Installation Operation Maintenance Custom Climate Changer™ Air Handlers Part No.
NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual. 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, may result in minor or moderate injury. It may also be used to alert against unsafe practices. CAUTION ...indicates a situation that may result in equipment or property-damage-only accidents.
Introduction 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. 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.
Contents Introduction ......................................................................... 3 Unit Description .................................................................................. 3 Protecting the Environment ................................................................ 3 Contents ............................................................................... 4 General Information ............................................................ 5 Operating Environment .....................
General Information Operating Environment When considering the placement of the Custom Climate Changer 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.
General Information Ultraviolet (UV) Germicidal Irradiation Lights (optional) The United States Environmental Protection Agency (EPA) believes that molds and bacteria inside buildings have the potential to cause health problems in sensitive individuals(1). If specified, Trane provides ultraviolet lights (UV-C) as a factory-engineered and installed option in select commercial air handling products.
Pre-Installation Requirements Receiving Checklist Based on customer requirements, Custom Climate Changer air handlers can ship as complete units or as individual sections to be field assembled. Upon receipt of the unit(s) and prior to unloading, remove any shipping material and inspect the unit for damage and verify that the shipment is complete. Note: Delivery cannot be refused. Trane is not responsible for shipping damage.
Pre-Installation Requirements 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.
Pre-Installation Requirements Roof Curb Installation 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) Figure 1.
Installation Lifting and Rigging Figure 3. Use proper lifting and rigging methods WARNING Lifting and Rigging! Do not lift, rig, or ceiling-suspend from the top of the unit. Lift from lifting lugs only, located at the bottom of the unit. Use all lifting lugs provided. 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.
Installation • • Personnel should be positioned overhead and on the ground to guide the crane or helicopter operator in positioning the sections. The air handler is not designed to be lifted, rigged or ceiling suspended from the top of the unit. • 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.
Installation TCP Model Assembly Instructions If your nameplate model number begins with TCP, use the assembly instructions below. Joining Sections Edge-toEdge 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.
Installation TCP Base Section Assembly (Typical) 3 Apply the 3-inch X 1/8-inch gasket evenly across the two joined edges of the splits. 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 Caulk the overlapping flange along the length of each split to maintain a seal.
Installation TCP Wall Section Assembly (Typical) 1 Apply the walls and join at the inside angles with number 14 sheet-metal screws on 12-inch centers along the length of the angles. 2 Apply the 1/8-inch gasket evenly to the exterior of the walls across the two joined edges of the splits. 3 Before installing the pre-cut joining strip over the gasket, predrill holes in the wall using the strip as a guide with a number 29 drill bit at 12-inch centers.
Installation TCP Indoor Roof Section Assembly (Typical) 1 Align the walls and join the inside angles with number 14 sheet metal screws on 12-inch centers along the length of the angles. 2 Apply a bead of caulk along the length of the roof seam joint. 3 Apply the 1/8-inch gasket on the exterior of the roof evenly across the roof split. 4 Before installing the pre-cut joining strip over the gasket, predrill holes in the roof using the strip as a guide with a number 29 drill bit at 12-inch centers.
Installation TCP Base to Interior Wall Section Assembly (Typical) 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 Illustration below. Note: Use a polyurethane or equivalent caulk.
Installation TCC Model Assembly Instructions Figure 9. Remove shipping blocks If your nameplate model number begins with TCC, use the assembly instructions below. Joining sections - Edge to Edge 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 multisection unit must be properly supported. Note: Leveling each section, beginning with the first section, is critical.
Installation • Apply 1.25-inch x 0.33-inch ribbed butyl tape to the shipping split channel and shipping split plates (see Figure 11). • Verify the section is level prior to proceeding with the next section of the unit. • • Move the next unit section as close as possible from the previous section. The two sections should be close enough to reduce the amount of dragging required. This is particularly important when mounting on a roof curb to minimize damage to the sealant on the roof curb.
Installation • Insert field provided threaded rods through the bottom lifting lug and shipping split plates on each sides of the unit. Draw both sides of the section together equally to prevent damage and distortion of the sections as they joined. Do not try to join sections by tightening only one side of the rods (see Figure 13). Figure 14. Add caulk along the seam Note: Field-provided threaded hardware should consist of 5/8-11x12 inch threaded rods 5/8-inch lock washers and 5/8-inch nuts.
Installation TCC internal shipping split frame assembly (typical) • Join the two sections and secure with field provided ½-13x8.5 inch threaded rods, ½-inch flat washers and ½-inch lock washers through each of the holes provided in the internal shipping split frame (see Figure 15) This frame runs around the entire perimeter of the unit (see Figure 11). Figure 15.
Installation TCC wall sections assembly (typical) TCC indoor roof sections assembly (typical) • Verify external unit squareness. • Verify external unit squareness. • Apply the 1.25-inch x 0.33-inch ribbed butyl tape to the exterior of the walls covering the seam of the two adjoining sections (see method sheet). • 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).
Installation TCC outdoor roof sections assembly (typical) • 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 17). Figure 17.
Installation • 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.
Installation 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.
Installation 3 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. 4 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.
Installation Air Filters Front Load Filters Side Load Filters Figure 21. C-70 fastener holds 2-inch filter Most filters in custom units are installed in unitary sheet metal frames. Filters are secured with a metal clip. There are several different styles. 2-inch or 4-inch flat filters. 1 Disconnect the power to the unit. To install filters: 1 Disconnect power to the unit. 2 Open or remove the filter clip. 3 Remove the filter from the rack. Figure 22.
Installation 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.
Installation Coil Piping and Connections Note: The contractor is responsible for supplying the installation hardware. CAUTION Prevent Coil Damage! • For best results, use a short pipe nipple on the coil headers prior to making any welded flange or welded elbow type connections. • Extended drain and vent connections are provided as standard on DD and D coils only. If extended drains and vents are required on other water coils, they must be field-installed or ordered as specials from the factory.
Installation Drain Pan Trapping Threaded condensate drain connections are provided on only one side of the coil module. Pitch the connection lines horizontal or downward toward an open drain. Trane recommends installing a plug to facilitate cleaning of the trap. Figure 26. Drain pan trapping for module under negative pressure Figure 26 illustrates the proper trapping, piping, and operation of the trap for negative pressure modules.
Installation Steam Coil Piping M-Series air handlers fitted with steam coils have labeled holes for piping penetrations. Figure 28 and Figure 29 illustrate typical steam coil piping configurations. See Table 2 for the codes of system components in these figures. Table 2.
Installation Figure 28. Typical piping for Type N steam coils and horizontal tubes for horizontal airflow 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. Figure 29.
Installation unless the condensate is drained by gravity into a receiver, vented to atmosphere, and returned to the condensate pump. Figure 30. Typical piping for type 5W one-row water coil 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.
Installation Refrigerant Coil Piping Note: Refer to the “Protecting the Environment” section on page 3 for information on handling refrigerants. Use Figure 33 to determine the proper, relative sequence of the components in the refrigerant lines that connect the condensing unit to an evaporator coil. Refer to the “Examples of Field-Installed Evaporator Piping” section on page 35 for more detailed schematics of evaporator piping. Liquid Lines Line Sizing.
Installation • 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 assure it will correctly meter refrigerant into the evaporator coil throughout the entire operating envelope of the system.
Installation • • 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.
Installation Figure 36. Single-circuit evaporator coil with two distributors Single-Circuit Condensing Units: Evaporator Coil with Two Distributors (see Figure 36) 1 Pitch the liquid line slightly— 1 inch/10 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator. 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.
Installation Figure 37. Single-circuit evaporator coil with four distributors Assure 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, humiditysensitive applications.
Installation Dual-Circuit Condensing Units: Evaporator Coil with Two Distributors (see Figure 38) 1 Pitch the liquid lines slightly—1 inch/10 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator. 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.
Installation Dual-Circuit Condensing Units: Evaporator Coil with Four Distributors (see Figure 39) Figure 39. 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. 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.
Installation Dual-Circuit Condensing Units: Evaporator Coil with Eight Distributors (see Figure 40) Figure 40. 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. 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.
Installation Wiring 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 fused disconnect switch in compliance with national and local electrical codes. Fan motors also require motor overload protective devices that are rated or selected in compliance with the National Electric Code or Canadian Electric Code.
Installation External Insulating Requirements Figure 44. Junction box mounting and wiring details 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 lowtemperature-air systems Valve jack wiring: .
Startup Once the Custom Climate Changer 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.
Startup 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. • 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.
Startup Tension the Fan Belt 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 (see Figure 46 and Figure 47). WARNING Proper belt tension is required to ensure maximum bearing and drive component life and is based on motor horsepower requirement.
Startup Table 3. Typical sheave diameter and deflection force1 Cross Section A, AX Smallest Sheave Diameter Range (in.) 3.0–3.6 3.8–4.8 5.0–7.0 3.4–4.2 B, BX 4.4–5.6 5.8–8.6 7.0–9.0 C, CX 9.5–16.0 12.0–16.0 D 18.0–20.0 2.2–2.4 3V, 3VX 2.65–3.65 4.12–6.90 4.4–6.7 5V, 5VX 7.1–10.9 11.8–16.0 12.5–17.0 8V 18.0–22.
Startup Determine Fan Speed Figure 48. Proper drive alignment 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.
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.
Routine Maintenance Air Filters Permanent Filters Side Load Filters Refer to product catalog CLCH-PRC003-EN for filter sizes, types, and quantities. To clean permanent 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: WARNING Hazardous Voltage with Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing.
Routine Maintenance See “ WARNING Hazardous Voltage with Capacitors!” on page 49 regarding disconnection of power. Drain Pans The condensate drain pan and drain line must be checked to assure the condensate drains as designed. This inspection should occur a minimum of every six months or more often as dictated by operating experience. areas of the unit or building. Properly dispose of all contaminated materials and cleaning solution.
Routine Maintenance See “ WARNING Hazardous Voltage with Capacitors!” on page 49 regarding disconnection of power. Fan Bearing Lubrication CAUTION 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.
Routine Maintenance See “ WARNING Hazardous Voltage with Capacitors!” on page 49 regarding disconnection of power. Coils 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.
Routine Maintenance 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. Coil Winterization Water coil winterization procedures consist primarily of draining water from the coil before the heating season.
Routine Maintenance See “ WARNING Hazardous Voltage with Capacitors!” on page 49 regarding disconnection of power. WARNING Hazardous Chemicals! Coil cleaning agents can be either acidic or highly alkaline. Handle chemical carefully. Proper handling should include goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety refer to the cleaning agent manufacturer’s Materials Safety Data Sheet and follow all recommended safe handling practices.
Routine Maintenance Ultraviolet (UV) Germicidal Irradiation Lights The intensity of the ultraviolet energy emitted from the ultraviolet bulbs provided in this unit 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.
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.
Troubleshooting Table 5.
Notes 58 CAH-SVX01A-EN
Notes CAH-SVX01A-EN 59
Trane A business of American Standard Companies www.trane.com For more information, contact your local Trane office or e-mail us at comfort@trane.com Literature Order Number CAH-SVX01A-EN Date July 2005 Supersedes New Stocking Location Inland Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.
