Trane Performance Air Handlers Installationshandbuch

July 2010CAH-SVX01B-ENInstallation Operation MaintenanceCustom Climate Changer™ Air HandlersX-code - X39640745010

10 CAH-SVX01B-ENPre-Installation RequirementsReceiving ChecklistBased on customer requirements, Trane air handlers can ship as complete units or as i

www.trane.comFor more information, contact your local Trane office or e-mail us at [email protected] Order Number CAH-SVX01B-ENDate July 1,

CAH-SVX01B-EN 11Pre-Installation RequirementsResolving Shipping DamageTrane air handlers ship free-on-board (FOB), meaning that the unit belongs to th

12 CAH-SVX01B-ENPre-Installation RequirementsOutdoor Storage ConsiderationsOutdoor storage is not recommended; however, when outdoor storage is neces

CAH-SVX01B-EN 13Pre-Installation Requirements• Wiring for units must be provided by the installer and must comply with all national and local electric

14 CAH-SVX01B-ENPre-Installation Requirements1. Verify that the roof structure can adequately support the combined weight of the unit and curb assemb

CAH-SVX01B-EN 15Installation - MechanicalInstallation - MechanicalLifting and Rigging WARNINGHeavy Objects!Do not use cables (chains or slings) excep

16 CAH-SVX01B-ENInstallation - MechanicalLifting Considerations. Figure 2. Recommended attachment to lifting lugs.• Before lifting the unit, estimate

CAH-SVX01B-EN 17Installation - MechanicalUnit AssemblyAll Trane air handlers are identified by a multiple-character model number that identifies each

18 CAH-SVX01B-ENInstallation - MechanicalTCP Model Assembly InstructionsIf the model number on the nameplate begins with TCP, use the assembly instru

CAH-SVX01B-EN 19Installation - MechanicalTCP Structural Roof Curb and I-Beam DunnageThe TCP base for structural roof curbs (see Figure 5) and I-beam d

© 2010 Trane All rights reserved CAH-SVX01B-ENWarnings, Cautions and NoticesWarnings, Cautions and Notices. Note that warnings, cautions and notices

20 CAH-SVX01B-ENInstallation - MechanicalTCP Flat Concrete PadThe TCP base for concrete is designed to sit flat on the concrete with full perimeter c

CAH-SVX01B-EN 21Installation - MechanicalTCP Roof Curbs for Large Units with Shipping SplitsLarger units with shipping splits may require full-width i

22 CAH-SVX01B-ENInstallation - MechanicalTCP Joining Sections Edge-to-EdgeUnits must be installed level for proper drainage of condensate from the dr

CAH-SVX01B-EN 23Installation - MechanicalTCP Base Section Assembly with Flat FloorNote: Failure to completely compress the gasketing may result in air

24 CAH-SVX01B-ENInstallation - MechanicalTCP Base Section Assembly with Turned-Up Floor1. See Figure 11. Apply 4-inch x ¼-inch neoprene gasket to the

CAH-SVX01B-EN 25Installation - MechanicalTCP Wall Section AssemblyExterior Wall Assembly (Typical)1. See Figure 12. Ensure shipping split sections are

26 CAH-SVX01B-ENInstallation - MechanicalTCP Outdoor Roof Assembly - Single Span1. Ensure shipping split sections are aligned and pulled together pro

CAH-SVX01B-EN 27Installation - MechanicalTCP Outdoor Roof Assembly - Multiple Span Follow instructions in Figure 13 for installation of J-Caps.4. The

28 CAH-SVX01B-ENInstallation - MechanicalTCP Indoor Roof Section Assembly (Typical)1. Ensure shipping split sections are aligned and pulled together

CAH-SVX01B-EN 29Installation - MechanicalTCP Indoor Roof Assembly - Multiple Span1. Ensure shipping split sections are aligned and pulled together pro

CAH-SVX01B-EN 3Warnings, Cautions and NoticesWARNINGHazard of Explosion!Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not

30 CAH-SVX01B-ENInstallation - MechanicalTCP Base-to-Interior Wall Section AssemblyNote: Failure to completely compress the gasketing may result in a

CAH-SVX01B-EN 31Installation - MechanicalTCP Stacked Unit Assembly1. Install and assemble all lower sections as described in typical assembly.2. Lift

32 CAH-SVX01B-ENInstallation - MechanicalTCC Model Assembly InstructionsNOTICERoof Curb Structurally SoundCheck with curb manufacturer and job engine

CAH-SVX01B-EN 33Installation - MechanicalTCC Joining Sections - Edge-to-EdgeNOTICEMicrobial Growth! The roof curb or foundation must be level and the

34 CAH-SVX01B-ENInstallation - Mechanical3. Install 3/16-inch x 1.25-inch ribbed grey butyl tape to bottom rail, each side wall, and top rail. Remove

CAH-SVX01B-EN 35Installation - MechanicalFigure 24. Remove lifting lug bolts 4. Lift next section into place sitting it as close to the previous secti

36 CAH-SVX01B-ENInstallation - MechanicalTCC Internal Shipping Split Frame Assembly (Typical)1. After exterior shipping split has been sealed, interi

CAH-SVX01B-EN 37Installation - MechanicalTCC Wall Section Assembly (Typical)1. Verify external unit squareness.2. To complete the exterior joint, inst

38 CAH-SVX01B-ENInstallation - MechanicalTCC Outdoor Roof Section Assembly (Typical)1. Join two outdoor roof panels together at the seams at the dire

CAH-SVX01B-EN 39Installation - MechanicalFigure 32. Trim roof joint stripFigure 33. Trim roof joint strip

4 CAH-SVX01B-ENTable of ContentsGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 CAH-SVX01B-ENInstallation - MechanicalTCC Stacking Procedure1. After bottom section of stacked arrangement is in place, ensure top is clean and fr

CAH-SVX01B-EN 41Installation - MechanicalFigure 35. Stacked assemblyRooflower unitScrew10-16 x .750 self-drillerFlashingWallBaseDetail BDetail AScrew

42 CAH-SVX01B-ENInstallation - MechanicalTCC Energy Wheel and CDQ Wheel AssemblyUnits are shipped unstacked.1. Set sections 1 – 5 of the unit in plac

CAH-SVX01B-EN 43Installation - Mechanical7. Units will have field installed flashing. Remove upper unit lifting lugs, in order to install flashing bet

44 CAH-SVX01B-ENInstallation - Mechanical5. Lift cabinet into place aligning base tab with lifting lug brackets on air handler base.6. Slide pipe cab

CAH-SVX01B-EN 45Installation - Mechanical10. Install inside corner cap. See Figure 39 Detail A and B.11. Install 3/16-inch x 1. 25-inch grey ribbed bu

46 CAH-SVX01B-ENInstallation - MechanicalDuct ConnectionsAll duct connections to the units should be installed in accordance with the standards of th

CAH-SVX01B-EN 47Installation - Mechanical3. Bottom of unit base elevation is ½ inch lower than edge of duct opening in bottom of unit. During unit ins

48 CAH-SVX01B-ENInstallation - MechanicalFansThe fan and motor assembly are internally isolated. The fan and motor bases are bolted to a minimum of f

CAH-SVX01B-EN 49Installation - MechanicalControl DampersIf the damper actuators are not factory mounted install damper actuators and connecting linkag

CAH-SVX01B-EN 5TCC Indoor Roof Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . 37TCC Outdoor Roof Section Assembly (Typical) .

50 CAH-SVX01B-ENInstallation - MechanicalSide Load FiltersMost filters in custom units are installed in unitary sheet metal frames. If unit is provid

CAH-SVX01B-EN 51Installation - MechanicalBag or Cartridge Filters1. Disconnect power to the unit.2. Keeping the bag filters folded, slide each filter

52 CAH-SVX01B-ENInstallation - MechanicalOutdoor Unit Weather Hood(s)1. Per the unit drawing determine mounting location of the unit weather hoods.2.

CAH-SVX01B-EN 53Coil Piping and ConnectionsGeneral Coil Piping RecommendationsProper installation, piping, and trapping is necessary to ensure satisfa

54 CAH-SVX01B-ENCoil Piping and ConnectionsDrain Pan Trapping WARNINGNo Step Surface! Do not walk on the sheet metal drain pan. Walking on the drain

CAH-SVX01B-EN 55Coil Piping and ConnectionsFigure 50. Drain pan trapping for section under negative pressureFigure 51. Drain pan trapping for section

56 CAH-SVX01B-ENCoil Piping and ConnectionsSteam Coil PipingAir handlers fitted with steam coils have labeled holes for piping penetrations. Figure 5

CAH-SVX01B-EN 57Coil Piping and ConnectionsNOTICEBreaker Cracking Pressure!The 1/2-inch NPT, 15 degree swing check valve vacuum breaker is recommended

58 CAH-SVX01B-ENCoil Piping and ConnectionsNote: Trane steam coils require a minimum of 2 psi of pressure to ensure even heat distribution.2. Trap ea

CAH-SVX01B-EN 59Coil Piping and ConnectionsFigure 56. Typical piping for type W or WA 1-row water coilFigure 57. Typical piping for stacked water coil

6 CAH-SVX01B-ENCoil-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Motor-Related Checks . . .

60 CAH-SVX01B-ENCoil Piping and ConnectionsRefrigerant Coil PipingNote: Refer to “Important Environmental Concerns!” on page 2 for information on ha

CAH-SVX01B-EN 61Coil Piping and ConnectionsInsulation. The liquid line is generally warmer than the surrounding air, so it does not require insulation

62 CAH-SVX01B-ENCoil Piping and ConnectionsNOTICEValve Damage!Disassemble the thermal expansion valve before completing the brazing connections. If n

CAH-SVX01B-EN 63Coil Piping and ConnectionsExamples of Field-Installed Evaporator PipingSingle-Circuit Condensing Unit: Evaporator Coil with One Distr

64 CAH-SVX01B-ENCoil Piping and ConnectionsSingle-Circuit Condensing Unit: Evaporator Coil with Two DistributorsFigure 61. Single-circuit evaporator

CAH-SVX01B-EN 65Coil Piping and ConnectionsSingle-Circuit Condensing Unit: Evaporator Coil with Four DistributorsFigure 62. Single-circuit evaporator

66 CAH-SVX01B-ENCoil Piping and ConnectionsDual-Circuit Condensing Unit: Evaporator Coil with Two Distributors)Figure 63. Dual-circuit evaporator coi

CAH-SVX01B-EN 67Coil Piping and ConnectionsDual-Circuit Condensing Unit: Evaporator Coil with Four DistributorsFigure 64. Dual-circuit evaporator coil

68 CAH-SVX01B-ENCoil Piping and ConnectionsDual-Circuit Condensing Unit: Evaporator Coil with Eight DistributorsFigure 65. Dual-circuit evaporator co

CAH-SVX01B-EN 69Installation - Electrical WARNINGHazardous Voltage w/ Capacitors!Disconnect all electric power, including remote disconnects before s

CAH-SVX01B-EN 7Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

70 CAH-SVX01B-ENInstallation - ElectricalFigure 66. Typical high voltage wiring schematic

CAH-SVX01B-EN 71Installation - ElectricalNOTICEPenetration Leaks!Properly seal all penetrations in unit casing. Failure to seal penetrations from inne

72 CAH-SVX01B-ENInstallation - ElectricalQuick ConnectsThe actuators, factory-mounted or field-supplied, are separately wired and controlled by a dir

CAH-SVX01B-EN 73Controls InterfaceThe portable operator display is used for temporary connection to and operation of Tracer MP580/581 and AH540/541 co

74 CAH-SVX01B-ENControls InterfaceAdjusting Brightness and ContrastTo adjust the brightness and contrast of the operator display:1. On the home scree

CAH-SVX01B-EN 75Start-UpOnce the air handler has been assembled and installed, attention must be directed to individual components for proper operatio

76 CAH-SVX01B-ENStart-UpCoil-Related ChecksNOTICEProper Water Treatment!The use of untreated or improperly treated water in coils may result in scali

CAH-SVX01B-EN 77Start-UpUnit Operation WARNINGRotating Components!During installation, testing, servicing and troubleshooting of this product it may

78 CAH-SVX01B-ENStart-UpTension the Fan BeltNOTICEBelt Tension!Do not over-tension belts. Excessive belt tension will reduce fan and motor bearing li

CAH-SVX01B-EN 79Start-UpDetermine Fan SpeedFan speed can be determined using a strobe-type tachometer, or revolution counter.Check unit vibration if t

8 CAH-SVX01B-ENGeneral InformationUse this manual to install, startup, operate, and maintain the Custom Climate Changer™ air handler. Carefully revie

80 CAH-SVX01B-ENStart-UpFigure 75. Proper drive alignmentAlign Fan and Motor SheavesAlign the fan and motor sheaves using a straightedge. The straigh

CAH-SVX01B-EN 81Start-UpTraq™ Dampers Traq dampers are low-leak dampers that modulate and measure airflow. Each Traq damper section is supplied with a

82 CAH-SVX01B-ENStart-UpFan Inlet Airflow Measuring SystemWiringIn the absence of a factory-provided control system, consult the transmitter manufact

CAH-SVX01B-EN 83Start-UpTrane air handlers use a 0-20 inch range transmitter as standard. To sufficiently cover VAV turndown on the smallest fans with

84 CAH-SVX01B-ENExternal Insulating RequirementsNOTICEMicrobial Growth!Wet interior unit insulation can become an amplification site for microbial gr

CAH-SVX01B-EN 85Routine MaintenanceThe following checklist is provided as an abbreviated guide to periodic maintenance. Detailed procedural informatio

86 CAH-SVX01B-ENRoutine MaintenanceAir Filters WARNINGRotating Components!Disconnect all electric power, including remote disconnects before servici

CAH-SVX01B-EN 87Routine MaintenanceSide Load FiltersMost filters in custom units are installed in unitary sheet metal frames. If unit is provided with

88 CAH-SVX01B-ENRoutine MaintenanceTo clean drain pans:1. Disconnect all electrical power to the unit.2. Wearing the appropriate personal protective

CAH-SVX01B-EN 89Routine MaintenanceFan Bearing LubricationNOTICEBearing Failure!Do not mix greases with different bases within the bearing. Mixing gre

CAH-SVX01B-EN 9General InformationFactory-Mounted ControlsTrane air handlers are available with a wide selection of factory-mounted controls, includin

90 CAH-SVX01B-ENRoutine MaintenanceMotor Bearing Lubrication WARNINGHazardous Voltage!Disconnect all electric power, including remote disconnects be

CAH-SVX01B-EN 91Routine MaintenanceCoils WARNINGHazardous Chemicals!Coil cleaning agents can be either acidic or highly alkaline. Handle chemical car

92 CAH-SVX01B-ENRoutine MaintenanceCleanable Cooling CoilsCleanable cooling coils have removable headers for cleaning:1. Remove the headers.2. Use a

CAH-SVX01B-EN 93Routine MaintenanceCoil WinterizationNOTICECoil Freeze-up!Properly drain and vent coils when not in use. Trane recommends glycol prote

94 CAH-SVX01B-ENRoutine MaintenanceProviding a moisture purge cycle 15 to 30 minutes after shutdown disperses the cold, humid air inside the air-hand

CAH-SVX01B-EN 95Routine Maintenance WARNINGHazardous Chemicals!Coil cleaning agents can be either acidic or highly alkaline. Handle chemical carefull

96 CAH-SVX01B-ENRoutine MaintenanceControlsOn units that have been selected with the external communications port, both the operator display and Rove

CAH-SVX01B-EN 97Routine MaintenanceReplacing the Bulbs WARNINGHazardous Vapors!If large numbers of UV bulbs are broken, an appropriate respirator sho

98 CAH-SVX01B-ENTroubleshootingThis section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact your local Trane

CAH-SVX01B-EN 99TroubleshootingShort belt lifeWorn sheaves Replace sheaves.Misaligned belt Realign drive with MVP sheave set at mean pitch diameter.