Installation, Operation, and Maintenance Intellipak™ Commercial Self-Contained Modular Series 20 to 35Tons Models SCWG -020, -025, -030, -032, -035 SIWG -020, -025, -030, -032, -035 SCRG -020, -025, -032 SIRG -020, -025, -032 SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
Introduction Read this manual thoroughly before operating or servicing this unit. Warnings, Cautions, and Notices Safety advisories appear throughout this manual as required.Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions. The three types of advisories are defined as follows: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Introduction WARNING Proper Field Wiring and Grounding Required! Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.
Table of Contents Model Number Descriptions . . . . . . . . . . . . . . 6 Modular Series Self-Contained . . . . . . . . . . 6 Self-Contained Ship-With Accessory Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote Air-Cooled Condenser . . . . . . . . . . 8 General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Modular Series Self-Contained Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General Data . . . . . . . . . . . . . . . . . . . . .
Table of Contents Variable Air Volume (VAV) Points . . . . . . 75 Adjusting Belt Tension . . . . . . . . . . . . . . .94 BCI-Points List . . . . . . . . . . . . . . . . . . . . . . . . 76 Refrigerant System . . . . . . . . . . . . . . . . . . . .95 Phase Monitor . . . . . . . . . . . . . . . . . . . . . . . 76 Refrigerant Leak Test Procedure . . . . . . . .95 Unit Control Components . . . . . . . . . . . . . . 76 Brazing Procedures . . . . . . . . . . . . . . . . . .
Model Number Descriptions Modular Series SelfContained Digit 13 - Plenum Type Digit 20 - Heating Type B C E F H = = = = = Digit 2 - Unit Type J = C I L = A = B = C = F = G = K = L = M = N = P = R = T = U = sep V = W = sep 0 = Digit 1 - Unit Model S = = = self contained commercial industrial Digit 3 - Condenser Medium W = R = water-cooled remote air-cooled Digit 4 - Development Sequence G = M = P = ship R = Digit 5 - Refrigerant Circuit Configuration U = U V = 0 = = modular seri
Model Number Descriptions Digit 28 - Ventilation Control B = C = E = F = H = J K = = 0= airside econ w/Traq™ damper (top O/A inlet) airside econ w/ standard dampers (top O/A inlet) airside econ w/Traq™ damper and comparative enthalpy (top O/A) airside econ w/ std dampers and comparative enthalpy (top O/A) none/ventilation for 2-position control interface airside economizer interface airside economizer interface w/ comparative enthalpy None Digit 29 - Water Piping A B C D E F J K L M 0 = = = =
Model Number Descriptions Self-Contained ShipWith Accessory Model Number Digit 1 - Parts/Accessories P = parts/accessories Digit 2 - Unit Model S = self-contained Remote Air-Cooled Condenser Digit 1 - Unit Model C = Condenser Digit 2 - Unit Type C I = = Commercial Industrial Digit 3 - Condenser Medium Digit 3 - Shipment R W = Digit 4 - Development Sequence with unit = Remote Digit 4 - Development Sequence C F G Digits 5, 6, 7 - Nominal Capacity = = signature series modular series
General Data Modular Series Self-Contained Unit Components Commercial self contained units are complete HVAC systems used in floor-by-floor applications. Units are easy to install because they feature a single point power connection, factory installed and tested controls, single water point connection, factory installed options, and an internally trapped drain connection. Modular selfcontained units can ship as split-apart units for installation ease.
General Data Unit Nameplate Unit nameplate, mounted on left end of unit control panel, identifies unit model number, service literature, and wiring diagram numbers. Figure 1.
General Data General Data Table 1. SCWG/SIWG/SCRG/SIRG general data Water-Cooled Units Unit Size 20 25 30 Air-Cooled Units 35 20 25 32 Compressor Data Quantity 2 2 1/1 2 2 1/1 2 Nominal Ton/Comp 10 10 10/15 15 10 10/15 15 Circuits 2 2 2 2 2 2 2 Evaporator Coil Data Rows 2 4 4 4 3 4 4 Sq. Ft. 22.5 25.0 25.0 25.0 25.0 25.0 25.
General Data Table 2. SCRG/SIRG self-contained and CCRC/CIRC remote air-cooled condenser SCRG/SIRG & CCRC/CIRC Unit Size 20/20 25/29 32/32 2 2 2 Operating Charge - lbs R-410A 36.5/36.5 48.5/36 46/46 Operating Charge - kg R-410A 16.6/16.6 22/16.3 20.9/20.9 37/37 51/37 51/51 No. of Refrigerant Circuits Cond. Storage Cap. - lbs R-410A Cond. Storage Cap. - kg R-410A 16.8/16.8 23.1/16.8 23.1/23.1 Notes: 1. Refrigerant charges are listed as circuit 1/circuit 2 and provide only an estimate.
Pre-Installation Considerations Receiving Receiving Checklist Complete the following checklist immediately after receiving unit shipment to detect possible shipping damage. • Inspect individual cartons before accepting. Check for rattles, bent carton corners, or other visible indications of shipping damage. • If a unit appears damaged, inspect it immediately before accepting the shipment. Make specific notations concerning the damage on the freight bill. Do not refuse delivery.
Pre-Installation Considerations Figure 2. Typical unit mounting on shipping skid Figure 3.
Pre-Installation Considerations Figure 4.
Dimensions & Weights Table 6. SCWG/SIWG weight, lbs. Unit Tons Base Weight - lb (kg) 20 2227 (1010) 25 2697 (1223) 30 2765 (1254) 35 2834 (1286) Notes: 1. All unit weights include refrigerant, water and controllers, electric heat and valves. 2. Add 150 lbs. to total weight to obtain approximate shipping weight. 3. Split-apart unit weights are approximately: 60% total unit weight = compressor section, 40% total unit weight = fan section. Table 7.
Dimensions & Weights Figure 5. SCWG/SIWG, in. 6.
Dimensions & Weights Figure 6. SCRG/SIRG, in. 6.
Dimensions & Weights Table 8. Detail dimensions, in. Model A SCWG/SCRG 20 20 SCWG/SCRG 25 SCWG 30 - 35 SCRG 32 Figure 7. B C D E F 10 3/4 58 1/2 5 1/8 13 1/4 11 1/2 19 1/4 12 1/4 57 5/8 5 1/8 13 1/4 11 1/2 18 14 5/8 56 1/2 5 1/8 13 1/4 11 1/2 SCRG/SIRG/SCWG/SIWG detail “A” electrical connections, in. Note: When unit is ordered with horizontal supply, ensure that all applicable codes are considered when installing equipment.
Dimensions & Weights Figure 9. CCRC/CIRC air-cooled condenser OPTIONAL LOW AMBIENT DAMPER (ONE DAMPER PER CIRCUIT) REFRIGERANT LINE CONNECTIONS AA FRONTAL VIEW AC AB REFRIGERANT CIRCUIT 2 REFRIGERANT CIRCUIT 1 OPTIONAL LOW AMBIENT DAMPER 24 VOLT WIRE ENTRY HOLE SIZED FOR 3/4” CONDUIT 115 VOLT WIRE ENTRY HOLE SIZED FOR / ” CONDUIT 34 SUPPLY VOLTAGE WIRE ENTRY HOLE SIZED FOR 1” CONDUIT (LIQUID LINE CONNECTION REFRIG. CIRCUIT 1) B (HOT GAS CONNECTION REFRIG.
Dimensions & Weights Figure 10. Table 12. Hot water coil: left-hand connections Hot water coil dimensions & weight, in-lbs A B C D E F G H J K Weight one-row coil 53 3/4 4 7/8 73 1/2 16 5/8 6 3/4 7 1/2 23 1/8 37 1/4 1 3/4 2 1/2 415 two-row coil 53 3/4 5 1/8 73 1/2 16 5/8 6 3/4 7 1/2 22 3/8 37 1/4 2 3/4 3 5/8 510 Figure 11.
Dimensions & Weights Figure 12. Steam coil: left connections 92 3/4" 73 1/2" 22 1/2" 53 13/16" 3 5/16" VERTICAL DISCHARGE 3/4" (4X) ISOLATOR MOUNTING LOCATION ON BOTTOM OF UNIT 30 7/8" CONDENSER FITTINGS 1 1/2" NPTI 15 7/8" 1" ELECTRICAL CONNECTIONS 36 15/16" 40 15/16" 2 1/8" 64 1/2" 14 9/16" TOP VIEW 11" 9 3/8" 35" 3 7/8" Note: Steam Coil Weight 460 Lbs. 6 3/4" 16 15/16" LEFT VIEW Figure 13.
Dimensions & Weights Figure 14. Electric Heat Coil Table 13. Figure 16. Waterside Economizer Electric heat coil dimensions & weight, in-lbs. Unit Size A B C D Weight 20 tons 70 1/4 4 7/8 11 1/2 19 460 25 tons 70 1/4 4 1/8 11 1/2 19 460 30 - 35 tons 70 1/4 2 7/8 11 1/2 19 460 Table 15. Waterside economizer weight, in-lbs. Weight Note: Coil box height is 8 in. Unit size 2-row 4-row 20 - 35 tons 488 584 Figure 15. Flexible horizontal discharge plenum Figure 17. Table 14.
Dimensions & Weights Service Clearances Figure 18. Detail “B” (top) and Detail “A” (bottom) See Figure 19, p. 24 and Figure 20, p. 24 for recommended service and code clearances. Figure 19. Top view CCRC/CIRC 20, 29, 32 96” (2132 mm) 48” (1066 mm) 48” (1066 mm) Control Panel 96” (2132 mm) Table 18. Side front left Table 17. Side front left Service and code clearance requirements Distance Purpose 42 in. NEC code requirement (20-38 tons) 18 in. 36 in. 77 in.
Installation - Mechanical Unit Handling Procedures 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 unit dropping and possibly crushing operator/technician which could result in death or serious injury and possible equipment or property-only damage.
Installation - Mechanical Figure 22. Split-apart unit gravity block location Fan Section Only Compressor Section Only Figure 23.
Installation - Mechanical Figure 24. Assembled modular unit proper rigging 6. Use hooks to lift fan section only. Do not hook into open channels to lift unit. 7. See unit nameplate for unit weight. 8. Do not stack units. Installation Preparation Important: Before installing the unit, perform the following procedures to ensure proper unit operation. Before installing the unit, perform the following procedures to ensure proper unit operation. 1.
Installation - Mechanical Split-Apart Unit Assembly 1. Ensure the tagging information on the fan section nameplate matches that on the compressor nameplate. 2. Remove the connector brackets holding the sheet metal shipping cover on compressor section. Retain brackets and screws. 3. Remove shipping cover from the compressor section and verify the ship-with package contains: a. suction and liquid line couplings b. insulation c. sheet metal screws 4.
Installation - Mechanical Figure 26. How to assemble the modular unit Unit Vibration Isolator Option If your job requires external vibration isolation, two options are available: isopads or spring-type isolators. Isopads should be placed under the unit at locations indicated on the factory-provided isolator sheet. Set the spring-type isolators (Figure 27, p. 29) in position after the unit is removed from skids before making electrical, piping, or duct connections.
Installation - Mechanical Duct Connections Figure 28. Duct connection recommendations WARNING Hazardous Voltage w/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.
Installation - Mechanical Figure 29. Correct plenum insulation placement Plenum Bottom View 11. Lower the damper cabinet until the holes in its side flanges are aligned with the holes in the C-channel collar. Install screws removed in step 3 through the damper cabinet’s side flanges and into the C-channel’s corresponding holes. 12. Attach ductwork to the top and back dampers according to local codes.
Installation - Mechanical Figure 30. Proper lifting of the airside economizer (top) and proper installation of the airside economizer option (bottom) Note: Four condenser waterline drain plugs ship in a bag in the unit’s left end.The installer must field install these four plugs using pipe thread sealer. An additional plug is provided for units with a waterside economizer. 1. Install the vent plugs in the economizer coil headers and condenser manifolds.
Installation - Mechanical Figure 31. Direct condenser connections Install the supply riser and its return in close proximity. Furnish both with permanent thermometers to check the waterside balance during start-up and routine maintenance checks. Also, include strainers at each pump inlet and unit. Install drain valves at the riser’s base to allow drainage points for system flushing during start-up and routine maintenance.
Installation - Mechanical Waterside Economizer Installation Procedure Figure 33. Installing the waterside economizer Waterside economizer must be lifted and hooked over flange in the opening of the unit channel. 1. Loosen and pull all end devices that go through the bushing on the filter rack (upper right corner of rack). 2. Remove the filter rack from the back of the unit by removing the 1/4” hex head screws from the top and bottom of the filter rack assembly.
Installation - Mechanical Figure 35. Waterside economizer with left-hand factory piping tubing assembly Waterside Economizer with right-hand factory piping components Figure 36. Waterside economizer with right-hand factory piping tubing assembly B A G E A F B F D C D Table 21. Waterside economizer ship-separate parts list left-hand piping Factory Piping Left-Hand C Figure 37. Item Part # Qty.
Installation - Mechanical Table 23. Waterside economizer ship-separate parts list right-hand piping Factory Piping Item Part # Qty. Right-Hand 4001 1 Tube; 2 5/8" x 9" 4607 1 Tube; 2 5/8" x 17" X17110026250 5 Elbow; 2 5/8" x 2 5/8" 4605 2 Tube; 2 5/8" x 9 1/2" Description X15330177010 1 Water Valve 4008 1 *Tube; 2 5/8" x 20 1/4" X17170031210 1 Tee; 2 5/8" x 2 1/8" x 2 5/8" X16120203570 1 Brass Plug, 1 1/2" X17150027060 1 Bushing; 2 1/8" ftg.
Installation - Mechanical If no nitrogen escapes the access valve, leak test the unit refrigerant system to determine the leak source, and repair. See Maintenance section, “Refrigerant LeakTest Procedure,” p. 95. After finding leak, remove test pressure and repair leak using proper brazing procedures. See Maintenance section, “Brazing Procedures,” p. 96. Retest unit(s) to ensure all leaks are repaired. Continue with piping installation.
Installation - Mechanical 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.
Installation - Electrical Unit Wiring Diagrams Specific unit wiring diagrams are provided on the inside of the control panel door. Use these diagrams for connections or trouble analysis. Supply Power Wiring It is the installer’s responsibility to provide power supply wiring to the unit terminal block or the non-fused disconnect switch option. Wiring should conform to NEC and all applicable code requirements. Bring supply wiring through the knockout in the lower left side of the unit control panel.
Installation - Electrical Selection Procedures Table 30. RLA = rated load amps Compressor LRA = locked rotor amps Fan motor LRA = locked rotor amps, N.E.C. table 430 - 150 FLA = full load amps, N.E.C. Table 430 - 150 Unit Size Tons Determination of minimum circuit ampacity (MCA). MCA = 1.25 x largest motor amps/VFD amps (FLA or RLA) + the sum of the remaining motor amps. Determination of maximum fuse size (MFS) and maximum circuit breaker size (MCB). MFS and MCB = 2.
Installation - Electrical WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors.
Installation - Electrical Figure 39. Frame B1: without bypass AIR OUTLET 10.28 9.56 SEE DETAIL A 0.63 Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 19.45 SEE DETAIL B 17.87 AIR INLET 8.27 0.63 MOUNTING BASE 0.35 0.35 0.35 0.47 0.35 0.75 DETAIL DETAIL B A Weight = 51 lbs (23.
Installation - Electrical Figure 40. Frame B2: without bypass 10.28 AIR OUTLET 9.57 SEE DETAIL A 0.64 Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 26.14 24.57 SEE DETAIL B AIR INLET 8.27 MOUNTING BASE 0.64 0.35 0.35 0.35 0.47 0.75 DETAIL A 0.35 DETAIL B Weight = 60 lbs (27.
Installation - Electrical Figure 41. Frame C1: without bypass 12.17 0.72 AIR OUTLET 12.17 SEE DETAIL A Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 27.28 25.51 AIR INLET SEE DETAIL B 10.71 0.72 MOUNTING BASE 0.35 0.39 0.49 0.39 0.35 0.75 DETAIL DETAIL B A Weight = 91 lbs (41.
Installation - Electrical Variable Frequency Drive With ByPass Table 34. With Bypass VFD Frame Sizes 200V 460V 575V HP Frame Frame Frame 7.5 B1 A3 A3 10 B1 A3 A3 15 B2 B1 B1 20 B2 B1 B1 25 C1 B1 B1 Notes: 1. See Figure 42, p. 45 through Figure 45, p. 48 for frame size details. 2. VFD wall-mounted by others. Figure 42. Frame A3: with bypass 9.73 7.63 4.72 1.45 Trane TR200 Status Quick Menu Main Menu Back Alarm Log SEE DETAIL A Cancel OK On Info Warn.
Installation - Electrical Figure 43. Frame B1: with bypass SEE DETAIL A TYP. 3 PLCS. 19.09 .69 8.86 8.86 12.65 Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 21.48 20.10 SEE DETAIL B TYP. 3 PLCS. 0.35 0.69 0.47 0.69 0.35 DETAIL B 0.75 DETAIL A Weight = 85 lbs (38.
Installation - Electrical Figure 44. Frame B2: with bypass 12.65 19.09 .69 8.86 8.86 SEE DETAIL A Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 28.17 26.79 SEE DETAIL B .35 .69 .69 .47 .75 DETAIL A .35 DETAIL B Weight = 105 lbs (47.
Installation - Electrical Figure 45. Frame C1: with bypass SEE DETAIL A TYP. 3 PLCS. 24.30 1.15 11.00 11.00 14.51 Trane TR200 Status Quick Menu Main Menu Back Alarm Log Cancel OK On Info Warn. Alarm Hand On Off Reset Auto On Reset 29.94 28.55 SEE DETAIL B TYP. 3 PLCS. 1.42 2.82 2.76 1.89 2.99 1.42 DETAIL B DETAIL A Weight = 145 lbs (65.
Installation - Electrical Static Pressure Transducer Installation (VAV units only) Electric Heat Installation Supply air static pressure controls the inverter option. A static pressure head assembly ships separate in control panel for field installation in the supply air duct work. Installer is responsible for providing pneumatic tubing. Transducer Location Place head assembly in an area of ductwork that will provide an average and evenly distributed airflow pattern.
Installation - Electrical Note: It is very important that electric heaters are selected based on unit voltage and tonnage because discharge opening sizes vary by unit tonnage. Electric Heat Coil Wiring Procedure • Before wiring the electric heater, remove the unit wiring diagram from the unit control panel and refer to the connection points. Figure 47. 50 Table 36.
Installation - Electrical Standard with All IntelliPak Units Zone Sensor Options for IntelliPak Control Units Zone sensor options are available and be ordered with the unit or after the unit ships. Following is a full description of zone sensors and their functions. See Table 44, p. 77 for the zone sensor temperature vs. resistance coefficient curve. BAYSENS077* Description This zone sensor module ships with all units, and can be used with BAYSENS019, BAYSENS020, or BAYSENS021 remote sensors.
Installation - Electrical Integrated Comfort™ Systems Sensors for CV and VAV Applications CV and VAV Unit Zone Sensor Options These zone sensor options are for use with cooling/heating Integrated Comfort System (ICS) systems. BAYSENS074 Description This electronic analog sensor features single setpoint capability and timed override with override cancellation.
Installation - Electrical Zone Sensor Installation All sensor options ship in the main control panel and are field-installed. Programmable option installation procedures. Mounting Location Mount the sensor on the wall in an area with good air circulation at an average temperature.
Installation - Electrical Figure 49. Typical zone sensor installation for vertically-oriented sensors Mounting Directly to the Wall Mounting to Junction Box Junction Programmable Zone Sensors The BAYSENS119 programmable night set back sensor provides multi functional flexibility for both Constant Volume and Variable Air Volume control.This electronic programmable sensor includes auto or manual cooling and heating changeover with 7 day programming.
Installation - Electrical Figure 50. Zone sensor mounting hole locations for: BAYSENS119 0.31 in (8 mm) 2.9 in (73.5 cm) 1.08 in (27.5 mm) 0.12 in (3 mm) 4.68 in (118.9 mm) TYP R.07 in (R1.80 mm) 3.39 in (86 mm) 0.24 in (6.00 mm) 0.58 in (14.76 mm) 1.34 in (34.14 mm) 2.62 in (66.
Installation - Electrical Time Clock Option Figure 51. Grasslin time clock option The time clock option has a programmable timer that is factory wired to the unoccupied input to provide on/off control.The time clock will not allow the unit to pass through the night setback/morning warm-up mode, except on units with optional night heat/morning warm up, or programmable night setback. See Figure 51, p. 56.
Installation - Electrical The HI displays top level information in the LCD window, unless the operator initiates other displays, for the various unit functions. It also displays menu readouts in a clear language 2 line, 40 character format.The 16-key keypad allows the operator to scroll through the various menus to set or modify the operating parameters. See Figure 52, p. 57 to reference the HI keypad.
Installation - Electrical c. Unlatch the door of the enclosure as if to open it, and slide the left hand side of the door upward away from the hinge. Lay it aside. d. With the key pad visible, remove the two (2) screws located on the right hand side of the key pad. e. Carefully slide the key pad plate upward from the bottom, releasing the extruded hinge pin from its socket at the top. 5. Remove the necessary knockouts for the wire or conduit entry before mounting the panel. 6.
Installation - Electrical Figure 53. Remote HI mounting holes and knockout locations Wiring the Remote Human Interface WARNING Proper Field Wiring and Grounding Required! All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.
Installation - Electrical WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors.
Installation - Electrical Interprocessor Communication Bridge Module Wiring Trim outer covering of shielded cable back approximately 1”. See Figure 54, p. 60. Cut bare shield wire even with outer covering. Strip approximately 1/2” of insulation from each insulated wire to connect to terminal strip at unit. Wrap tape around any exposed foil shield and base shield wire. Note: The communication link is polarity sensitive.
Installation - Electrical through Friday) appears in display. Repeated presses will cycle through all days of the week and back to 1 through 7 (Monday through Sunday). Select day or block of days desired. 7. Press “Prog.” key and repeat steps 2 through 6a to enter additional programs of ON and OFF times. (Note that more than one OFF time may be programmed, enabling automatic control or manual overrides.) 8. Press “” key to enter run mode. To review and change programs: 1.
Operating Principals Control Sequences of Operation Note: Unoccupied economizer operation can be enabled or disabled at the HI or usingTracer Summit. Occupied/Unoccupied Switching Figure 55. Typical cycling morning warmup cycle There are four ways to switch occupied/unoccupied: 1. Night setback zone sensor 2. Field-supplied contact closure (hard wired binary input to RTM) 3. Tracer Summit 4.
Operating Principals Timed Override Activation - ICS™ This function is operational whenever the unit’s RTM module is used as the zone temperature sensor source, which can be set at the HI panel. When this function is initiated by the push of the override button on the zone sensor, the unit will switch to the occupied mode. Unit operation (occupied mode) during timed override is terminated by a signal fromTracer.
Operating Principals with the highest priority attempts cooling first. Once it is operating at its maximum, and if additional cooling is necessary, the other economizer enables before mechanical cooling begins. Cooling/Waterside Economizer Waterside economizing enables when the unit’s entering water temperature is below the unit’s entering mixed air temperature by 4°F plus the user adjustable economizer approach temperature.The approach temperature default is 4°F.
Operating Principals For both outdoor air cooling reset and heating reset, there are three user defined parameters that are adjustable through the human interface panel. • Beginning reset temperature • Ending reset temperature • Maximum amount of temperature reset Reset based on zone temperature Zone reset is applied to the zone(s) in a building that tends to overcool or overheat.The supply air temperature setpoint is adjusted based on the temperature of the critical zone(s).
Operating Principals from 2 to 12°F. In a steady state, the unit will either maintain a constant level of cooling capacity with the supply air temperature within the control band, or the highest active cooling level will cycle to provide an average supply air temperature equal to the setpoint. circuit frost protection can override the “minimum” timer and reduce the five minute minimum required time period.
Operating Principals Figure 56. Typical pulldown curve for unit operating properly within control band Figure 57. Typical pulldown curve for unit operating improperly outside control band Compressor Safety Devices Evaporator Coil Frost Protection FROSTAT™ If a compressor low pressure cutout opens during compressor start-up, the UCM will not shut the compressor off during the first two to three minutes after start-up.This prevents possible nuisance trips during low ambient start conditions. SeeTable 41.
Operating Principals Water Purge NOTICE: Proper Water Treatment! The use of untreated or improperly treated water could 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.
Operating Principals Waterside Economizer Flow Control Variable Water Flow Units equipped with a waterside economizer can be set from the human interface panel for variable or constant water flow. Two-way modulating control shutoff valves are wired, controlled, and installed in the unit. One valve is located in the economizer’s water inlet, and the other is in the condenser water inlet. When the economizer valve is active, the condenser bypass valve closes.
Operating Principals Unit Airside Components The unit’s air delivery system consists of dampers, enthalpy switch option, airside economizer option, filters, low ambient sensors, and factory mounted single or double wall plenums. Supply Air Fan The unit has a single supply fan that runs at a constant speed. However, the fan may have the VFD option that modulates airflow based on supply air temperature control. Pressing the stop key on the HI will turn the supply fan off.
Operating Principals (adjustable 0-100% at the HI) for ventilation purposes. Also, the ability to alter the outside air damper position to compensate for VAV supply air modulation is inherent in the unit controls, and can be enabled by the operator. If the unit does not have an ECEM board, it will economize when the O/A temperature falls below the O/A economizer setpoint. The mixing box fabrication is galvanized steel.
Operating Principals lb (adjustable 19-28 BTu/lb.). During occupied mode, the outside air damper opens to 15% (adjustable 0-100%) for ventilation purposes. Also, the ability to alter the outside air damper position to compensate for VAV supply air modulation is inherent in the unit controls, and can be enabled by the operator. An analog 2-10 VDC output (adjustable (0-10 VDC) is provided to modulate the fieldprovided 30 second damper actuators (adjustable 1-255 seconds).
Controls Points List RTM Module Binary Inputs ECEM Module Analog inputs • Return air temperature • Return air humidity • Emergency stop • External auto/stop • Unoccupied/occupied Binary inputs • Dirty filter • VOM mode A, unit off • VAV changeover with hydronic heat • VOM mode B, pressurize • VOM mode C, exhaust • VOM mode D, purge • VOM mode E, purge w/duct pressure control Binary outputs In addition, units with a VOM have: • VAV box drive max (VAV units only) • CV unoccupied
Controls • Maintenance required time • Alarm status • Occupancy bypass time • Compressor on/off status • Outdoor air damper minimum position setpoint • Condenser circuit information • Outdoor air relative humidity • Condenser type (water or air cooled) • Outdoor air temperature • Condenser waterflow status • Unit start delay time setpoint • Condenser water pump status • Zone temperature Analog inputs • Zone temperature setpoint • Airside economizer dry bulb setpoint • Zone te
Controls BCI-Points List Refer to ACC-SVP*-EN Phase Monitor Unit is equipped with phase monitor in control box.The phase monitor will protect against phase loss, imbalance and reversal of line voltage. If a fault occurs, the red LED will energize. While the fault condition is present, the phase monitor interrupts the 115V control circuit. If no faults are observed, a green LED will be energized.
Controls Status/Annunciator Output The status annunciator output is an internal function within the RTM module on CV and VAV units. It provides: a. diagnostic and mode status signals to the remote panel (LEDs) and to the Human Interface. b. control of the binary alarm output on the RTM. c. control of the binary outputs on the GBAS module to inform the customer of the operational status and/or diagnostic conditions. Occupied/Unoccupied Inputs There are four ways to switch to occupied/unoccupied: 1.
Controls Table 45. RTM setpoint analog inputs Cooling or Heating Setpoint Input, °F (using RTM as zone temp. source) ohms Cooling Setpoint Input, °F (using RTM as supply air temp. source) resistance, 40 40 1084 45 45 992 50 50 899 55 55 796 60 60 695 65 65 597 70 70 500 75 75 403 80 80 305 NA 85 208 NA 90 111 Table 46. RTM resistance value vs.
Controls Once the ventilation sequences are configured, they can be changed unless they are locked using the HI. Once locked, the ventilation sequences cannot be unlocked. The compressors and condenser fans disable during the ventilation operation. If more than one ventilation sequence activates, the one with the highest priority (VOM “A”) begins first, withVOM “E” having lowest priority and beginning last.
Controls 3rd party building automation system, utilizing LonTalk, and allows external setpoint and configuration adjustment and monitoring of status and diagnostics.The LCI-I utilizes an FTT-10A FreeTopology transceiver, which supports nonpolarity sensitive, free topology wiring, which allows the system installer to utilize star, bus, and loop architectures.
Controls GBAS Binary Outputs IPV = (SP - 40)(0.029) + 0.5 Five binary outputs to provide diagnostics, signaling up to five alarms. Each of the five (5) relay outputs can be mapped to any/all of the available diagnostics. Each output contains a dry N.O. and N.C. contact with a VA rating of 2 amps at 24 VAC. SP = [(IPV - 0.5)/0.029] + 40 If the static pressure range is 0.03-0.3 iwc: IPV = (SP - 0.03)(14.8) + 0.5 SP = [(IPV - 0.5)/14.8] + 0.03 GBAS Binary Input If the static pressure range is 0.0-5.
Controls Input Devices and System Functions Table 48. GBAS analog input setpoints control parameter signal range occupied zone cooling setpoint 0.5 to 4.5 vdc setpoint range 50 to 90°F (CV units only) unoccupied zone cooling setpoint 0.5 to 4.5 vdc 50 to 90°F occupied zone heating setpoint 0.5 to 4.5 vdc 50 to 90°F Water Purge (CV and VAV) NOTICE: Proper Water Treatment! (CV units only) unoccupied zone heating setpoint 0.5 to 4.5 vdc 50 to 90°F 0.5 to 4.5 vdc 40 to 90°F 0.5 to 4.
Controls LP switches close at 74 (water-cooled) and 61 (air-cooled) ± 6 psig. Evaporator Temperature Sensor Frostat™ The evaporator temperature sensor is an analog input device used to monitor refrigerant temperature inside the evaporator coil to prevent coil freezing. It is attached to the suction line near the evaporator coil with circuits 1 and 2 connected to the SCM/MCM and circuits 3 and 4 connected to theWSM.The coil frost cutout temperature is factory set at 30°F.
Controls Supply Air Temperature Sensor The supply air temperature sensor is an analog input device. It monitors the supply air temperature for supply air temperature control, supply air temperature reset, supply air temperature low limiting, and supply air tempering. It is mounted in the supply air discharge section of the unit and connected to the RTM. Supply Airflow Proving Switches This is binary input device used on units to signal the RTM when the supply fan is operating.
Pre-Startup Pre-Startup Checklist Complete this checklist after installing unit to verify all recommended installation procedures are complete before start-up.This does not replace the detailed instructions in the appropriate sections of this manual. Always read the entire section carefully to become familiar with the procedures. Electrical • Verify electrical connections are tight. Components • Verify liquid line service valve, and suction and discharge service valves if present, are open at startup.
Start-up 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.
Start-up 14. Check amp draw at compressor terminals. RLA and LRA are on the unit nameplate. 15. Measure amp draw at evaporator fan motor terminals. FLA data is on the motor nameplate. NOTICE: Compressor Damage! Improper power phasing could cause the compressor to run backward. Compressor could be running backward if it is noisy, low side shell gets hot, suction pressure does not drop within 5 seconds after startup and compressor only draws half of the expected amps.
Start-up Operating & Programming Instructions not keeping the unit off.To preventTracer Summit from affecting unit operation, removeTracer wiring and make required changes to setpoint and sensor sources. Reference the IntelliPak™ Self-Contained Programming Guide, PKG-SVP01B-EN, for available unit operating setpoints and instructions. A copy ships with each unit. For units with theVFD option, reference the installer guide that ships with each VFD. Startup Log Complete this log at unit startup.
Start-up Water Cooled Units: Circuit A: entering water temperature °F: __________ leaving water temperature °F: __________ entering water pressure, psig: __________ leaving water pressure, psig: __________ enter water temperature °F: __________ leaving water temperature °F: __________ entering water pressure, psig: __________ leaving water pressure, psig: __________ entering water temperature °F: __________ leaving water temperature °F: __________ entering water pressure, psig: _______
Maintenance Service Access • Turn the two slotted-head fasteners on the right edge of the VFD panel fully counterclockwise. See “Service Clearances,” p. 24 for recommended service and code clearances. Access to thermostat unit controls is through a hinged access panel door on the front, lower left of the unit’s compressor section. • Pull on the handle to swing the panel 180°. IntelliPak unit controls access is through a panel on the middle right of the fan section.
Maintenance If evidence of standing water or condensate overflow exists, take steps to identify and remedy the cause immediately. See “Troubleshooting,” p. 104 for possible causes and solutions. WARNING Hazardous Voltage w/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.
Maintenance 8. Check the fan bearing locking collars for tightness on the shaft.To tighten the locking collar, loosen the set screw and slide the collar into its proper position over the extended end of the inner case.Tighten the set screw to torque value in Table 53, p. 93 and Table 54, p. 93. WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing.
Maintenance Table 51. AO smith bearing lubrication schedule Speed Service Frame Standard Service Severe Service Extreme Over 1800 rpm All 6 months 3 months 3 months 400-440 1 1/2 yrs 8 mths 4 mths Note: Service standard - 8 hrs/day, normal to lgith loading, 100°F ambient temp. max.Severe service - 24 hrs/day, shock loading, vibration, dirt or dust, 100 to 150°F ambient temp. Extreme service - heavy shock or vibration, dirt or dust, 100 to 150°F ambient temp. Table 54. Table 52.
Maintenance Figure 64. Belt tension gauge (top) and fan belt adjustment (bottom) 2. Loosen nuts C and D (as required for motor horsepower) to slide the motor on its mounting plate in the proper direction to tension or relieve tension on the belt. 3. Adjust nuts A-D and bolt E. Do not stretch the belts over the sheaves. 4. Retighten all nuts and bolts. 5. Verify tension is adjusted properly. Recommended belt tension range values are on the unit fan scroll.
Maintenance Figure 66. Fan assembly Refrigerant System Should refrigerant system repair be required, LeakTest, Brazing and Evacuation Procedures are described. Preliminary Charging is described in the InstallationMechanical section, “Preliminary Refrigerant Charging,” p. 37 and Final Charging is described in Start-up section, “Final Refrigerant Charge,” p. 87. Ignore Air Cooled Only steps for Water Cooled systems.
Maintenance WARNING R-410A Refrigerant under High Pressure! The units described in this manual use R-410A refrigerant. Use ONLY R-410A rated service equipment or components with these units. For specific handling concerns with R-410A, please contact your local Trane representative. Failure to use R-410A rated service equipment or components could result in equipment exploding under R-410A high pressures which could result in death, serious injury, or equipment damage.
Maintenance NOTICE: Install electronic micron vacuum gauge in common line ahead of vacuum pump shutoff valve, as shown in Figure 67, p. 98. Close valves B and C, open valve A. Remove, do not wrap, water cooled condenser pressure relief valves during brazing. Failure to do so could result in valve damage. Start vacuum pump. After several minutes, gauge reading will indicate maximum vacuum pump is capable of pulling. Rotary pumps should produce vacuums of 100 microns or less. Valve Damage! 5.
Maintenance Figure 67. Typical vacuum pump hookup Figure 68. Evacuation time vs. pressure rise Compressors Scroll Compressor Failure Diagnosis and Replacement If compressor failure is suspected, refer to COM-SVN01AEN for detailed information regarding compressor failure diagnosis and replacement of scroll compressors.
Maintenance Components Figure 69. Typical water-cooled (SXWG) compressor section components Important: On units ordered with a Design Special of Inlet Guide Vanes, refer to non-current IOM (SCXF-SVX01D-EN) dated on or before March 2008 for maintenance procedure.
Maintenance Coil Fin Cleaning WARNING Hazardous Chemicals! Coil cleaning agents can be either acidic or highly alkaline and can burn severely if contact with skin occurs. Handle chemical carefully and avoid contact with skin. ALWAYS wear Personal Protective Equipment (PPE) including 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.
Maintenance 9. Replace all panels and parts and restore electrical power to the unit. 10. Ensure that contaminated material does not contact other areas of the equipment or building. Properly dispose of all contaminated materials and cleaning solutions. Refrigerant Coils WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing.
Maintenance 5. To clean the economizer tubes, remove the cast iron header plates at both sides of the coil between the inlet and outlet headers (four-row coils only; two-row coils do not have cover plates at right end). Rotate round brush through tubes from left end to loosen contaminants. Flush tubes with water. 6. Replace condenser end plates and clamps.The end plates must be centered when tightening the clamp. 7. Replace coil headers with gaskets and torque bolts to 50 ft.-lb. 8.
Maintenance 7. Inspect the optional waterside economizer coil. Clean the coil to prevent airflow restrictions through the fins. 8. Check and record operating pressures. Semi-Annual Maintenance 1. Verify the fan motor is properly lubricated. Follow lubrication recommendations on the motor tag or nameplate. Contact the motor manufacturer for more information. 2. Lubricate fan bearings. For best results, lubricate bearings during unit operation. Refer to the “Fan Bearings” section. 3.
Diagnostics Troubleshooting System Checks 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.
Diagnostics A Auto Reset S/A Static Pressure Limit Problem:The supply air static pressure went too high. Reason for Diagnostic:The S/A static pressure exceeded the S/A static pressure limit setpoint for at least one second continuously. UCM Reaction: A "supply air pressure shutdown" signal is sent to the following functions: a. Compressor staging control, b. Economizer actuator control, c. Heat operation, d. Supply fan control, e.
Diagnostics Emergency Stop Problem:The emergency top input is open. Reason for Diagnostic: An open circuit has occurred on the emergency stop input caused either by a high duct temp tstat trip, or the opening of field-provided contacts, switch, etc. UCM Reaction: Off or close requests are issued as appropriate to the following functions; a. Compressor staging/chilled water cooling control b. Heat operation c. Supply fan control and proof of operation d. Exhaust fan control and proof of operation. e.
Diagnostics Heat Module Auxiliary Temperature Sensor Fail Problem:The heat mod aux temp sensor input is out of range. Check: Sensor resistance should be between 830 ohms (200°F) and 345.7 ohms (-40°F). If so, check field/unit wiring between sensor and heat module. Reason for Diagnostic: At least one enabled unit function has the heat module auxiliary temperature input designated as its sensor, and the unit is reading a signal that is out of range for this input (temp < -55°F or temp > 209°F).
Diagnostics Check: Check field/unit wiring between RTM and MCM. Reason for Diagnostic:The RTM has lost communications with the MCM. UCM Reaction: A “Lockout” request is sent to the compressor staging control function. And a failsafe function in the MCM will cause all MCM outputs to be zeroed and deenergized. Reason for Diagnostic:The unit is reading a signal that is out of range for the outside air humidity sensor (humidity < 5% or humidity > 100%).
Diagnostics Reason for Diagnostic:The unit is reading a signal that is out of range for the return air humidity sensor (humidity < 5% or humidity > 100%). UCM Reaction:The economizer enable r.e. enthalpy function reverts to reference enthalpy changeover (“Level 2”) control. Reset Required: (PMR) An automatic reset occurs after the RA humidity input returns to its allowable range continuously for 10 seconds.
Diagnostics Supply Air Pressure Sensor Failure Problem:The supply air pressure sensor voltage input is out of range. 10 continuous seconds, or after a different SA temp heating setpoint selection source is user-defined. Supply Air Temperature Failure Check: Check field/unit wiring between the sensor and RTM. Problem:The supply air temperature sensor input is out of range.
Diagnostics b. Activation conditions: supply fan VFD bypass has been activated and supply fan vfd bypass is installed. a. disallow any interaction between the HI and the RTM (or any other modules), c.Time to React: 10 sec
Diagnostics enabled or set to the default minimum position function if O/A flow compensation is disabled or not available. Reset Required: (PAR) An automatic reset occurs after communication is restored. Velocity Pressure Sensor Failure Problem:The velocity pressure input signal is out of range. Check: Check field/unit wiring between sensor and VCM.
Wiring Diagrams Note: For easier access, published unit wiring diagrams (individual, separate diagrams for unitary product lines) will become available via e-Library instead of through wiring manuals after 2007.
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