Trane Custom Climate Changer Air Handlers manual

Installation Oper ation Maint enance Cust om Climat e Chang er™ Air Handlers July 2005 CAH-S VX0 1A -EN P art No . X396407 450 1 0[...]

© 2005 American S tandard All rights reserved CAH-SVX0 1A-EN NO TICE: W arnings and Cautions appear at appropri a te sectio ns throughout this manu a l. Read these carefully .  W ARNING ...indicat es a potentially hazar dous situation whic h, if not avoided, could result in death or ser io us injury .  CA UTION ...indicat es a potentially ha[...]

CAH-SVX0 1A-EN 3 Intr oduction Use this ma nual to install, start up, operate, and maintain the Custom Climate Changer™ air handler . Carefully review the pr ocedures discussed in this ma nual to minimi ze installation an d startup dif fi culties. Unit Descr iption Custom Climate Changer™ air handler s are designed for a varie ty of controlled-[...]

4 CAH-SVX0 1A-EN Cont ents Intr oduction ............... ................ .......................................... 3 Unit Description .............. ................ ............. ................ ................ ....... 3 Protecting the Environment ......... ............. ................ ................ .......... 3 Cont ents ............ ...[...]

CAH-SVX0 1A-EN 5 Gener al Inf or mation Oper ating En vironment When considering the placement of the Custom Climate Changer air handler , it is impor tant to consider the operating environment. The acceptable ambient temperature range for unit opera tion is -40ºF to 1 40ºF (-40ºC to 60ºC). For heating applications, a special motor may be requi[...]

General Inf or mation 6 CAH-SVX0 1A-EN Ultr aviolet (UV) Ger micidal Ir radiation Lights (optional) The United States Environmental Protection Agency (EP A) believes that molds and bacteria inside buildings have the p otential to cause health problems in sensitive individuals (1) . If specified, T rane provides ultraviolet lights (UV -C) as a facto[...]

CAH-SVX0 1A-EN 7 Pr e-Installation Requir ements Receiving Chec klist Based on customer requirements, Custom Climat e Changer ai r handlers can ship as complete u nits or as individual sections to be field assembled. Upon receipt of th e unit(s) and prior to unloading, remo ve any shippin g material and inspect the unit for damage and verify that t[...]

Pr e-Installation Requirements 8 CAH-SVX0 1A-EN General St orage The unit controll er and all other electrical/electronic components should be stored i n conditions o f -20ºF to 120 ° F and 5 to 95 percent relative humidity , non-condensing. Electrical components are not moisture-tolerant. F actory protective coverings should be remo ved prior to[...]

Pr e-Installation Requirements CAH-SVX0 1A-EN 9 Figure 1. Cross section of typical curb installa tion on new construction Roof Curb Installation It is recommend ed that the curb be installed dire ctly on the support members and fa stened to the suppor ts using tac k welds or other equivalent method s. Properly supported dec king should be installed[...]

10 CAH-SVX0 1A-EN Installation Lif ting and Rigging  WA R N I N G Lif ting and Rigging! Do not lif t, r ig, or ceiling-susp end fr om the to p of the unit. Li ft fro m lif ting lugs only , located at the bott om of the unit. Us e all lifting lugs pr ovided. Do not use cables (c hains or slings) except as shown. Eac h of the cables (chains or sli[...]

Installation CAH-SVX0 1A-EN 11 • P ersonnel should be positioned overh ead and on the ground to guide the crane or helicopter operator in position ing the sections. • The air handler is n ot designed to be lif ted, rigged or ceiling suspended from the t op of the unit. • Never stac k the pipe cabinet and inlet hoods on the unit as the unit is[...]

Installation 12 CAH-SVX0 1A-EN TCP Model Assembly Instr uctions If your nameplat e model number begins with TCP , use the assembly instructions be low. Joining Sections Edg e-to- Edge Units must be installed le vel for proper drainag e of condensate from the drain pan. In ad dition, eac h section in a multi-section unit must be properly supported. [...]

Installation CAH-SVX0 1A-EN 13 TCP Base Section Assembly (T ypical) Note: Failure to completely compress the gasketing may result in air leakage. 1 Join the tw o units and secure with field provided 5/8-inc h flat wash er s and 5/8-inc h X 2-1/2-inc h grade 9 bol ts though each of the six holes. 2 Caulk the overlapp ing flange along the length of e[...]

Installation 14 CAH-SVX0 1A-EN TCP W all Section Assembly (T ypical) 1 Apply the walls and join at the inside angles with numbe r 1 4 sheet-metal screws on 12-inc h centers along the length of the angles. 2 Apply the 1/8-inc h gasket evenly to the exterior of the walls across the two joined edg es of the splits. 3 Before installing the pre-cut join[...]

Installation CAH-SVX0 1A-EN 15 TCP Indoor Roof Section Assembly (T ypical) 1 Align the w alls and join the inside angles with numbe r 1 4 sheet metal screws on 12-inc h centers along the length of the angles. 2 Apply a bead of caulk along the length of the roof seam jo int. 3 Apply the 1/8-inc h gasket on the exterior of the ro of evenly across the[...]

Installation 16 CAH-SVX0 1A-EN TCP Base to Int er ior W all Section Assembly (T ypical) Note: Failure to completely compress the gasketing may result in air leakage. 1 Join the tw o units and secure with field provided 5/8-inc h flat wash er s and 5/8-inc h X 2-1/2-inc h grade 9 bol ts though each of the six holes. Figure 8. TCP base to interior wa[...]

Installation CAH-SVX0 1A-EN 17 TCC Model Assembly Instr uctions If your nameplat e model number begins with TCC, use the assembly instructions be low. Joining sections - Edg e to Edge Units must be installed le vel for proper drainag e of condensate from the drain pan and for squa reness of the sections duri ng installation. In addition, eac h sect[...]

Installation 18 CAH-SVX0 1A-EN • Apply 1 .25-inch x 0.33-inc h ribbed butyl tape to the shipping split c hannel and shipping split plates (see Figure 1 1). • V erify the section is level prior to proceeding wi th the next section of the unit. Figure 11. Apply butyl tape to shipping splits • Move the next unit section as close as possible from[...]

Installation CAH-SVX0 1A-EN 19 • Insert field provided threaded rods through the bottom lifting lug and shipping split plates on eac h sides of the unit. Draw both sides of the section together equally to prevent dam age and distortion of the sections as they joined. Do not try to join sections by tightening only one side of the rods (see Figure [...]

Installation 20 CAH-SVX0 1A-EN TCC inter nal shipping split frame assembly (typical) • Join the two sect ions and secure with field provided ½-13x8.5 inc h threaded rods, ½-inc h flat washers and ½-inc h loc k washers through eac h of the holes provid ed in the internal shi pping split frame (see Figure 15) This frame runs around the entire pe[...]

Installation CAH-SVX0 1A-EN 21 TCC wall sections assembly (typical) • V erify external unit squareness. • Apply the 1 .25-inch x 0.33-inc h ribbed butyl tape to the exter ior of the walls co vering the seam of the two adjoining sections (see method sheet). • Install seam cap o ver the butyl, uniformly straddl ing the splits. Secure w ith the [...]

Installation 22 CAH-SVX0 1A-EN TCC outdoor r oof sections assembly (typical) • Joi n two outdoor roof panels together at the seams at the direction of airflow and secure them in place with 5/16-inc h x 3/4-inc h bolts and 5/16 loc k nuts. Cut the proper length of roof joint strip to cover the seam between two outdoor roof panels at the direction [...]

Installation CAH-SVX0 1A-EN 23 • Join outdoor roof panels together at the seams in the direction per pendicular to airflow and secure them in place with 5/16-inc h x 3/4-inc h bolts and 5/16 lo c k nuts. Install the roo f joint strip to cover the seam between two outdoor roof panels in the perpendicu lar to airflow direction of . Use 3/8-inc h bu[...]

Installation 24 CAH-SVX0 1A-EN Duct Connections All duct connections to the un its should be inst alled in accordanc e with the standards of the National Fire Protection As sociation (NFP A) for selecting and installing of ai r conditionin g and ventilating systems other than residence type (NFP A 90A), and residence type warm air heating and air c[...]

Installation CAH-SVX0 1A-EN 25 3 Chec k that the bushing on the isolator stud is centered in the isolator . Adjust to center by movi ng the stud in the fan base hole. 4 This procedure will raise the equipment l oad until the isolators are all off the shims (shipping tie-down bl oc ks) approximately 1/32-inc h (the thic kness of a credit card), and [...]

Installation 26 CAH-SVX0 1A-EN Air Filters Fr ont Load Filters Most filters in custom units are installed in unitar y sheet metal frames. Filters are secured with a metal clip. There are several different styles. T o install filters: 1 Disconnect power to the unit. 2 Open or remove the filter clip. 3 Remo ve the filter from the rac k. 4 Install new[...]

Installation CAH-SVX0 1A-EN 27 Bag or Cartr idg e Filt ers. 1 Disconnect power to the unit. 2 Keeping the bag filters folded, slide eac h filter into the filter rac k, pushi ng them tightly against the unit. Pleats should be in the vertical position. 3 If using opti onal pre-filters, slide them into the appropriate filter rac k. 4 If bloc k-offs ar[...]

Installation 28 CAH-SVX0 1A-EN Coil Piping and Connections Gener al Recommendations Proper installation, pipi ng, and trapping is necessary to ensure satisfactory coil operatio n and to prevent operational damage: • Support all piping indep endently of the coils. • P rovide swing jo ints or flexible fittings on all connections that are adjacent[...]

Installation CAH-SVX0 1A-EN 29 Drain P an T rapping Threaded condensate drain connections are pro vided on only one side of the coil mo dule. Pitc h the connection lin es horiz ontal or downw ard toward an open drain. T ra ne recommends in stalling a plug to facilitate clea ning of the trap. Figure 26 illustrates the proper trapping, pipi ng, and o[...]

Installation 30 CAH-SVX0 1A-EN Steam Coil Piping M-Series air handle rs fitted with steam coils have labeled holes for piping penetr ations. Figure 28 and Figure 29 illustrate typical steam coil piping config urations. See T able 2 for the codes of system components in these figures. The coil condensate return l ine must be piped full siz e of the [...]

Installation CAH-SVX0 1A-EN 31 Figure 28. Typical piping for Ty pe N stea m coils and horizontal tubes for horizontal airflow Figure 29. Typical piping for Type NS steam coils and horizontal tubes for horizontal airflow Proper steam trap installation is necessary for satisfactory coil performance and service life. F or steam trap installation: 1 In[...]

Installation 32 CAH-SVX0 1A-EN unless the condensate is d rained by gravity into a recei ver , vented to atmosphere, and re turned to the condensate pump. 6 Pitc h all supply and return steam piping down 1 inch for every 1 0 feet in the dire ction of the steam or condensate flow. Note: Do not drain the steam mains or tak e-offs through the coils. D[...]

Installation CAH-SVX0 1A-EN 33 Refr iger ant Coil Piping Note: Ref er to the “Protecting the Environmen t” section on page 3 for information o n handling refrigerants. Use Figu re 33 to d etermine the proper , r elativ e sequence of the components in the refrigerant lines that connect the co ndensing un it to an evaporator coil. Refer to the ?[...]

Installation 34 CAH-SVX0 1A-EN • Thermal expansion valve. The expansion valve is the throttling device that meter s the refrigerant into the evaporator coil. Metering too muc h refrigerant floods the compressor; meteri ng too l ittle elevates the compressor temperature. Choosing the correct siz e and type of expansion valve is critical to assure [...]

Installation CAH-SVX0 1A-EN 35 • Frostat™ coil fr ost protection. The Frostat contro l is the preferred method for protecting evaporator coils from freezing when the refrigerant coil is used with T rane condensing units. It senses the suction-line temperatu re and tempor arily disables mec h anical cooling if it detects frost conditio ns. The c[...]

Installation 36 CAH-SVX0 1A-EN Single-Cir cuit Condensing Units: Ev apo rat or Coil with T wo Distr i butors (see Figur e 36) 1 Pitc h the liquid line sl ightly— 1 inc h/10 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator . 2 Pro vide one expansion valve per distributor . 3 Slightly pitc h the outlet line from the suction header [...]

Installation CAH-SVX0 1A-EN 37 Single-Cir cuit Condensing Units: Ev apo rat or Coil with Four Distr i butors (see Figur e 37) 1 Pitc h the liquid line sl ightly— 1 inc h/1 0 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator . 2 Pro vide one expansion valve per distributor . 3 Slightly pitc h the outlet line from the suction header[...]

Installation 38 CAH-SVX0 1A-EN Dual-Cir cuit Cond ensing Units: Ev apo rat or Coil with T wo Distr i butors (see Figur e 38) 1 Pitc h the liquid lines s lightly—1 inc h/1 0 feet [1 cm/3 m ]—so the refrigerant drains toward the evaporator . 2 Pro vide one expansion valve per distributor . 3 Slightly pitc h the outlet line from the suction header[...]

Installation CAH-SVX0 1A-EN 39 Dual-Cir cuit Cond ensing Units: Ev apo rat or Coil with Four Distr i butors (see Figur e 39) 1 Pitc h the liquid line sl ightly— 1 inc h/10 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator . 2 Pro vide one expansion valve per distributor . 3 Slightly pitc h the outlet line from the suction header t[...]

Installation 40 CAH-SVX0 1A-EN Dual-Cir cuit Cond ensing Units: Ev apo rat or Coil with Eig ht Distr i butors (see Figur e 40) 1 Pitc h the liquid line sl ightly— 1 inc h/10 feet [1 cm/3 m]—so the refrigerant drains toward the evaporator . 2 Pro vide one expansion valve per distributor . 3 Slightly pitc h the outlet line from the suction header[...]

Installation CAH-SVX0 1A-EN 41 Wir i ng Wiring to the unit fan motor must be provid ed by the installer and must comply with all national and loc al electrical codes. The installer must also furnish a fused dis connect switc h in compliance with natio nal and local el ectrical codes. Fan m otors also require motor over load prote ctive devices that[...]

Installation 42 CAH-SVX0 1A-EN Figure 44. Junction box mounting and wiring details Figure 45. Typical quick connects with wiring identification V alve jack wiring: .Blac k connector is for 24 V ac power supply (blac k wire for GND and red wire for 24 V ac) .White connector is for 0 to 1 0 V ac an alog signal (blac k wire for GND and red wire for 0 [...]

CAH-SVX0 1A-EN 43 Star tup Once the Custom Climate Changer air handler has be en assemble d and installed, a ttention must be directed to individual comp onents for proper operation. Befo re operating th e unit, complete the pre- star tup chec klist.  WA R N I N G Hazardous V oltage with Capacitors! Disconnect all electr ic pow er , including r [...]

Start up 44 CAH-SVX0 1A-EN Gener al 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. • V erify damper operation and linkage alignmen t. • Chec k that air filters are in place and positioned pro perly[...]

Start up CAH-SVX0 1A-EN 45 T ension the F an Belt Chec k the fan belt tension at least three times du ring the first days of operation because there i s a rapid decrease in tension u ntil the belt sett les in (see Figure 46 and Figure 47).  WA R N I N G Hazardous V oltage with Capacitors! Disconnect all electr ic pow er , including r emote di sc[...]

Start up 46 CAH-SVX0 1A-EN Table 3. Typical sheave diamete r and deflection force1 Cross Section Smallest Sheave Diameter Range (in.) Speed (rpm) Range Belt Deflection Force (lbs) Super Gr ipbelts 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?[...]

Start up CAH-SVX0 1A-EN 47 Det er m ine F an Speed  WA R N I N G Rotating Components! Dur ing installation, t esting, servicing and tr oubleshooting of this product it may be necessary t o measure the speed of r otat ing components. Ha ve a qualifie d or licensed service in dividual who has been proper ly trained in handling exposed r otating co[...]

48 CAH-SVX0 1A-EN Routine Maint enance The following c hec klist is pro vided as an abbreviated guide to period ic maintenance. Detail ed procedural information is given after this c hec klist. Table 5. Routine maintenance checklist Frequency Maintenance After 48 hours of operation Belts have acqu ired their permanent set. R eadjust but do not over[...]

Routine Maintenance CAH-SVX0 1A-EN 49 Air Filt ers Refer to pro duc t catalog CLCH-PRC0 03-EN for filter sizes, types, and quantities.  WA R N I N G Hazardous V oltage with Capacitors! Disconnect all electr ic pow er , including r emote di sconnects and dischar ge all motor star t/ r un capacito rs befor e servicing. F ollow proper lock out/tago[...]

Routine Maintenance 50 CAH-SVX0 1A-EN See “  WARNING Hazardou s V oltage with Capacitor s!” on page 49 regarding disconnection of po wer . Dr ain P ans The condensate drai n pan and drain line must be c hec ked to assure th e condensate drains as de signed. This inspection shou ld occur a minimum of every six months or more often as dictated[...]

Routine Maintenance CAH-SVX0 1A-EN 51 See “  WARNING Hazardou s V oltage with Capacitor s!” on page 49 regarding disconnection of po wer . F an Bear ing Lubr ication CA U T IO N Bearing Failure! Do not mix gr e ases with diff erent bases within the beari ng. Mixing grease within the bearing m ay r esult in premat ure bear ing failur e. The g[...]

Routine Maintenance 52 CAH-SVX0 1A-EN See “  WARNING Hazardou s V oltage with Capacitor s!” on page 49 regarding disconnection of po wer . Coils All coils should be kept clean to maintain maximum performance. Steam and W ater Coils T o clean steam and water coils: 1 Disconnect all electrical power to the unit. 2 W earing the appropriate pers[...]

Routine Maintenance CAH-SVX0 1A-EN 53 11 Allow the unit to dry th oroughly before putting it bac k into service. 12 Repl ace all panels and parts and restore electrical power to the unit. 13 Be careful any contaminated material does not co ntact other areas of the unit or bui lding. Properly dispose of all contaminated materials and cleaning soluti[...]

Routine Maintenance 54 CAH-SVX0 1A-EN See “  WARNING Hazardou s V oltage with Capacitor s!” on page 49 regarding disconnection of po wer .  WA R N I N G Hazardous Chemicals! Coil cleaning agents can be either acidic or highly alk aline. Handle ch emical car efully . Proper h andling should include goggles or f ace shield, c hemical resi s[...]

Routine Maintenance CAH-SVX0 1A-EN 55 Ultr aviolet (UV) Ger micidal Ir radiation Lights The intensity of the ultraviolet energy emit ted fr om the ultraviolet bulbs provided in this unit is dependent on the cleanl iness and age of the bulb. Th e surface of the bulb should be k ept as clean as possible for opti mum intensity . Depending on the filtr[...]

56 CAH-SVX0 1A-EN T r oubleshooting This section is intended to be used as a diagnostic ai d only . For detailed repair procedures, cont act your local T ra ne service representati ve. Table 8. Air handler troubleshooting recommendations Sympto m Probab le Cause Recomme nded Act ion Bearing is excessively h ot First start after relubrication (greas[...]

T r oubleshooting CAH-SVX0 1A-EN 57 Table 5. Air handler troubleshooting recommendations Sympto m Probab le Cause Recomme nded Act ion Short belt life Worn she aves R eplace sheaves. Misaligned belt Realign drive with MVP sheave set at mean pitch d iameter . Grease or oil on belts Check for le aky bearings. Clean belts and sheaves. Belt slipping Im[...]

58 CAH-SVX0 1A-EN Not es[...]

Notes CAH-SVX0 1A-EN 59[...]

Tr a n e A business of Amer ican Standard Companies www .trane.com For more information, contact your local T r ane office or e-mail us at comfort@trane.com Literature Orde r Number CAH-SVX0 1A-EN Date July 2005 Super sed es New Stoc king Location Inland T rane has a policy of continuous product and prod uct data improvement and reserves the right [...]