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Trane Performance Air Handlers Installation and Maintenance Manual

1. Air handler basic structure eee Air handler Structural base structure Se steel curb _ Dunnage Zi 4 5 CAH SVX01B EN 19 S TRANE Installation Mechanical TCP Flat Concrete Pad The TCP base for concrete is designed to sit flat on the concrete with full perimeter contact Concrete pads should be perfectly level flat and sized to the minimum exterior base channel measurements See Figure 7 Figure 7 Flat concrete pad mount Air handler base structure P e Concrete i a pad A I g CAH SVXOIB EN e TRANE Installation Mechanical TCP Roof Curbs for Large Units with Shipping Splits CAH SVX01B EN Larger units with shipping splits may require full width intermediate support With any raised type roof support such as curbs or dunnage provisions must be made to carry the weight of the base cross members at the sectional splits Since these unit bases are designed with lifting lugs between the sections temporary support must be provided so additional sections can be set down with a 12 inch gap to allow for working room between sections and lug removal The use of field provided outriggers has proven to be a successful way to accomplish this as shown in Figure 8 Figure 8 Large units with shipping splits may require intermediate support Field supplied outriggers may be a useful too
2. 1TB1 4 24 Vac GND Trag dampers are low leak dampers that modulate and measure airflow Each Traq damper section is supplied with a factory mounted ventilation control module VCM on the interior of the mixing box The VCM has an input terminal for power and an output terminal for air velocity see Figure 76 A direct digital controller controls the factory mounted and wired actuators VCM Transducer Calibration The VCM has an auto zero function that recalibrates the transducer once every minute When troubleshooting allow for the recalibration time before making any measurements Input Power The only input the VCM needs is the 24 Vac power connected to terminals 1TB1 5 and 1TB1 6 Output Velocity Signal The 2 to 10 Vdc linear output signal from the VCM represents air velocity This voltage can be converted to represent airflow cfm or L s using the formula below Table 5 and Table 6 In Table 6 the cfm at 10Vdc is a calculated value based on area and peak velocity In certain situations it can be advantageous to raise the velocity of airthrough the remaining Trag dampers by closing off one or more dampers in the unit The cfm at 10Vdc can be recalculated based on the proportion of remaining Trag dampers or by multiplying the remaining area of dampers by peak velocity Table5 Altitude adjustment factors Airflow k cfm 10v 5 2 Sea level 1 0 or volts 2 Elevation feet k Airflow k L s 10V Te
3. base structure Concrete pad 4 Dunnage CAH SVXOIB EN S TRANE Installation Mechanical TCC J oining Sections Edge to Edge CAH SVX01B EN NOTICE Microbial Growth The roof curb or foundation must be level and the condensate drain at the proper height for proper coil drainage and condensate flow Standing water and wet surfaces inside the equipment can become an amplification site for microbial growth mold which may cause odors and damage to the equipment and building materials NOTICE Level Foundation A level foundation is critical to proper unit and door alignment operation and sealing Failure to level and align sections properly can lead to structural damage Important Units must be installed level for proper drainage of condensate from the drain pan and for squareness of the sections during installation In addition each section ina multi section unit must be properly supported Note Leveling each section beginning with the first section is critical Failure to level and align the sections immediately creates greater misalignment or even structural damage afterward L The end section must be installed first making sure it s properly aligned with the remainder of the curb Anchorthis section securely so the base lugs can be used to pull the next section for base connections 2 Forunits with curb base remove shipping blocks see Figure 21 Figure 21 Shipping
4. Check relief Liquid line Condensing unit valve 2 e Expansion e valves e o 8 B Moisture Se 5 indicating YANG Access i t Bi sight glass port Filter drier S p access E rt SE ES Im Distriburtor Manual ball valve Access port Manual ball valve i Frostat control Suction line Kit with sensor X13790452010 SEN 01212 Kit with switch X13100429010 THT 02442 Line Sizing Properly sizing the liquid line is critical to a successful split system application The selected tube diameter must provide at least 5 F 2 7 C of subcooling at the expansion valve throughout the operating envelope Increasing the size of the liquid line will not increase the available subcooling Routing Install the liquid line with a slight slope in the direction of flow so that it can be routed with the suction line Minimize tube bends and reducers because these items tend to increase pressure drop and to reduce subcooling at the expansion valve Liquid line receivers other than those that are factory installed are not recommended CAH SVX01B EN S TRANE Coil Piping and Connections Insulation The liquid line is generally warmer than the surrounding air so it does not require insulation In fact heat loss from the liquid line improves system capacity because it provides additional subcooling Components Liquid line refrigerant components necessary for a successful job include a filter drier access port solenoid valve moistur
5. 1000 0 982 2000 0 964 For example if the VCM on a size 30 air handler at sea level k 1 3000 0 949 has a 10 volt signal it would represent 17 335 cfm 4000 0 930 8181 L s through the Traq damper If the voltage were 6 volts 5000 0 914 airflow through the Traq damper would be 8 668 cfm 4091 L s 6000 0 897 7000 0 876 8000 0 860 9000 0 846 10 000 0 825 CAH SVXOIB EN 81 Table 6 Back or Top Inlet Traq Dampers Air Mixing and Economizer Section VCM voltage versus airflow at sea level Traq Damper Peak Velocity CFM 10VDC Part Number Size inches Quantity Total Area ft fpm Peak Velocity L S 10VDC DMP01123 13 1 0 9213 2500 2303 1087 DMP01124 16 1 1 3956 2650 3698 1745 DMP01663 20 1 2 1806 2650 5779 2727 DMP01125 24 1 3 1400 2700 8478 4001 DMP01126 28 1 4 2739 2700 11540 5446 Fan Inlet Airflow Measuring System Figure 77 Piezometer ring airflow A fan inlet airflow measuring system with a piezometer ring is available measurement on many centrifugal and plenum fans Each system comes with a differential pressure transmitter The piezometer ring is connected to the LO port of the transmitter and the reference pressure point is connected to or actually is the HI port of the transmitter See Figure 77 In the absence of a factory provided control system consult the transmitter manufacturer or the factory for wiring Note Ensure that the transmitter has a separate power source Transmitter Sizing The
6. Fans The fan and motor assembly are internally isolated The fan and motor bases are bolted to a minimum of four spring isolators The isolators are secured to the fan section support base Shipping tie down blocks are bolted to the isolators between the fan base and the isolator support frame To activate the isolation remove the shipping tie down blocks Retain these blocks for use in adjusting isolators if necessary Isolator Adjustment Note Isolators are pre adjusted and setatthe factory Follow this procedure only if necessary and as it applies to the isolators used in this unit This procedure can and should be performed by one person to ensure that the proper sequence is followed Figure 43 Isolator Isolators are selected for distribution of equipment weight but may not all compress the same This procedure assumes the base surface is level Isolators are not intended to be leveling devices 1 Verify that the shipping bolts that hold the fan base in a fixed position have been removed See Figure 43 Fan base PE P ees Jam Sh Si Se c a MAR Put 2 Removethejamnuton top of theisolator adjusting stud at the first isolator to be adjusted Check that the Adjusting shipping block is in place Shipping nut Se tie down 3 Turn the adjusting nut two or three turns only counterclockwise on each isolator in a sequenced block shim manner The equipment weight will compress the spring inside the hous
7. Pipe Cabinet Ribbed Butyl tape Ribbed Butyl tape Note 1 S see Note 1 Pipe cabinet wall Inside corner cap AHU outdoor roof DETAIL A Ribbed Butyl tape Screw 10 16 x 750 self driller Pipe cabinet outer roof Picture frame mounting chanels factory assembled to unit Slots provided to allow final adjustment of outer roof Inside corner cap Not ote 1 Seam to be sealed with three ribbed Butyl tape prior to attaching inside corner cap with screws 10 16 x 750 self driller Ribbed Butyl tape see Note 1 DETAIL B CAH SVXOIB EN 45 e TRANE Installation Mechanical Duct Connections All duct connections to the units should be installed in accordance with the standards of the National Fire Protection Association NFPA for selecting and installing of air conditioning and ventilating systems other than residence type NFPA 90A and residence type warm air heating and air conditioning systems NFPA 90B To ensure the highest fan efficiency duct turns and transitions must be made carefully minimizing air friction losses and turbulence Proper duct work installation by such organizations as SMACNA Sheet Metal and Air Conditioning Contractors National Association Inc should be adhered to Bottom Opening Duct Installation L Install gasket to duct flange to ensure air tight seal 2 Install duct into place underneath framed opening in unit base per Figure 40 Refer to factory curb l
8. Note The adjustable block off should always be installed last next to the access door 6 Close and secure the access door If the door can be closed without compressing the filter adjust the block off by loosening its screws and position it to provide an airtight seal Z WARNING Hazardous Chemicals Cleaning agents can be either acidic or highly alkaline Handle chemical carefully Proper handling should include goggles or face shield chemical resistant gloves boots apron or suit as required For personal safety refer to the cleaning agent manufacturer s Materials Safety Data Sheet and follow all recommended safe handling practices Failure to follow all safety instructions could result in death or serious injury Z WARNING No Step Surface Do not walk on the sheet metal drain pan Walking on the drain pan could cause the supporting metal to collapse Failure of the drain pan could result in death or serious injury The condensate drain pan and drain line must be checked to ensure the condensate drains as designed This inspection should occur a minimum of every six months or more often as dictated by operating experience If evidence of standing water or condensate overflow exists identify and remedy the cause immediately Refer to Troubleshooting on page 98 for possible causes and solutions 87 e TRANE Routine Maintenance Fans To clean drain pans L Disconnect all electrical power to the unit 2 Wearing
9. When the sheaves are aligned the straightedge will touch both sheaves at points A through D see Figure 75 to confirm the shaft is parallel For uneven width sheaves place a string in the center groove of both sheaves and pull tight Adjustthe sheaves and tighten the sheave set screws to the proper torque given in Table 4 Check Multiple Belts Tighten the belts slightly and rotate the drive several times Onmultiple beltdrives ensuretheforce of deflection is approximately the same on each belt by pushing each belt in an equal distance at a point halfway from each sheave see Figure 75 Ifthis force is notthe same for each belt the motor and fan shaft are not parallel Realign as required After realignment tighten the belts again to the standard belt tensioning specifications If the force is still not the same for all belts the belts or sheaves are worn and must be replaced unga Sheave Table 4 Fan and drive compound torque settings inches Screw Size Hex Key Square Head Hex Head Torque in Ib Torque ft Ib 1 4 1 8 3 8 7 16 66 90 5 5 7 5 5 16 5 32 1 2 1 2 126 164 10 5 13 7 3 8 3 16 9 16 9 16 228 300 19 0 25 0 7 15 7 32 5 8 5 8 348 450 29 0 37 5 1 2 1 4 3 4 3 4 504 650 42 0 54 2 5 8 5 16 15 16 15 16 1290 1390 107 0 116 0 10 3 32 28 40 2 3 3 3 80 CAH SVXOIB EN Traq Dampers Figure 76 Traq damper terminal connections Ventilation Control Module Velocity 2 10 Vdc GND
10. solenoid valve liquid line circuit 1 filter drier 10 Pitch the liquid line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator See Figure 64 Provide one expansion valve per distributor Slightly pitch the outlet line from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Usethe tube diameter that matches the suction header connection Arrange the suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward Use a double elbow configuration to isolate the thermal expansion valve bulb from other suction headers For horizontal tubing usethetube diameter recommended by the condensing unit manufacturer For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Ensure the top of the riser is higher than the evaporator coil Pitch the suction line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator Insulate the suction line ThetopoftheCircuit 1suction riser mustbe higher than the bottom evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser The top of the Circuit 2 suction riser must be higher than the top evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser 67 e TRANE C
11. CAH SVX01B EN 39 S TRANE Installation Mechanical TCC Stacking Procedure L After bottom section of stacked arrangement is in place ensure top is clean and free of debris 2 Apply two layers of 0 188 inch x 2 inch gasketing around perimeter of top section layout See Figure 34 3 Apply two layers of 1 inch x 2 inch tape around perimeter of openings in lower unit roof See Figure 34 and Figure 35 Lift upper section into place carefully aligning into proper position see Figure 35 5 Install 0 250 14 x 0 750 self drilling screws in each hole around upper unit base perimeter Install flashing at base of top section see Figure 35 Detail A Figure 34 Upper base connection to lower unit gasket Apply two layers of 1 inch x 2 inch gasketing around all openings in the lower unit roof Upper unit Factory installed engagement plate Apply 188 inch x 2 inch gasketing around lower Lower unit unit perimeter 250 14 x 75 leached self driller screws in every hole around upper unit base perimeter 40 CAH SVXOIB EN e TRANE Installation Mechanical Figure 35 Stacked assembly Base N Flashing Detail A Screw 10 16 x 750 Apply two layers of 1 in x 2 in gasket around all openings in the lower unit roof PCAP Upper unit 250 14 x 750 leached self driller screws in every hole around upper unit base perimeter Apply 2 layers of 188 x 2 in gasket around l
12. For all other applications install a single solenoid valve the pumpdown solenoid valve between the liquid line filter drier and the sight glass CAH SVX01B EN S TRANE Coil Piping and Connections Single Circuit Condensing Unit Evaporator Coil with Four Distributors Figure 62 Single circuit evaporator coil with four distributors suction line thermal expansion valves TXV 7 8 aaa v ef IR 3 i pumpdown solenoid valve 3 4 distributor suction line 78 thermal expansion valves TXV Wem trim solenoid valve 6 5 pumpdown solenoid valve 3 GN 3 uj 4 distributor CAH SVX01B EN Evaporator Coil with Horizontal Split Standard Circuiting filter drier Evaporator Coil with Intertwined Circuiting filter drier Pitch the liquid line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator See Figure 62 Provide one expansion valve per distributor Slightly pitch the outletline from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Use the tube diameter that matches the suction header connection Arrange the suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward Use a double elbow configuration to isolate the thermal expansion valve bulb from other suction headers For horizont
13. K acca esee e Rr AREE Ir RE ER wd E 83 External Insulating Requirements 84 Routine Maintenance enn 85 AN cp PE 86 Throwaway Filters ccc ren 86 Permanent Filters res 86 Front Load Filters 2 0 0 0 cette 86 Side Load Filters 2 62 ee eem eee ele eee eS 87 Drain PANS eene tee ae haw a deed ath d aln pe dor IR Rn emia ake d abd 87 FANS fT 88 Inspecting and Cleaning Fans 000 c cece eee 88 Fan Bearing Lubrication 89 Bearing Set Screw Alignment 89 Motor Bearing Lubrication 90 Fan Motor Inspection res 90 CONS C 91 Steam and Water Coils eee 91 Cleanable Cooling Coils ccc eee 92 Refrigerant Coils 0 0 0 tte 92 Coil Winterization ee 93 Chilled Water Coils nh 93 Cleanable Coils i i naaa oda dem e nbn e ce Bede Sr IRR dn d 93 Moisture Purge Cycle tees 93 Internal Insulation isses rnm eR Ra tex x TEARS 94 Elle te uiu sedere eos ber a e doe Buon Ec Sere arbe had Oe RU e Rie d 96 Multiple Fatis coiere RE Rr Rhe E eee E s 96 Ultraviolet UV Light Maintenance 96 Cleaning the Bulbs e 96 Replacing the Bulbs eres 97 Disposal of Bulbs raam ranana z aaa aaao a ren 97 CAH SVX01B EN CAH SVX01B EN Troubleshooting TRANE General Information Use this manual to install startup operate and maintain the Custom Climate Changer air handler Carefully review the procedures discussed in
14. Routine Maintenance Coil Winterization NOTICE Coil Freeze up Properly drain and vent coils when not in use Trane recommends glycol protection in all possible freezing applications Use a glycol approved for use with commercial cooling and heating systems and copper tube coils Failure to do so may result in equipment damage In general most coil manufacturers recommend the same method to protect coils from subfreezing temperatures Primarily this consists of draining water from the coil before the heating season and thoroughly blowing the coil out with compressed air Trane also recommends flushing the coil with glycol if coils will be exposed to temperatures below 35 degrees If coils are purchased from a manufacturer other than Trane contact that coil manufacturer for recommendations specific to their product Install field fitted drains and vents to permit winterization of coils not in use and to assist in evacuating air from the water system during startup If draining is questionable because of dirt or scale deposits inside the coil fill the coil with glycol before the heating season begins Note On many units there are multiple coils in the coil section Be sure to winterize all coils in a given coil section Chilled Water Coils Cleanable Coils Note Use care in removing header plugs from coils Over torquing may result in twisted tubes 1 Removethe vent and drain plugs 2 Blow the coil out as completely as possible with
15. Trane specification requires that the flow meter option have a total accuracy of 5 percent The total accuracy is a combination of how accurately the piezometer ring itself is in sensing airflow how accurately the transmitter senses the differential pressure how accurately the controller translates the signal from the transmitter to a differential pressure Selecting the proper transmitter is critical in orderto get accurate airflow measurements using the piezometer ring How accurately the transmitter senses the differential pressure is dependent on the pressure range selected accuracy of the selected transmitter 82 CAH SVXOIB EN Trane air handlers use a 0 20 inch range transmitter as standard To sufficiently cover VAV turndown on the smallest fans with the above range a transmitter with an accuracy of 0 25 percent full scale is used as standard If a field provided transmitter with a lower accuracy is selected the range should be chosen closer to the actual maximum pressure differential expected for the application The transmitter outputs a signal that represents the differential pressure which is used to calculate airflow To adequately calculate and display the airflow for the smaller fans ensure that the analog inputis programmed with enough decimal places to sufficiently represent the pressure differential being measured For instance Rover should be used to increase the number of decimal places being used to a ma
16. Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Note For additional information regarding the safe discharge of capacitors see PROD SVBO6A EN or PROD SVBO6A FR NOTICE Use Copper Conductors Only Unit terminals are not designed to accept other types of conductors Use of aluminum or other type of wiring may result in galvanic corrosion or overheating Failure to use copper conductors may result in equipment damage If the unit does not include a factory mounted starter wiring to the unit fan motor must be provided by the installer and must comply with all national and local electrical codes The installer must also furnish a service disconnect switch in compliance with national and local electrical codes Fan motors require motor overload protective devices that are rated or selected in compliance with the National Electric Code NEC or Canadian Electric Code Specific unit and motor connection diagrams are provided on the starter VFD if Trane provided or refer to the motor nameplate If wiring directly to the motor a flexible connection at the motor to permit fan belt adjustment should be provided Fractional horsepower motors may be factory connected to a terminal box on the unit If this construction is provided the installer should complete field wiring to this connection box For a typical high volt
17. Washer 563 ID x 1 375 OD Bolt 500 13 x 3 500 Hex Figure 28 J oin intemal shipping split frame Graphic 1 Figure 29 J oin intemal shipping split frame Graphic 2 AN Da VN TIPP UI n p IYAN i 36 CAH SVX01B EN e TRANE Installation Mechanical TCC Wall Section Assembly Typical L Verify external unit squareness 2 To complete the exterior joint install a bead of caulk full height of side panel joint 3 Over caulk install 3 16 inch x 1 25 inch ribbed grey butyl the full height of the side panel up to underside of roof overhang Leave the paper backing on this tape sealing the joint does not require this to be removed The paper will be facing out towards seam cap 4 Install side seam cap over butyl tape and secure with 10 16 x 0 750 self drilling screw The bottom two screws on this seam cap will be larger 74x 20 self drillers with neoprene gasket see Figure 30 TCC Indoor Roof Section Assembly Typical L Verify external unit squareness 2 Apply the 125 inch x 0 33 inch ribbed butyl tape to the exterior of the roofs covering the seam of the two adjoining sections see method sheet 3 Install seam cap over the butyl uniformly straddling the splits Secure with the provided number 10 sheet metal screws See Figure 30 Figure 30 Install seam cap over the butyl tape Screw 10 16 x 750 self driller Screw 10 16 x 750 self driller Seam cap Butyl tape Joint cap DETAIL A Screw 10
18. brush to remove loose debris from both sides of the coil 3 Install a block off to prevent spray from going through the coil and into a dry section of the unit and or system ductwork 4 Mixa high quality coil cleaning detergent with water according to the manufacturer s instructions Note If the detergent is strongly alkaline after mixing PH 8 5 or higher it must contain an inhibitor Follow the cleaning solution manufacturer s instructions regarding the use of the product 5 Place the mixed solution in a garden pump up sprayer or high pressure sprayer If a high pressure sprayer is to be used Maintain minimum nozzle spray angle of 15 degrees Spray perpendicular to the coil face Keep the nozzle at least 6 inches from the coil Do not exceed 600 psi Spray the leaving air side of the coil first then the entering air side Thoroughly rinse both sides of the coil and the drain pan with cool clean water Repeat steps 6 and 7 as necessary Q0 0 x 9 Straighten any coil fins damaged during the cleaning process 10 Confirm the drain line is open following the cleaning process 1L Allow the unitto dry thoroughly before putting it back into service 12 Replace all panels and parts and restore electrical power to the unit 13 Be careful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials and cleaning solution 92 CAH SVXOIB EN e TRANE
19. compressed air 3 Fill and drain the coil several times with full strength glycol so that it mixes thoroughly with the water retained in the coil Drain the coil out as completely as possible 5 To ensure no water remains in the coil do not replace the vent and drain plugs until the coils are put back into service Remove all vent and drain plugs Allow the water to drain from the coil Remove the header covers If tubes are fouled clean the tubes with a nylon or wire brush To ensure no water remains in the coil do not replace the header covers until the coils are put back into service UU P DH FH Note When the coils are put back into service use new gaskets Trane recommends washers be used under the bolt heads and bolts be evenly tightened to 50 ft Ibs torque Moisture Purge Cycle CAH SVX01B EN By it s very nature any HVAC unit with a cooling coil serves as a dehumidifier reducing the surrounding air s ability to hold water vapor as its temperature falls This normally doesn t present a problem when the unit is running However when the fan stops water vapor condenses on the cold metal surfaces inside the air handler and remains there until the air warms sufficiently to re evaporate it This damp dark environment though temporary can encourage the growth of mold mildew and other microbial contaminants 93 e TRANE Routine Maintenance Providing a moisture purge cycle 15 to 30 minutes after shutdown
20. disperses the cold humid air inside the air handling system more evenly throughout the building This four step cycle Closes the outdoor air dampers Turns off the cooling coil Opens any variable air volume terminals connected to the air handler Operates the supply fan for 10 to 15 minutes Airmovementdiscourages water condensation and hastens re evaporation of any condensate that does happen to form This simple preventative measure effectively combats microbial growth and curbs moisture related deterioration of air handling components Intemal Insulation 94 NOTICE Microbial Growth Wet interior unit insulation can become an amplification site for microbial growth mold which may cause odors and damage to the equipment and building materials If there is evidence of microbial growth on the interior insulation the insulation should be removed and replaced prior to operating the system The process of cooling and dehumidification produces condensate that must be continuously removed from the air handling unit The section of the unit from the entering air side of the cooling coil to the leaving edge of the drain pan is considered to be the wet section of the unit Other potentially wet sections are immediately downstream of a humidifier and or an outside air intake section Internal insulation in areas of the unit that are normally considered to be dry must also be periodically inspected to ensure the ins
21. expansion valve The expansion valve is the throttling device that meters the refrigerant into the evaporator coil Metering too much refrigerant floods the compressor metering too little elevates the compressor temperature Choosing the correct size and type of expansion valve is critical to ensure it will correctly meter refrigerant into the evaporator coil throughout the entire operating envelope of thesystem Correct refrigerant distribution into the coil requires an expansion valve for each distributor Figure 59 Type F refrigerant coil with packed elbow CAH SVX01B EN The thermal expansion valve must be selected for proper size and capacity The size of the Cut here expansion valve should cover the full range of for piping loadings Check that the valve will successfully operate at the lightest load condition For improved modulation choose expansion valves with balanced port construction and external equalization Perforated plate packed elbow Cutthe process tube and cap assembly from the liquid connection as shown in Figure 59 and install the expansion valve directly to the liquid connections Venturi type distributor 61 e TRANE Coil Piping and Connections Suction Lines 62 NOTICE Valve Damage Disassemble the thermal expansion valve before completing the brazing connections If necessary wrap the valve in a cool wet cloth while brazing Failure to protect the valve from high temperatures ma
22. in and on the equipment which could result in corrosion damage or wet storage stains The unit controller and all other electrical electronic components should be stored in conditions of 20 F to 120 F and 5 to 95 percent relative humidity non condensing Electrical components are not moisture tolerant Factory protective coverings should be removed prior to storage Long Term Storage CAH SVX01B EN For longer periods of storage allow proper clearance around the unit to perform periodic inspection and maintenance of the equipment While the unit is in storage e Every two weeks rotate the fan and motor shaft 30 revolutions by hand Check for free rotation Every six months check fan shaft bearings and grease lines Add grease using a manual grease gun following the lubrications recommendations in Fan Bearing Lubrication on page 89 e Check the motor lubrication remove and clean grease plugs and check for the presence of moisture in the grease If moisture is present remove the motor and send it to an authorized repair shop for bearing inspection replacement If no moisture if present refer to the motor manufacturer s lubrication recommendation for proper lubrication e TRANE Pre Installation Requirements Outdoor Storage Considerations Outdoor storage is not recommended however when outdoor storage is necessary several things must be done to prevent damage Note Keep the equipment in the original shipping con
23. leaves the factory If damage has occurred to the unit during shipment follow these instructions Note Trane is not responsible for shipping damage L Makespecific notation describing the damage on the freight bill Take photos of the damaged material if possible 2 Report all claims of shipping damage to the delivering carrier immediately and coordinate carrier inspection if necessary Note Do not attempt to repair the unit without consulting the delivering carrier 3 Notify your Trane sales representative of the damage and arrange for repair Note Do not attempt to repair the unit without consulting the Trane sales representative 4 Keep the damaged material in the same location as it was received Note Itis the receiver s responsibility to provide reasonable evidence that concealed damage was not incurred after delivery Storage Recommendations General Storage Air handlers and or field installed accessories that must be stored for a period of time before installation must be protected from the elements A controlled indoor environment is recommended for proper storage Note The warranty does not cover damage to the unit or controls due to negligence during storage NOTICE Use Canvas Only All factory shipping protection should be removed This wrapping is for transit protection only and should not be used for jobsite storage Use only canvas tarps to cover air handlers Plastic tarps can cause condensation to form
24. making any welded flange or welded elbow type connections If extended drains and vents are required on water coils they must be field installed or ordered from the factory Pipe coils counterflow to airflow NOTICE Connection Leaks Use a backup wrench when attaching piping to coils with copper headers to prevent damage to the coil header Do not use brass connectors because they distort easily and could cause connection leaks When attaching the piping to the coil header make the connection only tight enough to prevent leaks Maximum recommended torque is 200 foot pounds NOTICE Over Tightening Do not use teflon based products for any field connections because their high lubricity may allow connections to be over tightened resulting in damage to the coil header Use pipe sealer on all thread connections NOTICE Leakage Properly seal all penetrations in unit casing Failure to seal penetrations from inner panel to outer panel may result in unconditioned air entering the unit and water infiltrating the insulation resulting in equipment damage After completing the piping connections seal around pipe from inner panel to outer panel 53 e TRANE Coil Piping and Connections Drain Pan Trapping 54 N WARNING No Step Surface Do not walk on the sheet metal drain pan Walking on the drain pan could cause the supporting metal to collapse Failure of the drain pan could result in death or serious injury Thr
25. or realign drive for clearance Bearing noise Poor alignment Failed bearing Inadequate lubrication Loosen bearing set screws and realign see Bearing Set Screw Alignment on page 89 Replace bearing Replace bearing Low water coil capacity Incorrect airflow Incorrect water flow Incorrect water temperature Coil is piped incorrectly Dirty fin surface Incorrect glycol mixture Check fan operating condition Inspect the water pumps and valves for proper operation and check the lines for obstructions Adjust the chiller or boiler to provide the proper water temperature Verify coil piping see Coil Piping and Connections section on page 53 Clean the fin surface see Coils section on page 91 Verify glycol mixture and adjust if necessary Low refrigerant coil capacity Incorrect airflow Expansion valve is not operating properly or is sized incorrectly Incorrect refrigerant charge Condensing unit failure Coil is piped incorrectly Clogged refrigerant line filter Failure of suction liquid line components Dirty fin surface Fin frosting Check fan operating condition Check sensing bulb temperature Verify valve operation Verify proper valve size Verify refrigerant charge and adjust if necessary Verify condensing unit operation Verify coil piping see Coil Piping and Connections section on page 53 Change filter core Verify component operation Clean
26. such as the duct static control signal to modulate the fan speed Ultraviolet UV Light Maintenance Z WARNING Hazardous Voltage and Exposure to Ultraviolet Radiation If UV lights are present in this unit it contains components that emit high intensity ultraviolet UV C radiation which can be harmful to unprotected eyes and skin Disconnect all electrical power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the equipment cannot be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury The intensity of the ultraviolet energy emitted from the ultraviolet bulbs is dependent on the cleanliness and age of the bulb The surface of the bulb should be kept as clean as possible for optimum intensity Depending on the filtration level of the HVAC system and the general hygiene of the building periodic cleaning may be necessary Before attempting any maintenance procedures always follow all warnings and cautions as detailed in this maintenance section Cleaning the Bulbs 96 Note If bulbs are found to be broken see the proper warning and cautions below regarding broken bulbs and hazardous vapors L Disconnect all electrical power to the unit and the ultraviolet bulbs 2 Wearing soft cloth gloves and safety glasses usetwo hands and firmly grasp the bulb at each end 3 Rotate the bulb 90 degrees in either direction and move bulb aw
27. the appropriate personal protective equipment remove any standing water 3 Scrape solid matter off of the drain pan 4 Vacuum the drain pan with a vacuum device that uses high efficiency particulate arrestance HEPA filters with a minimum efficiency of 99 97 percent at 0 3 micron particle size 5 Thoroughly clean any contaminated area s with a mild bleach and water solution or an EPA approved sanitizer specifically designed for HVAC use 6 Immediately rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of metal surfaces Allow the unitto dry completely before putting it back into service Be careful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials and cleaning solution N WARNING Rotating Components Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the equipment can not be inadvertently energized Secure drive sheaves to ensure rotor cannot freewheel Failure to secure drive sheaves or disconnect power before servicing could result in death or serious injury N WARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the equipment can not be inadvertently energized Failure to disconnect power before servicing could res
28. the fin surface see Coils section on page 91 Do not use steam to clean refrigerant coils Verify defrost cycle operation Verify Frostat operation Verify refrigerant charge Low steam coil capacity Incorrect airflow Coil is piped incorrectly Incorrect steam pressure Excessive steam superheat Failure of steam line condensate return components Boiler failure Dirty fin surface Check fan operating condition Verify coil piping see Coil Piping and Connections section on page 53 Verify steam pressure and adjust if necessary Check steam superheat Steam superheat should not exceed 50 F Verify component operation Verify boiler operation Clean the fin surface see Coils section on page 91 Drain pan is overflowing Plugged Drain Line Unit not level Improper trap design Clean drain line Level unit Design trap per unit installation instructions Standing water in drain pan Improper trap design Unit not level Plugged drain line Design trap per unit installation instructions Level unit Clean drain line Wet interior insulation Coil face velocity too high Improper trap design Drain pan leaks overflows Condensation on surfaces Reduce fan speed Design trap per unit installation instructions Repair leaks Insulate surfaces Excess dirt in unit Missing filters Filter bypass Replace filters Reduce filter bypass by ensuring all blockoffs are in place Mi
29. tube diameter that matches the suction header connection 4 The top of the Circuit 1 suction riser must be higher than the bottom evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser 5 Arrange the suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward 6 Thetop of the Circuit 2 suction riser must be higher than the top evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser 7 Pitch the suction lines slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator 8 Insulate the suction lines 66 CAH SVX01B EN e TRANE Coil Piping and Connections Dual Circuit Condensing Unit Evaporator Coil with Four Distributors Figure 64 Dual circuit evaporator coil with four distributors suction line circuit 2 thermal expansion 78 valves TXV suction line 5 3 doc EN circuit 1 ce 78 3 EL 4 DI 5 3 JS 3 4 distributor suction lines thermal expansion 78 aq a valves TXV 3 Es E e i s KE pang 3 5 a 5 3 6 6 3 Esch CR 4 distributor CAH SVX01B EN solenoid valve Evaporator Coil with Horizontal Split Standard Circuiting liquid line circuit 2 liquid line circuit 1 filter drier Evaporator Coil with Intertwined Circuiting liquid line circuit 2
30. 0 0 851 1 500 25 6 38 0 n a n a 1 000 2 500 n a n a 3 3 4 9 2 2 2 4 2 501 4 000 n a n a 2 9 4 3 1 000 2 500 3 6 5 1 4 2 6 2 3V 3VX 2 65 3 65 2 501 4 000 3 0 4 4 3 8 5 6 1 000 2 500 4 9 7 3 5 3 7 9 4 12 6 90 2 501 4 000 4 4 6 6 4 9 7 3 500 1 749 n a n a 10 2 15 2 4 4 6 7 1 750 3 000 n a n a 8 8 13 2 3 001 4 000 n a n a 5 6 8 5 5V 5VX dins 500 1 749 HE 18 9 14 8 22 1 1 750 3 000 11 2 16 7 13 7 20 1 500 1 749 15 5 23 4 17 1 25 5 11 8 16 0 1 750 3 000 14 6 21 8 16 8 25 0 200 850 0 49 12 5 17 0 33 3 n a n a av 851 1 500 26 8 39 9 n a n a 200 850 39 6 59 2 n a n a 18 0 22 4 851 1 500 35 3 52 7 n a n a Determine Fan Speed CAH SVXOIB EN Fan speed can be determined using a strobe type tachometer or revolution counter Check unit vibration if the fan speed is changed more than five percent from the original designed speed or if parts such as shafts fan wheels bearings or other drive components are replaced Do not exceed the maximum fan speed Pay particular attention to any vibration noise or overheating of the motor and fan bearings however note that bearings may run warm during break in 79 Figure 75 Proper drive alignment Fixed Sheave Center line must coincide Lines must gt be parallel Straight Edge Align Fan and Motor Sheaves Align the fan and motor sheaves using a straightedge The straightedge must be long enough to span the distance between the outside edges of the sheaves
31. 16 x 750 self driller Screws 250 14 x 1 00 Hes WSH HD self driller CAH SVXOIB EN 37 38 e TRANE Installation Mechanical TCC Outdoor Roof Section Assembly Typical L J oin two outdoor roof panels together at the seams at the direction of airflow and secure them in place with 5 16 inch x 3 4 inch bolts and 5 16 lock nuts Cut the proper length of roof joint strip to cover the seam between two outdoor roof panels at the direction of airflow exclude single outdoor roof panel See Figure 31 Figure 31 J oin outdoor roof panels at the seams SCREW 10 24 X 56 SELF DRILLER 2 Join outdoor roof panels together at the seams in the direction perpendicular to airflow and secure them in place with 5 16 inch x 3 4 inch bolts and 5 16 lock nuts Install the roof joint strip to cover the seam between two outdoor roof panels in the perpendicular to airflow direction of Use 3 8 inch butyl tape to cover the seam between two outdoor roof panels overhang at the side the unit Bend joint strip over roof panel and use two number 10 sheet metal screws one in each roof panel to secure joint strip Trim the roof joint strip to insure that it does not protrude more than 1 16 inch beyond outdoor roof overhang see Figure 32 and Figure 33 CAH SVXOIB EN e TRANE Installation Mechanical Figure 32 Trim roof joint strip Si BUTYL TAPE NUT 313 18 BOLT 313 18 X 0 750 HEX DETAIL A Figure 33 Trim roof joint strip
32. 18 ga galv CAH SVX01B EN e TRANE Installation Mechanical TCP Base to Interior Wall Section Assembly Note Failure to completely compress the gasketing may result in air leakage L Jointhetwo units and secure with field provided 5 8 inch flat washers and 5 8 inch X 2 1 2 inch grade 9 bolts though each of the six holes 2 Apply caulk the length of the base between the 2 inch X 2 inch angle on the one base section and the wall on the adjoining section See Figure 17 below Note Use a polyurethane or equivalent caulk 3 Secure the 2 inch X 2 inch angle to the adjoining wall with 14 sheet metal crews on 12 inch centers along the length of the angle and wall Figure 17 TCP base to interior wall sections 4 in x 1 4 in gasket Secure 2 in x 2 in angle to wall with 14 SM screws at 12 in centers Caulk kaaa __ i Interior wall Split Interior wall Split Split Base to Wall Assembly Complete 30 CAH SVX01B EN e TRANE Installation Mechanical TCP Stacked Unit Assembly L Install and assemble all lower sections as described in typical assembly 2 Liftfirst piece of upper section into place assuring proper alignment with lower unit 3 Install 10 gauge 12 inch angle clips as shown in Figure 18 and secure with grade 5 self tapping screws placed 4 inches on center 4 Lift next upper piece into place and secure shipping split with appropriate hardware then anchor to lower se
33. 2 7 16 20 UNF 45 1 2 13 UNC 69 1 2 20 UNF 83 9 16 12 UNC 99 9 16 18 UNF 118 5 8 11 UNC 150 5 8 18 UNF 176 3 4 10 UNC 254 3 4 16 UNF 301 7 8 9 UNC 358 7 8 14 UNF 422 1 8 UNC 500 1 14 UNF 602 Note Soft metric conversions are not acceptable for screw and hex sizes Motor Bearing Lubrication AN WARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedure to ensure the power cannot be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury Obtain an IOM from the motor manufacturer for the specific motor installed The motor manufacturer s recommendations take precedence for all matters related to the start up and routine maintenance of the motor Motor grease fittings have been removed from factory installed motors in compliance with UL regulations Motor bearings require periodic maintenance throughout their life Many different styles of motors come as standard selections so please obtain the motor IOM and use the manufacturer recommended grease Fan Motor Inspection 90 Inspect fan motors periodically for excessive vibration or temperature CAH SVXOIB EN e TRANE Routine Maintenance Coils Z WARNING Hazardous Chemicals Coil cleaning agents can be either acidic or highly alkaline Handle chemical carefully Proper handling should include goggles or face shield chemical resist
34. N y Y NUS S AN 18 ga trim cap AN 10 SMS ee d EP P d Zip screw 18 ga strip 18 ga trim cap 18 ga strip No greater than 6 inch spacing on all fasteners 18 ga trim cap 28 CAH SVX01B EN S TRANE Installation Mechanical TCP Indoor Roof Assembly Multiple Span Ensure shipping split sections are aligned and pulled together properly Apply a bead of caulk to full height of wall joint Apply 3 inch x 1 8 inch adhesive backed foam gasket to inner joining strip Install inner joining strip using 14 x 15 inch gasketed tec screws Fit the pre cut hub cap over the joining strip the vertical height of the wall flush with the roof and secure it to the wall with 8 sheet metal screws 6 Fill the top and bottom openings with caulk as a moisture seal Screw holes can be pre drilled with a 29 bit Apply a bead of caulk over top corner of cap seam Using 10 sheet metal screws attach corner seam trip cap as shown in Figure 16 UP WN H Figure 16 TCP indoor roof assembly multiple span 6 inch trim cap xul HE 10 sheet metal screw Cap and Caulk gasket Standing seam 10 ga galv 14 sheet metal screw on 10 inch centers Zip screws
35. S TRANE Installation Operation Maintenance Custom Climate Changer Air Handlers X code X39640745010 J uly 2010 CAH SVX01B EN TRANE Wamings Cautions and Notices Wamings Cautions and Notices Note that warnings cautions and notices appear at appropriate intervals throughoutthis manual Warnings are provide to alert installing contractors to potential hazards that could result in personal injury or death Cautions are designed to alert personnel to hazardous situations that could result in personal injury while notices indicate a situation that may result in equipment or property damage only accidents Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions ATTENTION Warnings Cautions and Notices appear at appropriate sections throughout this literature Read these carefully WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided could resultin minor or moderate injury It could also be used to alert against unsafe practices NOTICE Indicates a situation that may result in equipment or property damage only accidents Important Environmental Concems Scientific research has shown that certain man made chemicals can affect the earth s naturally occurring stratospheric ozone layer when released to the atm
36. This gasket must be applied to the full perimeter of the section split on both sections to be joined Move the next mating section into alignment with the positioned section Alignment of sections must be completed before gasket surfaces meet The two sections should be within 12 inches to reduce the amount of dragging required Remove lifting lugs on mating section as required Figure 9 Insert supplied bolts through each hole of 9 Pulling sections together on a flat surface can be done by mating connecting plate using chain come alongs hooked onto the welded square E Connecting plate 22 tubes located on each side of the shipping split These square tubes are designed to fully support the stress of pulling sections together Sections should be pulled together until mating gaskets make contact and factory supplied bolts can be installed in connecting plate 10 When sections are close enough to allow full threading of the factory supplied nut onto the bolt chain come alongs can be removed The use of an electric impact gun to tighten bolts in a sequential manner will allow the additional section to be pulled into the final position 1L Check overall unit length to assure proper joint compression Note Failure to compress the gasketing may result in air leakage 12 Once the sections are pulled together install the assembly hardware as applicable for the walls roof and the base as demonstrated in the following assembl
37. ace and bypass control is used NOTICE Coil Condensate Condensate must flow freely from the coil at all times to prevent coil damage from water hammer unequal thermal stresses freeze up and or corrosion In all steam coil installations the condensate retum connections must be at the low point of the coil Failure to follow these instructions may result in equipment damage Proper steam trap installation is necessary for satisfactory coil performance and service life For steam trap installation L Install the steam trap discharge 12 inches below the condensate return connection Twelve inches provides sufficient hydrostatic head pressure to overcome trap losses and ensures complete condensate removal a Usefloatand thermostatic traps with atmospheric pressure gravity condensate return with automatic controls or where the possibility of low pressure supply steam exists Float and thermostatic traps are recommended because of gravity drain and continuous discharge operation b Use bucket traps only when the supply steam is not modulated and is 25 psig or higher 57 e TRANE Coil Piping and Connections Note Trane steam coils require a minimum of 2 psi of pressure to ensure even heat distribution 2 Trap each coil separately to prevent holding up condensate in one or more of the coils 3 Install strainers as close as possible to the inlet side of the trap 4 If installing coils in series airflow control each coil bank ind
38. aced prior to operating the system The following areas should be specifically addressed as applicable Supply and return water piping connections Supply and return refrigerant piping connections Condensate drain lines and connections Outdoor air intake duct connections Discharge duct connections Special requirements for low temperature air systems CAH SVX01B EN S TRANE Routine Maintenance The following checklist is provided as an abbreviated guide to periodic maintenance Detailed procedural information is given after this checklist N WARNING Hazardous Service Procedures The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical mechanical or other potential safety hazards Always refer to the safety wamings provided throughout this manual conceming these procedures When possible disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized When necessary to work with live electrical components have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks Failure to follow all of the recommended safety wamings provided could result in death or serious injury WARNING Rotating Components Disconnect
39. aft failure Under tensioning belts is the primary cause of premature belt failure Belts should not squeal at startup Recheck belt tension after 8 hours 24 hours and 100 hours of operation and monthly thereafter Figure 72 Tension drive belt label gut V BELT DRIVE KIT 1627373 MODULE 0400 PURCHASE ORD NUMBER B24597 061 H5D073B A CUSTOMER S KIT H5D073B A 012 0400 MTR HP 10 0 FAN RPM 1458 CD 9 4 AT 3 00 TRN OPN TENSION INFO 3 86 LB 0 14 IN DRIVE S BELTS B40 MOTOR SHEAVE 2VP75X 1 3 8 MOTOR BUSHING NONE REQUIRED FAN SHEAVE 2B5V80 FAN BUSHING B 1 7 16 Figure 73 Belt tensioner Proper belt tension is required to ensure maximum bearing and drive component life and is based on motor horsepower requirement A label located on the bearing support on the drive side of the unit lists all drive parts the proper belt tension and deflection for that tension for the specific drive Figure 72 If the drive is changed from the original proper belt tension can be estimated using Table 3 The correct operation tension for a V belt drive is the lowest tension at which the belts will not slip under the peak load conditions It may be necessary however to increase the tension of some drives to reduce excessive belt flopping or to reduce excessive startup squealing Check the fan belt tension at least three times during the first days of Span Scale Large O Ring 78 Deflection operation because the
40. age wiring schematic see Figure 66 69 e TRANE rica Installation Elect igh voltage wiring schematic Ih Figure 66 Typical CAH SVX01B EN BE gees APP SAP MOWC Emer aupen ANO MEDLL FELD sn TIMOG E 200 070 SHOWN SEE WSET A FOR OTHER VOLTAGES mem CONTACTS SRVER CADMIUM ONDE 1 0HP SAMP 12000 TD SEE ze SCHDIATC maa FOR ACTUAL QUANTITY OF TRANSFORMERS E 122 MG ASSOCHIED PLUG SETS USED WITH UPCH OPTION ONLY TES crit ue uiu eu ns Saa lal i itj PT fii 3 al ah ji ii EY LI fli d d SH bh A WARNING HAZARDOUS Y VOLTAGE 70 S TRANE Installation Electrical NOTICE Penetration Leaks Properly seal all penetrations in unit casing Failure to seal penetrations from inner panel to outer panel may result in unconditioned air entering the unit and water infiltrating the insulation resulting in equipment damage Figure 67 Transfo plate Figure 68 EE eg Control Figure 69 ue ce drive All units with starters or variable frequency drives VFDs that have direct digital controllers DDCs are provided with line voltage to 120 Vac power transformers see Figure 67 with power 120 Vac to 24 Vac control transformers see Figure 68 Figure 69 shows a typical VFD power box To provide field wiring to units with DDC or low limit controls e IfVFDorstarteris notfactory mounted provide 120 Vac power to a transformer in th
41. ains or slings may not be of the same length Adjust as necessary for even unit lift Other lifting arrangements may cause equipment or property only damage Failure to properly lift unit could result in death or serious injury See details below N WARNING Heavy Objects Always place assemble and suspend sections subassemblies one at a time Do not lift units in windy conditions Do not raise units overhead with personnel below unit Failure to follow these instructions could result in death serious injury or equipment damage WARNING Z WARNING Improper Unit Lift Test lift unit approximately 24 inches to verify proper center of gravity lift point To avoid dropping of unit reposition lifting point if unit is not level Failure to properly lift unit could result in death or serious injury or possible equipment or property only damage NOTICE Equipment Damage Do not use a fork lift on air handlers or subassemblies Improper use of fork lifts on units may result in equipment damage Trane is not responsible for equipment damage resulting from improper forklifting practices Preparation of the roof curb or pier mount and roof openings should be completed before lifting unit to the roof Per job requirements air handlers will ship as a complete assembly or in sections Tranerecommends thatthe contractor use spreader bars and slings to rig units and sub assemblies sections CAH SVX01B EN 15 e TRANE Installation Mechani
42. al tubing usethetube diameter recommended by the condensing unit manufacturer For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Ensure the top of the riser is higher than the evaporator coil Pitch thesuction line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator Insulate the suction line Only use a trim solenoid valve for constant volume humidity sensitive applications For all other applications install a single solenoid valve the pumpdown solenoid valve between the liquid line filter drier and the sight glass 65 e TRANE Coil Piping and Connections Dual Circuit Condensing Unit Evaporator Coil with Two Distributors Figure 63 Dual circuit evaporator coil with two distributors suction line Evaporator Coil circuit 2 with Horizontal Split 78 RERUM liquid line Standard Circuiting circuit 2 j C H distrib solenoid suction line tsiributor valve circuit 1 circuit 1 3 78 5 SO liquid line circuit 1 4 j thermal filter drier E expansion 3 valve TXV L Pitch the liquid lines slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator See Figure 63 2 Provide one expansion valve per distributor Slightly pitch the outlet line from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Use the
43. all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Secure drive sheaves to ensure rotor cannot freewheel Failure to secure drive sheaves or disconnect power before servicing could result in death or serious injury Table 7 Routine maintenance checklist Frequency Maintenance After 48 hours of operation Belts have acquired their permanent set Readjust but do not overtighten See Tension the Fan Belt on page 78 for more information Every week Observe unit weekly for any change in running condition and unusual noise Clean or replace air filters if clogged or dirty coat permanent filters with oil after cleaning and change bag filters when pressure drop is 1 in wg See Air Filters on page 86 for more information Relubricate fan bearings if necessary See Fan Bearing Lubrication on page 89 for more information Every month Check and adjust fan belt tension Every three to six months Check fan bearing grease line connections Lines should be tight to the bearings Check bearing and motor bracket bolt torque and bearing setscrew torque Align fan and motor sheaves Tighten sheave set screws to the proper torque See Align Fan and Motor Sheaves on page 80 for more information Inspect and clean drain pans See the Drain Pans section on page 87 for more information Tighten electrical connecti
44. am 10 ga galv 14 sheet metal screw on 10 inch centers Zip screws 18 ga galv e e Apply a bead of caulk to the seam the full length that roof cap will cover Apply 3 inch x 1 8 inch adhesive backed neoprene gasket to underside of roof cap Install roof cap using 10 sheet metal screws in pre punched holes Apply a bead of caulk over the butt joint where roof caps meet 10 Install roof cap trim piece at joint of each roof cap using 10 sheet metal screws om x 9 CAH SVXOIB EN e TRANE Installation Mechanical TCP Indoor Roof Section Assembly Typical Ensure shipping split sections are aligned and pulled together properly Apply a bead of caulk to full height of wall joint Apply 3 inch x 1 8 inch adhesive backed foam gasket to inner joining strip Install inner joining strip using 14 x 15 inch gasketed tec screws Fit the pre cut hub cap over the joining strip the vertical height of the wall flush with the roof and secure it to the wall with 8 sheet metal screws 6 Fill the top and bottom openings with caulk as a moisture seal Screw holes can be pre drilled with a 29 bit 7 Apply a bead of caulk over top corner of cap seam UU BA WN H 8 Using 10 sheet metal screws attach corner seam trip cap as shown in Figure 15 Figure 15 TCP indoor wall and roof assembly trim cap 18 ga strip Interior Gasket of unit TI
45. amely eyes and skin To reduce the potential for inadvertent exposure to the lights by operating and maintenance personnel electrical interlocks that automatically disconnect power to the lights are provided at all unit entry points to equipment where lights are located Z WARNING Equipment Damage From Ultraviolet UV Lights Trane does not recommend field installation of ultraviolet lights in its air handling equipment for the intended purpose of improving indoor air quality High intensity C band ultraviolet light is known to severely damage polymer plastic materials and poses a personal safety risk to anyone exposed to the light without proper personal protective equipment could cause damage to eyes and skin Polymer materials commonly found in HVAC equipment that may be susceptible include insulation on electrical wiring fan belts thermal insulation various fasteners and bushings Degradation of these materials can result in serious damage to the equipment Trane accepts no responsibility for the performance or operation of our air handling equipment in which ultraviolet devices were installed outside of the Trane factory e TRANE Table of Contents General Information 8 Operating Environment 8 Unit Description 8 Factory Mounted Controls 0 0 0 ccc ccc eee n 9 lg ME PPP 9 Pre Installation Requirements 10 Receiving Checker 10 Assembly Hardware 10 Resolving Shipping Damage 11 Storage Reco
46. an be pre drilled with a 29 bit Interior Wall and Roof J oint Assembly Typical 1 See Figure 12 Ensure shipping split sections are aligned and pulled together properly 2 Pre drill interior joining strip screw holes using 29 drill bit 3 Apply a bead of caulkthe full height of interior wall joint 4 Install joining strips using 10 sheet metal screws Figure 12 Wall section assembly 8 x 1 in Phillips zip screw 2 3 4 in wide joining strip LIZ Add caulking before 4 in x 1 4 in gasket installing J strip 6 wa Wall panel section split 3 in x 1 8 in neoprene gasket is sms applied to metal joining strip Apply gasket to metal strip 4 72 2 3 4 in wide joining strip before installation 8 x 1 in Phillips zip screw Trim cap i E 10 x 1 in self tapping screw Add caulking after quM J strip iL La CAH SVXOIB EN 25 e TRANE Installation Mechanical TCP Outdoor Roof Assembly Single Span L Ensure shipping split sections are aligned and pulled together properly See Figure 13 2 Adda bead of caulk along the length of the roof seams Install the pre cut cap over the seam and secure with 14 sheet metal screws
47. ant gloves boots apron or suit as required For personal safety refer to the cleaning agent manufacturer s Materials Safety Data Sheet and follow all recommended safe handling practices Failure to follow all safety instructions could result in death or serious injury All coils should be kept clean to maintain maximum performance Steam and Water Coils To clean steam and water coils L Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment use a soft brush to remove loose debris from both sides of the coil 3 Install a block off to prevent spray from going through the coil and into a dry section of the unit and or system ductwork 4 Mixa high quality coil cleaning detergent with water according to the manufacturer s instructions Note If the detergent is strongly alkaline after mixing PH 8 5 or higher it must contain an inhibitor Follow the cleaning solution manufacturer s instructions regarding the use of the product 5 Placethe mixed solution in a garden pump up sprayer or high pressure sprayer If a high pressure sprayer is to be used a Maintain minimum nozzle spray angle of 15 degrees b Spray perpendicular to the coil face c Keep the nozzle at least 6 inches from the coil d Do not exceed 600 psi Spray the leaving air side of the coil first then the entering air side Thoroughly rinse both sides of the coil and the drain pan with cool clean water Repeat
48. aring failure The grease used in electric motor bearings is usually not compatible with the grease used in fan bearings Never mix the two grease types See Table 8 for compatible greases and Table 9 for maximum grease capacity Note Lubricate the bearing according to the motor manufacturer s recommendations and use the manufacturer recommended grease Fan bearings without lubrication lines are sealed bearings Re lubrication is not required Fanbearings equipped with lubrication lines should be lubricated with a lithium based grease that conforms to NLGI No 2 for consistency Table8 Compatible Greases Table 9 Fan bearing maximum grease capacity Type Shaft size inches Capacity fluid ounce Texaco Multi Fak 2 1 2 3 4 1 7 Shell Alvania 2 7 8 13 16 3 8 Mobil 532 11 4 11 2 5 8 Chevron Dura Lith 2 111 16 1 15 16 7 8 Exxon Beacon 2 27 16 11 4 Keystone 84H 2 1 2 2 15 16 2 Refer to Table 10 for minimum torque of motor mounting and bearings bolts Figure 78 Bearing set screw alignment Bearing Set Screw Alignment Align bearing set screws as illustrated in Figure 78 Table 10 provides bearing set screw torque measurements 89 e TRANE Routine Maintenance Table 10 Minimum hex head bolt torque in Ib ft Grade 5 bolts Size inches Thread Designation Minimum Torque 1 4 20 UNC 6 1 4 28 UNF 7 65 16 18 UNC 14 5 16 24 UNF 16 3 8 16 UNC 24 3 8 24 UNF 28 7 16 14 UNC 4
49. aves or disconnect power before servicing could result in death or serious injury Throwaway Filters To replace throwaway filters install new filters with the directional arrows pointing in the direction of airflow Note Bag and cartridge filters must have an airtight seal to prevent air bypass If using other than Trane supplied filters apply foam gasketing to the vertical edges of the filter Permanent Filters To clean permanent filters L Disconnect all electrical power to the unit Wash the filter under a stream of water to remove dirt and lint Remove oil from the filter with a wash of mild alkali solution Rinse the filter in clean hot water and allow to dry Coat both sides of the filter by immersing or spraying it with Air Maze Filter Kote W or an equivalent 6 Allow to drain and dry for about 12 hours 7 Reinstall the filter Note It may be preferable to keep extra clean filters to replace the dirty filters to minimize unit downtime for filter maintenance uk WN Front Load Filters 86 Most filters in custom units are installed in unitary sheet metal frames Filters are secured with a metal clip There are several different styles To install filters Disconnect power to the unit Open or remove the filter clip Remove the filter from the rack Install new filters with the directional arrows pointing in the direction of airflow Secure the filter using the appropriate clip for each filter The filte
50. ay from the fixture and out of unit 4 Wipe down each bulb with a clean cloth and alcohol Avoid touching the bulb with bare hands as skin oils can accelerate future glass soiling and degrade the bulb performance 5 Carefully return the bulb to the fixture and rotate it 90 degrees in either direction until itis firmly secured 6 Close and latch all unit panels and reenergize power to the lights CAH SVXOIB EN e TRANE Routine Maintenance Replacing the Bulbs Z WARNING Hazardous Vapors If large numbers of UV bulbs are broken an appropriate respirator should be considered to prevent inhalation of mercury vapors Failure to use a respirator could result in death or serious injury N CAUTION Broken Glass Bulbs are fragile and can be easily broken Always use gloves and eye protection when handling these bulbs Failure to handle bulbs properly may result in minor to moderate injury Refer to the MSDS sheet from the bulb manufacturer for additional safety information Ultraviolet bulbs should be replaced annually if operated continuously or after 9 000 hours of use if operated intermittently Replacement bulbs must be the specific size and wattage as originally supplied from the factory Note Although the lights may continue to generate a characteristic blue glow beyond 9 000 operating hours the ultraviolet radiation emitted by the bulbs degrades over time and will no longer provide the intended benefit Disconnect powe
51. ayout provided with unit submittals for duct size and location Figure 40 Field supplied duct connection to AHU bottom supply retum air opening Bottom supply return Trane NYA base typical E Trane AHU __ Field supplied base typical rigid duct Field supplied rigid duct 46 CAH SVX01B EN S TRANE Installation Mechanical 3 Bottom of unit base elevation is AG inch lower than edge of duct opening in bottom of unit During unit installation on roof curb either raisefield provided duct per Option A see Figure 41 or add additional gasket material to compensate for the AG inch offset per Option B see Figure 42 Figure 41 Field supplied duct connection option details Figure 42 Field supplied duct connection option details Option A Option B Supply opening in floor Supply opening in floor Edge of supply opening Edge of supply opening Gasket x Additional 1 2 in gasket Bottom of unit base elevation Bottom of unit base elevation Building roofing and structure may vary per job Building Option A Option B roofing Additional 1 2 inch of and structure Additional 1 2 inch duct length option may vary per job of gasket material Not to scale option Not to scale Note Bottom of unit base elevation is 1 2 inch lower than edge of duct Note Bottom of unit base elevation is 1 2 inch lower than edge of duct opening in bottom of unit During unit instal
52. block removal Remove shipping blocks 33 S TRANE Installation Mechanical 3 Install 3 16 inch x 125 inch ribbed grey butyl tape to bottom rail each side wall and top rail Remove paper backing from butyl tape This will ensure the module to module joint is water tight along the bottom See Figure 22 and Figure 23 Figure 22 Apply butyl tape to shipping splits Butyl tape Butyl tape 34 CAH SVXOLB EN e TRANE Installation Mechanical Figure 24 Remove lifting lug bolts 4 Lift next section into place sitting it as close to the previous section as possible 5 Remove lifting lug bolts See Figure 24 Using a come along on each side in unison pull second section securely to first section Insert all 5 8 inch threaded rod through base lugs and tighten nuts to pull sections firmly together for final fit See Figure 25 and Figure 26 for assembly details Remove bottom hardware Figure 25 Insert field provided threaded rods Rod threaded 62 11x13 38 THD Nut 62 11 CAH SVX01B EN 35 e TRANE Installation Mechanical TCC Intemal Shipping Split Frame Assembly Typical L After exterior shipping split has been sealed interior 2 5 inch x 2 5 inch angles can be bolted together using supplied hardware see Figure 27 Figure 28 and Figure 29 Figure 27 J oin intemal shipping split frame Washer 563 ID x 1 375 OD Nut 500 13 Hex Mach
53. cal Lifting Considerations Figure 2 Recommended attachment to lifting lugs 16 Before lifting the unit estimate the approximate center of gravity for lifting safety Because of the placement of internal components the unit weight may be unevenly distributed with more weight in the coil and fan areas Refer to the unit submittals for section weights Test the unit for proper balance and rigging before lifting Always assemble unit at the installation site Never bolt sections together before rigging Always rig subassemblies or sections as they ship from the factory See the unit submittal drawings for correct placement of sections Lift all sections individually using all lifting lugs provided See Figure 2 See specific instructions for handling the pipe cabinet see TCC Wall Section Assembly Typical on page 37 and inlet and exhaust hoods see Outdoor Unit Weather Hood s on page 52 Make the loop of the sling parallel to the direction of airflow whenever possible Each of the cables used to lift the unit must be capable of supporting the entire weight of the unit e When hoisting the unit into position use the proper rigging method such as straps slings spreader bars or lifting lugs for protection and safety See Figure 3 e The air handler is not designed to be lifted rigged or ceiling suspended from the top of the unit Never lift units in windy conditions Personnel should be po
54. commended in this section of the manual could result in exposure to electrical mechanical or other potential safety hazards Always refer to the safety wamings provided throughout this manual conceming these procedures When possible disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized When necessary to work with live electrical components have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks Failure to follow all of the recommended safety wamings provided could result in death or serious injury including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized When necessary to work with live electrical components have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks Failure to follow all of the recommended safety wamings provided could result in death or serious injury Table 1L Air handler troubleshooting recommendations Symptom Probable Cause Recommended Action First start after relubrication Grease distribution As e Over lubrication Bearing is excessively Over tensioned belts hot No lubricant Misalign
55. crobial growth mold inside air handler Standing water in drain pan Moisture problems See Standing water in drain pan above See Wet interior insulation above CAH SVX01B EN 99 e TRANE www trane com For more information contact your local Trane office or e mail us at comfort trane com Literature Order Number CAH SVXOIB EN Date July 1 2010 Supersedes CAH SVXOIA EN J uly 2005 Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice Only qualified technicians should perform the installation and servicing of equipment referred to in this literature
56. ction as described above 5 Continue until all sections are installed and anchored properly Install the 18 gauge cover trim cap using 10 self drilling screws See Figure 18 Figure 18 Stacked unit trim assembly Cap Upper unit 18 ga steel 050 if aluminum 10 1 2 S 777 WY Yj YG yy 7 1 2 12 in clip every 8 ft NI and at all corners use 41 2 grade 5 self tapping screws 4 in ctc _______ e 11 2 10 ga steel y me 125 if aluminum 0 Roof trim cap 0T 14 ga minimum 125 if aluminum Lower unit F CAH SVX01B EN 31 e TRANE Installation Mechanical TCC Model Assembly Instructions NOTICE Roof Curb Structurally Sound Check with curb manufacturer and job engineer to ensure the roof curb is structurally sufficient to support the weight of the unit The curb should be checked to ensure it is level and square Curb bowing buckling or sagging can lead to unit assembly and operation problems up to complete failure If your nameplate model number begins with TCC use the assembly instructions below TCC Overhang Base on Common Roof Curb L A base designed for use with a roof curb allows for 1 2 inch clearance around the full perimeter of the curb Theend section must be installed first making
57. e at worst case loaded filters minus external pressure Figure 51 Drain pan trapping for section under positive pressure L H K pipe diameter where K 1 2 inch minimum H 1 2 inch plus the total unit static pressure at worst case loaded filters CAH SVX01B EN 55 e TRANE Coil Piping and Connections Steam Coil Piping Air handlers fitted with steam coils have labeled holes for piping penetrations Figure 52 and Figure 53 illustrate typical steam coil piping configurations See Table 2 for the codes of system components in these figures The coil condensate return line must be piped full size of the condensate trap connection except for a short nipple screwed directly into the coil header s condensate return tapping Do not bush or reduce the coil return tapping size Table 2 Code of system components for piping figures Code System component FT Float and thermostatic steam trap GV Gate valve OV Automatic two position ON OFF control valve VB Vacuum breaker ST Strainer AV Automatic or manual air vent MV Modulating control valve Figure 52 Typical piping for Type N steam coils and Figure 53 Typical piping for Type NS steam coils and horizontal tubes for horizontal airflow horizontal tubes for horizontal airflow FULL SIZE OF COIL CONNECTION 56 CAH SVX01B EN CAH SVX01B EN e TRANE Coil Piping and Connections NOTICE Breaker Cracking Pressure The 1 2 inch NPT 15 degree sw
58. e indicating sight glass expansion valve s and ball shutoff valves Figure 58 illustrates the proper sequence for positioning them in the liquid line Position the components as close to the evaporator as possible Filter drier There is no substitute for cleanliness during system installation The filter drier prevents residual contaminants introduced during installation from entering the expansion valve and solenoid valve Access port The access port allows the unit to be charged with liquid refrigerant and is used to determine subcooling This port is usually a Schraeder valve with a core Solenoid valve In split systems solenoid valves isolate the refrigerant from the evaporator during off cycles under certain conditions they may also trim the amount of active evaporator as compressors unload Generally the trim solenoid valve is unnecessary for variable air volume comfort cooling applications and is only required for constant volume applications when dehumidification is a concern Moisture indicating sight glass Be sure to install one moisture indicating sight glass in the main liquid line The only value of the sight glass is its moisture indication ability Use actual measurements of temperature and pressure not the sight glass to determine subcooling and whether the system is properly charged The moisture indicator sight glass must be sized to match the size of the liquid line at the thermal expansion valve Thermal
59. e the tube diameter recommended by the condensing unit manufacturer Forthe vertical riser usethetube diameter recommended by the condensing unit manufacturer Ensure the top of the riser is higher than the evaporator coil Pitch the suction line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator Insulate the suction line The top of the Circuit 1 suction riser must be higher than the bottom evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser 10 The top of the Circuit 2 suction riser must be higher than the top evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser Only use a trim solenoid valve for constant volume humidity sensitive applications For all other applications install a single solenoid valve the pumpdown solenoid valve between the liquid line filter drier and the sight glass CAH SVX01B EN TRANE Installation Electrical CAH SVX01B EN Z WARNING Hazardous Voltage w Capacitors Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the equipment cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors
60. e valve jack when a separate circuit is recommended see Figure 68 Install outside air sensor and space sensor if ordered For valve jack mounting and wiring detail see Figure 70 Note The valve jackis typically located atthe air leaving side of the coil connection inside panel For coils with headers on both sides of the unit the valve jack is located at the return connection for water coils and the supply connection for steam coils CAH SVXOIB EN 71 S TRANE Installation Electrical Figure 70 Valve jack wiring details Conduit assembly Valve quick connect Quick Connects The actuators factory mounted or field supplied are separately wired and controlled by a direct digital controller or other building logic Figure 71 illustrates the typical quick connect scheme Figure 7L Typical quick connects with wiring identification 72 CAH SVX01B EN TRANE Controls Interface The portable operator display is used for temporary connection to and operation of Tracer M P580 581 and AH540 541 controllers With the portable operator display you can monitor data change setpoints monitor alarms and override points The portable operator display includes a 10 ft 3 m cable with connector that is stored in the storage compartment of the carrying bag The cable cannot be disconnected from the operator display Keep this document with the portable operator display for access to calibration and cleaning instruction
61. eaded condensate drain connections are provided on only one side of the coil section Pitch the connection lines horizontal or downward toward an open drain Trane recommends installing a plug to facilitate cleaning of the trap Figure 50 illustrates the proper trapping piping and operation of the trap for negative pressure sections Use the formula under the figure to determine the correct minimum depth for the condensate trap Figure 51 illustrates the proper trapping piping and operation of the trap for positive pressure sections Note Positive pressure traps require a different design than negative pressure traps If a section has a drain pan for cleaning purposes only it does not need a trap however a cap or shutoff valve should be installed on the drain connection Only sections handling condensate such as a cooling coil section or moisture eliminator section require a trap NOTICE Water Damage When more than one section has a drain pain trap each section individually Connecting all drains to a common line with only one trap can result in condensate retention and possible water damage to the air handler or adjoining space CAH SVX01B EN e TRANE Coil Piping and Connections Figure 50 Drain pan trapping for section under negative pressure Normal operation L H J pipe diameter where H 1 inch for each inch of negative pressure plus 1 inch J 1 2 H Negative pressure total unit static pressur
62. eating and or cooling coils filters and dampers See the unit submittal drawings for detailed descriptions The fans are internally isolated To insure fan stability the unit ships with a minimum of four lock down devices that prevent the fan from shifting during shipment and installation These spacers must be removed prior to fan operation to ensure proper vibration isolation Retain these spacers for use in adjusting fan isolators if required Theunits are available with factory mounted controls for climate and humidity control These can be use as stand alone devices or operate with a complete controls system End devices include factory mounted starters and variable speed drives Custom Climate Changer air handlers ship as complete assemblies or in sections Some jobsite assembly is required when the units ship in sections 8 CAH SVXOIB EN e TRANE General Infomation Factory Mounted Controls CAH SVX01B EN Trane air handlers are available with a wide selection of factory mounted controls including controllers motor starters and variable frequency drives VFD Most control components are mounted inside the unit Depending on the system configuration this may include damper actuators dirty filter switches averaging temperature sensors and low limit switches VFDs starters controllers control transformers static pressure transducers DC power supplies and customer interface relays will be in enclosures mounted on the
63. ed bearing Allo w machine to cool down and restart Clean surface of grease and purge Adjust belt tension App ly lubricant Check bearings for damage Correct alignment Check shaft level Blown fuse or open circuit breaker Overload trip Improper wiring or connections Motor fails to start Improper current supply Rep Che Che lace fuse or reset circuit breaker ck and reset overload ck wiring with diagram supplied on unit Compare actual supply power with motor nameplate recommendations Contact power company for adjustments p z Check that motor and drive rotate freely Check bearing Mechanical failure lubricant Open phase Check line for an open phase Motor stalls Overloaded motor Reduce load or replace with larger motor Low line voltage Che Ck across AC line Correct voltage if possible Poor alignment Excessive vibration Shipping spacers not removed Over tensioned belts Misaligned drive Alig n bearing set screws see Bearing Set Screw Alignment on page 89 Loosen and retighten bearing set screws Remove shipping spacers and or bolts see Fans section on pag e 48 Adjust belt tension Alig n drive Motor runs and then Partial loss of line voltage dies down Starter shorts when motor warms up Che ck for loose connections Determine adequacy of main power supply Rep ace starter Motor does not come Low voltage at motor termina
64. ependently with an automatic steam control valve Size the traps for each coil using the capacity of the first coil in direction of airflow 5 Usea modulating valve that has linear flow characteristics to obtain gradual modulation of the coil steam supply Note Do not modulate systems with overhead or pressurized returns unless the condensate is drained by gravity into a receiver vented to atmosphere and returned to the condensate pump 6 Pitch all supply and return steam piping down 1 inch for every 10 feet in the direction of the steam or condensate flow Note Do not drain the steam mains or take offs through the coils Drain the mains ahead of the coils through a steam trap to the return line 7 Ensure overhead returns have 1 psig of pressure at the steam trap discharge for every 2 feet of elevation for continuous condensate removal Water Coil Piping Figure 54 Typical piping for type 5W one row water coil Figure 54 Figure 55 and Figure 56 illustrate typical water coil piping configurations Type WA 5A 5W D K W UW TT P2 P4 and P8 water coils are self venting only if the water velocity exceeds 15 feet per second fps in the coil tubes Type UU WD and 5D water coils are self venting only if the water velocity exceeds 2 5 fps in the coil tubes See the unit submittals for coil water velocity If the water velocity is VE Water su pply main b Water below these minimums ventthe coil by Drain one
65. h One Distributor 63 Single Circuit Condensing Unit Evaporator Coil with Two Distributors 64 Single Circuit Condensing Unit Evaporator Coil with Four Distributors 65 Dual Circuit Condensing Unit Evaporator Coil with Two Distributors 66 Dual Circuit Condensing Unit Evaporator Coil with Four Distributors 67 Dual Circuit Condensing Unit Evaporator Coil with Eight Distributors 68 Installation Electrical Aa kaa a odes deer En adden mas m Roh dob kc Pd 69 Quick Connects 72 Controls Interface 113 2s sca Ak Ie o CR Ren eR RCR RR GR ICE CADRE RC TIR TRAC mA av a 73 Connecting the Operator Display 73 Setting Up the Operator Display esses eee 73 Calibrating the Operator Display 73 Adjusting Brightness and Contrat 74 External Communications Port saaara aranna 74 erudi AY 75 Pre Startup Checker 75 General Checks 75 Fan Related Check 75 CAH SVX01B EN 5 Coil Related Check 76 Motor Related Check 76 Unit Operation 77 Calculate Motor Voltage Imbalance 000 cece eee 77 Tension the Fan Belt eres 78 Determine Fan Speed 79 Align Fan and Motor Sheaves esses eres 80 Check Multiple Belt 80 Traq Dampers ed E eee RR RR RR ERI ERES 81 Fan Inlet Airflow Measuring System 0 00 cece eee eens 82 Villa EE 82 Transmitter Sizing rs angna aao maaa aa Aaa A E a RO aa AA AA A 82 Transmitter Calibration 0 0 0 cece 83 Constant Factor
66. hanged due to shipping and handling vibration e Check that air filters are in place and positioned properly Remove any debris from the unit interior Close and secure all unit access doors Note UL listed units require a removable latch on access doors The door clip shipped with the unit meets this requirement Inspect electrical connections to the unit and unit controllers Connections should be clean and secure Compare the actual wiring with the unit diagrams Reference the appropriate controller manual for more details about starting units with factory mounted controls e Leave this manual with the unit Fan Related Checks CAH SVXOIB EN e Ifthe unit is internally isolated ensure that the fan isolator tie down bolts have been removed e Rotate all fan wheels manually to confirm they turn freely in the proper direction e Check fan shaft bearings fan wheel and drive sheave set screws for proper torque settings Fan sheaves should be tight and aligned Bearing set screws should be torqued Inspect the inlet vane assembly for freedom of movement If resistance is above the recommended torques checkthe assembly for any binding or misalignment Do notforce the vanes e Check fan drive belt tension nspectfan motor and bearings for proper lubrication if necessary 75 Start Up Coil Related Checks NOTICE Proper Water Treatment The use of untreated or improperly treated water in coils may result in
67. ing approximately 1 4 inch 4 Check that the bushing on the isolator stud is centered in the isolator Adjust to center by moving the stud in ib e E the fan base hole 5 This procedure will raise the equipment load until the isolators are all off the shims shipping tie down blocks approximately 1 32 inch the thickness of a credit card and the internal gap is approximately equal to the external gap Note Do not adjust isolators once the fan base is off of the shipping tie down blocks 6 Continue adjusting other isolators in sequence and repeat the same adjustment Continue until all isolators are adjusted 7 Replace the jam nut on each isolator adjusting bolt tighten the nut and remove the shipping tie down block 48 CAH SVX01B EN e TRANE Installation Mechanical Control Dampers If the damper actuators are not factory mounted install damper actuators and connecting linkage Check damper operation and linkage alignment Damper blades should be non binding Adjust damper frame as necessary to ensure free blade movement Magnahelic Air Filter Gage Air Filters CAH SVX01B EN Check zero adjustment of the gage Turn both vent valves to the Vent position and adjustthe gage pointer to zero by means of the external adjustment screw in the face of the gage After zeroing turn the vent valves to the Line position Z WARNING Hazardous Voltage with Capacitors Disconnect all electric power incl
68. ing check valve vacuum breaker is recommended because other vacuum breakers such as spring loaded ball check breakers have cracking pressures as high as 1 25 inches Hg 17 inches of water Vacuum breakers with fitting sizes smaller than 1 2 inch NPT are too small to relieve vacuum quick enough to ensure complete condensate drainage Other types of swing check valve vacuum breakers are acceptable if the fittings size is not smaller than 1 2 inch NPT and the cracking pressure is not larger than 0 25 inches Hg 3 4 inches of water Failure to follow these instructions may result in equipment damage To prevent coil damage complete the following recommendations e Install a 1 2 inch NPT 15 degree swing check valve vacuum breaker with cracking pressure of 0 25 inches Hg 3 4 inches water or lower at the top of the coil This vacuum breaker should be installed as close to the coil as possible e ForcoiltypesA AA N NS and NN install the vacuum breaker in the unused condensate return tapping at the top of the coil Types T and ST coils require that the vacuum breaker be located as near as possible to the supply connection e Ventthe vacuum breaker line to atmosphere or connect it into the return main at the discharge side of the steam trap Note Vacuum breaker relief is mandatory when the coil is controlled by a modulating steam supply or automatic two position ON OFF steam supply valve Vacuum breaker relief is also recommended when f
69. inside of the unit Small items that cannot be factory mounted such as space temperature sensors outside air temperature sensors and humidity sensors will ship inside the control enclosures or packaged and shipped inside the fan or mixing box section Larger items are shipped inside the fan section Note All control valves ship directly to the ship to address from the vendor unless another address is given on the Trane sales order All factory mounted control systems controls that are factory wired to a unit controller or terminal strip ordered without starters or variable frequency drives VFDs are provided with 120 to 24 Vac control transformers mounted and wired in the auxiliary control panel The customer must provide 120 Vac 50 60 Hz control power A dedicated 15 amp circuit is recommended Factory mounted control systems ordered with factory mounted starters or VFDs are supplied with line to 24 Vac control transformers No additional power wiring is required For a more in depth understanding of controls refer to the following manuals e Tracer MP580 581 Programmable Controllers catalog CNT PRC002 EN Tracer MP581 Programmable Controllers Hardware Installation CNT SVNO1C EN Variable Frequency Drives TR200 Series BAS SLBO26 EN Custom air handlers and or field installed accessories that must be stored for a period of time prior to being installed must be protected from the elements All controllers and electrical elect
70. installed PE Add caulking after Tf trimming gasket A R LT l Eas CAH SVX01B EN 23 e TRANE Installation Mechanical TCP Base Section Assembly with Tumed Up Floor L SeeFigure 11 Apply 4 inch x Y inch neoprene gasket to the full perimeter face of each shipping split section 2 Join the two sections and secure with field provided 5 8 inch flat washers and 5 8 inch x 2 Y gt inch grade 9 bolts through each of the six holes 3 Apply a heavy bead of caulk to the inside of the U channel Press U channel down over upturned flanges with moderate pressure to ensure itis fully seated onto upturned flanges The caulk will cure and act as an adhesive to hold U channel in place no fasteners are required Figure IL Uptumed floor assembly 24 CAH SVXOIB EN S TRANE Installation Mechanical TCP Wall Section Assembly Exterior Wall Assembly Typical L See Figure 12 Ensure shipping split sections are aligned and pulled together properly Apply a bead of caulk to full height of wall joint Apply 3 inch x 1 8 inch adhesive backed foam gasket to inner joining strip Install inner joining strip using 14 x L5 inch gasketed tec screws uk WN Fit the pre cut hub cap over the joining strip the vertical height of the wall flush with the roof and secure it to the wall with 8 sheet metal screws Fill the top and bottom openings with caulk as a moisture seal Screw holes c
71. ions when exposed to live electrical components could result in death or serious injury Before complete startup bump start the unit and confirm the fan wheel rotates properly as indicated by the rotation arrow located on the fan housing After initial startup Calculate the motor voltage imbalance notifying the power company to correct unacceptable imbalances Periodically check the fan belt tension Calculate Motor Voltage Imbalance After startup measure the motor voltage and amperage on all phases to ensure proper operation Thereadings should fall within the range given on the motor nameplate The maximum allowable voltage imbalance is 2 percent Voltage imbalance is defined as 100 times the sum of the absolute deviation of the three voltages from the average divided by twice the average voltage For example if the three measured voltages are 221 230 and 227 the average voltage would be 226 volts The percent of voltage imbalance is then calculated 100A Voltage imbalance 2xAvgVoltage where A 226 221 230 226 227 226 Voltage imbalance 2 2 not acceptable Inthe example 2 2 percent imbalance is not acceptable and the power company should be notified to correct it CAH SVX01B EN 77 Start Up Tension the Fan Belt NOTICE Belt Tension Do not over tension belts Excessive belt tension will reduce fan and motor bearing life accelerate belt wear and possibly cause sh
72. l in making this field joint 21 e TRANE Installation Mechanical TCP J oining Sections Edge to Edge Units must be installed level for proper drainage of condensate from the drain pan In addition each section in a multi section unit must be properly supported Note Leveling each section beginning with the first is critical Failure to level and align the L 2 sections immediately creates greater misalignment or even structural damage afterward Remove all crating and wrapping from the surfaces to be joined Place one section of the air handler into the desired position Verify section is installed level front to back and side to side Verify section is square to support structure this is critical to insure proper alignment for next adjoining sections Check squareness measuring the critical dimensions given U se preselected method to anchor first piece in place This is necessary so movement will not affect pulling next sections into alignment When the unit is positioned and squareness is ensured within 1 8 inch remove all lifting lugs located along the split plane After assuring positioning is correct anchor in place either by welding unit base to the curb or by mechanical fasteners The first section will be used to pull remaining sections up tight so it s critical that first section be secured Install 4 inch x 1 4 inch neoprene gasket to all mating surfaces of the section including any internal walls
73. lass insulation L Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment use a vacuum device with a HEPA filter 99 97 percent efficient at 0 3 micron particles to remove the accumulated dirt and organic matter Note Be careful notto tear the insulation surface or edges 3 Confirm the drain line is open following the cleaning process 4 Allow the unit to dry thoroughly before putting it back into service 5 Replace all panels and parts and restore electrical power to the unit 6 Be careful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials and cleaning solution CAH SVXOIB EN 95 e TRANE Routine Maintenance Controls Multiple Fans On units that have been selected with the external communications port both the operator display and Rover service tool can be connected without shutting off the unit through the external communications port Remove the cover plate on the port and plug into the RJ 11 port for the operator display or the RS 485 port for the Rover service tool This enables continuous operation of the Air Handling unit without disruption to the operating conditions of the unit When servicing of the unitis complete replace the cover plate on the external port to eliminate the air leakage path When controlled in a bank of fans these fan units must be controlled using a common control signal
74. lation on roof curb either opening in bottom of unit During unit installation on roof curb either raise raise field provided duct or add additional gasket material to field provided duct or add additional gasket material to compensate for compensate for the 1 2 inch offset the 1 2 inch offset Component Installation Requirements Z WARNING Hazardous Voltage with Capacitors Disconnect all electric power including remote disconnects and discharge all motor start run capacitors before servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Each componentin the Custom air handler may have installation requirements that could affect the unit s performance Note For components included in the unit but not included in this manual reference the component manufacturers specific Installation Maintenance and Operation manual Copies of these manuals are either included in the package with this unitlOM or are attached to the components mounted in the unit CAH SVXOIB EN 47 e TRANE Installation Mechanical
75. lled Evaporator Piping Single Circuit Condensing Unit Evaporator Coil with One Distributor CAH SVX01B EN Figure 60 Single circuit evaporator coil with one distributor Evaporator Coil with Standard Circuiting suction line 6 7 4 thermal solenoid filter drier wgl expansion valve valve TXV 3 5 distributor Pitch the liquid line slightly 1 inch 10 feet 1 cm 3 m so that the refrigerant drains toward the evaporator See Figure 60 Provide one expansion valve per distributor 3 Slightly pitch the outlet line from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Use the tube diameter that matches the suction header connection For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Ensure the top of the riser is higher than the evaporator coil Arrange the suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward Pitch the suction line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator Insulate the suction line 63 e TRANE Coil Piping and Connections Single Circuit Condensing Unit Evaporator Coil with Two Distributors Figure 6L Single circuit evaporator coil with two distributors Evaporator coil Suction line with horizontal split standard circuiting Trim solenoid val
76. ls up to speed Line wiring to motor too small Che Rep ck across AC line and correct voltage loss if possible ace with larger sized wiring Motor overheats Overloaded motor Motor fan is clogged with dirt preventing proper ventilation Red uce load or replace with a larger motor Remove fan cover clean fan and replace cover Motor mounting bolts loose Rigid coupling connections Worn motor bearings Fan rubbing on fan cover Excessive motor noise Tighten motor mounting bolts Rep Rep ace with flexible connections ace bearings and seals Remove interference in motor fan housing Rapid motor bearing Excessive overhung load due to overtensioned drive Excessive overhung load due to a small diameter motor Che ck belt tension and overhung load wear Replace sheave with larger one sheave Motor is poorly positioned Adjust belt tension Loose fan belt Worn or damaged belt Replace belt or belt set Check sheave alignment Worn sheaves Replace sheaves 98 CAH SVXOLB EN Table 1L Air handler troubleshooting recommendations e TRANE Troubleshooting Symptom Probable Cause Recommended Action Short belt life Worn sheaves Misaligned belt Grease or oil on belts Belt slipping Belts rubbing Replace sheaves Realign drive with MVP sheave set at mean pitch diameter Check for leaky bearings Clean belts and sheaves Improper belt tension Adjust tension Remove obstruction
77. m tape See Figure 37 Figure 37 Pipe cabinet installation CAH SVXOIB EN 43 S TRANE Installation Mechanical 5 Lift cabinet into place aligning base tab with lifting lug brackets on air handler base 6 Slide pipe cabinet tight up against mounting channels on side wall of air handler 7 Install bolts through lifting lug gussets to anchor pipe cabinet base to the air handler See Figure 38 and Table 1 Figure 38 Pipe cabinet detail Unit Table L Pipe cabinet hardware Qty X Code Code Description Description 4 X25017800000 BOLT 0 625 11 X 1 750 5 8 1 75 in Bolt 4 X28021500000 NUT 0 62 11 5 8 11 Nut 4 X22020800000 LOCKWASHER 0 625 ID 5 8 in Lock Washer 8 X22050313010 WASHER 0 656 ID X 1 312 OD Flat Washer 8 Check pipe cabinet side walls to ensure they are plumb O Apply a bead of caulk along the corner between the pipe cabinet and air handler wall prior to installing connecting angle 44 CAH SVX01B EN e TRANE Installation Mechanical 10 Install inside corner cap See Figure 39 Detail A and B 1L Install 3 16 inch x 1 25 inch grey ribbed butyl tape to unit wall where pipe cabinet roof connects 12 Lift pipe cabinet roof into place and attach to unit wall with screws See Figure 39 Figure 39 Pipe cabinet See Detail B IH TOP VIEW Roof and base parts removed for clarity AHU Picture frame mounting chanels factory assembled to unit
78. manufacturer s lubrication recommendations for proper lubrication The motor manufacturer may recommend lubricating the motor as part of their routine startup instructions Checkmotor winding An acceptable winding resistance reading is from 6 meg ohms to infinity If reading is less than 5 mega ohms the winding should be dried out in an oven or by a blower Inspect the entire motor for rust and corrosion Bump start the unit and confirm the fan wheel rotates properly as indicated by the rotation arrow located on the fan housing Note Note For motor warranty needs contact you local Trane sales office 76 CAH SVXOIB EN Unit Operation Z WARNING Rotating Components During installation testing servicing and troubleshooting of this product it may be necessary to measure the speed of rotating components Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components perform these tasks Failure to follow all safety precautions when exposed to rotating components could result in death or serious injury N WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precaut
79. mmendations 0 cee een eee 11 General Storage ete ee 11 Long Term Storage i e one epee Ek ex eee eds eee Rm RE Rs 11 Outdoor Storage Considerations 12 Preparing the Unit Site 2 0 nannan aaaea 12 Roof Curb Installation Checker 13 Suggested Tools 14 Installation Mechanical 1 iae a Ah e do DER RR a ew wade eben de dee Ra 15 Lifting and Rigging cece cette n 15 Lifting Considerations 16 Unit Assembly 2 nent teen nee 17 TCP Model Assembly Instructions 0 0 0 cece cece eee eae 18 TCP Standard Roof Cube 18 TCP Structural Roof Curb and I Beam Dunnage ssassn sranna 19 TCP Flat Concrete bad 20 TCP Roof Curbs for Large Units with Shipping Splits 21 TCP J oining Sections Edge to Edge 22 TCP Base Section Assembly with Flat Floor 23 TCP Base Section Assembly with Turned Up Floor 24 TCP Wall Section Assembly 25 TCP Outdoor Roof Assembly Single Span lusus 26 TCP Outdoor Roof Assembly Multiple Gpnan nannan 27 TCP Indoor Roof Section Assembly Typical 28 TCP Indoor Roof Assembly Multiple Span aaa 29 TCP Base to Interior Wall Section Assembly s 30 TCP Stacked Unit Assembly 0 0 cece eee 31 TCC Model Assembly Instructions 00 ccc eee eee eee 32 TCC Overhang Base on Common Roof Cube 32 TCC Flat Base to Steel Dunnage or C
80. o the operating conditions of the unit When servicing of the unitis complete replace the cover plate on the external port to eliminate the air leakage path 74 CAH SVXOIB EN Start Up TRANE Once the air handler has been assembled and installed attention must be directed to individual components for proper operation Before operating the unit complete the pre startup checklist Z WARNING Hazardous Voltage with Capacitors Disconnect all electric power including remote disconnects and discharge all motor start run capacitors before servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Note For additional information regarding the safe discharge of capacitors see PROD SVBOGA EN Pre Startup Checklist General Checks Ensure the unit has been installed level Ensure supply air and return air ducts have been connected Ensure damper operator motors and connecting linkage have been installed e Verify damper operation and linkage alignment Damper blade and linkage positioning may have c
81. of the following methods Figure 55 Typical piping for SA 5W two row K W 3 to 12 row WD D L Install an air vent in the top pipe and DD water coils plug tapping of the return header 2 When the return line rises above the top of the coil vent from the top of the return header horizontally to the return piping Note T ST and TT coils are designed with larger than normal end tube sheet holes to allow for maximum expansion Air leakage around tubes should be expected and handled by capping over coil ends or by sealing around tubes with a pliable sealant such as silicon dq 58 CAH SVXOIB EN e TRANE Coil Piping and Connections Figure 56 Typical piping for type W or WA 1 row water coil CAH SVX01B EN 59 e TRANE Coil Piping and Connections Refrigerant Coil Piping Liquid Lines 60 Note Refer to Important Environmental Concerns on page 2 for information on handling refrigerants Use Figure 58 to determine the proper relative sequence ofthe components in the refrigerant lines that connect the condensing unit to an evaporator coil Refer to Examples of Field Installed Evaporator Piping on page 63 for more detailed schematics of evaporator piping Figure 58 Example of placement for split system components Access T port n Discharge em SELA line Access E port SS ii d Filter 9 o Manual co angle valves oo o 9 Manual 7 ou Compressors ball valve DI
82. oil Piping and Connections Dual Circuit Condensing Unit Evaporator Coil with Eight Distributors Figure 65 Dual circuit evaporator coil with eight distributors suction line 7 8 circuit 2 o suction line 78 circuit 1 4 suction lines 28 g 3 e 8 5 6 6 4 68 a 3 3 L 3n2419 Evaporator Coil thermal expansion with Horizontal Split eet valves TXV Es distributor distributor Standard Circuiting liquid line circuit 2 liquid line circuit 1 pump down solenoid valve Evaporator Coil with Intertwined Circuiting thermal expansion TN valves TXV trim solenoid valve G 11 liquid line circuit 2 liquid line circuit 1 filter drier pump down solenoid valve Pitch the liquid line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator See Figure 65 Provide one expansion valve per distributor Slightly pitch the outlet line from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Use the tube diameter that matches the suction header connection Arrangethe suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward Use a double elbow configuration to isolate the TXV bulb from other suction headers For horizontal tubing us
83. olds 2 inch filter b 4 Side Load Filters Most filters in custom units are installed in unitary sheet metal frames If unit is provided with side access rack do the following for installation 2 inch or 4 inch flat filters L Disconnect the power to the unit 2 Open the filter section access door and remove the filters and block offs from their installed position 3 Slide the filter into the rack 4 Some side load racks will be provided with block off plates 5 Close and secure the door making certain the door closes snug against the block off see Figure 48 50 CAH SVX01B EN S TRANE Installation Mechanical Figure 48 Filter block off placement Bag or Cartridge Filters L Disconnect power to the unit 2 Keeping the bag filters folded slide each filter into the filter rack pushing them tightly against the unit Pleats should be in the vertical position 3 If using optional pre filters slide them into the appropriate filter rack 4 If block offs are provided with the unit slide the block offs into the filter track 5 Close and secure the access door making certain the door closes snug against the rack Note The block off is intended to make a seal when the access door is closed It may require a few adjustments to ensure a proper seal CAH SVX01B EN 51 e TRANE Installation Mechanical Outdoor Unit Weather Hood s L Perthe unit drawing determine mounting location of the unit wea
84. ollow all recommended safe handling practices Failure to follow all safety instructions could result in death or serious injury Cleaning Non Porous Insulating Surface If microbial growth on a non porous insulating surface closed cell insulation or sheet metal surface is observed L Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment use a brush for sheet metal surfaces or a soft sponge on a foil face or closed cell foam surface to mechanically remove the microbial growth Note Be careful not to damage the non porous surface of the insulation 3 Install a block off to prevent spray from going into a dry section of the unit and or system ductwork 4 Thoroughly clean the contaminated area s with an EPA approved sanitizer specifically designed for HVAC use 5 Rinsethe affected surfaces thoroughly with fresh water and a fresh spongeto prevent potential corrosion of the drain pan and drain line Repeat steps 4 and 5 as necessary Confirm the drain line is open following the cleaning process Allow the unit to dry thoroughly before putting it back into service 0 OND Replace all panels and parts and restore electrical power to the unit 10 Be careful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials and cleaning solution Cleaning Porous Insulating Surface To clean a porous insulating surface fiberg
85. on 12 inch centers Note Use a polyurethane or equivalent caulk It may be necessary to clamp the joint together or pre drill to prevent separation when drilling with screws 3 Apply caulk to end of J cap to seal thoroughly Figure 13 TCP outdoor roof assembly single span Joining cap Add caulking before P dd installing J cap EN 4 in x 1 4 in gasket 10 x 1 in self tapping screw o 6 e e e e J Roof split outdoor unit w Roof panel a ees section split 3 in x 1 8 in neoprene gasket is 2 3 4 in wide joining strip applied to metal joining strip Apply gasket to metal strip before Installation 8 x 1 in Phillips zip screw 26 CAH SVXOIB EN e TRANE Installation Mechanical TCP Outdoor Roof Assembly Multiple Span Follow instructions in Figure 13 for installation of J Caps 4 The multiple roof split requires and additional cap that covers the center T shaped seam running parallel to air flow 5 Install 14 self drilling screws on 10 inch centers on underside of center split as shown in Figure 14 Figure 14 TCP outdoor roof assembly multiple span S Cap and Caulk gasket 6 inch trim cap ao 10 sheet metal screw Standing se
86. oncrete Pad 32 TCC J oining Sections Edge to Edge 0c eee eee 33 TCC Internal Shipping Split Frame Assembly Typical 36 TCC Wall Section Assembly Typical 00000 e eee eee 37 CAH SVX01B EN TCC Indoor Roof Section Assembly Typical 37 TCC Outdoor Roof Section Assembly Typical 38 TCC Stacking Procedure 40 TCC Energy Wheel and CDQ Wheel Assembly 42 Pipe Cabinet Installation cece 43 Duct Connectons x Xe p p NAG EG aa WERE PAN MERE ERG rui ea 46 Bottom Opening Duct Installation 46 Component Installation Requirements 47 FANS 453 fxs edie EA S Ux CE ew ee INTR ONG EROR ed 48 Isolator Adjustment 0 00 000 nanena 48 Control Dampers 2 tee 49 Magnahelic Air Filter Gage tee 49 X duca LL 49 Outdoor Unit Weather Hood s aaaeeeaa 52 Coil Piping and VONNECHONS lt aciem amc road dam md d erbe Ert ees 53 General Coil Piping Recommendations 53 Drain Pan Trapping 0 ccc n 54 Steam Coil Piping 2 0 56 Water Coil Piping 0 ccc eI I 58 Refrigerant Coil Piping ccc es 60 Liquid LINES iioi ana amend NAA MA KIA A gd DAAN ebe E E 60 SUCTION LINES 1er eres hha ha a chia ke dear S Qa P E E 62 Examples of Field Installed Evaporator Piping lusus 63 Single Circuit Condensing Unit Evaporator Coil wit
87. ons Inspect coils for dirt build up See Coils on page 91 for more information Every year Inspect the unit casing for corrosion If damage is found clean and repaint the surface with a rust resistant primer Clean the fan wheels and fan shaft See Fans on page 88 for more information Inspect and clean drain pans Check damper linkages set screws and blade adjustment Clean but do not lubricate the nylon damper rod bushings Clean damper operators Inspect electrical components and insulation Inspect wiring for damage Rotate the fan wheel and check for obstructions in the fan housing The wheel should not rub on the fan housing Adjust the center if necessary and tighten wheel set screws to the proper torque Lubricate motor bearings in accordance with motor manufacturer s recommendations see the Motor Bearing Lubrication section on page 90 for more information This may only need to be done every 2 to 3 years Check condition of gasketing and insulation around unit door and dampers Examine flex connections for cracks or leaks Repair or replace damaged material CAH SVXOIB EN 85 e TRANE Routine Maintenance Air Filters N WARNING Rotating Components Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Secure drive sheaves to ensure rotor cannot freewheel Failure to secure drive she
88. or units may be mounted on housekeeping pads Refer to submittals for unit dimensions and openings Note For proper operation the unit must be supported around the entire unit base perimeter If the unit is shipped in sections the entire section perimeter must be supported as well as at the base channels of the unit splits Provide clearance around the unit to allow adequate free air and necessary service access Also allow room for supply and return piping ductwork electrical connections and coil removal The building roof must be able to support the entire weight of the unit roof curb and accessories See submittals for approximate unit weights Prepare the roof curb or pier mount and roof openings before lifting the unit to the roof e Check that the gasketing or sealant on the roof curb is intact and provides an airtight seal with the unit base Complete all ductwork piping and electrical connections only after mounting the unit 17 e TRANE Installation Mechanical TCP Model Assembly Instructions Ifthe model number on the nameplate begins with TCP usethe assembly instructions below The TCP base is constructed for specific installation requirements such as standard roof curbs structural support curbs steel I beam dunnage support and pier mounting NOTICE Roof Curb Structurally Sound Check with curb manufacturer and job engineer to ensure the roof curb is structurally sufficient to support the weight of
89. osphere In particular several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine Fluorine and Carbon CFCs and those containing Hydrogen Chlorine Fluorine and Carbon HCFCs Notall refrigerants containing these compounds have the same potential impact to the environment Trane advocates the responsible handling of all refrigerants including industry replacements for CFCs such as HCFCs and HFCs Responsible Refrigerant Practices Trane believes that responsible refrigerant practices are important to the environment our customers and the air conditioning industry All technicians who handle refrigerants must be certified The Federal Clean Air Act Section 608 sets forth the requirements for handling reclaiming recovering and recycling of certain refrigerants and the equipment that is used in these service procedures In addition some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants Know the applicable laws and follow them Z WARNING Refrigerant waming information System contains oil and refrigerant under high pressure Recover refrigerant to relieve pressure before opening the system See unit nameplate for refrigerant type Do not use non approved refrigerants refrigerant substitutes or refrigerant additives Failure to follow proper procedures or the use of non approved refrigerants refrigerant substi
90. ower unit perimeter Factory installed Detail A engagement plate Lower unit Wall Flashing Screw 10 16 x 750 self driller Base Roof lower unit Detail B CAH SVX01B EN 41 e TRANE Installation Mechanical TCC Energy Wheel and CDQ Wheel Assembly Units are shipped unstacked 1 Set sections 1 5 of the unit in place in sequence order as shown in Figure 36 and secure as needed Prior to setting section 2 and 3 apply 2 in x 1 in thick gasket across full unit width along the wheel s upper to lower septum Figure 36 Energy wheel and CDQ wheel assembly 2 3 Section 5 Section 4 Section 4 X SN E Ip A A Flashin INA Ge SPA AG ii Screw 1 10 16 x 750 Section 1 Detail A Prior to upper unit placement install 0 188 in x 2 in gasketing on entire length of engagement plate and or lower unit perimeter as needed Engagement plates are used when the upper and lower unit dimensions are not matched Refer to TCC Stacking Procedure on page 40 Apply two layers of Lin tall x 2 in wide gasketing around perimeter of roof opening in lower unit section prior to lifting upper unit Refer to TCC Stacking Procedure on page 40 Note If gasketing is not installed first leakage may occur between the upper and lower units and 4 ui o will result in CFM loss Upper unit with duct opening should be placed within 1 inch of lowe
91. ped in sub assemblies locate the assembly hardware which should be packaged and shipped inside the fan or mixing box section Inspect and test all piping for possible shipping damage Nipples may be installed on coils at thefactory butshould always betightened and tested before any connections are made Rough handling during shipping in addition to other factors can cause pipe connections to become loose Note Trane will not be responsible for any leak at the field connections Coils have been factory pressure tested before shipping Assembly Hardware 10 Trane air handlers ship with all necessary assembly hardware and gasket material This hardware is packaged in either a clear plastic envelope or cardboard box and can be found inside the fan mixing box or access section If there is not enough space inside the section a crate or pallet will be loaded onto the bed of the truck Check the parts list on the field assembly drawing against the contents of the crate Do not proceed with unit assembly until verification that all materials are present Sometimes it is necessary to use more than one section to ship hardware Please check all sections thoroughly before contacting your local Trane sales engineer to report missing hardware CAH SVXOIB EN e TRANE Pre Installation Requirements Resolving Shipping Damage Trane air handlers ship free on board FOB meaning that the unit belongs to the customer the moment the delivery truck
92. ping on page 54 Note If unit is installed in a mechanical room on a pad inadequate height may necessitate core drilling the floor to attain proper trap height Insufficient height could inhibit condensate drainage and result in flooding the unit and or equipment room Confirm the roof curb or foundation of the mounting platform is level and large enough to accommodate the unit Refer to the unit submittals for specific dimensions Provide adequate lighting for maintenance personnel to perform maintenance duties Provide permanent power outlets in close proximity to the unit for installation and maintenance Depending upon job requirements the customer may need to provide 120 Vac power to the unit controller Refer to submittals for more information A dedicated 15 amp circuit is recommended CAH SVXOIB EN e TRANE Pre Installation Requirements Wiring for units must be provided by the installer and must comply with all national and local electrical codes e Rooftop curb mounted units must be sealed tightly to the curb Use proper sealants and roof to curb sealing techniques to prevent water and air leakage Note Preparation ofthe roof curb or pier mountand roof openings should be completed prior to lifting the unit to the roof Roof Curb Installation Checklist Itis recommended thatthe curb be installed directly on the support members and fastened to the supports using tack welds or other equivalent methods P
93. r duct opening in order to sufficiently compress gasket Once unit is set in place verify the gasket seal between openings After installing all of the upper unit sections Install all thread rods field provided fastening both upper and lower sections to the wheel section Fasten the upper unit to the lower unit perimeter cap with Ys inch self drilling screws through base rail Note A drill extension will be required to ensure straight alignment 42 CAH SVXOIB EN e TRANE Installation Mechanical 7 Units will have field installed flashing Remove upper unitlifting lugs in order to install flashing between the upper and lower unit Parts are number matched to the unit Each piece of flashing will be identified with a unit section number in which it applies Top edge of flashing will be placed behind upper unit base rail flange and fastened to lower unit perimeter cap Use 10 screws to install flashing For external outdoor units caulk the corners and top edge of the flashing Pipe Cabinet Installation L After air handler is completely installed and checked for accuracy of level and square pipe cabinet install can begin Remove bolts holding the lifting lugs in place from the base of the air handler 3 Checkto ensure that the structure the pipe cabinet is to be installed on is square and level Install 3 16 inch x 1 25 inch grey ribbed butyl tape to flanged side of pipe cabinet wall and remove paper backing fro
94. r the lip of the curb flanges and over the felt Apply sealantto the four corners Caulk all joints between the curb and the roof Attach the gasket material to the curb s top flanges entire perimeter and to the supply and return air duct opening panel flanges Two chain come alongs These havethe pulling powerto bring the shipping splits together one on each side of the unit Cable come alongs are not strong enough and normally will fail The chain versions work well Two long drift pins to keep holes aligned as the sections come together One half inch or 3 4 inch electric impact gun These are very effectiveto tighten the bolts at the base once it s close enough together to getthe bolts in Caulk guns Standard battery impact gun or battery drill for installation of screw in joint strips hubcaps and inlet or exhaust hoods Nut setters for battery impact gun 3 8 inch and 5 16 inch Utility knives for cutting section to section gasket A couple of large pry bars Proper size sockets and wrenches to remove lifting lugs when in positions Multiple size sockets Must have 15 16 inch and 1 1 16 inch sockets CAH SVXOIB EN S TRANE Installation Mechanical Installation Mechanical Lifting and Rigging N WARNING Heavy Objects Do not use cables chains or slings except as shown Each of the cables chains or slings used to lift the unit must be capable of supporting the entire weight of the unit Lifting cables ch
95. r to the HVAC unit and the ultraviolet bulbs SEE WARNING ABOVE 2 Wearing soft cloth gloves and safety glasses use two hands and firmly grasp the bulb at each end 3 Rotate the bulb 90 degrees in either direction and move bulb away from the fixture and out of unit 4 Carefully install anew replacement bulb in the fixture and rotate it 90 degrees in either direction until itis firmly secured 5 If broken bulbs are found or if you are required to dispose of used bulbs the proper warning and cautions must be followed 6 Always use cloth gloves and suitable eye protection when cleaning or replacing these bulbs Bulbs may break if dropped or handled improperly Disposal of Bulbs UV bulbs like fluorescent bulbs contain mercury which is a regulated hazardous waste The disposal requirements for hazardous wastes are determined by local state and federal guidelines Check all regulations before disposing of bulbs to ensure you have met all requirements Refer to the MSDS sheet from the bulb manufacturer for additional disposal handling and safety information After replacing bulbs close and latch all unit panels and reenergize power to the lights CAH SVXOIB EN 97 TRANE Troubleshooting This section is intended to be used as a diagnostic aid only For detailed repair procedures contact your local Trane service representative Z WARNING Hazardous Service Procedures The maintenance and troubleshooting procedures re
96. re is a rapid decrease in tension until the belt settles in To measure belt tension use a belt tensiometer See Figure 73 Determine actual deflection by depressing one belt with the belt tensiometer and measuring the deflection relative to the other belts or to Force Scale belt line See Figure 74 Adjust the belt tension to the correct pounds force and tighten all set screws to the proper torque Figure 74 Belt tension measurement Belt Span 64 Belt Span 9 CAH SVX01B EN Table 3 Typical sheave diameter and deflection force Smallest sheave Belt Deflection Force Ibs Super gripbelts and Gripnotch belts and Cross diameter range Speed rpm unnotched gripbands notched gripbands section in range Used belt New belt Used belt New belt 1 000 2 500 3 7 5 5 4 1 6 4 3 0 3 6 2 501 4 000 2 8 4 2 3 4 5 0 1 000 2 500 4 5 6 8 5 0 7 4 A AX 3 8 4 8 2 501 4 000 3 8 5 7 4 3 6 4 1 000 2 500 5 4 8 0 5 7 9 4 5 0 7 0 2 501 4 000 4 7 7 0 5 1 7 6 860 2 500 n a n a 4 9 7 2 3 4 4 2 2 501 4 000 n a n a 4 2 6 2 860 2 500 5 3 7 9 7 1 10 5 B BX 4 4 5 6 2 501 4 000 4 5 6 7 7 1 9 1 860 2 500 6 3 9 4 8 5 12 6 5 8 8 6 2 501 4 000 6 0 8 9 TG 10 9 Deen 500 1 740 11 5 17 0 14 7 21 8 ik mM 1 741 3 000 9 4 13 8 11 9 17 5 500 1 740 14 1 21 0 15 9 23 5 9 5 16 0 1 741 3 000 12 5 18 5 14 6 21 6 200 850 24 9 37 0 n a n a 12 0 16 0 D 851 1 500 21 2 31 3 n a n a 200 850 30 4 45 2 n a n a 18 0 2
97. ronic components should be stored in conditions of 20 to 120 F and 5 to 95 percent relative humidity non condensing Electrical components are not moisture tolerant Note The warranty will not cover damage to theunitor controls due to negligence during storage A controlled indoor environment is recommended for proper storage For further storage considerations refer to Storage Recommendations on page 11 Z WARNING Grounding Required All field installed wiring must be completed by qualified personnel All field installed wiring must comply with NEC and applicable local codes Failure to follow these instructions could result in death or serious injuries On outdoor units entrances are provided for field installation of high and low voltage wiring through a pipe nipple connection in the base of the unit As a standard there are no penetrations into the Custom air handler for any field provided wiring or device Before installation consider overall unit serviceability and accessibility before mounting running wires power making cabinet penetrations or mounting any components to the cabinet Wiring to the unit must be provided by the installer and must comply with all national and local electrical codes The fan motor nameplate includes a wiring diagram If there are any questions concerning the wiring of the motor be sure to write down the information from the motor nameplate and contact your local fan motor manufacturer representa
98. roperly supported decking should be installed inside the air handler section of the curb when this method is used See Figure 1 NOTICE Roof Curb Structurally Sound Check with curb manufacturer and job engineer to ensure the roof curb is structurally sufficient to support the weight of the unit The curb should be checked to ensure it is level and square Curb bowing buckling or sagging can lead to unit assembly and operation problems up to complete failure Figure L Cross section of typical curb installation on new construction Screw secruing roof felt to rigid insulation or2x 10 Flashing field supplied Ss Roofing felt field supplied 4 x 4 cant field supplied H EN hd Roof deck Support channels CAH SVX01B EN 13 e TRANE Pre Installation Requirements Suggested Tools 14 N o Q x Oo Uu E Y Verify that the roof structure can adequately support the combined weight of the unit and curb assembly Ensure that the selected installation location provides sufficient service and operational clearances Remove any twist within the curb due to roof supports and square the curb Level the curb Secure the curb to the roof support members Install 2 inch thick boards or rigid insulation around the curb Install cant strips around the curb Bring field supplied roofing felt up to the top of the curb nailing strips Nail felt into place Install field supplied flashing unde
99. rs are often installed in a pre post filter configuration Be sure to note the order of installation Note Filters must have an airtight seal to prevent air bypass UP WN H CAH SVX01B EN e TRANE Routine Maintenance Side Load Filters Drain Pans CAH SVX01B EN Most filters in custom units are installed in unitary sheet metal frames If unit is provided with side access rack do the following for installation 2 inch or 4 inch flat filters L Disconnect the power to the unit 2 Open the filter section access door and remove the filters and block offs from their installed position 3 Slide the filter into the rack 4 Some side load racks will be provided with block off plates Install them into the rack last before closing the door 5 Close and secure the door making certain the door closes snug against the block off Cartridge or Bag Filters To replace cartridge or bag filters L Disconnect all electrical power to the unit 2 Remove the dirty filters and block offs from their installed position 3 Keeping the new bag filters folded slide each filter into the filter rack pushing them tightly against the unit Note The pleats on bag filters should be in the vertical position 4 If using the optional pre filters replace them on the appropriate filter rack 5 If fixed and adjustable block offs are provided with the unit slide the fixed block offs into the filter track before the adjustable block off
100. s Note The portable operator display is not used for timeclock scheduling To provide scheduling you must use a Tracer Summit system Connecting the Operator Display To connect the portable operator display L Open the controller enclosure door 2 Attach the operator display cable to the operator display connector on the controller circuit board The operator display receives power from the controller and turns on automatically when it is connected to the controller Setting Up the Operator Display NOTICE Equipment Damage To clean the operator display use a cloth dampened with commercial liquid glass cleaner Spraying water or cleansers directly on the screen may result in equipment damage This section shows how to calibrate the operator display touch screen and how to adjust the brightness and contrast To set up the operator display screens and security see CNT SVPOIC EN Programming Tracer MP580 581 Programmable Controller programming guide Calibrating the Operator Display CAH SVXOIB EN To calibrate the operator display 1 Onthehome screen press Setup The Setup menu appears 2 Page down to view the next screen 3 Press Calibrate Touch Screen A calibration screen appears NOTICE Equipment Damage Do not allow the operator display to come in contact with sharp objects This may result in equipment damage 4 Touch thetarget using a small pliable blunt object such as a pencil eraser or your finger Hold
101. scaling erosion corrosion algae or slime It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment if any is required Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water or saline or brackish water Ensure coil and condensate drain piping connections are complete e Check the piping and valves for leaks Open or close the valves to check operation Thedrain lines should be open e If unit has a refrigerant coil ensure that it has been charged and leak tested according to the instructions provided with the condenser equipment Adjust the superheat setting e Remove all foreign material from the drain pan and check the pan opening and condensate line for obstructions e For steam coils slowly turn the steam on full for at least 10 minutes before opening the fresh air intake on units with fresh air dampers Motor Related Checks Obtain an IOM from the motor manufacturer for the specific motor installed The motor manufacturer s recommendations take precedence for all matters related to the start up and routine maintenance of the motor Check the motor lubrication for moisture and rust Remove and clean grease plugs to inspect Ifmoistureis present consultan authorized repair shop for bearing inspection replacement This may require removal and transport of motor fnomoistureis present referto the motor
102. sitioned overhead and on the ground to guide the crane or helicopter operator in positioning the sections Never stack the pipe cabinet and inlet hoods on the unit as the unit is being lifted Do not attach the intake exhaust hoods to the unit prior to lifting the unit Doing so may damage the equipment Attach the hoods to the unitonly after all sections are in place Remove all wooden blocks before installing the unit to the roof curb CAH SVXOIB EN e TRANE Installation Mechanical Unit Assembly CAH SVX01B EN All Trane air handlers are identified by a multiple character model number that identifies each section Itis located on the panel on the inside of the supply fan section access door Be sure to refer to the information on the nameplate when ordering replacement parts or requesting service Note If the unit is shipped as a complete assembly go to Coil Piping and Connections on page 53 Prior to unit assembly refer to the unit submittal drawings and unit tagging for correct placement of sections Failure to review the submittal drawings could result in performance or assembly problems If there are any discrepancies contact your local Trane sales representative before proceeding All shipping supports and crating on the face of the sections must be removed and discarded to permit proper fit up and sealing of the surfaces Outdoor units may be mounted on the roof with a roof curb or pier mount Indo
103. steps 6 and 7 as necessary 0020 Straighten any coil fins that may have been damaged during the cleaning process 10 Confirm the drain line is open following the cleaning process 1L Allow the unitto dry thoroughly before putting it back into service 12 Replace all panels and parts and restore electrical power to the unit 13 Be careful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials CAH SVXOIB EN 91 e TRANE Routine Maintenance Cleanable Cooling Coils Cleanable cooling coils have removable headers for cleaning 1 Remove the headers 2 Useasmall nylon or fiber brush to clean the tubes 3 Flush the tubes with water 4 Install a new rubber sealing gasket and be sure it seats properly when the header is replaced Note Apply washers under the bolt heads Bolts should be evenly tightened to 50 foot pounds of torque beginning in the center and working toward the outside Refrigerant Coils N WARNING Hazardous Pressures Coils contain refrigerant under pressure When cleaning coils maintain coil cleaning solution temperature under 150 F to avoid excessive pressure in the coil Failure to follow these safety precautions could result in coil bursting which could result in death or serious injury To clean refrigerant coils L Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment use a soft
104. sure it s properly aligned with the remainder of the curb Anchorthis section securely so the base lugs can be used to pull the next section for base connections Install 3 16 inch x 125 inch grey butyl tapeto bottom rail of installed section allowing the tape to turn up each side wall approximately 8 inches Remove paper backing from butyl tape This will ensure the module to module joint is water tight along the bottom Lift next section onto roof curb using come alongs to pull securely to first section See TCC J oining Sections Edge to Edge on page 33 for assembly details TCC Flat Base to Steel Dunnage or Concrete Pad Figure 19 Steel base to concrete pad 32 Important Units must be installed level for proper drainage of condensate from the drain pan and for squareness of the sections during installation In addition each section in a multi section unit must be properly supported A base designed for concrete or steel dunnage has a flat channel basethat allows the sections to be installed level and square Pad and dunnage should have unit perimeter marked clearly allowing a completely square installation See Figure 19 and Figure 20 Install first section and anchor with best method to hold securely Proceed with remaining sections per installation guidelines Figure 20 Flat base to steel dunnage Air handler base structure Air handler
105. tainer for protection and ease of handling Selecta well drained area preferably a concrete pad or blacktop surface Place the unit on a dry surface or raised off the ground to ensure adequate air circulation beneath the unit and to ensure no portion of the unit will contact standing water at any time Loosen the belttension on the drive belts e Cover the unit securely with a canvas tarp Do not stack units Do not pile other material on the unit Preparing the Unit Site 12 NOTICE Microbial Growth The roof curb or foundation must be level and the condensate drain at the proper height for proper coil drainage and condensate flow Standing water and wet surfaces inside the equipment can become an amplification site for microbial growth mold which may cause odors and damage to the equipment and building materials NOTICE Level Foundation A level foundation is critical to proper unit and door alignment operation and sealing Failure to level and align sections properly can lead to structural damage Ensure the installation site can support the total weight of the unit Refer to the unit submittals for weights Allow sufficient space for adequate free air and necessary service access Refer to submittals for specific minimums Allow room for supply and return piping ductwork electrical connections and coil removal e Ensure there is adequate height for condensate drain requirements See Drain Pan Trap
106. the unit The curb should be checked to ensure it is level and square Curb bowing buckling or sagging can lead to unit assembly and operation problems up to complete failure TCP Standard Roof Curb Figure 4 Standard roof curb Air handler base structure Roof curb 18 Insulation The TCP unit exterior base channel is constructed to overhang the roof curb Unit support is provide by a square tube channel locate inside of exterior base channel See Figure 4 The standard curb should be designed to properly support the unit s weight without bow and sized to fit within the perimeter base channel For large units shipped in sections see additional requirements in TCP Roof Curbs for Large Units with Shipping Splits on page 21 CAH SVXOIB EN S TRANE Installation Mechanical TCP Structural Roof Curb and I Beam Dunnage The TCP base for structural roof curbs see Figure 5 and l beam dunnage see Figure 6 are designed to sit directly onto unit support with no overhang The structure should be designed to properly support unit weight without bow and sized to the unit s perimeter exterior base channel For large units shipped in sections see additional requirements in TCP Roof Curbs for Large Units with Shipping Splits on page 21 Figure 5 Structural roof curb Figure 6 I beam dunnage mount
107. ther hoods 2 Using the factory provided screws mount the weather hoods to the unit 3 On larger units weather hoods may be large enough to require angled down supports In those cases the angles are shipped attached to the hood but will need to be connected to the air handler by the installing contractor See Figure 49 Note Itis required that the hoods be sealed to the unit using field provided caulk or gasket Figure 49 Hood installation Butyl caulk tape AHU outdoor roof 1 00 W x 125T Screw self driller 10 16 x 750 Butyl caulk tape 1 00 W x 125T Nut Hex 31 18 Bolt 313 18 x 750 Hex Hood Bracket Support NA Nut Hex 31 18 Angle Hood Support when required Bolt 313 18 x 750 Hex Detail A 52 CAH SVXOIB EN TRANE Coil Piping and Connections General Coil Piping Recommendations Proper installation piping and trapping is necessary to ensure satisfactory coil operation and to prevent operational damage CAH SVX01B EN Support all piping independently of the coils Provide swing joints or flexible fittings on all connections that are adjacent to heating coils to absorb thermal expansion and contraction strains If the coil was ordered with factory mounted controls install the control valves The valves ship separately Note The contractor is responsible for supplying the installation hardware For best results use a short pipe nipple on the coil headers prior to
108. this manual to minimize installation and startup difficulties Each Trane air handler section is provided with a nameplate which identifies the type of section customer tagging information the section serial number the section position the service model number and electrical data Note This information is required when ordering parts or requesting service for a Trane air handler Operating Environment When considering the placement of the air handler it is important to consider the operating environment The acceptable ambient temperature range for unit operation is 402F to 1409F 402C to 60 C For heating applications a special motor may be required to withstand the higher temperatures Motors with Class B insulation are acceptable for ambient temperatures up to 1049 F while motors with Class F insulation can withstand ambient temperatures to 1402 F 609 C For the units furnished with gas furnaces the heating demands require a special motor to withstand the higher temperatures These motors are furnished with Class H insulation to withstand this rigorous duty Note Units with UL approval have a maximum ambient temperature requirement of 1049F The customer should provide adequate freeze protection for the coils See Coil Winterization on page 93 for more information Unit Description Custom Climate Changer air handlers are designed for a variety of controlled air applications The basic unit consists of a fan h
109. tive for assistance TRANE Pre Installation Requirements Receiving Checklist Based on customer requirements Trane air handlers can ship as complete units or as individual sections to be field assembled Upon receiptofthe air handler s a thorough inspection should be performed to note any shipping damage that may have occurred and that the shipment is complete All factory shipping protection should be removed immediately to allow complete access for the inspection Note The shipping protection provided by the factory is for transit protection only and should not be used as a jobsite storage cover Note Delivery cannot be refused Trane is not responsible for shipping damage e Check all access doors to confirm that the latches and hinges are not damaged nspectthe interior of each section for any internal damage Note Concealed damage must be reported within 15 days of receipt Inspect the coils for damage to the fin surface and or coil connections Ifthe unit was ordered with factory mounted controls locate all sensors Note Items that cannot be factory mounted should ship inside the control enclosures or should be packaged inside the fan or mixing box section e Check all control devices attached to the unit exterior and confirm that they are not damaged Manually rotate the fan wheel to ensure free movement of the shaft bearings and drive Inspect the fan housing for any foreign objects e Ifthe unitis ship
110. tutes or refrigerant additives could result in death or serious injury or equipment damage 2010 Trane All rights reserved CAH SVXOLB EN CAH SVX01B EN e TRANE Wamings Cautions and Notices ZAWARNING Hazard of Explosion Use only dry nitrogen with a pressure regulator for pressurizing unit Do not use acetylene oxygen or compressed air or mixtures containing them for pressure testing Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion Refrigerant when used as a trace gas should only be mixed with dry nitrogen for pressurizing units Failure to follow these recommendations could result in death or serious injury or equipment or property only damage Ultraviolet UV Germicidal Irradiation Lights The United States Environmental Protection Agency EPA believes that molds and bacteria inside buildings have the potential to cause health problems in sensitive individuals If specified Trane provides ultraviolet lights UV C as a factory engineered and installed option in select commercial air handling products for the purpose of reducing microbiological growth mold and bacteria within the equipment When factory provided polymer materials that are susceptible to deterioration by the UV C light will be substituted or shielded from direct exposure to the light In addition UV C radiation can damage human tissue n
111. uction lines all the way to inner side panel to prevent heat gain and unwanted condensation Components Installing the suction line requires field installation of these components a filter access port and a Frostat control when the refrigerant coil is used with Trane condensing units Position them as close to the compressor as possible Note Placement of the Frostat control is illustrated in Figure 58 on page 60 Filter The suction filter prevents contaminants introduced during installation from entering the compressor For this reason the suction filter should be the replaceable core type and a clean core should be installed after the system is cleaned up Access port The access port is used to determine suction pressure This port is usually a Schraeder valve with a core e Frostat coil frost protection The Frostat control is the preferred method for protecting evaporator coils from freezing when the refrigerant coil is used with Trane condensing units It senses the suction line temperature and temporarily disables mechanical cooling if it detects frost conditions The control is mechanically attached to the outside of the refrigerant line near the evaporator and wired to the unit control panel Ball shutoff valve Adding manual ball type shutoff valves upstream and downstream of the filter simplifies replacement of the filter core CAH SVXOIB EN e TRANE Coil Piping and Connections Examples of Field Insta
112. uding remote disconnects and discharge all motor start run capacitors before servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Front Load Filters Most filters in custom units are installed in unitary sheet metal frames Filters are secured with a metal clip There are several different styles To install filters Disconnect power to the unit Open or remove the filter clip Remove the filter from the rack PWN FH Install new filters with the directional arrows pointing in the direction of airflow 5 Secure the filter using the appropriate clip for each filter Review Figure 44 through Figure 47 for an explanation of the methods for securing the different types of filters The filters are often installed in a pre post filter configuration Be sure to note the order of installation Note Filters must have an airtight seal to prevent air bypass 49 e TRANE Installation Mechanical Figure 45 C 86 fastener shown or C 77 fastener holds 4 inch pleated filters Figure 44 C 70 fastener h
113. ulation is clean and dry Wet insulation in an area that is normally considered to be dry can indicate an operational problem referto Troubleshooting on page 98 for further information The equipment should be inspected a minimum of every six months or more frequently as operating experience dictates Accumulated dirt and other organic matter exposed to water or extended periods of high relative humidity 60 percent or higher can support microbial growth which must be removed to prevent the unit from becoming a contaminant source If evidence of contamination exists in either the wet or dry sections Determine and eliminate the cause Remove the contamination Sanitize the affected area See Troubleshooting on page 98 for assistance in identifying the cause Z WARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury CAH SVXOIB EN e TRANE Routine Maintenance N WARNING Hazardous Chemicals Coil cleaning agents can be either acidic or highly alkaline Handle chemical carefully Proper handling should include goggles or face shield chemical resistant gloves boots apron or suit as required For personal safety refer to the cleaning agent manufacturer s Materials Safety Data Sheet and f
114. ult in death or serious injury Inspecting and Cleaning Fans 88 Fan sections of air handlers should be inspected every six months ata minimum or morefrequently if operating experience dictates If evidence of microbial growth mold is found identify and remedy the cause immediately Refer to Troubleshooting on page 98 for possible causes and solutions To clean the fan section L Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment remove any contamination 3 Vacuum the section with a vacuum device that uses high efficiency particulate arrestance HEPA filters with a minimum efficiency of 99 97 percent at 0 3 micron particle size 4 Thoroughly clean any contaminated area s with a mild bleach and water solution or an EPA approved sanitizer specifically designed for HVAC use 5 Immediately rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of metal surfaces 6 Allow the unit to dry completely before putting it back into service 7 Becareful any contaminated material does not contact other areas of the unit or building Properly dispose of all contaminated materials and cleaning solution CAH SVXOIB EN e TRANE Routine Maintenance Fan Bearing Lubrication CAH SVX01B EN NOTICE Bearing Failure Do not mix greases with different bases within the bearing Mixing grease within the bearing may result in premature be
115. until the beeping stops A second calibration screen appears 5 Again touch the target with the object Hold until the beeping stops The Advanced Selection screen appears 6 Press Home The home screen appears 73 e TRANE Controls Interface Adjusting Brightness and Contrast To adjust the brightness and contrast of the operator display L 2 3 4 To increase the brightness press the buttons along the top row in sequence from left to right On the home screen press Setup The Setup menu appears Page down to view the next screen Press the Adjust Brightness and Contrast buttons The Brightness and Contrast screen appears To decrease the brightness press the buttons from right to left Note Contrast adjustment is not available on all computer display models 5 6 To increase the contrast press the buttons along the bottom row in sequence from left to right To decrease the contrast press the buttons from right to left Press Home The home screen appears Extemal Communications Port On units that have been selected with the external communications port both the operator display and Rover service tool can be connected without shutting off the unit through the external communications port Remove the cover plate on the port and plug into the RJ 11 port for the operator display or the RS 485 port for the Rover service tool This enables continuous operation of the Air Handling unit without disruption t
116. ve Thermal expansion 25 lt gt valve TXV iQ E Filter drier Pump down solenoid valve Distributor Evaporator coil with intertwined circuiting eee Liquid so oe 23 oe Solenoid m Ee valve Filter drier 6 OP Thermal OP expansion valve TXV Distributor Pitch the liquid line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator See Figure 61 Provide one expansion valve per distributor Slightly pitch the outlet line from the suction header toward the suction riser that is 1 inch 10 feet 1 cm 3 m in the direction of flow Use the tube diameter that matches the suction header connection Arrange the suction line so the refrigerant gas leaving the coil flows downward past the lowest suction header outlet before turning upward Use a double elbow configuration to isolate the thermal expansion valve bulb from other suction headers For horizontal tubing usethetube diameter recommended by the condensing unit manufacturer For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Ensure the top of the riser is higher than the evaporator coil Pitch the suction line slightly 1 inch 10 feet 1 cm 3 m so the refrigerant drains toward the evaporator Insulate the suction line Only use a trim solenoid valve for constant volume humidity sensitive applications
117. ve ACFM CFM SQRT 0 075 p Where ACFM Actual airflow ft3 min corrected for non standard air density p Density Ibm ft3 of the air at the inlet to the fan Note Alternative units including SI can be used in place of the IP units above although the K factor must be converted appropriately Constant Factor K CAH SVXOIB EN The constant factor K is unique for each fan and is primarily a function of the area and the geometry of the fan inlet Pre engineered factors are available from the factory for fan types where the airflow measurement system is available Field obtained factors can provide maximum accuracy To obtain the factor in the field measure the differential pressure being output from the transmitter while measuring the airflow through the system Once these two values have been measured simply solve for K using the following equation K ACFM SQRT DP Where K Field provided constant factor ACFM Actual airflow ft3 min being measured at the air density being measured DP Differential pressure inches w g being measured by the transmitter 83 TRANE Extemal Insulating Requirements 84 NOTICE Microbial Growth Wet interior unit insulation can become an amplification site for microbial growth mold which may cause odors and damage to the equipment and building materials If there is evidence of microbial growth on the interior insulation the insulation should be removed and repl
118. ximum of 4 on an MP 580 581 controller in lieu of the default zero Note that the adjustment of the Zero and Span controls on the transmitter itself are not required at time of installation The transmitter is factory calibrated to the range selected and cannot be significantly adjusted to tighten the range closer to the pressure being read for the given application The adjustments are primarily provided to account for any drift that may occur over time Transmitter Calibration Thetransmitter is factory calibrated to a specific pressure range with a 0 20 inch w g range being used in most cases To check calibration and to adjust if necessary consult the transmitter manufacturer or the factory for specific procedures Thetransmitter outputs a linear 4 20 mA signal representing a differential pressure measurement With this measurement the airflow through the fan can be calculated using the following equation CFM K SQRT DP Where CFM Airflow ft3 min assuming a standard air density of 0 075 Ibm ft3 K A constant factor that s unique for each fan See next section for more information DP Differential pressure inches w g being measured by the transmitter Significant differences in elevation and or temperature will affect the density of air For air at a constant non standard density a field obtained K factor can be used Alternatively the following equation can be used to continuously correct the equation abo
119. y result in damage to intemal components Line sizing Proper suction line sizing is required to guarantee the oil returns to the compressor throughout the system s operating envelope At the same time the line must be sized so that the pressure drop does not excessively affect capacity or efficiency To accomplish both objectives it may be necessary to use two different line diameters one for the horizontal run and for vertical drops and another for the vertical lifts Routing To prevent residual or condensed refrigerantfrom free flowing toward the compressor install the suction line so it slopes slightly that is by Ya inch to 1 inch per 10 feet of run toward the evaporator When the application includes a suction riser oil must be forced to travel the height of the riser Riser traps and double risers are unnecessary in the suction line when the refrigerant coil is used with Trane condensing units Avoid putting refrigerant lines underground Refrigerant condensation or installation debris inside the line service access and abrasion corrosion can quickly impair reliability Insulation Any heat that transfers from the surrounding air to the cooler suction lines increases the load on the condenser reducing the system s airconditioning capacity and promotes condensate formation adversely affecting indoor air quality After operating the system and testing all fittings and joints to verify the system is leak free insulate the s
120. y sections CAH SVX01B EN e TRANE Installation Mechanical TCP Base Section Assembly with Flat Floor Note Failure to completely compress the gasketing may result in air leakage L Join the two units and secure with factory provided 5 8 inch flat washers and 5 8 inch X 2 1 2 inch grade 9 bolts though each of the six holes See Figure 10 2 Caulk the overlapping flange along the length of each split to maintain a seal Note Use a polyurethane or equivalent caulk 3 Beforeinstalling the pre cut 4 inch 18 gauge joining strips pre drill holes in the floor using the 4 inch strip as a guide with a 7 32 inch drill bit at 12 inch centers 4 After holes are pre drilled apply an ample bead of caulkto the joint then install 4 inch strip with 14 sheet metal screws uniformly straddling the split 5 In cases of tread plate floor some job specifications may call for the seam to be welded In those cases make sure the sections are pulled together tightly then weld with appropriate method The floor construction in those cases will be such that the heat from welding will not affect the insulation Figure 10 TCP base assembly with flat floor 14 SMS screw Joining strip 1 f 3 in x 1 8 in gasket ff y oW 4 in x 1 4 in gasket je Joining trim N mM Add caulking before Top floor N zi installing J strip __ Trim gasket after strips are

Trane Performance Air Handlers Installation and Maintenance Manual

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