Trane Performance Air Handlers Installation And Maintenance Manual

2015-04-02

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July 2010 CAH-SVX01B-EN
Installation
Operation
Maintenance
Custom Climate Changer™
Air Handlers
X-code - X39640745010
© 2010 Trane All rights reserved CAH-SVX01B-EN
Warnings, Cautions and Notices
Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at
appropriate intervals throughout this 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.
Important
Environmental Concerns!
Scientific research has shown that certain man-made chemicals can affect the earth's naturally
occurring stratospheric ozone layer when released to the atmosphere. 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). Not all
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.
WARNING
Refrigerant warning 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
substitutes, or refrigerant additives could result in death or serious injury or equipment damage.
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
result in 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.
CAH-SVX01B-EN 3
Warnings, Cautions and Notices
WARNING
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, namely 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.
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.
4 CAH-SVX01B-EN
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Factory-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Receiving Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Resolving Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outdoor Storage Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preparing the Unit Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Roof Curb Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Suggested Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TCP Model Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TCP Standard Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TCP Structural Roof Curb and I-Beam Dunnage . . . . . . . . . . . . . . . . . . . . 19
TCP Flat Concrete Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TCP Roof Curbs for Large Units with Shipping Splits . . . . . . . . . . . . . . . 21
TCP Joining 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 . . . . . . . . . . . . . . . . . . . . . . . 26
TCP Outdoor Roof Assembly - Multiple Span . . . . . . . . . . . . . . . . . . . . . . 27
TCP Indoor Roof Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . 28
TCP Indoor Roof Assembly - Multiple Span . . . . . . . . . . . . . . . . . . . . . . . 29
TCP Base-to-Interior Wall Section Assembly . . . . . . . . . . . . . . . . . . . . . . 30
TCP Stacked Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TCC Model Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TCC Overhang Base on Common Roof Curb . . . . . . . . . . . . . . . . . . . . . . 32
TCC Flat Base to Steel Dunnage or Concrete Pad . . . . . . . . . . . . . . . . . . 32
TCC Joining Sections - Edge-to-Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TCC Internal Shipping Split Frame Assembly (Typical) . . . . . . . . . . . . . . 36
TCC Wall Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CAH-SVX01B-EN 5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bottom Opening Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Component Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Isolator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Magnahelic Air Filter Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Outdoor Unit Weather Hood(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Coil Piping and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General Coil Piping Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drain Pan Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Steam Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Water Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Refrigerant Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Suction Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Examples of Field-Installed Evaporator Piping . . . . . . . . . . . . . . . . . . . . . . . . 63
Single-Circuit Condensing Unit: Evaporator Coil with 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Quick Connects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Setting Up the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Calibrating the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjusting Brightness and Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
External Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pre-Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fan-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 CAH-SVX01B-EN
Coil-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Motor-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Calculate Motor Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tension the Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Determine Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Align Fan and Motor Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Check Multiple Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Traq™ Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fan Inlet Airflow Measuring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transmitter Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transmitter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Constant Factor K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
External Insulating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Throwaway Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Permanent Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Front Load Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Side Load Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Inspecting and Cleaning Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Bearing Set Screw Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motor Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fan Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Steam and Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cleanable Cooling Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Refrigerant Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Coil Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Chilled Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cleanable Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Moisture Purge Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Internal Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Multiple Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Ultraviolet (UV) Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cleaning the Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Disposal of Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CAH-SVX01B-EN 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8 CAH-SVX01B-EN
General Information
Use this manual to install, startup, operate, and maintain the Custom Climate Changer™ air
handler. Carefully review the procedures discussed in 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 -40ºF to 140ºF (-40ºC
to 60ºC).
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 104º F, while motors
with Class F insulation can withstand ambient temperatures to +140º F (60º 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 104ºF. 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, heating 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.
The units 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.
CAH-SVX01B-EN 9
General Information
Factory-Mounted Controls
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 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:
Tracer MP580/581 Programmable Controllers catalog, CNT-PRC002-EN
Tracer MP581 Programmable Controllers Hardware Installation, CNT-SVN01C-EN
Variable Frequency Drives TR200 Series, BAS-SLB026-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/electronic
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 the unit or 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.
Wiring
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 representative for assistance.
10 CAH-SVX01B-EN
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 receipt of the 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.
Check all access doors to confirm that the latches and hinges are not damaged.
Inspect the 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.
If the 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.
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.
If the unit is shipped 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
the factory but should always be tightened 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
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-SVX01B-EN 11
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 leaves the factory. If damage has occurred to the unit during shipment,
follow these instructions:
Note: Trane is not responsible for shipping damage.
1. Make specific 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: It is the receiver's responsibility to provide reasonable evidence that concealed damage was
not incurred after delivery.
Storage Recommendations
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 in and on the equipment, which could result in corrosion
damage or wet storage stains.
General Storage
The unit controller and all other electrical/electronic components should be stored in conditions of
-20ºF 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
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:
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.
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
manufacturers lubrication recommendation for proper lubrication
12 CAH-SVX01B-EN
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 container for protection and ease of handling.
Select a 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 belt tension on the drive belts.
Cover the unit securely with a canvas tarp.
Do not stack units.
Do not pile other material on the unit.
Preparing the Unit Site
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.
Ensure there is adequate height for condensate drain requirements. See “Drain Pan Trapping
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-SVX01B-EN 13
Pre-Installation Requirements
Wiring for units must be provided by the installer and must comply with all national and local
electrical codes.
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 of the roof curb or pier mount and roof openings should be completed prior to
lifting the unit to the roof.
Roof Curb Installation Checklist
It is recommended that the curb be installed directly on the support members and fastened to the
supports using tack welds or other equivalent methods. Properly 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 1. Cross section of typical curb installation on new construction
14 CAH-SVX01B-EN
Pre-Installation Requirements
1. Verify that the roof structure can adequately support the combined weight of the unit and curb
assembly.
2. Ensure that the selected installation location provides sufficient service and operational
clearances.
3. Remove any twist within the curb due to roof supports and square the curb.
4. Level the curb.
5. Secure the curb to the roof support members.
6. Install 2-inch thick boards or rigid insulation around the curb.
7. Install cant strips around the curb.
8. Bring field supplied roofing felt up to the top of the curb nailing strips. Nail felt into place.
9. Install field supplied flashing under the lip of the curb flanges and over the felt.
10. Apply sealant to 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
Suggested Tools
Two chain come-alongs. These have the pulling power to 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 effective to tighten the bolts at the
base once it’s close enough together to get the 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-SVX01B-EN 15
Installation - Mechanical
Installation - Mechanical
Lifting and Rigging
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 (chains
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.
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
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.
Trane recommends that the contractor use spreader bars and slings to rig units and sub-assemblies
(sections).
16 CAH-SVX01B-EN
Installation - Mechanical
Lifting Considerations
.
Figure 2. Recommended
attachment to lifting lugs. 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).
Figure 3. Use proper lifting and rigging methods 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.
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.
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 positioned
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
unit only after all sections are in place.
Remove all wooden blocks before
installing the unit to the roof curb.
CAH-SVX01B-EN 17
Installation - Mechanical
Unit Assembly
All Trane air handlers are identified by a multiple-character model number that identifies each
section. It is 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. Indoor 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.
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.
18 CAH-SVX01B-EN
Installation - Mechanical
TCP Model Assembly Instructions
If the model number on the nameplate begins with TCP, use the 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 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 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.
Air handler
base structure
Roof curb Insulation
CAH-SVX01B-EN 19
Installation - Mechanical
TCP Structural Roof Curb and I-Beam Dunnage
The TCP base for structural roof curbs (see Figure 5) and I-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
Air handler
basic structure
Structural
steel curb
Air handler
base structure
Dunnage
20 CAH-SVX01B-EN
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
Concrete
pad
CAH-SVX01B-EN 21
Installation - Mechanical
TCP Roof Curbs for Large Units with Shipping Splits
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 tool in making this field joint.
22 CAH-SVX01B-EN
Installation - Mechanical
TCP Joining 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
sections immediately creates greater misalignment or even structural damage afterward.
1. Remove all crating and wrapping from the surfaces to be joined.
2. 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.
3. Check squareness measuring the critical dimensions given. Use preselected method to anchor
first piece in place. This is necessary so movement will not affect pulling next sections into
alignment.
4. When the unit is positioned and squareness is ensured within 1/8-inch, remove all lifting lugs
located along the split plane.
5. 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.
6. Install 4-inch x 1/4-inch neoprene gasket to all mating surfaces of the section, including any
internal walls. This gasket must be applied to the full perimeter of the section split on both
sections to be joined.
7. 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.
8. Remove lifting lugs on mating section as required.
Figure 9. Insert supplied bolts through each hole of
mating connecting plate. 9. Pulling sections together on a flat surface can be done by
using chain come-alongs hooked onto the welded square
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.
11. 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 assembly sections.
CAH-SVX01B-EN 23
Installation - Mechanical
TCP Base Section Assembly with Flat Floor
Note: Failure to completely compress the gasketing may result in air leakage.
1. 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. Before installing 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 caulk to 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
3-in. x 1/8-in. gasket
4-in. x 1/4-in. gasket
Joining trim
Top floor Add caulking before
installing J strip
Trim gasket after
strips are installed
Add caulking after
trimming gasket
24 CAH-SVX01B-EN
Installation - Mechanical
TCP Base Section Assembly with Turned-Up Floor
1. See Figure 11. Apply 4-inch x ¼-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 ½-
inch grade 9 bolts through each of the six holes.
3. Apply a heavy bead of caulk to the inside of the U-channel.
4. Press U-channel down over upturned flanges with moderate pressure to ensure it is 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 11. Upturned floor assembly
Cap
Caulk
Floor
Cap
Caulk
Floor
Floor
Floor
Gasket
Gasket
CAH-SVX01B-EN 25
Installation - Mechanical
TCP Wall Section Assembly
Exterior Wall Assembly (Typical)
1. See Figure 12. Ensure shipping split sections are aligned and pulled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec screws.
5. 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 can be pre-drilled with a #29 bit.
Interior Wall and Roof Joint 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 caulk the full height of interior wall joint.
4. Install joining strips using #10 sheet metal screws.
Figure 12. Wall section assembly
Add caulking after
installing J strip
#8 x 1-in. Phillips zip screw
2 3/4-in. wide joining strip
Wall split
4-in. x 1/4-in. gasket
Add caulking before
installing J strip
Wall panel section split
2 3/4-in. wide joining strip
Trim cap
#10 x 1-in. self tapping screw
3-in. x 1/8-in. neoprene gasket is
applied to metal joining strip.
Apply gasket to metal strip
before installation.
#8 x 1-in. Phillips zip screw
26 CAH-SVX01B-EN
Installation - Mechanical
TCP Outdoor Roof Assembly - Single Span
1. Ensure shipping split sections are aligned and pulled together properly. See Figure 13.
2. Add a bead of caulk along the length of the roof seams. Install the pre-cut J-cap over the seam
and secure with #14 sheet metal screws 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
Add caulking before
installing J cap
Joining cap
4-in. x 1/4-in. gasket #10 x 1-in. self-tapping screw
Roof panel
section split
2 3/4-in. wide joining strip
#8 x 1-in. Phillips zip screw
3-in. x 1/8-in. neoprene gasket is
applied to metal joining strip.
Apply gasket to metal strip
before installation.
Roof split outdoor unit
CAH-SVX01B-EN 27
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.
6. Apply a bead of caulk to the seam the full length that roof cap will cover.
7. Apply 3-inch x 1/8-inch adhesive-backed neoprene gasket to underside of roof cap.
8. Install roof cap using #10 sheet metal screws in pre-punched holes.
9. 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.
Figure 14. TCP outdoor roof assembly - multiple span
6-inch trim cap #10 sheet metal screw
CaulkCap and
gasket
Standing seam
10 ga. galv
#14 sheet metal screw
on 10-inch centers
18 ga. galv
Zip screws
28 CAH-SVX01B-EN
Installation - Mechanical
TCP Indoor Roof Section Assembly (Typical)
1. Ensure shipping split sections are aligned and pulled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec screws.
5. 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.
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
18 ga. trim cap
No greater than 6 inch spacing
on all fasteners
18 ga. trim cap
Gasket
#10 SMS
“Zip” screw
18 ga. strip
18 ga. trim cap
18 ga. strip
Interior
of unit
CAH-SVX01B-EN 29
Installation - Mechanical
TCP Indoor Roof Assembly - Multiple Span
1. Ensure shipping split sections are aligned and pulled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec screws.
5. 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.
8. Using #10 sheet metal screws, attach corner seam trip cap as shown in Figure 16.
Figure 16. TCP indoor roof assembly - multiple span
6-inch trim cap #10 sheet metal screw
CaulkCap and
gasket
Standing seam
10 ga. galv
#14 sheet metal screw
on 10-inch centers
18 ga. galv
Zip screws
30 CAH-SVX01B-EN
Installation - Mechanical
TCP Base-to-Interior Wall Section Assembly
Note: Failure to completely compress the gasketing may result in air leakage.
1. Join the two 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
Interior
wall
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
Split
Split
Interior
wall Caulk
Caulk
Split
Split
Base-to-Wall Assembly Complete
CAH-SVX01B-EN 31
Installation - Mechanical
TCP Stacked Unit Assembly
1. Install and assemble all lower sections as described in typical assembly.
2. Lift first 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 section as described above.
5. Continue until all sections are installed and anchored properly.
6. Install the 18-gauge cover trim cap using #10 self drilling screws. See Figure 18.
Figure 18. Stacked unit trim assembly
Cap
18 ga. steel
.050 if aluminum
Upper unit
Lower unit
Roof trim cap
14 ga. minimum
.125 if aluminum
12-in. clip every 8 ft.
and at all corners use
grade 5 self-tapping
screws 4-in. ctc
10 ga. steel
.125 if aluminum
10 1/2
7 1/2
4 1/2
1 1/2
0
32 CAH-SVX01B-EN
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
1. A base designed for use with a roof curb allows for 1/2- inch clearance around the full perimeter
of the curb.
2. The end section must be installed first making sure it’s properly aligned with the remainder of
the curb. Anchor this section securely so the base lugs can be used to pull the next section for
base connections.
3. Install 3/16-inch x 1.25-inch grey butyl tape to 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.
4. Lift next section onto roof curb using come-alongs to pull securely to first section. See “TCC
Joining Sections - Edge-to-Edge” on page 33 for assembly details.
TCC Flat Base to Steel Dunnage or Concrete Pad
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.
1. A base designed for concrete or steel dunnage has a flat channel base that 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.
2. Install first section and anchor with best method to hold securely.
3. Proceed with remaining sections per installation guidelines.
Figure 19. Steel base to concrete pad Figure 20. Flat base to steel dunnage
Air handler
base structure
Concrete
pad
Air handler
base structure
Dunnage
CAH-SVX01B-EN 33
Installation - Mechanical
TCC Joining Sections - Edge-to-Edge
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 in a
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.
1. The end section must be installed first making sure it’s properly aligned with the remainder of
the curb. Anchor this section securely so the base lugs can be used to pull the next section for
base connections.
2. For units with curb base, remove shipping blocks (see Figure 21).
Figure 21. Shipping block removal.
Remove shipping blocks
34 CAH-SVX01B-EN
Installation - Mechanical
3. Install 3/16-inch x 1.25-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
Figure 23. Butyl tape is applied to shipping splits
Butyl tape
Butyl tape
Butyl tape
Butyl tape
Insert hardware in each hole
CAH-SVX01B-EN 35
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.
6. 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.
Figure 25. Insert field provided threaded rods
Figure 26. Insert threaded rods
Remove bottom hardware
Rod threaded
62-11x13.38, THD
Lockwasher .625
Nut 62-11
36 CAH-SVX01B-EN
Installation - Mechanical
TCC Internal Shipping Split Frame Assembly (Typical)
1. 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. Join internal shipping split frame
Washer .563 ID x 1.375 OD
Washer .563 ID x 1.375 OD
Bolt .500-13 x 3.500 Hex
Nut .500-13 Hex Mach
Figure 28. Join internal shipping split frame- Graphic 1 Figure 29. Join internal shipping split frame- Graphic 2
CAH-SVX01B-EN 37
Installation - Mechanical
TCC Wall Section Assembly (Typical)
1. 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, ¼ x 20 self drillers with neoprene gasket (see
Figure 30).
TCC Indoor Roof Section Assembly (Typical)
1. Verify external unit squareness.
2. Apply the 1.25-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
A
DETAIL A
Screw 10-16 x .750 self-driller
Screw 10-16 x .750
self-driller
Screw 10-16 x .750 self-driller
2 Screws .250-14 x 1.00 Hes WSH HD self-driller
Butyl tape
Seam cap
Seam cap
Butyl tape
Joint cap
38 CAH-SVX01B-EN
Installation - Mechanical
TCC Outdoor Roof Section Assembly (Typical)
1. Join 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).
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).
Figure 31. Join outdoor roof panels at the seams
CAH-SVX01B-EN 39
Installation - Mechanical
Figure 32. Trim roof joint strip
Figure 33. Trim roof joint strip
40 CAH-SVX01B-EN
Installation - Mechanical
TCC Stacking Procedure
1. 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.
4. 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.
6. 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
Lower unit
Factory installed
engagement plate Apply .188-inch x 2-inch
gasketing around lower
unit perimeter
.250 - 14 x .75 leached self-driller
screws in every hole, around upper
unit base perimeter.
CAH-SVX01B-EN 41
Installation - Mechanical
Figure 35. Stacked assembly
Roof
lower unit
Screw
10-16 x .750 self-driller
Flashing
Wall
Base
Detail B
Detail A Screw 10-16 x .750
Flashing
Base
PCAP
Detail A
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 lower unit perimeter
Factory-installed
engagement plate
Lower unit
Detail B
Apply two layers of 1-in. x 2-in. gasket
around all openings in the lower
unit roof.
42 CAH-SVX01B-EN
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.
2. 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.
3. Apply two layers of 1-in. 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
will result in CFM loss.
4. Upper unit with duct opening should be placed within 1-inch of lower duct opening in order to
sufficiently compress gasket.
Once unit is set in place verify the gasket seal between openings.
5. After installing all of the upper unit sections, Install all-thread rods (field-provided) fastening
both upper and lower sections to the wheel section.
6. Fasten the upper unit to the lower unit perimeter cap with ¼-inch self-drilling screws through
base rail.
Note: A drill extension will be required to ensure straight alignment.
Figure 36. Energy wheel and CDQ wheel assembly
Section 5
Section 4 Section 4
Flashing
Screw
10-16 x .750
Section 1
Detail A
Detail A
Section 1
Section 2
Section 3
CAH-SVX01B-EN 43
Installation - Mechanical
7. Units will have field installed flashing. Remove upper unit lifting 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
1. After air handler is completely installed and checked for accuracy of level and square, pipe
cabinet install can begin.
2. Remove bolts holding the lifting lugs in place from the base of the air handler.
3. Check to ensure that the structure the pipe cabinet is to be installed on is square and level.
4. Install 3/16-inch x 1. 25-inch grey ribbed butyl tape to flanged side of pipe cabinet wall and
remove paper backing from tape. See Figure 37.
Figure 37. Pipe cabinet installation
Butyl Tape Hood
Butyl Tape
Pipe Cabinet
Roof Curb
Unit Base Rail
Mounting
Channel
44 CAH-SVX01B-EN
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.
8. Check pipe cabinet side walls to ensure they are plumb.
9. Apply a bead of caulk along the corner between the pipe cabinet and air handler wall prior to
installing connecting angle.
Figure 38. Pipe cabinet detail
Table 1. Pipe cabinet hardware
Qty X-Code Code Description Description
4 X25017800000 BOLT; 0.625-11 X 1.750 5/8-1.75 in. Bolt
4X28021500000 NUT; 0.62-11 5/8-11 Nut
4 X22020800000 LOCKWASHER; 0.625 ID 5/8-in. Lock Washer
8X22050313010 WASHER; 0.656 ID X 1.312 OD Flat Washer
Pipe Cabinet
Unit
CAH-SVX01B-EN 45
Installation - Mechanical
10. Install inside corner cap. See Figure 39 Detail A and B.
11. 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
TOP VIEW
A
DETAIL A
DETAIL B
See Detail B
AHU
Pipe Cabinet
Ribbed Butyl tape
Screw 10-16 x .750 self-driller
Pipe cabinet outer roof
Slots provided to allow
final adjustment of outer roof
AHU outdoor roof
“Picture frame” mounting chanels
factory assembled to unit
Inside corner cap
Ribbed Butyl tape
(see Note 1)
Roof and base parts
removed for clarity
“Picture frame” mounting chanels
factory assembled to unit
Ribbed Butyl tape
Ribbed Butyl tape
(see Note 1)
Inside corner cap
Pipe cabinet wall
Note:
1. Seam to be sealed with three-ribbed Butyl tape
prior to attaching inside corner cap with screws
(10-16 x .750 self-driller).
46 CAH-SVX01B-EN
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
1. 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 layout provided with unit submittals for duct size and location.
Figure 40. Field-supplied duct connection to AHU bottom supply/return air opening
Bottom
supply/return
airflow
Trane AHU
base (typical)
Field-supplied
rigid duct
Trane AHU
base (typical)
Field-supplied
rigid duct
CAH-SVX01B-EN 47
Installation - Mechanical
3. Bottom of unit base elevation is ½ inch lower than edge of duct opening in bottom of unit.
During unit installation on roof curb, either raise field provided duct per Option A (see Figure 41)
or add additional gasket material to compensate for the ½ inch offset per Option B (see
Figure 42).
Component Installation Requirements
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 manufacturers 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 component in 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 unit IOM or are attached
to the components mounted in the unit.
Figure 41. Field-supplied duct connection option details -
Option A Figure 42. Field-supplied duct connection option details -
Option B
Unit
wall Unit floor Supply opening
in floor
Edge of
supply
opening
Unit
base
Roof
curb
Bottom of
unit base
elevation Field-
supplied
duct
Gasket
Building roofing
and structure
may vary per job
0.5
Additional 1/2 inch of
duct length option
Not to scale.
Option A
Note: Bottom of unit base elevation is 1/2 inch lower than edge of duct
opening in bottom of unit. During unit installation on roof curb, either
raise field-provided duct or add additional gasket material to
compensate for the 1/2 inch offset.
Unit
wall
Unit
base
Unit floor
Supply opening
in floor
Additional
1/2 in. gasket
Edge of
supply
opening
Bottom
of unit
base
elevation
Building
roofing
and structure
may vary per job
Note: Bottom of unit base elevation is 1/2 inch lower than edge of duct
opening in bottom of unit. During unit installation on roof curb, either raise
field-provided duct or add additional gasket material to compensate for
the 1/2 inch offset.
Option B
Additional 1/2 inch
of gasket material
option. Not to scale.
0.5
Field-
supplied
duct
Gasket
Roof
curb
48 CAH-SVX01B-EN
Installation - Mechanical
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 set at the 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.
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.
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.
2. Remove the jam nut on top of the isolator adjusting stud
at the first isolator to be adjusted. Check that the
shipping block is in place.
3. Turn the adjusting nut two or three turns only,
counterclockwise on each isolator in a sequenced
manner. The equipment weight will compress the
spring inside the housing 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
the fan base hole.
Jam
nut
Shipping
bolt
Fan
base
Shipping
tie-down
block (shim)
Adjusting
nut
CAH-SVX01B-EN 49
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
Check zero adjustment of the gage. Turn both vent valves to the “Vent” position and adjust the 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.
Air Filters
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 manufacturers 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:
1. Disconnect power to the unit.
2. Open or remove the filter clip.
3. Remove the filter from the rack.
4. 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.
50 CAH-SVX01B-EN
Installation - Mechanical
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
1. 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).
Figure 44. C-70 fastener holds 2-inch filter Figure 45. C-86 fastener (shown) or C-77 fastener holds 4-
inch pleated filters
Figure 46. Bag filter show with C-70 fastener Figure 47. C-80 spring fastener secures cartridge
CAH-SVX01B-EN 51
Installation - Mechanical
Bag or Cartridge Filters
1. 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.
Figure 48. Filter block-off placement
52 CAH-SVX01B-EN
Installation - Mechanical
Outdoor Unit Weather Hood(s)
1. Per the unit drawing determine mounting location of the unit weather 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: It is required that the hoods be sealed to the unit using field provided caulk or gasket.
Figure 49. Hood installation
AHU outdoor roof Butyl caulk tape
1.00 W x .125T.
Hood
Nut-Hex .31-18
Detail A
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
Bracket Support
Angle Hood Support
(when required)
Bolt .313-18 x .750 Hex
CAH-SVX01B-EN 53
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:
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 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.
54 CAH-SVX01B-EN
Coil Piping and Connections
Drain Pan Trapping
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.
Threaded 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 55
Coil Piping and Connections
Figure 50. Drain pan trapping for section under negative pressure
Figure 51. Drain pan trapping for section under positive pressure
Normal operation
L
H
J
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
pressure at worst case (loaded filters)
minus external pressure
K
H
L
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)
56 CAH-SVX01B-EN
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 headers 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
horizontal tubes for horizontal airflow Figure 53. Typical piping for Type NS steam coils and
horizontal tubes for horizontal airflow
CAH-SVX01B-EN 57
Coil Piping and Connections
NOTICE
Breaker Cracking Pressure!
The 1/2-inch NPT, 15 degree swing 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:
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.
For coil types A, 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.
Vent the 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 face-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 return 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:
1. 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. Use float and 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.
58 CAH-SVX01B-EN
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 independently with an automatic
steam-control valve. Size the traps for each coil using the capacity of the first coil in direction
of airflow.
5. Use a 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, Figure 55, and Figure 56
illustrate typical water coil piping
configurations.
Type WA, 5A, 5W, D, K, W, UW, TT, P,2,
P4, and P8 water coils are self-venting
only if the water velocity exceeds
1.5 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
below these minimums, vent the coil by
one of the following methods:
1. Install an air vent in the top pipe
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.
Figure 54. Typical piping for type 5W one-row water coil
Figure 55. Typical piping for type 5A, 5W two-row, K, W 3- to 12-row, WD, D,
and DD water coils
GV
GV
GV
GV
AV
AV
TV
Water supply
main
Water
return main
Drain
Level
Air flow
AV
AV
AV
GV
MW
Water supply
main
Water
return main
Drain
Air flow
Pitch down
CAH-SVX01B-EN 59
Coil Piping and Connections
Figure 56. Typical piping for type W or WA 1-row water coil
Figure 57. Typical piping for stacked water coils
AV
AV
TV
GV
GV
GV
GV
GV
Drain
Air flow
Water supply main
Water return main
18 Pitch down
Pitch down
AV
AV
AV
Water
supply main
Water
return main
GV
Drain
Air flow
GV
MV
60 CAH-SVX01B-EN
Coil Piping and Connections
Refrigerant Coil Piping
Note: Refer to “Important Environmental Concerns!” on page 2 for information on handling
refrigerants.
Use Figure 58 to determine the proper, relative sequence of the 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.
Liquid Lines
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.
Figure 58. Example of placement for split-system components
Discharge
line
Manual
ball valve Access
port Filter
Access
port
Access
port
Filter drier
with access
port
Manual
angle valves
Check/relief
valve
Condensing unit
Condenser and
sbucooler coil
Compressors
Liquid line
Access
port
Manual
ball valve
Solenoid
valve
Moisture-
indicating
sight glass
Expansion
valves
Evaporator coil
Distriburtor
Manual ball valve
Suction lineFrostat™ control
Manual
ball valve
Kit with sensor - X13790452010 SEN-01212
Kit with switch - X13100429010 THT 02442
CAH-SVX01B-EN 61
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, moisture-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 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 the system. Correct refrigerant distribution into the
coil requires an expansion valve for each distributor.
Figure 59. Type F refrigerant coil with packed elbow The thermal expansion valve must be selected
for proper size and capacity. The size of the
expansion valve should cover the full range of
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.
Cut the process tube and cap assembly from the
liquid connection as shown in Figure 59 and
install the expansion valve directly to the liquid
connections.
Cut here
for piping
Perforated plate
(packed elbow)
Panel
Venturi type
distributor
Coil
62 CAH-SVX01B-EN
Coil Piping and Connections
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 may result in damage to internal components.
Suction Lines
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 refrigerant from “free-flowing” toward the compressor,
install the suction line so it slopes slightly—that is, by ¼ 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 air-conditioning 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 suction 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.
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-SVX01B-EN 63
Coil Piping and Connections
Examples of Field-Installed Evaporator Piping
Single-Circuit Condensing Unit: Evaporator Coil with One Distributor
Figure 60. Single-circuit evaporator coil with one distributor
1. Pitch the liquid line slightly—1 inch/10 feet [1 cm/3 m]—so that the refrigerant drains toward
the evaporator. See Figure 60.
2. 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.
4. 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.
5. Arrange the suction line so the refrigerant gas leaving the coil flows downward, past the lowest
suction-header outlet, before turning upward.
6. Pitch the suction line slightly—1 inch/10 feet [1 cm/3 m]—so the refrigerant drains toward the
evaporator.
7. Insulate the suction line.
64 CAH-SVX01B-EN
Coil Piping and Connections
Single-Circuit Condensing Unit: Evaporator Coil with Two Distributors
Figure 61. Single-circuit evaporator coil with two distributors 1. Pitch the liquid line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator. See Figure 61.
2. 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.
4. 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.
5. For horizontal tubing, use the tube diameter
recommended by the condensing unit
manufacturer.
6. 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.
7. Pitch the suction line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator.
8. Insulate the suction line.
9. 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.
Suction line
7, 8
Liquid
line
Evaporator coil
with horizontal-split
(standard) circuiting
Evaporator coil with
intertwined circuiting
Liquid
line
‘Trim’
solenoid valve
‘Pump-down’
solenoid valve
Sight
glass 1
Filter drier
Filter drier
Solenoid
valve
Thermal
expansion
valve (TXV)
9
2
2
1
9
7, 8
3
4
4
5
5
6
6
3
Distributor
Thermal
expansion
valve (TXV)
Sight
glass
Distributor
S
S
S
CAH-SVX01B-EN 65
Coil Piping and Connections
Single-Circuit Condensing Unit: Evaporator Coil with Four Distributors
Figure 62. Single-circuit evaporator coil with four distributors 1. Pitch the liquid line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator. See Figure 62.
2. 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.
4. 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.
5. For horizontal tubing, use the tube diameter
recommended by the condensing unit
manufacturer.
6. 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.
7. Pitch the suction line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator.
8. Insulate the suction line.
9. 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.
66 CAH-SVX01B-EN
Coil Piping and Connections
Dual-Circuit Condensing Unit: Evaporator Coil with Two Distributors)
Figure 63. Dual-circuit evaporator coil with two distributors
1. 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.
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.
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. 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.
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.
CAH-SVX01B-EN 67
Coil Piping and Connections
Dual-Circuit Condensing Unit: Evaporator Coil with Four Distributors
Figure 64. Dual-circuit evaporator coil with four distributors 1. Pitch the liquid line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator. See Figure 64.
2. 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.
4. 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.
5. For horizontal tubing, use the tube diameter
recommended by the condensing unit
manufacturer.
6. 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.
7. Pitch the suction line slightly—1 inch/
10 feet [1 cm/3 m]—so the refrigerant
drains toward the evaporator.
8. Insulate the suction line.
9. 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.
68 CAH-SVX01B-EN
Coil Piping and Connections
Dual-Circuit Condensing Unit: Evaporator Coil with Eight Distributors
Figure 65. Dual-circuit evaporator coil with eight distributors 1. Pitch the liquid line slightly—1 inch/10 feet
[1 cm/3 m]—so the refrigerant drains
toward the evaporator. See Figure 65.
2. 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.
4. 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 TXV bulb from
other suction headers.
5. For horizontal tubing, use the tube
diameter recommended by the
condensing unit manufacturer.
6. 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.
7. Pitch the suction line slightly—1 inch/
10 feet [1 cm/3 m]—so the refrigerant
drains toward the evaporator.
8. Insulate the suction line.
9. 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.
11. 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 69
Installation - Electrical
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. 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-SVB06A-EN or PROD-SVB06A-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 voltage wiring schematic, see Figure 66.
70 CAH-SVX01B-EN
Installation - Electrical
Figure 66. Typical high voltage wiring schematic
CAH-SVX01B-EN 71
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.
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:
If VFD or starter is not factory-mounted, provide 120 Vac power to a transformer in the 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 jack is typically located at the 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.
Figure 67. Transformer plate Figure 68. 120 to 24 Vac Control
Transformer Figure 69. Variable-frequency drive
(VFD)
72 CAH-SVX01B-EN
Installation - Electrical
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 70. Valve jack wiring details
Valve
quick
connect
Conduit
assembly
Figure 71. Typical quick connects with wiring identification
CAH-SVX01B-EN 73
Controls Interface
The portable operator display is used for temporary connection to and operation of Tracer MP580/
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 instructions.
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:
1. 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-SVP01C-EN
Programming Tracer MP580/581 Programmable Controller programming guide.
Calibrating the Operator Display
To calibrate the operator display:
1. On the home 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 the target using a small, pliable, blunt object, such as a pencil eraser or your finger. Hold
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.
74 CAH-SVX01B-EN
Controls Interface
Adjusting Brightness and Contrast
To adjust the brightness and contrast of the operator display:
1. On the home screen, press Setup. The Setup menu appears.
2. Page down to view the next screen.
3. Press the Adjust Brightness and Contrast buttons. The Brightness and Contrast screen appears.
4. To increase the brightness, press the buttons along the top row, in sequence, from left to right.
To decrease the brightness, press the buttons from right to left.
Note: Contrast adjustment is not available on all computer display models.
5. 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.
6. Press Home. The home screen appears.
External 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 to the operating conditions of the unit. When servicing
of the unit is complete, replace the cover plate on the external port to eliminate the air leakage path.
CAH-SVX01B-EN 75
Start-Up
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.
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 manufacturers 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-SVB06A-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.
Verify damper operation and linkage alignment. Damper blade and linkage positioning may
have changed due to shipping and handling vibration.
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.
Leave this manual with the unit.
Fan-Related Checks
If the unit is internally isolated, ensure that the fan isolator tie-down bolts have been removed.
Rotate all fan wheels manually to confirm they turn freely in the proper direction.
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, check the assembly for any binding or misalignment. Do not force the
vanes.
Check fan drive belt tension.
Inspect fan motor and bearings for proper lubrication, if necessary.
76 CAH-SVX01B-EN
Start-Up
Coil-Related Checks
NOTICE
Proper Water Treatment!
The use of untreated or improperly treated water in coils may result in 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.
Check the piping and valves for leaks.
Open or close the valves to check operation.
The drain lines should be open.
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.
Remove all foreign material from the drain pan and check the pan opening and condensate line
for obstructions.
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
manufacturers 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.
If moisture is present, consult an authorized repair shop for bearing inspection/replacement.
This may require removal and transport of motor.
If no moisture is present, refer to the motor manufacturers lubrication recommendations for
proper lubrication.
The motor manufacturer may recommend lubricating the motor as part of their routine
startup instructions.
Check motor 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.
CAH-SVX01B-EN 77
Start-Up
Unit Operation
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.
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 precautions 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.
The readings 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:
Voltage imbalance =
where:
A = (226-221) + (230-226) + (227-226)
Voltage imbalance = 2.2% (not acceptable)
In the example, 2.2 percent imbalance is not acceptable and the power company should be notified
to correct it.
100A
2AvgVoltage×
--------------------------------------------------
78 CAH-SVX01B-EN
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 shaft 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
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.
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
Check the fan belt tension at least three times during the first days of
operation because there 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
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
Small O-Ring
Force Scale
Large O-Ring
Span Scale
Belt Span
Belt Span
64
Deflection =
CAH-SVX01B-EN 79
Start-Up
Determine Fan Speed
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.
Table 3. Typical sheave diameter and deflection force
Cross
section
Smallest sheave
diameter range
(in.) Speed (rpm)
range
Belt Deflection Force (lbs)
Super gripbelts and
unnotched gripbands Gripnotch belts and
notched gripbands
Used belt New belt Used belt New belt
A, AX
3.0–3.6 1,000–2,500 3.7 5.5 4.1 6.4
2,501–4,000 2.8 4.2 3.4 5.0
3.8–4.8 1,000–2,500 4.5 6.8 5.0 7.4
2,501–4,000 3.8 5.7 4.3 6.4
5.0–7.0 1,000–2,500 5.4 8.0 5.7 9.4
2,501–4,000 4.7 7.0 5.1 7.6
B, BX
3.4–4.2 860–2,500 n/a n/a 4.9 7.2
2,501–4,000 n/a n/a 4.2 6.2
4.4–5.6 860–2,500 5.3 7.9 7.1 10.5
2,501–4,000 4.5 6.7 7.1 9.1
5.8–8.6 860–2,500 6.3 9.4 8.5 12.6
2,501–4,000 6.0 8.9 7.3 10.9
C, CX 7.0–9.0 500–1,740 11.5 17.0 14.7 21.8
1,741–3,000 9.4 13.8 11.9 17.5
9.5–16.0 500–1,740 14.1 21.0 15.9 23.5
1,741–3,000 12.5 18.5 14.6 21.6
D12.0–16.0 200–850 24.9 37.0 n/a n/a
851–1,500 21.2 31.3 n/a n/a
18.0–20.0 200–850 30.4 45.2 n/a n/a
851–1,500 25.6 38.0 n/a n/a
3V, 3VX
2.2–2.4 1,000–2,500 n/a n/a 3.3 4.9
2,501–4,000 n/a n/a 2.9 4.3
2.65–3.65 1,000–2,500 3.6 5.1 4.2 6.2
2,501–4,000 3.0 4.4 3.8 5.6
4.12–6.90 1,000–2,500 4.9 7.3 5.3 7.9
2,501–4,000 4.4 6.6 4.9 7.3
5V, 5VX
4.4–6.7 500–1,749 n/a n/a 10.2 15.2
1,750–3,000 n/a n/a 8.8 13.2
3,001–4,000 n/a n/a 5.6 8.5
7.1–10.9 500–1,749 12.7 18.9 14.8 22.1
1,750–3,000 11.2 16.7 13.7 20.1
11.8–16.0 500–1,749 15.5 23.4 17.1 25.5
1,750–3,000 14.6 21.8 16.8 25.0
8V 12.5–17.0 200–850 33.0 49.3 n/a n/a
851–1,500 26.8 39.9 n/a n/a
18.0–22.4 200–850 39.6 59.2 n/a n/a
851–1,500 35.3 52.7 n/a n/a
80 CAH-SVX01B-EN
Start-Up
Figure 75. Proper drive alignment
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. 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. Adjust the 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.
On multiple belt drives, ensure the force 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). If this force is not the 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.
D
Fixed
Sheave C
B
A
Adjustable
Sheave
Straight
Edge
Lines must
be parallel
Center line
must coincide
Fixed
Sheave
Table 4. Fan and drive compound torque settings (inches)
Screw Size Hex Key Square Head Hex Head Torque (in.-lb.) Torque (ft.-lb.)
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
CAH-SVX01B-EN 81
Start-Up
Traq™ Dampers
Traq 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 air through the remaining Traq dampers
by closing off one or more dampers in the unit. The cfm at 10Vdc can be recalculated based on the
proportion of remaining Traq dampers or by multiplying the remaining area of dampers by peak
velocity.
Figure 76. Traq damper terminal connections
Ventilation Control Module
Velocity (2-10 Vdc)
GND
24 Vac
GND
1TB1-3
1TB1-4
1TB1-5
1TB1-6
Table 5. Altitude adjustment factors Airflow = k (cfm @ 10V)
or
Airflow = k (L/s @ 10V)
For example, if the VCM on a size 30 air handler at sea level (k=1)
has a 10-volt signal, it would represent 17,335 cfm
(8181 L/s) through the Traq damper. If the voltage were 6 volts,
airflow through the Traq damper would be 8,668 cfm (4091 L/s).
Sea level = 1.0
Elevation (feet) k
1000 0.982
2000 0.964
3000 0.949
4000 0.930
5000 0.914
6000 0.897
7000 0.876
8000 0.860
9000 0.846
10,000 0.825
volts 2()
8
------------------------------
volts 2()
8
------------------------------
82 CAH-SVX01B-EN
Start-Up
Fan Inlet Airflow Measuring System
Wiring
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 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 order to 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
Table 6. Back or Top Inlet Traq Dampers - Air-Mixing and Economizer Section - VCM voltage versus airflow at sea level
Part Number Traq Damper
Size (inches) Quantity Total Area (ft2)Peak Velocity
(fpm) CFM @ 10VDC
Peak Velocity L/S @ 10VDC
DMP01123 13 1 0.9213 2500 2303 1087
DMP01124 16 11.3956 2650 3698 1745
DMP01663 20 1 2.1806 2650 5779 2727
DMP01125 24 13.1400 2700 8478 4001
DMP01126 28 1 4.2739 2700 11540 5446
Figure 77. Piezometer ring airflow
measurement A fan inlet airflow measuring system with a piezometer ring is available
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.
CAH-SVX01B-EN 83
Start-Up
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
input is 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 maximum 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
The transmitter 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.
The transmitter 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:
Constant Factor K
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:
CFM = K * SQRT(DP)
Where:
CFM = Airflow (ft3/min.) assuming a standard air density of 0.075 lbm/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 above:
ACFM = CFM * SQRT(0.075/ρ)
Where:
ACFM = Actual airflow (ft3/min) corrected for non-standard air density.
ρ = Density (lbm/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.
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.
84 CAH-SVX01B-EN
External Insulating Requirements
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 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 85
Routine Maintenance
The following checklist is provided as an abbreviated guide to periodic maintenance. Detailed
procedural information is given after this checklist.
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 warnings provided throughout this manual concerning 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 warnings provided, could result in death or serious injury.
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 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.
Every month
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.
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 connections.
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.
86 CAH-SVX01B-EN
Routine Maintenance
Air Filters
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 sheaves 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:
1. Disconnect all electrical power to the unit.
2. Wash the filter under a stream of water to remove dirt and lint.
3. Remove oil from the filter with a wash of mild alkali solution.
4. Rinse the filter in clean, hot water and allow to dry.
5. 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.
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:
1. Disconnect power to the unit.
2. Open or remove the filter clip.
3. Remove the filter from the rack.
4. Install new filters with the directional arrows pointing in the direction of airflow.
5. Secure the filter using the appropriate clip for each filter.
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.
CAH-SVX01B-EN 87
Routine Maintenance
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
1. 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:
1. 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.
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.
Drain Pans
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 manufacturers Materials Safety Data
Sheet and follow all recommended safe handling practices. Failure to follow all safety
instructions could result in death or serious injury.
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.
88 CAH-SVX01B-EN
Routine Maintenance
To clean drain pans:
1. Disconnect all electrical power to the unit.
2. Wearing 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.
7. Allow the unit to dry completely before putting it back into service.
8. Be careful any contaminated material does not contact other areas of the unit or building.
Properly dispose of all contaminated materials and cleaning solution.
Fans
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.
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 result in death or serious injury.
Inspecting and Cleaning Fans
Fan sections of air handlers should be inspected every six months at a minimum or more frequently
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:
1. 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. 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-SVX01B-EN 89
Routine Maintenance
Fan Bearing Lubrication
NOTICE
Bearing Failure!
Do not mix greases with different bases within the bearing. Mixing grease within the bearing
may result in premature bearing 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 manufacturers recommendations and use the
manufacturer-recommended grease.
Fan bearings without lubrication lines are sealed bearings. Re-lubrication is not required.
Fan bearings equipped with lubrication lines should be lubricated with a lithium-based grease
that conforms to NLGI No. 2 for consistency.
Refer to Table 10 for minimum torque of motor mounting and bearings bolts.
Table 8. 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 - 1 3/16 3/8
Mobil 532 1 1/4 - 1 1/2 5/8
Chevron Dura-Lith 2 1 11/16 - 1 15/16 7/8
Exxon Beacon 2 - 2 7/16 1 1/4
Keystone 84H 2 1/2 - 2 15/16 2
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.
Align set screws
Align set screws
90 CAH-SVX01B-EN
Routine Maintenance
Motor Bearing Lubrication
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
manufacturers 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
Inspect fan motors periodically for excessive vibration or temperature.
Table 10. Minimum hex head bolt torque in lb.-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 42
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.
CAH-SVX01B-EN 91
Routine Maintenance
Coils
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 manufacturers 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:
1. 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. Mix a high-quality coil cleaning detergent with water according to the manufacturers
instructions.
Note: If the detergent is strongly alkaline after mixing (PH 8.5 or higher), it must contain an
inhibitor. Follow the cleaning solution manufacturers 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:
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.
6. Spray the leaving air side of the coil first, then the entering air side.
7. Thoroughly rinse both sides of the coil and the drain pan with cool, clean water.
8. Repeat steps 6 and 7 as necessary.
9. Straighten any coil fins that may have been damaged during the cleaning process.
10. Confirm the drain line is open following the cleaning process.
11. Allow the unit to 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.
92 CAH-SVX01B-EN
Routine Maintenance
Cleanable Cooling Coils
Cleanable cooling coils have removable headers for cleaning:
1. Remove the headers.
2. Use a small 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
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:
1. 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. Mix a high-quality coil cleaning detergent with water according to the manufacturers
instructions.
Note: If the detergent is strongly alkaline after mixing (PH 8.5 or higher), it must contain an
inhibitor. Follow the cleaning solution manufacturers 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.
6. Spray the leaving air side of the coil first, then the entering air side.
7. Thoroughly rinse both sides of the coil and the drain pan with cool, clean water.
8. Repeat steps 6 and 7 as necessary.
9. Straighten any coil fins damaged during the cleaning process.
10. Confirm the drain line is open following the cleaning process.
11. Allow the unit to 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.
CAH-SVX01B-EN 93
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
Note: Use care in removing header plugs from coils. Over-torquing may result in twisted tubes.
1. Remove the vent and drain plugs.
2. Blow the coil out as completely as possible with 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.
4. 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.
Cleanable Coils
1. Remove all vent and drain plugs.
2. Allow the water to drain from the coil.
3. Remove the header covers.
4. If tubes are fouled, clean the tubes with a nylon or wire brush.
5. To ensure no water remains in the coil, do not replace the header covers until the coils are put
back into service.
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-lbs torque.
Moisture Purge Cycle
By it’s very nature, any HVAC unit with a cooling coil serves as a dehumidifier, reducing the
surrounding airs 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.
94 CAH-SVX01B-EN
Routine Maintenance
Providing a moisture purge cycle 15 to 30 minutes after shutdown 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.
Air movement discourages 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.
Internal Insulation
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 insulation is clean and dry. Wet insulation in an area that is
normally considered to be “dry” can indicate an operational problem (refer to “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.
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-SVX01B-EN 95
Routine Maintenance
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 manufacturers Materials Safety Data
Sheet and follow 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:
1. 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. Rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential
corrosion of the drain pan and drain line
6. Repeat steps 4 and 5 as necessary.
7. Confirm the drain line is open following the cleaning process.
8. Allow the unit to dry thoroughly before putting it back into service.
9. 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 (fiberglass insulation):
1. 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 not to 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.
96 CAH-SVX01B-EN
Routine Maintenance
Controls
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 unit is complete, replace the cover plate on the external port to eliminate the air leakage path.
Multiple Fans
When controlled in a bank of fans, these fan units must be controlled using a common control
signal, such as the duct static control signal, to modulate the fan speed.
Ultraviolet (UV) Light Maintenance
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
Note: If bulbs are found to be broken, see the proper warning and cautions below regarding
broken bulbs and hazardous vapors.
1. Disconnect all electrical power to the unit and the ultraviolet bulbs.
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. 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 it is firmly
secured.
6. Close and latch all unit panels and reenergize power to the lights.
CAH-SVX01B-EN 97
Routine Maintenance
Replacing the Bulbs
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.
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.
1. Disconnect power 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 a new replacement bulb in the fixture and rotate it 90 degrees in either direction
until it is 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.
98 CAH-SVX01B-EN
Troubleshooting
This section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact
your local Trane service representative.
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 warnings provided throughout this manual concerning 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 warnings 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 warnings provided, could result in death or serious injury.
Table 11. Air handler troubleshooting recommendations
Symptom Probable Cause Recommended Action
Bearing is excessively
hot
First start after relubrication (Grease distribution) Allow machine to cool down and restart.
Over-lubrication Clean surface of grease and purge.
Over tensioned belts Adjust belt tension.
No lubricant Apply lubricant. Check bearings for damage.
Misaligned bearing Correct alignment. Check shaft level.
Motor fails to start
Blown fuse or open circuit breaker Replace fuse or reset circuit breaker.
Overload trip Check and reset overload.
Improper wiring or connections Check wiring with diagram supplied on unit.
Improper current supply Compare actual supply power with motor nameplate
recommendations. Contact power company for adjustments.
Mechanical failure Check that motor and drive rotate freely. Check bearing
lubricant.
Motor stalls Open phase Check line for an open phase.
Overloaded motor Reduce load or replace with larger motor.
Low line voltage Check across AC line. Correct voltage if possible.
Excessive vibration
Poor alignment Align bearing set screws (see “Bearing Set Screw Alignment”
on page 89). Loosen and retighten bearing set screws.
Shipping spacers not removed Remove shipping spacers and/or bolts (see “Fans” section on
page 48).
Over tensioned belts Adjust belt tension.
Misaligned drive Align drive.
Motor runs and then
dies down Partial loss of line voltage Check for loose connections. Determine adequacy of main
power supply.
Starter shorts when motor warms up Replace starter.
Motor does not come
up to speed Low voltage at motor terminals Check across AC line and correct voltage loss if possible.
Line wiring to motor too small Replace with larger sized wiring.
Motor overheats Overloaded motor Reduce load or replace with a larger motor.
Motor fan is clogged with dirt preventing proper ventilation Remove fan cover, clean fan and replace cover.
Excessive motor noise
Motor mounting bolts loose Tighten motor mounting bolts.
Rigid coupling connections Replace with flexible connections.
Worn motor bearings Replace bearings and seals.
Fan rubbing on fan cover Remove interference in motor fan housing.
Rapid motor bearing
wear
Excessive overhung load due to overtensioned drive Check belt tension and overhung load.
Excessive overhung load due to a small diameter motor
sheave Replace sheave with larger one.
Loose fan belt Motor is poorly positioned Adjust belt tension.
Worn or damaged belt Replace belt or belt set. Check sheave alignment.
Worn sheaves Replace sheaves.
CAH-SVX01B-EN 99
Troubleshooting
Short belt life
Worn sheaves Replace sheaves.
Misaligned belt Realign drive with MVP sheave set at mean pitch diameter.
Grease or oil on belts Check for leaky bearings. Clean belts and sheaves.
Belt slipping Improper belt tension. Adjust tension.
Belts rubbing Remove obstruction or realign drive for clearance.
Bearing noise Poor alignment Loosen bearing set screws and realign (see “Bearing Set
Screw Alignment” on page 89)
Failed bearing Replace bearing.
Inadequate lubrication Replace bearing.
Low water coil
capacity
Incorrect airflow Check fan operating condition.
Incorrect water flow Inspect the water pumps and valves for proper operation and
check the lines for obstructions.
Incorrect water temperature Adjust the chiller or boiler to provide the proper water
temperature.
Coil is piped incorrectly Verify coil piping (see “Coil Piping and Connections” section
on page 53).
Dirty fin surface Clean the fin surface (see “Coils” section on page 91).
Incorrect glycol mixture Verify glycol mixture and adjust if necessary.
Low refrigerant coil
capacity
Incorrect airflow Check fan operating condition.
Expansion valve is not operating properly or is sized
incorrectly
Check sensing bulb temperature.
Verify valve operation.
Verify proper valve size.
Incorrect refrigerant charge Verify refrigerant charge and adjust if necessary.
Condensing unit failure Verify condensing unit operation.
Coil is piped incorrectly Verify coil piping (see “Coil Piping and Connections” section
on page 53).
Clogged refrigerant line filter Change filter core.
Failure of suction/liquid line components Verify component operation
Dirty fin surface Clean the fin surface (see “Coils” section on page 91).
Do not use steam to clean refrigerant coils.
Fin frosting Verify defrost cycle operation.
Verify Frostat operation.
Verify refrigerant charge.
Low steam coil
capacity
Incorrect airflow Check fan operating condition.
Coil is piped incorrectly Verify coil piping (see “Coil Piping and Connections” section
on page 53).
Incorrect steam pressure Verify steam pressure and adjust if necessary.
Excessive steam superheat Check steam superheat.
Steam superheat should not exceed 50ºF.
Failure of steam line/condensate return components Verify component operation
Boiler failure Verify boiler operation
Dirty fin surface Clean the fin surface (see “Coils” section on page 91).
Drain pan is
overflowing
Plugged Drain Line Clean drain line
Unit not level Level unit
Improper trap design Design trap per unit installation instructions
Standing water in
drain pan
Improper trap design Design trap per unit installation instructions
Unit not level Level unit
Plugged drain line Clean drain line
Wet interior insulation
Coil face velocity too high Reduce fan speed
Improper trap design Design trap per unit installation instructions
Drain pan leaks/overflows Repair leaks
Condensation on surfaces Insulate surfaces
Excess dirt in unit Missing filters Replace filters
Filter bypass Reduce filter bypass by ensuring all blockoffs are in place.
Microbial growth
(mold) inside air
handler
Standing water in drain pan See “Standing water in drain pan” above
Moisture problems See “Wet interior insulation” above
Table 11. Air handler troubleshooting recommendations
Symptom Probable Cause Recommended Action
www.trane.com
For more information, contact your local Trane
office or e-mail us at comfort@trane.com
Literature Order Number CAH-SVX01B-EN
Date July 1, 2010
Supersedes CAH-SVX01A-EN (July 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.

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