Trane Climate Changer T Series Owner's manual

Installation

Operation

Maintenance

T-Series Climate Changer™

Air Handlers

Sizes 3 to 100

Part No. X39510024010A

January 2008 CLCH-SVX06A-EN

Warnings and Cautions

Protecting the Environment

World environmental scientists have concluded, based on the best currently available

evidence,thatozoneinourupperatmosphereisbeingreducedduetothereleaseof CFC

(chlorofluorocarbon) fully halogenated compounds.

Trane urges that all HVAC servicers working on Trane equipment, or any manufacturer’s

products, make every effort to eliminate, if possible, or vigorously reduce the emission

of CFC, HCFC (halocarbon that contains fluorine, chlorine, carbon, and hydrogen), and

HFC (halocarbon that contains only fluorine, carbon, and hydrogen) refrigerants to the

atmosphereresultingfrominstallation,operation,routinemaintenance,ormajorservice

on this equipment. Always act in a responsible manner to conserve refrigerants for

continued use even when acceptable alternatives are available.

Refrigerant used in any type of air-conditioning or refrigerating equipment should be

recovered for reuse, recovered and/or recycled for reuse, reprocessed (reclaimed), or

properly destroyed, whenever it is removed from equipment. Never release it to the

atmosphere!

NOTICE:

Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.

WARNING

...indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

...indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

It may also be used to alert against unsafe practices.

CAUTION

...indicates a situation that may result in equipment or property-damage-only accidents.

CLCH-SVX06A-EN • T-Series Climate Changer Air Handler 3

Warnings and Cautions

 WARNING

Equipment Damage From Ultraviolet (UV) Lights!

Trane does not recommend field-installation of ultraviolet lights in its air handling

equipment for the intended purpose of improving indoor air quality. High intensity

C-band ultraviolet light is known to severely damage polymer (plastic) materials and

poses a personal safety risk to anyone exposed to the light without proper personal

protective equipment (could cause damage to eyes and skin). Polymer materials

commonly found in HVAC equipment that may be susceptible include insulation on

electrical wiring, fan belts, thermal insulation, various fasteners and bushings.

Degradation of these materials can result in serious damage to the equipment.

Trane accepts no responsibility for the performance or operation of our air handling

equipment in which ultraviolet devices were installed outside of the Trane factory.

Ultraviolet (UV) Germicidal Irradiation Lights (optional)

The United States Environmental Protection Agency (EPA) believes that molds and

bacteria inside buildings have the potential to cause health problems in sensitive

individuals. If specified, Trane provides ultraviolet lights (UV-C) as a factory-engineered

and installed option in select commercial air handling products for the purpose of

reducing microbiological growth (mold and bacteria) within the equipment. When

factory provided, polymer materials 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. To reduce the potential for

inadvertent exposure to the lights by operating and maintenance personnel, electrical

interlocks that automatically disconnect power to the lights are providedat all unit entry

points to equipment where lights are located.

4CLCH-SVX06A-EN

Contents

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Protecting the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ultraviolet (UV) Germicidal Irradiation Lights (optional) . . . . . . . . . . . . . . . . 3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Overview of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Factory-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Resolving Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Storage Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Preparing the Unit Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Unit Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation-Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Lifting and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Assembly Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Assembling the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fan Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installation - Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Coil Piping and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Examples of Field-Installed Evaporator Piping . . . . . . . . . . . . . . . . . . . . . . . 61

Installation - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

CLCH-SVX06A-EN 5

Contents

Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Connecting the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Setting up the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Calibrating the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Adjusting brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

External communications port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

External Insulating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Coil Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Ultraviolet (UV) Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

6T-Series Climate Changer Air Handler IOM • CLCH-SVX06A-EN

Description

Overview of Manual

Usethismanual toinstall,startup,operate,and maintaintheT-SeriesClimateChanger™

air handler. Carefully review the procedures discussed in this manual to minimize

installation and startup difficulties.

Nameplate

Each T-Series section is provided with a nameplate/label (seeFigure 1), which identifies

thetypeof section,customertagginginformation,thesection serialnumber,thesection

position, and the service model number.

Note: This information is required when ordering parts or requesting service for a

T-Series air handler.

Figure 1. T-Series air handler section nameplate

Module type

Module location

in direction of

airflow

Module serial

number

Unit tagging

Module service

model number

Additional module

specific information:

-Filter sizes

-Fan motor data

-Coil(s) service

model number

Trane order

number

Unit level

serial number

and service

model number

Controls serial

number and

service model

number

Agency listing

and/or agency

certification

symbols

CLCH-SVX06A-EN • T-Series Climate Changer Air Handler 7

General Information

Operating Environment

The T-Series Climate Changer air handler is a central station outdoor air handler. When

considering the placement of the T-Series air handler, it is important to consider the

operatingenvironment.The acceptableambient temperaturerangeforunit operationis

-40ºF to 140ºF (-40ºC to 60ºC).

For heating applications, a special motor may be required to withstand the higher

temperatures. Motors with Class B insulation are acceptable for ambient temperatures

up to 104º F, while motors with Class F insulation can withstand ambient temperatures

to +140º F (60º C).

Note: Units with UL approval have a maximum ambient temperature requirement of

104ºF. The customer should provide adequate freeze protection for the coils. See

“Coil Winterization,” on page 94 for more information.

Unit Description

TheT-SeriesClimateChangerair handleris anoutdoor airhandlerdesigned fora variety

of controlled-air applications. The basic unit consists of a fan, heating and/or cooling

coils, filters, and dampers.

T-Series airhandlers shipas complete assembliesor in sub-assembliesif shipping splits

are required. Some assembly is required when the unit ships in subassemblies.

A wide variety of components is available for the T-Series air handler, including

numerous fan, coil, and filter options, access sections, diffusers, discharge plenums,

face-and-bypasssections,UL-approvedelectricheatsections,humidifiers,mixingboxes,

moisture eliminator sections, exhaust dampers, controls, blenders and airflow

monitoring stations.

For more information, refer to the following documents, available from your local Trane

sales engineer:

• T-Series air handler catalog, CLCH-DS-9

• Gas Heat for M-Series and T-Series Climate Changer™ Air Handlers

–CLCH-SVX04C-EN

• Energy Wheels for T-Series Climate Changer™ Air Handlers

–CLCH-SVX01B-EN

• LJ Wing Coils - installation manuals available from www.ljwing.com

–IOMIFB-5

–IOMVIFB-5

• Humidifiers - installation manual available from www.armstrong-intl.com

–Armstrong Bulletin No. 560-G

8T-Series Climate Changer Air Handler • CLCH-SVX06A-EN

General Information

Factory-Mounted Controls

The T-Series air handler is available with a wide selection of factory-mounted controls,

including controllers, motor starters, and variable frequency drives (VFD).

Most control components are mounted inside the unit. Depending on the system

configuration, this may include damper actuators, dirty filter switches, averaging

temperature sensors, and low limit switches. VFDs, starters, controllers, control

transformers, static pressure transducers, DC power supplies, and customer interface

relays will be in enclosures mounted on the inside of the unit.

Smallitemsthatcannotbefactory-mounted,suchasspacetemperaturesensors,outside

air temperature sensors, and humidity sensors, will ship inside the control enclosures,

or packaged and shipped inside the fan or mixing box section. Larger items are shipped

inside the fan section.

Note: All control valves ship directly to the “ship-to address” from the vendor unless

another address is 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) are

provided with 120 to 24 Vac control transformers mounted and wired in the auxiliary

control panel. The customer must provide 120 Vac control power, 50/60 Hz, typically

3 ampsforunitsizes3to57and5 ampsforunitsizes66to100.Adedicated15-ampcircuit

is recommended.

Factory-mounted control systems ordered with factory-mounted starters or VFDs are

suppliedwithlineto24 Vaccontroltransformers.Noadditionalpowerwiringisrequired.

Pre-Packaged Solutions for Controls

If the T-Series airhandler has been selectedusing one of Trane’s pre-packaged solutions

options for controls, there are a number of resources available to aid in commissioning

and start-up of the unit. These resources include commissioning sheets, graphics and

technical application notes. The technical application notes include the control

sequencing, Trane Graphic Programming (TGP) and Rover set-up files for the specific

unit selected. These resources are available through your local Trane sales office.

For a more in-depth understanding of controls, refer to the following manuals:

• For factory-configured AH540/AH541 controllers

–CNT-SVX05B-EN

• For programmable MP580 controllers

–CNT-SVP01A-EN

• For hardware installation

–CNT-SVN01A-EN

• For Trane TR1 Drives (from Danfoss)

–TR1-SVX10A-EN

CLCH-SVX06A-EN • T-Series Climate Changer Air Handler 9

General Information

Wiring

WARNING

Grounding Required!

All field-installed wiring must be completed by qualified personnel. All field-installed

wiring must comply with NEC and applicable local codes. Failure to follow these

instructions could result in death or serious injuries.

Entrances are provided for field-installation of high and low voltage wiring through a

pipe/nippleconnectioninthebaseoftheunit.Thelow-andhigh-voltageconnectionsare

onoppositesides oftheunit onsizes3-57andon thesamesideforsizes66-100. Before

installation, consider overall unit serviceability and accessibility before mounting,

running wires (power), making penetrations, or mounting any components to the

cabinet.

Wiring to T-Series units must be provided by the installer and must comply with all

nationalandlocalcodes.Thefanmotornameplateincludesawiringdiagram.Ifthereare

any questions concerning the wiring of the motor, write down the information on the

motor nameplate and contact your local Trane sales office.

10 T-Series Climate Changer Air Handler • CLCH-SVX06A-EN

Pre-Installation Requirements

The T-Series air handler typically ships as a complete air handler, but if shipping splits

are required, it can ship in individual sections, or in section sub-assemblies. Unit sizes

3 to 100 have an integral base rail.

The specifications provided in Table 1 indicate the maximum values for a single-piece

shipment. If either the maximum weight or maximum length is exceeded, the T-Series

unit will ship in multiple pieces.

Note: These limits are based on a four-point lift.

Inspection Checklist

Upon receipt of the air-handling unit, prior to unloading, visually check the components

foranydamagethatmayhaveoccurredduringshipment.Conductathoroughinspection

immediately before accepting the shipment.

Note: Delivery cannot be refused. Trane is not responsible for shipping damage.

• Check all access doors to confirm the latches and hinges are not damaged.

• Inspect the interior of each section for any internal damage.

• Concealed damage must be reported within 15 days of receipt.

• Inspect the coils for damage to the fin surface and/or coil connections.

• If the unit was ordered with factory-mounted controls, locate all sensors.

• Items that cannot be factory-mounted should ship inside the control enclosures, or

should be packaged inside the fan or mixing box section.

• Check all control devices attached to the unit exterior and confirm they are not

damaged.

• Manually rotate the fan wheel to ensure free movement of the shaft, bearings, and

drive.

• Inspect the fan housing for any foreign objects.

• Iftheunitshippedinsub-assemblies,locatetheassemblyhardware,whichshouldbe

packaged and shipped inside the fan or mixing box section.

Table 1. Shipping length and weight limitations for single piece shipments

Unit Size Max Weight (lbs) Max Length (in)

3-40 15,000 360

50 15,000 336

57-66 15,000 112

80 15,000 120

100 15,000 124

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