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

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

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

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

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

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

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)

This manual suits for next models

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