Trane Climate Changer TCFS, Nstallation, Operation, And Maintenance

Page 1: ...raining Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and...

Page 2: ...three types of advisories are defined as follows WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTIONs Indicates a potentially haza...

Page 3: ...ferenced in this document are the trademarks of their respective owners Revision History Added information for model TCFS and TCPA and additional custom features including K factors for direct drive p...

Page 4: ...e 16 Flat Concrete Pad 17 Roof Curb for Large Unit with Shipping Splits 17 Joining Sections Edge to Edge 17 Base with Flat Floor 19 Base with Turned Up Floor 20 Walls 21 Outdoor Roof Single Span 22 Ou...

Page 5: ...Maintenance Checklist 63 Air to Air Plate Heat Exchangers 64 Coils 64 Steam and Water Coils 64 Refrigerant Coils 65 Coil Winterization 66 Moisture Purge Cycle 66 Cleaning Non Porous Surfaces 66 Cleani...

Page 6: ...late Each Performance air handler includes a nameplate see Figure 1 which identifies the type of section and functional components customer tagging information the unit serial number the unit sales or...

Page 7: ...nd energy recovery compliance Factory Mounted Controls Trane air handlers are available with a wide selection of factory mounted controls including controllers motor starters and variable frequency dr...

Page 8: ...ng penetrations or mounting any components to the cabinet Wiring to the air handler must be provided by the installer and must comply with all national and local codes The fan motor nameplate includes...

Page 9: ...receiving shipment to detect possible shipping damage Jobsite Storage Air handlers and field installed accessories must be protected from the elements A controlled indoor environment is recommended fo...

Page 10: ...height for condensate drain requirements See Drain Pan Trapping p 37 Note If unit is installed in a mechanical room on a pad inadequate height may necessitate core drilling the floor to attain proper...

Page 11: ...perimeter and to the supply and return air duct opening panel flanges 10 Use a lubricant on top of the roof curb is recommended to ease friction from lateral movements when securing sections Suggeste...

Page 12: ...ule subassemblies dropping and crushing technicians which could result in death serious injury or equipment damage WARNING Improper Unit Lift Failure to properly lift unit could result in unit droppin...

Page 13: ...et and exhaust hoods into position use the proper rigging method such as straps slings or spreader bars for protection and safety Inlet and exhaust hoods will either ship inside the unit if space perm...

Page 14: ...be installed level zero tolerance in both horizontal axes For vertical discharge units allow space under the unit for supply air ductwork connections WARNING Risk of Roof Collapsing Failure to ensure...

Page 15: ...istribution of the individual sections and install the channels so that both ends of every section are supported see Figure 9 WARNING Risk of Unit Dropping Do not use mounting legs for ceiling suspens...

Page 16: ...gure 11 and I beam dunnage Figure 12 are designed to sit directly onto unit support with no overhang The structure should be designed to properly support unit weight without bow and sized to the unit...

Page 17: ...e to Edge Units must be installed level for proper drainage of condensate from the drain pan In addition each section in a multi section unit must be properly supported Note Leveling each section begi...

Page 18: ...t evenly on both sides will ensure connecting plates will line up Sections should be pulled together until mating gaskets make contact and factory supplied bolts can be installed in connecting plate 1...

Page 19: ...rill holes in the floor using the 4 inch strip as a guide with a 7 32 inch drill bit at 12 inch centers 4 After holes are pre drilled apply an ample bead of caulk to the joint then install 4 inch stri...

Page 20: ...d secure with field provided 5 8 inch flat washers and 5 8 inch x 2 inch grade 9 bolts through each of the six holes 3 Apply a heavy bead of caulk to the inside of the U channel 4 Press U channel down...

Page 21: ...f Joint Note Corner gussets are to ensure unit squareness during shipping lifting and assembly Please remove when unit is set in place 1 Ensure shipping split sections are aligned and pulled together...

Page 22: ...d of J cap to seal thoroughly Figure 20 Section split indoor Figure 21 Section split outdoor Edge view Section trim cap Wall Trim Hubcap Roof Ends of hubcaps fit unter lip on trim Hubcap Section split...

Page 23: ...a bead of caulk to the seam the full length that roof cap will cover 7 Apply 3 inch x 1 8 inch adhesive backed neoprene gasket to underside of roof cap 8 Install roof cap using 10 sheet metal screws...

Page 24: ...ed TEK screws 5 Fit the pre cut hub cap over the joining strip the vertical height of the wall flush with the roof and secure it to the wall with 8 sheet metal screws 6 Fill the top and bottom opening...

Page 25: ...r the joining strip the vertical height of the wall flush with the roof and secure it to the wall with 8 sheet metal screws 6 Fill the top and bottom openings with caulk as a moisture seal Screw holes...

Page 26: ...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 Note Note Use a polyurethane or equivalent caulk 3 S...

Page 27: ...next upper piece into place and secure shipping split with appropriate hardware then anchor to lower section as described above 5 Continue until all sections are installed and anchored properly 6 Inst...

Page 28: ...all and remove paper backing from tape 5 Lift cabinet into place aligning base tab with lifting lug brackets on air handler base 6 Slide pipe cabinet tight up against mounting channels on side wall of...

Page 29: ...lf driller Pipe cabinet outer roof Slots provided to allow final adjustment of outer roof AHU outdoor roof Picture frame mounting chanels factory assembled to unit Inside corner cap Ribbed Butyl tape...

Page 30: ...isolator Adjust to center by moving the stud in the fan base hole 5 This procedure will raise the equipment load until the isolators are all off the shims shipping tie down blocks approximately 1 32...

Page 31: ...min concrete slab thickness b On steel dunnage steel curb 3 4 in dia ASTM A325 or SAE grade 5 bolts at 24 in o c or 1 in long 3 16 in welds at 24 in o c 4 Stacked double wide 164 in 328 in grade to r...

Page 32: ...ters are often installed in a pre post filter configuration Be sure to note the order of installation Note Filters must have an airtight seal to prevent air bypass WARNING Hazardous Voltage w Capacito...

Page 33: ...intended to make a seal when the access door is closed It may require a few adjustments to ensure a proper seal Magnahelic Air Filter Gage Check zero adjustment of the gage Turn both vent valves to th...

Page 34: ...tion on roof curb either raise field provided duct per Option A see Figure 39 or add additional gasket material to compensate for the offset per Option B see Figure 40 Note Bottom of unit base elevati...

Page 35: ...ly affect fan performance and acoustics Damper Connections Standard damper sections include mixing sections filter mixing sections face dampers sections internal face and bypass sections and economize...

Page 36: ...ing to be insulated by the installing contractor up to the bell mouth radius to prevent condensation see Figure 45 The bell mouth fitting extends through the casing by one inch Traq Damper Connections...

Page 37: ...ward an open drain Trane recommends installing a plug to facilitate cleaning of the trap Figure 47 illustrates the proper trapping piping and operation of the trap Use the formula under the figure to...

Page 38: ...ure L H J pipe diameter where H 1 inch for each inch of negative pressure plus 1 inch with loaded filters J 1 2 H Section under positive pressure L H J pipe diameter where H 1 2 inch minimum J 1 2 inc...

Page 39: ...of the trap 4 If installing coils in series airflow control each coil bank independently with an automatic steam control valve Size the traps for each coil using the capacity of the first coil in dire...

Page 40: ...is below these minimums vent the coil by one of the following methods 1 Install an air vent in the top pipe plug tapping of the return header 2 When the return line rises above the top of the coil ve...

Page 41: ...led schematics of evaporator piping Figure 51 Example of placement for split system components Discharge line Manual ball valve Access port Filter Access port Access port Filter drier with access port...

Page 42: ...constant volume applications when dehumidification is a concern In split systems with mircochannel heat exchanger condensers MCHE solenoid valves isolate the refrigerant from the evaporator during th...

Page 43: ...ressor For this reason the suction filter should be the replaceable core type and a clean core should be installed after the system is cleaned up Access port The access port is used to determine sucti...

Page 44: ...and smaller of type L copper are suitable for use with R 410A These same lines sized at 1 5 8 OD or 2 1 8 OD must use type K or thicker wall Expansion valves need to be reselected Expansion valves ar...

Page 45: ...r connection 4 Use the tube diameter recommended in the condensing unit application manual for a vertical rise Ensure that the top of the riser is higher than the evaporator coil 5 Pitch the suction l...

Page 46: ...e the tube diameter recommended for a vertical rise as specified in the condensing unit application manual Assure the top of the riser is higher than the evaporator coil 7 Pitch the suction line sligh...

Page 47: ...ter recommended for a vertical rise as specified in the condensing unit application manual Ensure that the top of the riser is higher than the evaporator coil 7 Pitch the suction line slightly 1 inch...

Page 48: ...a vertical rise as specified in the condensing unit application manual 5 The top of the Circuit 2 suction riser must be higher than the top evaporator coil Use the tube diameter recommended for a ver...

Page 49: ...specified in the condensing unit application manual Ensure that the top of the riser is higher than the evaporator coil 7 Pitch the suction line slightly 1 inch 10 feet so that the refrigerant drains...

Page 50: ...tor 8 Insulate the suction line 9 The top of the Circuit 1 suction riser must be higher than the bottom evaporator coil Use the tube diameter recommended for a vertical rise as specified in the conden...

Page 51: ...on the packing list All piping accessories should be installed in accordance with all applicable building plumbing and electrical codes Condensate discharged from the humidifier separator header is es...

Page 52: ...s are provided with line voltage to 120 Vac power transformers with power 120 Vac to 24 Vac control transformers Figure 60 shows a typical VFD power box A motor driven by a VFD may operate over 60HZ P...

Page 53: ...ttings see Table 3 on page 57 Fan sheaves should be tight and aligned Check fan drive belt tension See Tension the Fan Belt section on page 55 Inspect fan motor and bearings for proper lubrication if...

Page 54: ...cally check the fan belt tension Calculate Motor Voltage Imbalance After startup measure the motor voltage and amperage on all phases to ensure proper operation The readings should fall within the ran...

Page 55: ...igure 62 Determine actual deflection by depressing one belt with the belt tensiometer and measuring the deflection relative to the other belts or to belt line see Figure 63 Adjust the belt tension to...

Page 56: ...00 6 00 8 90 7 30 10 90 C CX 7 0 9 0 500 1 740 11 50 17 00 14 70 21 80 1 741 3 000 9 40 13 80 11 90 17 50 9 5 16 0 500 1 740 14 10 21 00 15 90 23 50 1 741 3 000 12 50 18 50 14 60 21 60 D 12 0 16 0 200...

Page 57: ...ifications If the force is still not the same for all belts the belts or sheaves are worn and must be replaced Airflow Measuring Systems Traq Dampers Traq dampers are low leak dampers that modulate an...

Page 58: ...multiplying the remaining area of dampers by peak velocity Calculations are based on VCM voltage versus airflow at sea level Figure 66 Traq damper terminal connections Airflow k cfm 10V or Airflow k...

Page 59: ...ansmitter with a lower accuracy is selected the range should be chosen closer to the actual maximum pressure differential expected for the application The transmitter outputs a signal that represents...

Page 60: ...e summed to get the total Table 6 Constant K Factor for Twin City Fans Size Model EPF EPQ Arrangement 1 Model EPFN EPQN Arrangement 4 Model BAE DWDI Model MPQN 122 911 46 944 92 793 96 150 1163 68 120...

Page 61: ...objects away from moving parts activate the wheel and confirm the wheel rotation The correct rotation direction is clockwise as viewed from the pulley side 5 Start and stop the wheel several times to...

Page 62: ...rim 6 If the wheel has difficulty starting turn off the power and inspect for excessive interference between the wheel surface and the four diameter seals To correct loosen the diameter seal adjustin...

Page 63: ...or replace air filters if clogged or dirty coat permanent filters with oil after cleaning change bag filters when pressure drop is 1 in w g See the Filters section on page 78 for more information Bel...

Page 64: ...appropriate personal protective equipment use a soft brush to remove loose debris from both sides of the coil 3 Install a block off to prevent spray from going through the coil and into a dry section...

Page 65: ...ructions regarding the use of the product 5 Place the mixed solution in a garden pump up sprayer or high pressure sprayer If a high pressure sprayer is to be used Maintain minimum nozzle spray angle o...

Page 66: ...en the fan stops water vapor condenses on the cold metal surfaces inside the air handler and remains there until the air warms sufficiently to re evaporate it This damp dark environment though tempora...

Page 67: ...s 1 Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective equipment remove any standing water 3 Scrape solid matter off of the drain pan 4 Vacuum the drain pan with...

Page 68: ...ate drainage system exists to collect runoff water from the bottom of the unit 4 Using standard pressure water do not use a high pressure washer and working from the lower half of the wheel wash the w...

Page 69: ...el withwoodenblocks onbothsidesofthe wheel 3 Make sure the wheel is secure The short posts are removed first 4 To prevent wheel from flipping out cut two 1 inch x 4 inch boards for placement across th...

Page 70: ...using a rod or punch passed through the other bearing It is best to use brass or other soft metal but if bearing is being replaced it is okay to use a steel rod Gently work around the race with a ser...

Page 71: ...bearings It may be necessary to tap it gently with a hammer 15 After the shaft is through the bearings and snap ring is against the inner race install the other snap ring 16 Install the long post on...

Page 72: ...bearing 1 Remove belt from motor and wheel 2 Support wheel withwoodenblocks onbothsidesofthe wheel 3 Remove cover plate from bearing housing if present 4 Remove the bolt and washer from the end of the...

Page 73: ...equidistant from each post If not loosen the bearing mounting bolts and adjust as necessary Flange bearing units have jack bolts See Figure 86 13 Pillow block bearing units require shims to adjust the...

Page 74: ...ond tab through CDQ Seal Adjustment Neoprene brush seals are located on both sides of the cassette around the wheel perimeter and the center diameter posts The seals are designed to come in contact wi...

Page 75: ...build up on the wheel If more aggressive cleaning is needed consult manufacturer s instructions Cleaning Frequency In reasonably clean office or school buildings cleaning with a solution may not be re...

Page 76: ...osition it around the wheel rim 3 Measure and record the distance from the inner edge of the pulley to the mounting wall 4 Loosen the set screw in the wheel drive pulley using an Allen wrench and remo...

Page 77: ...Refer to Table 8 for minimum torque of motor mounting and bearings bolts Refer to Table 2 p 56 for minimum setscrew torque Fan Bearing Lubrication For belt drive fans the grease used in electric motor...

Page 78: ...t operation of p trap drain lines Throwaway Filters To replace throwaway filters install new filters with the directional arrows pointing in the direction of airflow Bag and cartridge filters must hav...

Page 79: ...and block offs from their installed position 3 Slide the filter into the rack 4 Some side load racks will be provided with block off plates Install them into the rack last before closing the door 5 C...

Page 80: ...h Note Note If Teflon coated EncapsuLamp is used it is not necessary to clean the surface 3 Wearing soft cloth gloves and safety glasses install lamp by grasping each non glass end with the thumb and...

Page 81: ...d on unit Improper current supply Compare actual supply power with motor nameplate recommendations Contact power company for adjustments Mechanical failure Check that motor and drive rotate freely Che...

Page 82: ...Clogged refrigerant line filter Change filter core Failure of suction liquid line components Verify component operation Dirty fin surface Clean the fin surface see Coils p 64 Do not use steam to clea...

Page 83: ...spect visually Replace the drive belt Wheel main shaft bearing is seized Replace the seized bearing Loss of energy wheel capacity Wheel is not rotating See above Wheel is rotating too slowly Belt is s...

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