEMENT
ELECTRIC HEAT SECTION
(behind hinged panel)
1−Electric Heat Relay K9
Electric heat relay K9 is a N.O. SPST pilot relay located on
the main control panel (figure 2). K9 electrically isolates
the unit’s 24V circuit from the electric heat 24V circuit 9 is
energized by main control A45 which in turn energizes
timer DL2.
2−Time Delay DL2
DL2 is a factory installed solid state timer used in
22.5 to 60 kW electric heat units. DL2 is located on the
main control panel (figure 2). DL2 allows staging by
providing a timed−interval between the first and sec-
ond heating elements. When the timer is energized,
the contacts are delayed for 30 seconds before clos-
ing. When the timer is de−energized, the contacts are
delayed 1 second before opening.
3−Contactors K15, K16
Contactors K15 and K16 are three−pole double−break
contactors located on the electric heat vestibule. All
contactors are equipped with a 24VAC coil. The coils in
the K15 and K16 contactors are energized by the
main panel A45. Contactor K15 energizes the first
stage heating elements, while K16 energizes the second
stage heating elements.
4−High Temperature Limits S15 (Primary)
S15 is a SPST N.C. auto-reset thermostat located on the
back panel of the electric heat section below the heating
elements. S15 is the high temperature limit for the electric
heat section. When S15 opens, indicating a problem in
the system, contactor K15 is de-energized. When K15 is
de-energized, first stage and all subsequent stages of
heat are de-energized. For EHA102/150 units, the high
temperature limit is factory set to open at 170F + 5F
(76C + 2.8C) on a temperature rise and automatical-
ly reset at 130F + 6F (54.4C + 3.3C) on a tempera-
ture fall. For EHA100 units, the limit is factory set to
open at 160F + 5F (71.0C + 2.8C) on a tempera-
ture rise and automatically reset at 120F + 6F
(49.0C + 3.3C) on a temperature fall. The limit is not
adjustable.
5−High Temperature Limit S20 (Secondary)
S20 is a SPST N.C. manual-reset thermostat . Like the
primary temperature limit, S20 is wired in series with the
first stage contactor coil (K15) and second stage contactor
coil (K16). When S20 opens, contactors (K15, K16) are
de-energized. When the contactors are de-energized, first
stage and all subsequent stages of heat are de-energized.
The limit is factory set to open at 220F + 6 F (104C +
3.3C) on a temperature rise and can be manually reset
when temperature falls below 160F (71.0C).
6−Terminal Strip TB3
Electric heat line voltage connections are made to termi-
nal strip TB3 (or a fuse block on some models) located in
the upper left corner of the electric heat vestibule.
7−Heating Elements HE1, HE2, HE6 and HE7
Heating elements are composed of helix wound bare
nichrome wire exposed directly to the airstream. Three
elements are connected in a three-phase arrange-
ment. The elements in 208/230V units are connected
in a Delta" arrangement. Elements in 460 and 575V
units are connected in Wye" arrangement. Each stage
is energized independently by the corresponding contac-
tors located on the electric heat vestibule panel. Once
energized, heat transfer is instantaneous. High temper-
ature protection is provided by primary and redundant
high temperature limits and overcurrent protection is
provided by fuses.
8−Fuse F3
Fuse F3 are housed in a fuse block which holds three
fuses. Each F3 fuse is connected in series with each leg of
electric heat. Figure 11 and table 8 show the fuses used
with each electric heat section. For simplicity, the ser-
vice manual labels the fuses F3 − 1 through F3 − 4.
9−Fuse F4
Fuse F4 is used only with single point power along with
TB2. F4 gives over amperage protection to the compres-
sor and other cooling components while F3 protects the
electrical heat component. The F 4 fuse block is located
inside a sheetmetal enclosure (figure 1).

Page 20
TABLE 8
TCA ELECTRIC HEAT SECTION FUSE RATING
EHA QUANTITY
& SIZE VOLTAGES FUSE (3 each)
F3 − 1 F3 − 2 F3 − 3 F3 − 4
EHA100−7.5
208/230V 25 Amp 250V −−−−− −−−−− −−−−−
460V 15 Amp 600V −−−−− −−−−− −−−−−
575V 10 Amp 600V −−−−− −−−−− −−−−−
EHA100−15
208/230V 50 Amp 250V −−−−− −−−−− −−−−−
460V 25 Amp 600V −−−−− −−−−− −−−−−
575V 20 Amp 600V −−−−− −−−−− −−−−−
EHA100−22.5
208/230V 50 Amp250V −−−−− −−−−− 25 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 15 Amp 600V
575V 20 Amp 600V −−−−− −−−−− 10 Amp 600V
EHA100−30
208/230V 50 Amp 250V −−−−− −−−−− 50 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 25 Amp 600V
575V 20 Amp 600V −−−−− −−−−− 20 Amp 600V
EHA100−45
208/230V 50 Amp 250V −−−−− 60 Amp 250V 60 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 50 Amp 600V
575V 20 Amp
600V −−−−− −−−−− 40 Amp 600V
EHA102−7.5
208/230V 25 Amp 250V −−−−− −−−−− −−−−−
460V 15 Amp 600V −−−−− −−−−− −−−−−
575V 10 Amp 600V −−−−− −−−−− −−−−−
EHA150−15
208/230V 50 Amp 250V −−−−− −−−−− −−−−−
460V 25 Amp 600V −−−−− −−−−− −−−−−
575V 20 Amp 600V −−−−− −−−−− −−−−−
EHA360−22.5
208/230V 50 Amp 250V −−−−− −−−−− 25 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 15 Amp 600V
575V 20 Amp 600V −−−−− −−−−− 10 Amp 600V
EHA150−30
208/230V 50 Amp 250V −−−−− −−−−− 50 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 25 Amp 600V
575V 20 Amp 600V −−−−− −−−−− 20 Amp 600V
EHA150−45
208/230V 50 Amp 250V −−−−− 60 Amp 250V 60 Amp 250V
460V 25 Amp 600V −−−−− −−−−− 50 Amp 600V
575V 20 Amp 600V −−−−− −−−−− 40 Amp 600V
EHA150−60
208/230V 60 Amp 250V 60 Amp 250V 60 Amp 250V 60 Amp 250V
460V 50 Amp 600V −−−−− −−−−− 50 Amp 600V
575V 40 Amp 600V −−−−− −−−−− 40 Amp 600V