Johnson Controls TSS Owner's manual

INSTALLATION, OPERATION & MAINTENANCE
SINGLE DUCT VAV TERMINALS
New Release Form 130.13-NOM1 (114)
MODELS TSS & TSL
TSS
TSL

JOHNSON CONTROLS
2
FORM 130.13-NOM1 (114)
SAFETY CONSIDERATIONS........................................................................................................................3
INSPECTION.................................................................................................................................................4
STORAGE .....................................................................................................................................................4
PRE-INSTALLATION INSPECTION..............................................................................................................5
SEQUENCE OF OPERATION.......................................................................................................................5
Single Duct.............................................................................................................................................5
INSTALLATION .............................................................................................................................................5
Clearances .............................................................................................................................................5
Hanging and Mounting Equipment......................................................................................................5
Unit Weights...........................................................................................................................................6
Duct Connections..................................................................................................................................6
Critically Sound Applications...............................................................................................................7
Coil Connections...................................................................................................................................7
Electrical.................................................................................................................................................7
OPERATION..................................................................................................................................................7
Start-Up ..................................................................................................................................................7
3 Phase Balancing.................................................................................................................................7
MAINTENANCE ............................................................................................................................................8
Optional Damper Actuator....................................................................................................................8
Manual Override ....................................................................................................................................8
Mechanical Angle of Rotation Stops ...................................................................................................8
External Terminal Strip .........................................................................................................................8
Overload Protection..............................................................................................................................8
Checkout Instructions...........................................................................................................................8
Damper Shaft.........................................................................................................................................8
Coil..........................................................................................................................................................8
Cleaning............................................................................................................................................9
Electric Heat..........................................................................................................................................9
Minimum Operating Conditions......................................................................................................9
Electric Heater Rack Replacement.................................................................................................9
Electric Heater Element Replacement............................................................................................9
Heater Troubleshooting Guide......................................................................................................10
(SSR) Troubleshooting Guide.......................................................................................................11
Calibration Charts ...............................................................................................................................15
TABLE OF CONTENTS

JOHNSON CONTROLS 3
FORM 130.13-NOM1 (114)
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
SAFETY CONSIDERATIONS
The equipment covered in this manual is designed for
safe and reliable operation when installed and operated
within its’ design specication limits. To avoid personal
injury or damage to equipment or property while
installing or operating this equipment, it is essential
that qualied, experience personnel familiar with local
codes and regulations, perform these functions using
good judgment and safe practices. See the following
cautionary statements.
ELECTRICAL SHOCK HAZARDS
All power must be disconnected prior
to installation and servicing this equip-
ment. More then one source of power
may be present. Disconnect all power
sources to avoid electrocution or shock
hazards.
HOT PARTS HAZARD
Electric resistance heating elements
must be disconnected prior to servic-
ing. Electric heaters may start auto-
matically; disconnect all power and
control circuits prior to servicing to
avoid burns.
Check that rigging and lifting equip-
ment can safely support the unit as-
sembly and component weights.
All assemblies must be adequately
secured during lifting and rigging by
temporary supports and restraints un-
til equipment is permanently fastened
and set in its’ nal location.
All unit temporary and permanent
supports must be capable of safely
supporting the equipment’s weight and
any additional live, seismic or dead
loads that may be encountered. All
supports must be designed to meet ap-
plicable local codes and ordinances.
All fastening devices must be designed
to mechanically lock the assembly in
place without the capability of loosen-
ing or breaking away due to system
operation and vibration.
Secure all dampers when servicing
damper, actuators or linkage. Damp-
ers may activate automatically, discon-
nect the control circuits or pneumatic
control systems to avoid injury.
Protect adjacent ammable material
when brazing. Use ame and heat
protection barriers where needed.
Have re extinguisher ready for im-
mediate use.

JOHNSON CONTROLS
4
FORM 130.13-NOM1 (114)
INSPECTION
Upon receipt of equipment, carefully check all items
against the bill oflading to ensure that allequipment has
been received (including shipped loose items). Note any
discrepancy on the bill of lading before signing.
Inspect all equipment for any signs of damage caused
during transit. On units with re-heat, check the coil
ns and/or ensure that the resistance heat coils are
not damaged. Note any visual damage on the bill of
lading before signing. Immediately report all visual
and concealed damage to the carrier and le a claim
with the carrier.
Locate the model number on the nameplate and check
that the correct units have been received. Verify that all
options have been included, such as controls, heating
coils, etc. Also ensure that unit voltage agrees with the
building parameters. If a discrepancy is discovered
between what was ordered and received, contact your
local Johnson Controls representative immediately.
DO NOT USE FLOW SENSOR,
CONNECTING TUBES, COIL STU-
BOUTS OR DAMPER SHAFT AS
A HANDLE WHEN LIFTING OR
MOVING EQUIPMENT, AS DAM-
AGE MAY OCCUR.
DO NOT HANDLE EQUIPMENT’S
HEATING ELEMENTS, AS PERMA-
NENT DAMAGE MAY OCCUR.
CHECK assembly and component
weights to be sure that the rigging
equipment can handle them safely.
Note; also check the centers of gravity
and any specic rigging instructions.
CHECK for adequate ventilation
so fumes do not migrate through
ductwork to occupied spaces when
welding or cutting around the unit.
DO NOT work on damper until associ-
ated actuator is disconnected.
NEVER pressurize equipment above
specied test pressure.
PROTECT adjacent ammable ma-
terials when brazing. Use ame and
heat protection barriers where needed.
Have a re extinguisher at hand and
ready for immediate use.
STORAGE
If equipment is to be stored prior to installation, observe
the following precautions:
1. Choose a dry storage site that is reasonably level
and sturdy to prevent undue stress or permanent
damage to the equipment. Set equipment off
ground if in moisture prone areas.
2. Tag and store in a safe place until needed. Cover
entire equipment with protective tarp or moisture
proof cover. Extend cover under equipment if
stored on ground. Secure cover with adequate tie
downs and store indoors. Be sure that piping con-
nections have protective shipping caps installed.

JOHNSON CONTROLS 5
FORM 130.13-NOM1 (114)
PRE-INSTALLATION INSPECTION
DO NOT USE FLOW SENSOR,
CONNECTING TUBES, COIL STU-
BOUTS OR DAMPER SHAFT AS
A HANDLE WHEN LIFTING OR
MOVING EQUIPMENT, AS DAM-
AGE MAY OCCUR.
DO NOT HANDLE EQUIPMENT’S
HEATING ELEMENTS, AS PERMA-
NENT DAMAGE MAY OCCUR.
Ensure that all linkages are connected properly. Check
the linkage thatconnects the actuatorto the dampershaft
to ensure that the nuts are tight.
While viewing the damper from the discharge of the
unit, rotate the shaft fully. The damper should close
fully and there should be no gaps between the damper
gasketing and the inside of the valve.
SEQUENCE OF OPERATION
Single Duct
The basic unit consists of a sheet metal casing and an air
valve, which is used to modulate the air being delivered
into the occupied zone. Air enters the air valve inlet
and exits into the sheet metal casing to be distributed
to the occupied zone through ductwork attached to the
discharge of the unit.
The basic unit can be ordered with either a factory
mounted hot water heating coil or an electric heater.
These re-heat units are used primarily to reheat the
air-to-zone temperature when the load in the occupied
space drops off.
The primary air is modulated through the FlowStar™
air valve by rotating the damper blade. The air valves
come in rectangular and round. The round valves only
come in diameters of 4, 5, 6, 8, 10, 12, 14 and 16 inches;
an adapter must be used for metric ductwork.
INSTALLATION
DO NOT USE FLOW SENSOR,
CONNECTING TUBES, COIL STU-
BOUTS OR DAMPER SHAFT AS
A HANDLE WHEN LIFTING OR
MOVING EQUIPMENT, AS DAM-
AGE MAY OCCUR.
DO NOT HANDLE EQUIPMENT’S
HEATING ELEMENTS, AS PERMA-
NENT DAMAGE MAY OCCUR.
All terminal equipment with electric heaters must
be installed in a horizontal plane with respect to the
airow stream. Low height equipment (Model TSL)
can be ipped over in the eld to vary or change control
section handing.
Clearances
All equipment covered in this document, including those
with electric heat, are ETL listed for 0.0" clearance to
combustibles. Refer to NEC and/or local codes for
minimum electrical clearances required for service.
Equipment should not make contact with any structure
located above the equipment without appropriate
isolation. Equipment supplied with bottom access
panels requires sufcient clearance to access fasteners,
and to lower and slide panel horizontally until clear of
bottom of unit.
Hanging and Mounting Equipment
Although the basic equipment is generally light enough
that it can be supported by the ductwork, Johnson
Controls strongly recommends that all equipment be
suspended from the upper most ceiling or a structural
element of the building, independent of the false ceiling
grid. Suspension devises are eld supplied, sized and
designed by others. Johnson Controls will not accept
responsibility for unit support. Equipment must be
installed in a level horizontal plane. Failure to level
equipment properly may prevent proper operation of
controls. Provisions for proper support in seismically
active regions is the responsibility of others. See table
1 through 4 for unit weights.

JOHNSON CONTROLS
6
FORM 130.13-NOM1 (114)
UNIT WEIGHTS
When requested, equipment is supplied with optional
hanger brackets for use with up to a 3/8" diameter
hanger rod. See submittal drawings for hanger bracket
locations.
Hanger straps may be utilized as an alternate means of
suspending the equipment. Do not secure hanger straps
to electric heaters, coils or control enclosures. Hanger
straps can be mounted directly to the sides and bottom
of equipment casing, such that they do not interfere with
working components or accesspanels, using screws that
do not penetrate the unit cabinet more than 3/8".
When hanging equipment, always use the support
method as prescribed for rectangular duct in the job
specications.
Duct Connections
When fastening ductwork to equip-
ment, DO NOT use fasteners that
penetrate equipment cabinet more
than 3/8" [10mm]. Fasteners penetrat-
ing the equipment cabinet over 3/8"
[10mm] may come in contact with live
electrical parts or penetrate other com-
ponents within the equipment casing
causing damage.
All duct connections should be congured and installed
in accordance with SMACNA guidelines and all local
code requirements.
TABLE 4 - TSL WATER COIL WEIGHT
ADDS
UNIT
SIZE # OF ROWS
1 ROW 2 ROW 3 ROW 4 ROW
10 9 (4) 12 (5) 15 (7) 18 (8)
12 11 (5) 15 (7) 19 (9) 23 (10)
14 13 (6) 18 (8) 22 (10) 27 (12)
16 15 (7) 21 (9) 27 (12) 32 (15)
Adds for water coils reect actual operating weight.
TABLE 1 - SINGLE DUCT TERMINAL UNIT WEIGHTS
UNIT
SIZE TSS TSS w/ SA TSS w/ EH
SINGLE
WALL DOU- BLE
WALL
SINGLE
WALL DOU- BLE
WALL
SINGLE
WALL DOU- BLE
WALL
04 20 (9) 25 (11) 35 (16) 50 (23) 64 (29) 79 (36)
05 20 (9) 25 (11) 35 (16) 50 (23) 64 (29) 79 (36)
06 19 (9) 24 (11) 34 (15) 49 (22) 62 (28) 77 (35}
08 20 (9) 26 (12) 37 (17) 53 (24) 71 (32) 87 (39)
10 25 (11) 32 (15) 44 (20) 62 (28) 78 (35) 96 (44)
12 28 (13 36 (16) 50 (23) 71 (32) 89 (40) 110 (50)
14 35 (16) 44 (20) 59 (27) 84 (38) 106 (48) 131 (59)
16 37 (17) 47 (21) 63 (29) 90 (41) 113 (51) 140 (64)
19 49 (22) 62 (28) 85 (39) 120 (55) 141 (64) 176 (80)
22 51 (23) 65 (29) 90 (41) 127 (58) 148 (67) 185 (84)
TABLE 2 - TSS WATER COIL WEIGHT ADDS
UNIT
SIZE # OF ROWS
1 ROW 2 ROW 3 ROW 4 ROW
04 4 (2) 5 (2) 8 (4) 12 (5)
05 4 (2) 5 (2) 8 (4) 12 (5)
06 4 (2) 5 (2) 8 (4) 12 (5)
08 4 (2) 6 (3) 9 (4) 13 (6)
10 5 (2) 8 (4) 12 (5) 18 (8)
12 7 (3) 10 (5) 16 (7) 22 (10)
14 9 (4) 14 (6) 21 (10) 30 (14)
16 10 (5) 16 (7) 24 (11) 34 (15)
19 12 (5) 20 (9) 28 (13) 40 (18)
22 13 (6) 22 (10) 32 (15) 44 (20)
Adds for water coils reect actual operating weight.
TABLE 3 - SINGLE DUCT LOW HEIGHT TERMINAL UNIT
WEIGHTS
UNIT
SIZE TSL TSL w/ SA TSL w/ EH
SINGLE
WALL DOUBLE WALL SINGLE WALL DOUBLE WALL SINGLE WALL DOUBLE WALL
10 26 (12) 30 (14) 43 (19) 58 (26) 62 (28) 77 (35)
12 28 (13) 35 (16) 49 (22) 68 (31) 74 (34) 93 (42)
14 39 (18) 47 (21) 62 (28) 82 (37) 90 (41) 110 (50)
16 45 (20) 55 (25) 73 (33) 96 (44) 103 (47) 126 (57)

JOHNSON CONTROLS 7
FORM 130.13-NOM1 (114)
Allow a minimum of 1½-duct diameters of straight
duct prior to equipment inlet and equipment discharge.
The diameter of the inlet duct for round valves must
be equal to the listed size of the equipment. The round
air valve inlet collar of the equipment is 1/8" smaller
then listed size in order to allow the round ductwork to
slip over the air valve inlet collar. DO NOT INSERT
DUCTWORK INTO AIR VALVE INLET COLLAR.
When making ductwork connection to air valve inlet
collar and insulating air valve inlet, take caution not to
damage or remove the ow sensor connections, which
are vital to unit control. Provide insulation around entire
inlet collar (all the way to the equipment casing).
Permissible discharge duct connections are straight
anged, slip and drive or drive and screw.
If equipment is to be installed in a location with high
humidity, external insulation around the heating coil
should be installed.
Sound Critical Applications
Flexible duct connectors are not recommended on
equipment discharge. The sagging membrane of these
ttings can cause turbulence and higher air velocities
that generate noise. Also, lightweight membrane
material allows noise to breakout, which can increase
sound levels in the space below.
Coil Connections
Hot water and steam coils are male sweat connections.
Use appropriate brazing alloy for system temperature
and pressure. Refer to unit construction submittal
drawing for specic connection size. MAXIMUM
HYDRONIC SYSTEM OPERATING PRESSURE
MUST NOT EXCEED 300 PSIG. MAXIMUM
STEAM SYSTEM PRESSURE MUST NOT EXCEED
15 PSIG.
Electrical
All eld wiring must comply with NEC and all local
codes. Electrical and/or control wiring diagrams are
located on the control enclosure box. All electric heaters
are staged per specications.
The installing electrician should rotate the incoming
electric service by phase to help balance the building
electrical load.
Minimum circuit ampacity (MCA) designates the
maximum operating load of the equipment for sizing
wire feeders. Fuse size of the internal fuse if supplied.
Maximum Overcurrent Protection (MOP) designates
the largest breaker or fuse in the electrical service panel
that can be used to protect the equipment.
Use Copper conductors only.
OPERATION
Start-Up
Thorough safety precautions should always be taken
when performing startup and service. Only qualied
individuals should perform these tasks.
Check that all electrical work is nished and properly
terminated. Check that all electrical connections are
tight and that the proper voltage is connected.
3 Phase Balancing
AC power imbalance must not exceed 2%. Be sure that
the following guides are met:
1. AC power is within 10% of rated voltage at rated
frequency. (See equipment nameplate for rat-
ings).
2. AC power is within 5% of rated frequency at rated
voltage.
3. A combined variation in the voltage and frequency
of 10% (sum of absolute values) of rated values,
provided the frequency variation does not exceed
5% of rated frequency.
Equipment with electric heat requires
a minimum of 0.1" w.g. downstream
static pressure.
Prior to start-up, the project control sequence/wiring
diagram should be obtained and thoroughly understood.
If factory supplied analog or DDC controls are utilized,
refer to the applicable Operation Manual for start-up
and balancing information.

JOHNSON CONTROLS
8
FORM 130.13-NOM1 (114)
MAINTENANCE
Optional DamperActuator
An optional factory mounted oating type actuator
is available, which mounts directly to the damper
operating shaft. The actuator is not provided with and
does not require any limit switches but is electronically
protected against overload.
Manual Override
A button on the side of the actuator cover disengages
the gear train so the drain shaft can be moved manually.
Releasing the button will re-engage the gear train.
Mechanical Angle of Rotation Stops
The adjustable stops may be field adjusted to halt
the rotation of the damper blade before the damper
blade reaches the damper stops. The actuator can be
indenitely stalled in any position without harm.
1. Loosen the two end stop screws using a No. 2
Phillips head screwdriver, being careful not to
unscrew the captive nut under the slot.
2. Move the stops (in 2.5° steps) to the desired posi-
tion and retighten the screws.
External Terminal Strip
The external terminal strip is located on the top of the
actuator. Connections are numbered. The terminals
are designed for 26 to 16 gauge wires. For most
installations, 18 or 16 gauge wire will work well with
the actuator (see table 5 for maximum wire lengths).
Overload Protection
The actuators are electronically protected against
mechanical overload. In the actuator, an electronic
circuit maintains the current at a level that will not
damage the motor while providing adequate holding
torque.
Checkout Instructions
1. Disconnect actuator from the controller.
2. Apply 24 VAC to the COM and CW terminals on
the actuator. Actuator should rotate in a clockwise
direction.
3. Apply 24 VAC to the COM and CCW terminals on
the actuator. Actuator should rotate in a counter
clockwise direction.
4. If actuator moves in both directions, it is opera-
tional.
5. If the actuator does not rotate, it may be at an end
stop or there is a problem with the damper.
6. Loosen the set screw to free the actuator from the
damper shaft. Check to make sure that the damper
shaft rotates freely.
7. Check to make sure that actuator is not against
stop. Repeat steps 2 and 3.
8. If actuator does not rotate, replace.
Damper Shaft
There is an indicator on the end of the damper shaft that
can be used to determine the position of the damper
blade. If the indicator is horizontal, the damper is
completely open. The damper shaft is ½" diameter.
Coil
The frequency of required cleaning is dependent on the
operating hours of the system, lter maintenance and
efciency as well as dirt load.
Important: Coils may become exter-
nally dirty as result of normal opera-
tion. Dirt on the surface of the coil
reduces its ability to transfer heat that
can result in reduced performance,
and increased operating energy cost.
If the dirt on the surface of the coil
becomes wet, microbial growth (mold)
can result, possibly causing unpleas-
ant odors and serious health related
indoor air quality problems.
Fin edges are sharp. Fins are fragile;
care must be exercised to avoid damag-
ing ns. Do not use solutions to clean
coils; drain pans are not present to
remove collected solution.
TABLE 5 - MAXIMUM WIRE LENGTHS
WIRE SIZE MAX FEET
16 GA 1225 FT
18 GA 725 FT
20 GA 400 FT
22 GA 200 FT

JOHNSON CONTROLS 9
FORM 130.13-NOM1 (114)
Cleaning
1. Disconnect all electrical power to the equipment,
tag and lock out power source.
2. Gain access to coil either through ductwork or
optional coil access panel.
3. Use soft brush and vacuum to remove loose debris
from sides of coil. Do not use uid or solvents to
clean coils, as no provisions for collecting liquids
exist on this type of equipment.
4. Straighten any coil ns that may have been dam-
aged during cleaning process with n comb.
5. Replace ductwork or access panel and restore
electrical power to equipment.
Electric Heat
Johnson Controls electric heaters require little or no
maintenance.
Electric heaters come equipped with a primary auto-reset
limit switch. These limit switches provide protection
against overheating. The auto-reset limits switches
automatically cut the heater off when overheating
occurs, and turns the heater back on when the elements
have cooled down. Electric heaters also come equipped
with a secondary one-time trip limit switch. Should
the secondary limit switches trip, they will need to
be replaced with a limit switch that has the same trip
temperature as the one-time trip limit switch that was
originally supplied with the electric heater. An optional
manual reset secondary is available, which can be reset
by depressing the reset switch.
Minimum Operating Conditions
Airow must be at least 70 CFM per kW. A minimum
of 0.1" w.g. external pressure is required.
Electric Heater Rack Replacement
JOHNSON CONTROLS HEATERS
1. Turn off power supply before servicing.
2. Locate T-Plate inside on heater control enclo-
sure.
3. Before removing wires from the element rack
T-Plate, mark where the wires are connected so
that they can be reconnected correctly on the new
element rack.
4. Remove the wires and screws holding the heater
T-plate in the control enclosure and remove ele-
ment rack.
5. Insert new element rack into control enclosure and
replace screws tosecure the element rackto control
enclosure.
6. Replace wires.
7. Close control enclosure cover before turning on
the power.
Electric Heater Element Replacement
TUTCO HEATERS
1. Turn off power supply before servicing.
2. Disconnect eld wiring from Electric Heater Con-
trol Enclosure.
3. Disconnect Amp Plug Connectors if equipped.
4. Remove 4 mounting screws from inside Electric
Heater Control Enclosure.
5. Slide entire heater assembly out of Single Duct
Terminal.
6. Remove wires and any jumpers from heater ele-
ment terminal ends, noting which wire and jumper
goes to which terminal.
7. Remove ¼" hex head screws located near terminal
ends.
8. Remove ¼" hex head screws from opposite of
terminal end on heater rack.
9. Remove elements and replace with new ones.
10. Reassemble, replace wires correctly.
11. Close control enclosure cover before turning on
power.

JOHNSON CONTROLS
10
FORM 130.13-NOM1 (114)
ELECTRIC HEATER TROUBLESHOOTING GUIDE
JOHNSON CONTROLS AND TUTCO
TABLE 6 - HEATER TROUBLESHOOTING GUIDE
Check wiring diagrams to ensure that heater is properly wired.
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
HEATER DOES NOT OPERATE
No Power Check Disconnect.
No Control Voltage
Check Control Signal (i.e. 24 VAC).
Check transformer and transformer fus-
ing (if applicable), replace if necessary.
Blown Fuse Replace fuse.
Open Limit (primary or secondary)
Replace limits or reset as applicable.
Check for continuity across limit to de-
termine if open, replace as necessary.
Airow Incorrect Direction Check sensing tube, rotate if needed.
Low Airow Static Pressure Increase airow.
Damaged Elements Check for open or damaged elements
and replace as necessary.
LOW OR HIGH TEMPERATURE RISE
Incompatible Thermostat or Controller Check Wiring.
Check for compatibility.
Problems with Additional Stages
Check location of thermostat; may be
installed in a “too hot” or “too cold loca-
tion. Check heat outputs on controller.
Check contactors for open coil.
Check for damaged elements.
Incorrect CFM Check for blocked duct or location of
heater.
SHORT CYCLING
Improper Airow
Check for even airow across the face
of the element section.
Check for blocked duct.
Verify installation per SMACNA and
ASHRAE guidelines.
Check for dirty lters.
Low CFM See remedies for “Improper Airow”.
Check air velocity of 70 CFM per kW.
HEATER WITH SSR DOES NOT
OPERATE
Incorrect Signal Applied Verify signal input.
Interface Board Fuse Blown Replace fuse.
See SSR Troubleshooting (next page)