Trane BAYRLAY004A Assembly instructions

Model:
BAYECON200A
BAYECON201A
BAYRLAY004A
Horizontal Economizer & Rain Hood
Used with:
2/4TC*,WC*,YC*,DC* *018-036A
2/4TC*,WC*,YC*,DC* *042-060A
(Required with WC* models)
General
The economizer is a multi-damper design. It inserts into the
return air stream and is connected to the unit low voltage
supply through wire leads. The economizer is fully acces-
sible through an access panel.
Use care when inserting the economizer in the return air
compartment, to prevent damaging the foil faced insula-
tion.
WARNING
!
WARNING
!
CAUTION
!
18-HE39D9-6
Installer’s Guide
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service
information pack upon completion of work.
HAZARDOUS VOLTAGE - DISCONNECT POWER BEFORE SERVICING
WARNING:
Important: The Economizer installation requires that you first
install an air filter rack ordered separately. Use:
BAYFLTR101A for 2/4YC*, WC*, TC*, DC* *018-3036A
BAYFLTR201A for 2/4YC*, WC*, TC*, DC* *042-3060A.
When the economizer is installed in WC* models, relay
accessory kit BAYRLAY004A is required. Refer to the drawing
on page 6 to make your relay wiring connections in the Control
Box.
Inspect Contents
You must report damage and make claims to the transporta-
tion company immediately. Report missing parts to your
supplier immediately and replace with authorized parts
only.
Identify Economizer Kit Contents
Refer to Figure 2 on page 3 to identify the kit contents.
ELECTRIC SHOCK HAZARD
OPEN AND LOCK OUT ALL UNIT DISCONNECTS PRIOR
TO ACCESSORY INSTALLATION OR UNIT MAINTENANCE,
TO PREVENT INJURY OR DEATH FROM ELECTRICAL
SHOCK OR CONTACT WITH MOVING PARTS.
SAFETY HAZARD
DO NOT REMOVE END COVERS FROM ECONOMIZER AC-
TUATOR; THE SPRING-RETURN ASSEMBLY MAY RELEASE
AND CAUSE PERSONAL INJURY.
Install Economizer Kit
1. Remove the unit economizer/filter access panel, the
evaporator coil and blower access panel, and the electri
cal control box access panel, see Figure 1 on page 2.
2. Filter frame must be installed prior to economizer installa-
tion.
3. Apply two gaskets to horizontal economizer mounting
flanges. See Figure 2 on page 3.
4a. Small Cabinet - BAYECON200A
(TC*,WC*,YC*,DC* *018A to 3036A)
Set the horizontal economizer over the horizontal return
air opening on the unit. The notches in the bottom
flange of the economizer clear the two existing screws
below the return air opening of the unit.
4b. Medium Cabinet Only - - BAYECON201A
(TC*,WC*,YC*,DC* *042A to 3060A)
Apply a gasket to the economizer and slide the top
flange of the economizer under the lip between the top
and bottom sections of the unit. Mate the notches on
the top flange of the economizer with the existing screws
between the top and bottom sections of the unit. The
notches on the bottom flange of the economizer clear
the two existing screws below the return air opening of
the unit.

Page 2
INSTALLER’S GUIDE
11. Connect the two (2) Mixed Air Sensor wires (pulled from harness)
to the mating pigtail wires (with Stake-Ons) from the Mixed Air
Sensor.
12. In the Control Box, complete the wiring connections per the wiring
diagram on page 5. Secure all wires with wire ties so that there
is no interference with any moving parts in the unit.
IMPORTANT - When the economizer is installed in heat
pump models (WC*), a relay accessory kit
(BAYRLAY004A) is required. Mount relay accessory kit
in unit control box as illustrated on page 6.
13. Attach the return duct to the economizer.
5. Drill three (3) 9/64” holes through the mating holes in
the top flange of economizer and into the unit. Then,
drive three (3) #10 sheet metal screws to secure the top.
6. Drill three (3) 9/64” engagement holes on each side of the
economizer. Then, drive three (3) #10 sheet metal screws
into each side of the economizer to the unit.
7. Mount the Mixed Air sensor to the left Blower partition
using two sheetmetal screw. See Figure 4, page 4. The 2 yellow
wires will connect to the Economizer wiring harness in a later step.
Install any economizer options (enthalpy sensor or CO2 sensor)
at this time per instructions provided with the sensor.
8. Apply a gasket to the Rain Hood flanges. See Figure 2.
9. Place the Rain Hood over the horizontal return air opening
of the economizer. See Figure 2. Use the #10 sheet metal
screws provided to attach the hood to the economizer.
10. Route the main wiring harness. From the Economizer assembly,
route the main wiring harness to the Mixed Air sensor and to the
Control Box. See Figure 3.
14. Power the economizer and run the checkout procedure on page
7. Make desired adjustments to the controller: set the minimum
occupied damper position, set the outside air (if enthalpy used),
and the IAQ sensor (if used).
15. Replace the unit Coil access panel, the Blower access panel, and the
Control Box access panel.
Figure 1. Remove Panels
TC, WC, or
YC Unit
Horizontal
Return Air
Panel
Down Flow
Return Air
Panel
Blower Access Panel
Control Box Access
Panel
Coil Access
Panel
Top Sealing
Flange

Page 3
INSTALLER’S GUIDE
A
B
C
Economizer
Gaskets (2)
Rain Hood
Duct
D
E
Horizontal Economizer Assembly
NOTE: BAYECON200A economizer only contains two clearance notches in the top flange.
Figure 2. Apply Two Gaskets to Mounting Flanges
Figure 3. Main Wire Harness Routing
1.) From
EconomizerAssembly,
Pass Wire Harness
Through Coil Grom-
met. See View A.
2.) Continue Routing
Behind Compressor
Compartment and into
Blower Compartment.
3.) Pull the 2 Mixed Air Sensor
Wires (with Stake-Ons) from the
Harness and Route Down Near
the Mixed Air Sensor.
Location of
Mixed Air Sensor
4.) Continue Routing the
Remaining Harness
Through the Grommet
and into the Control Box.
Economizer A B C D E
BAYECON200AA 22" 20" 16-7/8" 15-11/16 11-11/16
BAYECON201AA 26" 22-21/32" 19" 17-11/16 14-11/16

Page 4
INSTALLER’S GUIDE
1.80"
2.82"
Figure 4. Mount Mixed Air Sensor in Blower Compartment
View ‘A’ Approximate
Mounting Dimension
See View ‘A’
Mount the Mixed Air
Sensor to the partition
using two sheetmetal
screws. See View A
for approximate
positioning.

Page 5
INSTALLER’S GUIDE
Figure 5. TC*/YC* Economizer Connection Diagram

Page 6
INSTALLER’S GUIDE
Figure 6. WC* Economizer Connection Diagram

Page 7
INSTALLER’S GUIDE
Checkout
Figure 7. SINGLE ENTHALPY CHANGEOVER SET POINT
Single enthalpy: The enthalpy
changeover set point is set to return the
outdoor air damper to minimum posi-
tion when the enthalpy rises above its
set point. The enthalpy set point scale
markings, located on W7459, are
A,B,C,D; see table for the correspond-
ing control point. The factory-installed
R4 WHITE 620-ohm jumper must be in
place across terminals + and SR.
Operate the motor through its complete open-close
stroke. If necessary, release one of the previously
tightened linkage connections to prevent damage.
Check for proper operation, making sure that the
linkage does not bind and that the motor travels
smoothly throughout its fully open and closed posi-
tion. Table 1 describes how to drive motors full open
and closed (power connected). If there is excess
length of linkage rod, cut it to size. Make necessary
minor adjustments until desired operation is ob-
tained, and tighten all nuts and set screws. This
motor checkout ensures that:
1. The motor operates the load.
2. The motor responds properly to the controller.
3. There is no binding of the linkage or motor
stalling at any point of travel.
If motor does not operate properly, check for
proper voltage or mechanical binding in linkage or
damper.
If questions arise regarding this product, contact
your distributor or representative.
CONTROL
CURVE
A
B
C
D
CONTROL POINT
APPROX. F ( C)
AT 50% RH
73 (23)
70 (21)
67 (19)
63 (17)
12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
90
100
80
70
60
50
40
30
20
10
ENTHALPY—BTU PER POUND DRY AIR
85
(29)
90
(32)
95
(35)
100
(38)
105
(41)
110
(43)
35
(2)
35
(2)
40
(4)
40
(4)
105
(41)
110
(43)
45
(7)
45
(7)
50
(10)
50
(10)
55
(13)
55
(13)
60
(16)
60
(16)
65
(18)
65
(18)
70
(21)
70
(21)
75
(24)
75
(24)
80
(27)
80
(27)
85
(29)
90
(32)
95
(35)
100
(38)
APPROXIMATE DRY BULB TEMPERATURE— F ( C)
A
A
B
B
C
C
D
D
M11681
RELATIVE HUMIDITY (%)
1
1
HIGH LIMIT CURVE FOR W7459D.
MODEL DRIVE MOTOR OPEN DRIVE MOTOR CLOSED SPRING RETURN
M7415 Power to TR and TR1, jumper T and T1. Disconnect jumper at T or T1 and
disconnect P or P1,if connected. Disconnect power at TR and TR1.
Table 1. Motor Operation Checkout

Page 8
INSTALLER’S GUIDE
Checkout Procedure Response
A1. Disconnect power at TR and TR1.
2. Disconnect jumper P to P1.
3. Jumper TR to 1.
4. Jumper T1 to T.
5. If connected, remove C7400 Solid State Enthalpy Sensor
from teminals S0 and +. Ensure factory-installed 620 ohm
resistor is connected to terminals Sr and +.
6. Apply power (24Vac) to terminals TR and TR1
LED is off.
Motor is in closed position.
B1. Disconnect factory-installed 620 ohm resistor from
terminals Sr and +. Led turns on, motor drives toward open.
C 1. To simulate high and low enthalpy (single enthalpy
sensor) reconnect factory-installed 620 ohm resistor from
termonals Sr and +. Connect 1.2K ohm 4074EJM Checkout
Resistor across terminals So and +.
__
2. Turn enthalpy setpoint potentiometer to "A". LED turns on, indicating low enthalpy.
Motor drives toward open.
3. Turn enthalpy setpoint potentiometer to "D". LED turns off, indicating high enthalpy.
Motor drives toward closed.
4. Disconnect the 1.2 K ohm checkout resistor. __
D1. To verify sensor operation, reconnect the + lead of the
outdoor enthalpy sensor to the + terminal of W7459. __
2 Connect a DC millimeter between terminal So of the
W7459A and terminal S of the enthalpy sensor. See Fig. 10
(positive meter lead to terminal S of the enthalpy sensor).
Millimeter indication is between 3 and 25
mA if sensor is operating properly.
If millimeter indicates zero, the sensor may
be wired backward.
3. When using differential enthalpy, check the return air
enthalpy sensor by connecting a DC millimeter between
terminal Sr of the W7459A and terminal S of the return air
enthalpy sensor. (positve meter lead to terminal S of the
enthalpy sensor).
Millimeter indication is between 3 and 25
mA if sensor is operating properly.
If millimeter indicates zero, the sensor may
be wired backward.
1
1
2
2
M9097
ENTHALPY CHANGEOVER
SETPOINT
LED LIGHTS WHEN
OUTDOOR AIR IS SUITABLE
FOR FREE COOLING
INSERT DC MILLIMETER BETWEEN SOAND S FOR CHECKOUT
AND TROUBLESHOOTING.
JUMPER USED FOR SINGLE ENTHALPY CONTROL.
TR TR1
A
BC
D
SO
SR
+
+
+
C7400
620 OHM
JUMPER
DC
MILLIMETER
W7459
S
+
1
1
M9098B
ENTHALPY
CHANGEOVER
SETPOINT
MINIMUM
DAMPER
POSITION
SETTING
LED LIGHTS
WHEN OUTDOOR
AIR IS SUITABLE
FOR FREE COOLING
MINIMUM DAMPER POSITION ADJUSTMENT
IS PRESENT ONLY ON W7459A,D MODELS.
Meter Location for Checkout and Trouble-
shooting
Location of Enthalpy Set Point, Minimum Position
and LED
Table 2. Enthalpy Checkout Procedure
Figure 8. Enthalpy LEDs and Checkout
Trane
6200 Troup Highway
Tyler, TX 75707-9010
The manufacturer has a policy of continuous product and
product data improvement. It reserves the right to
change design and specification without notice.
© 2008 Trane All rights reserved