Trane Climate Changer M Series, Installation Operation & Maintenance

Page 1: ...December 2008 CLCH SVX03C EN Installation Operation Maintenance M Series Climate Changer Air Handlers Unit sizes 3 to 120...

Page 2: ...sponsible refrigerant practices are important to the environment our customers and the air conditioning industry All technicians who handle refrigerants must be certified The Federal Clean Air Act Sec...

Page 3: ...rials that are susceptible to deterioration by the UV C light will be substituted or shielded from direct exposure to the light In addition UV C radiation can damage human tissue namely eyes and skin...

Page 4: ...ensions and Weights 13 Service Clearances 13 Single Wall Construction Weights 14 Double Wall Construction Weights 16 Single Piece Shipment Limitations 18 Base Rail Weight Calculations 18 Motor Weights...

Page 5: ...54 Refrigerant Coil Piping 56 Liquid Lines 57 Suction Lines 59 Examples of Field Installed Evaporator Piping 60 Single Circuit Condensing Unit Evaporator Coil with One Distributor 60 Single Circuit Co...

Page 6: ...ne Maintenance 82 Air Filters 83 Throwaway Filters 83 Permanent Filters 83 Cartridge or Bag Filters 83 Drain Pans 84 Fans 85 Inspecting and Cleaning Fans 85 Bearing Set Screw Alignment 85 Fan Bearing...

Page 7: ...n and space requirements The wide array of available components is key to fine tuning the performance of the M Series air handler The broad spectrum of fan coil filter and control options allows you t...

Page 8: ...given on the Trane sales order All factory mounted control systems controls that are factory wired to a unit controller or termination strip ordered without starters or variable frequency drives VFDs...

Page 9: ...hecklist Upon receipt of the air handling unit prior to unloading visually check the components for any damage that may have occurred during shipment Conduct a thorough inspection immediately before a...

Page 10: ...Take photos of the damaged material if possible 2 Report all claims of shipping damage to the delivering carrier immediately and coordinate carrier inspection if necessary Note Do not attempt to repa...

Page 11: ...or storage is necessary several things must be done to prevent damage Note Keep the equipment in the original shipping container for protection and ease of handling 1 Remove any shrink wrap material w...

Page 12: ...and condensate flow Standing water and wet surfaces inside the equipment can become an amplification site for microbial growth mold which may cause odors and damage to the equipment and building mate...

Page 13: ...5 70 77 77 93 91 101 101 D starter or VFD 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 Note At a minimum the above clearance dimensions are recommended on one side of the unit for regular ser...

Page 14: ...315 349 Face and bypass internal 78 107 131 155 195 185 212 259 291 Face damper 83 109 133 158 188 199 236 267 299 Coil small w 2 row UW n a n a n a n a n a n a n a n a n a Coil medium w 8 row UW n a...

Page 15: ...9 Face and bypass internal 332 409 446 586 662 910 997 1180 1363 Face damper 340 372 408 517 570 825 945 1128 1311 Coil small w 2 row UW n a n a n a n a n a n a n a n a n a Coil medium w 8 row UW n a...

Page 16: ...and bypass internal 94 127 153 181 213 224 244 293 328 Face damper 99 129 156 184 216 228 268 301 335 Coil small w 2 row UW 108 139 159 186 215 232 256 296 329 Coil medium w 8 row UW 174 238 281 339 4...

Page 17: ...3 495 654 734 990 1082 1274 1467 Face damper 381 427 468 584 642 905 1030 1223 1415 Coil small w 2 row UW 370 444 483 625 693 899 1008 1169 1333 Coil medium w 8 row UW 782 921 1025 n a n a n a n a n a...

Page 18: ...pieces a base rail may be provided for each piece if ordered In these instances the base rail weight must be calculated for each piece M Series unit sizes 66 to 120 have integral base rails module we...

Page 19: ...4 250 290 358 639 705 794 860 1224 230 460 3 60 60 65 84 90 140 138 252 283 356 436 661 705 794 860 1224 1562 575 3 60 60 65 81 89 142 154 250 287 358 436 661 705 NEMA Premiu m ODP HEOP 200 3 83 94 14...

Page 20: ...or possible equipment or property only damage NOTICE Equipment Damage Keep skid in place until unit is ready to set Do not move unit or subassembly without the skid in place as shipped from the factor...

Page 21: ...r subassembly Figure 4 Lifting detail for unit sizes 66 to 120 per shipping split General Lifting Considerations Always rig subassemblies or modules as they ship from the factory Make the loop of the...

Page 22: ...ails ship separately only if the sales order specifies special base rails and or separate shipment for the base rails Forklifting Units Attached to Skids While attached to the skids unitsorsub assembl...

Page 23: ...us injury or equipment damage Unit Assembly Note There are no penetrations into the M Series air handler for any field provided wiring or device Consider overall unit serviceability and accessibility...

Page 24: ...mounting leg installation Assembling Optional 6 Inch Mounting Legs All units or subassemblies that do not ship on a base rail ship with 4 inch mounting legs that secure the unit to the shipping skid...

Page 25: ...pendicular to airflow For parallel to airflow channels size the channels based on a four point load distribution see Figure 10 For perpendicular to airflow channels size the channels based on the load...

Page 26: ...of the mating surfaces and hardware to bolt the modules together The gasketing for module to module joints is a closed cell foam with adhesive backing WARNING Heavy Objects Always place assemble and...

Page 27: ...ners No seams in corners HF HF HAH White Butyl tape required between adjacent drain pans adjacent splash guard with J channels between coil module and module downstream of a coil Note If air gaps are...

Page 28: ...llation Mechanical Figure 16 Stacked unit assembly Figure 16 shows stacked unit assembly GKT 03870 Figure 17 Unit roof installation sizes 3 to 57 Figure 17 shows module to module assembly for unit siz...

Page 29: ...unit roof 66 to 120 Figure 18 shows module to module assembly for unit sizes 66 to 120 with a roof GKT 03870 Figure 19 Seam cap installation unit sizes 66 to 120 Figure 19 shows seam cap installation...

Page 30: ...ontal module to module quick connects Figure 21 Vertical module to module quick connects Use 2 x 4 inch wood to protect hands from accidental pinching Couple like cables together H1 to H1 H2 to H2 H3...

Page 31: ...22 Bracket installation 10 Self drilling screws on 8 in centers SCR01789 0 25 in self drilling screw SCR01369 0 31 in self tapping screw SCR01454 Flat bracket BRK03008 0 31 in self tapping screw SCR01...

Page 32: ...igure 23 For unit sizes 66 to 120 bolt the base rail together using grade 5 1 2 inch bolts nuts and locking washers see Figure 24 Figure 23 Base rail split assembly size 3 to 57 Figure 24 Base rail as...

Page 33: ...ter track If using filters supplied by another manufacturer filters should be purchased with a 7 8 inch header In some cases it may be necessary to gasket other manufacturers filters to ensure a good...

Page 34: ...install filters 1 Disconnect the power to the unit 2 Open the filter module access door 3 Remove the block off from the filter track 4 Slide the filters into the tracks Note Bag filters must be instal...

Page 35: ...CLCH SVX03C EN 35 Component Installation Requirements Filter Placement Figure 28 2 inch and 4 inch Angled Filter Layout...

Page 36: ...36 CLCH SVX03C EN Component Installation Requirements Figure 29 Bag and Cartridge Filter Layout...

Page 37: ...CLCH SVX03C EN 37 Component Installation Requirements Figure 30 2 inch and 4 inch Open or Flat Filter and 2 inch and 4 inch High Efficiency Filter Layout...

Page 38: ...24 24 24 24 30 24 24 30 24 24 30 30 30 30 24 24 24 30 24 24 24 6 24 24 24 24 6 24 24 24 24 24 4 ft 2 24 12 6 ft 2 24 12 8 ft 2 24 24 10 ft 2 24 24 12 ft 2 30 30 14 ft 2 24 24 12 18 ft 2 30 24 12 22 ft...

Page 39: ...ping tie downs secure the isolation base to the support assembly to prevent any damage to the fan module during shipment Note Remove the tie downs only if the factory provided isolation is to be used...

Page 40: ...rding the safe discharge of capacitors see PROD SVB06A EN To remove the shipping tie downs 1 Disconnect the power to the unit 2 Remove the access panels adjacent to the isolators isolators are at each...

Page 41: ...g Box Multizone torque per blade Integral face and bypass Traq linked to parallel or opposed Traq linked to Traq Parallel or opposed linked to parallel or opposed Parallel or opposed non linked Traq n...

Page 42: ...0 to 120 as well as internal and external face and bypass modules have centered dampers with an internal jack shaft see Figure 36 Figure 37 and Figure 38 A 95 degree actuator rotation gives a 90 degre...

Page 43: ...rod Adjusting Zone Dampers Zone dampers should be installed and adjusted prior to making duct connections assuring proper setup of the damper zones 1 Check the damper blades to confirm they are not b...

Page 44: ...d ventilating systems other than residence type NFPA 90B for residence type warm air heating and air conditioning systems Fan Discharge Connections To ensure the highest fan efficiency duct turns and...

Page 45: ...hed ductwork to fit the opening of the damper The duct opening dimensions should be in the unit submittals Ensure the insulation does not obstruct the damper opening when using a lined duct see Figure...

Page 46: ...ss Connections The external face and bypass damper modules will require a field fabricated duct to direct the bypass air into the appropriate module Duct sizing recommendations are listed in Table 13...

Page 47: ...s duct In other words the length of the opening should be the same as the height of the duct see Figure 43 Figure 44 and Figure 45 When bypassing into an access module remove a panel it is not necessa...

Page 48: ...h sizes 35 to 120 frame for connecting the ductwork If the duct is lined it is important the insulation does not obstruct the opening of the module Multizone units require field provided zone duct cli...

Page 49: ...water coils they must be field installed or ordered as specials from the factory Pipe coils counter flow to airflow NOTICE Connection Leaks Use a backup wrench when attaching piping to coils with copp...

Page 50: ...a plug to facilitate cleaning of the trap The drain connection size is 1 inch NPT National Pipe Thread external for unit sizes 3 to 30 1 1 4 inch NPT external for unit sizes 35 40 50 and 57 and 1 1 2...

Page 51: ...positive pressure Normal operation L H J L H J pipe diameter where H 1 inch for each inch of negative pressure plus 1 inch J 1 2 H Negative pressure total unit static pressure at worst case loaded fil...

Page 52: ...pt for a short nipple screwed directly into the coil header s condensate return tapping Do not bush or reduce the coil return trapping size Figure 48 Typical piping for Type N steam coils and horizont...

Page 53: ...ker line to atmosphere or connect it into the return main at the discharge side of the steam trap Note Vacuum breaker relief is mandatory when the coil is controlled by a modulating steam supply or au...

Page 54: ...rough a steam trap to the return line 7 Ensure overhead returns have 1 psig of pressure at the steam trap discharge for every 2 feet of elevation for continuous condensate removal Water Coil Piping Fi...

Page 55: ...w K W 3 to 12 row WD D 5D and DD water coils Figure 52 Typical piping for type W or WA 1 row water coil GV GV GV GV AV AV TV Water supply main Water return main Drain Level Air flow AV AV AV GV MW Wat...

Page 56: ...t the condensing unit to an evaporator coil Refer to Examples of Field Installed Evaporator Piping on page 60 for more detailed schematics of evaporator piping See SS APG002 EN Application Guide Tube...

Page 57: ...e insulation In fact heat loss from the liquid line improves system capacity because it provides additional subcooling Components Liquid line refrigerant components necessary for a successful job incl...

Page 58: ...etermine subcooling and whether the system is properly charged The moisture indicator sight glass must be sized to match the size of the liquid line at the thermal expansion valve NOTICE Valve Damage...

Page 59: ...surrounding air to the cooler suction lines increases the load on the condenser reducing the system s air conditioning capacity and promotes condensate formation adversely affecting indoor air quality...

Page 60: ...nch 10 feet 1 cm 3 m in the direction of flow Use the tube diameter that matches the suction header connection 4 For the vertical riser use the tube diameter recommended by the condensing unit manufac...

Page 61: ...r horizontal tubing use the tube diameter recommended by the condensing unit manufacturer 6 For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Assure the top...

Page 62: ...il flows downward past the lowest suction header outlet before turning upward Use a double elbow configuration to isolate the thermal expansion valve bulb from other suction headers 5 For horizontal t...

Page 63: ...top of the Circuit 1 suction riser must be higher than the bottom evaporator coil Use the tube diameter recommended by the condensing unit manufacturer for the riser 5 Arrange the suction line so the...

Page 64: ...before turning upward Use a double elbow configuration to isolate the thermal expansion valve bulb from other suction headers 5 For horizontal tubing use the tube diameter recommended by the condensi...

Page 65: ...5 For horizontal tubing use the tube diameter recommended by the condensing unit manufacturer 6 For the vertical riser use the tube diameter recommended by the condensing unit manufacturer Assure the...

Page 66: ...e NOTICE Penetration Leaks Properly seal all penetrations in unit casing Failure to seal penetrations from inner panel to outer panel may result in unconditioned air entering the module and water infi...

Page 67: ...d wired in the auxiliary control panel see Figure 64 Figure 63 shows a typical VFD power box Note The valve jack junction box is typically located at the air leaving side of the coil connection inside...

Page 68: ...tor wiring Black connector is for 24 Vac power supply black wire for GND and red wire for 24 Vac White connector is for 0 to 10 Vac analog signal brown wire for GND and white wire for 0 to 10 Vac sign...

Page 69: ...automatically when it is connected to the controller Setting up the operator display NOTICE Equipment Damage To clean the operator display use a cloth dampened with commercial liquid glass cleaner Spr...

Page 70: ...s The Brightness and Contrast screen appears 4 To increase the brightness press the buttons along the top row in sequence from left to right To decrease the brightness press the buttons from right to...

Page 71: ...D SVB06A EN or PROD SVB06A FR General Checks Ensure the unit has been installed level Ensure supply air and return air ducts have been connected Ensure damper operator motors and connecting linkage ha...

Page 72: ...nt If no moisture is present refer to the motor manufacturer s lubrication recommendations for proper lubrication Coil Related Checks NOTICE Proper Water Treatment The use of untreated or improperly t...

Page 73: ...ote For motor warranty needs contact you local Trane sales office Unit Operation WARNING Rotating Components During installation testing servicing and troubleshooting of this product it may be necessa...

Page 74: ...is defined as 100 times the sum of the deviation of the three voltages from the average divided by twice the average voltage For example if the three measured voltages are 221 230 and 227 the average...

Page 75: ...ch the belts will not slip under the peak load conditions It may be necessary however to increase the tension of some drives to reduce excessive belt flopping or to reduce excessive startup squealing...

Page 76: ...1 000 2 500 5 4 8 0 5 7 9 4 2 501 4 000 4 7 7 0 5 1 7 6 B BX 3 4 4 2 860 2 500 n a n a 4 9 7 2 2 501 4 000 n a n a 4 2 6 2 4 4 5 6 860 2 500 5 3 7 9 7 1 10 5 2 501 4 000 4 5 6 7 7 1 9 1 5 8 8 6 860 2...

Page 77: ...alignment tighten the belts again to the standard belt tensioning specifications If the force is still not the same for all belts the belts or sheaves are worn and must be replaced D Fixed Sheave C B...

Page 78: ...elocity Table 17 Altitude adjustment factors Airflow k cfm 10V or Airflow k L s 10V For example if the VCM on a size 30 M Series air handler at sea level k 1 has a 10 volt signal it would represent 18...

Page 79: ...and the reference pressure point is connected to or actually is the HI port of the transmitter E10 10 820 F40 17 080 F10 8 540 G40 17 080 G10 8 540 40P 25 56 10P 11 93 50A 28 404 12A 12 124 50B 26 03...

Page 80: ...in the field measure the differential pressure being output from the transmitter while measuring the airflow through the system Once these two values have been measured simply solve for K using the fo...

Page 81: ...rials If there is evidence of microbial growth on the interior insulation the insulation should be removed and replaced prior to operating the system The following areas should be specifically address...

Page 82: ...replace air filters if clogged or dirty coat permanent filters with oil after cleaning and change bag filters when pressure drop is 1 in wg See the Air Filters section on page 83 for more information...

Page 83: ...lkali solution 4 Rinse the filter in clean hot water and allow to dry 5 Coat both sides of the filter by immersing or spraying it with Air Maze Filter Kote W or an equivalent 6 Allow to drain and dry...

Page 84: ...erating experience If evidence of standing water or condensate overflow exists identify and remedy the cause immediately Refer to the Troubleshooting section on page 94 for possible causes and solutio...

Page 85: ...Refer to the Troubleshooting section on page 94 for possible causes and solutions To clean the fan section 1 Disconnect all electrical power to the unit 2 Wearing the appropriate personal protective e...

Page 86: ...ith a lithium based grease that conforms to NLGI No 2 for consistency Refer to Table 23 for minimum torque of motor mounting and bearings bolts Table 21 Compatible Greases Table 22 Fan bearing maximum...

Page 87: ...ude 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 recommend...

Page 88: ...the header is replaced Note Apply washers under the bolt heads Bolts should be evenly tightened to 50 foot pounds of torque beginning in the center and working toward the outside Refrigerant Coils WA...

Page 89: ...imarily of draining water from the coil before the heating season Trane recommends flushing the coil with glycol if coils will be exposed to temperatures below 35 degrees Install field fitted drains a...

Page 90: ...connected to the air handler Operates the supply fan for 10 to 15 minutes Air movement discourages water condensation and hastens re evaporation of any condensate that does happen to form This simple...

Page 91: ...follow all recommended safe handling practices Failure to follow all safety instructions could result in death or serious injury If microbial growth on a non porous insulating surface closed cell insu...

Page 92: ...pment cannot be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury The intensity of the ultraviolet energy emitted from the ultraviolet bulbs...

Page 93: ...he intended benefit 1 Disconnect power to the HVAC unit and the ultraviolet bulbs SEE WARNING ABOVE 2 Wearing soft cloth gloves and safety glasses use two hands and firmly grasp the bulb at each end 3...

Page 94: ...t Apply lubricant Check bearings for damage Misaligned bearing Correct alignment Check shaft level Motor fails to start Blown fuse or open circuit breaker Replace fuse or reset circuit breaker Overloa...

Page 95: ...g see the Coil Piping and Connections section on page 49 Clogged refrigerant line filter Change filter core Failure of suction liquid line components Verify component operation Dirty fin surface Clean...

Page 96: ...e mail us at comfort trane com Literature Order Number CLCH SVX03C EN Date December 2008 Supersedes CLCH SVX03C EN March 2006 Trane has a policy of continuous product and product data improvement and...