Ceiling mounted precision air conditioners/ air handlers 3.5-35 kw / 60 hz (52 pages)
Summary of Contents for Trane Climate Changer TCFS
Page 1
Installation, Operation, and Maintenance Performance Climate Changer™ Air Handlers Model TCFS and TCPA Custom Air Handlers for Any Application SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
This document and the information in it are the property of reclaiming, recovering and recycling of certain Trane, and may not be used or reproduced in whole or in refrigerants and the equipment that is used in these part without written permission. Trane reserves the right service procedures.
Page 3
Introduction Trademarks All trademarks referenced 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 plenum fans, airflow monitoring station, and removed model TCC.
Pre-Packaged Solutions for Controls Though not limited to pre-tested Trane components, validated performance is available for many options, If the air handler has been selected using one of Trane’s including: pre-packaged solutions options for controls, there are a number of resources available to aid in commissioning •...
General Information – BAS-SVX50*-EN, Tracer TD7 Display for the Tracer UC600 Programmable Controller Installation, Operation, and Maintenance Guide • Variable Frequency Drives – BAS-PRC077-EN Trane TR-150 Drive – BAS-PRC034-EN Trane TR-200 Series Wiring WARNING Proper Field Wiring and Grounding Required! All field wiring MUST be performed by qualified personnel.
Check the parts list to ensure all materials Note: Delivery cannot be refused. All units are shipped are present. If any component is missing, contact your F .O.B. factory. Trane is not responsible for shipping local Trane sales office. damage.
Pre-Installation Outdoor Storage • Allow room for supply and return piping, ductwork, electrical connections, and coil removal. • Ensure there is adequate height for condensate drain NOTICE: requirements. See “Drain Pan Trapping, ” p. Note: If unit is installed in a mechanical room on a pad, Corrosion! inadequate height may necessitate core-drilling Use only canvas tarps to cover air handlers.
Pre-Installation Roof Curb Installation Suggested Tools Refer to curb manufacturer’s installation instructions for • Two chain come-alongs. These have the pulling power more details. to bring the shipping splits together, one on each side of the unit. Cable come-alongs are not strong enough It is recommended that the curb be installed directly on the and normally will fail.
Installation - Mechanical Lifting and Rigging WARNING General Lifting Considerations Heavy Objects! Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted. Each of the WARNING cables (chains or slings), hooks, and shackles used to Risk of Unit Dropping! lift the unit must be capable of supporting the entire weight of the unit.
Failure to review the submittal drawings could result in • Remove all wooden blocks before installing the unit to performance or assembly problems. If there are any the roof curb. discrepancies, contact your local Trane sales representative before proceeding. CLCH-SVX010A-EN...
Installation - Mechanical Provide clearance around the unit to allow adequate free When mounting the unit on a roof curb, make sure the air and necessary service access. Also, allow room for gasketing between the roof curb and unit base provides an supply and return piping, ductwork, electrical airtight seal.
Installation - Mechanical Unit Assembly • For perpendicular-to-airflow channels, size channels based on the load distribution of the individual Note: Air handlers often include optional factory- sections and install the channels so that both ends of provided casing penetration entry points for field- every section are supported (see Figure provided wiring.
Installation - Mechanical Assembly Instructions Structural Roof Curb and I-Beam Dunnage The base for structural roof curbs (Figure 11) and The base is constructed for specific installation I-beam dunnage (Figure 12) are designed to sit directly requirements such as standard roof curbs, structural onto unit support with no overhang.
Installation - Mechanical Seismic restrictions will require the use of welding or fasteners to secure unit to roof curb. Please refer to Figure 14. Field-supplied outriggers submittal package for guidelines All section perimeters must be continuously supported. Failure to may result in door misalignment, leakage, and incorrect or non-functioning drain pan operation.
Page 18
Installation - Mechanical 7. Move the next mating section into alignment with the 10. When sections are close enough to allow full threading positioned section. Alignment of sections must be of the factory-supplied nut onto the bolt, chain come- completed before gasket surfaces meet. The two alongs can be removed.
Installation - Mechanical Base with Flat Floor 3. Before installing the pre-cut 4-inch 18-gauge joining strips, pre-drill holes in the floor using the 4-inch strip Note: Corner gussets are to ensure unit squareness as a guide with a 7/32-inch drill bit at 12-inch centers. during shipping, lifting, and assembly.
Installation - Mechanical Base with Turned-Up Floor Figure 18. Press U-channel in place Note: Corner gussets are to ensure unit squareness during shipping, lifting, and assembly. Please remove, when unit is set in place. 1. Apply 4-inch x ¼-inch neoprene gasket to the full perimeter face of each shipping split section.
Installation - Mechanical Walls Interior Wall and Roof Joint Note: Corner gussets are to ensure unit squareness Exterior Wall during shipping, lifting, and assembly. Please 1. Ensure shipping split sections are aligned and pulled remove, when unit is set in place. together properly.
Installation - Mechanical Figure 20. Section split - indoor Figure 21. Section split - outdoor Edge view Edge view Hubcap Roof End of hubcap fits under lip on trip Section Ends of hubcaps trim cap fit unter lip on trim Trim Trim Wall...
Installation - Mechanical Outdoor Roof - Multiple Span 7. Apply 3-inch x 1/8-inch adhesive-backed neoprene gasket to underside of roof cap. Follow instructions in Figure 22 for installation of J-Caps. 8. Install roof cap using #10 sheet metal screws in pre- 4.
Installation - Mechanical Indoor Roof 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 Note: Corner gussets are to ensure unit squareness wall with #8 sheet metal screws. during shipping, lifting, and assembly.
Installation - Mechanical Indoor Roof - Multiple Span 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 1. Ensure shipping split sections are aligned and pulled wall with #8 sheet metal screws.
Installation - Mechanical Base-to-Interior Wall 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 Note: Corner gussets are to ensure unit squareness the adjoining section. during shipping, lifting, and assembly. Please Note: Note: Use a polyurethane or equivalent caulk.
Installation - Mechanical Stacked Unit 4. Lift next upper piece into place and secure shipping split with appropriate hardware then anchor to lower 1. Install and assemble all lower sections as described in section as described above. typical assembly. 5. Continue until all sections are installed and anchored 2.
Installation - Mechanical Pipe Cabinet Figure 28. Pipe cabinet installation Butyl tape Pipe cabinet Unit base rail Roof curb Butyl Hood tape 1. After air handler is completely installed and checked for accuracy of level and square, pipe cabinet install Figure 29.
IOM or are attached to the components mounted in inadvertently energized. For variable frequency drives the unit. or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s Fan Section literature for allowable waiting periods for discharge of capacitors.
Component Installation Requirements Figure 31. Isolator WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety Fan base hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures.
Seismic Requirements • 3/4-in. dia. ASTM A325 or SAE grade 5 bolts at 24 in; o.c. Air handling equipment manufactured by Trane is capable of structurally and operationally withstanding the seismic response criteria as required by the International Building • 1-in. long 3/16-in. welds at 24 in. o.c.
Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors.
Component Installation Requirements Side-Load Filters Bag or Cartridge Side-Load Filters Filters are also available with a side access rack. 1. Disconnect power to the unit. 2. Keeping the bag filters folded, slide each filter into the 2-inch or 4-inch Flat Side-Load Filters filter rack, pushing them tightly against the unit.
Proper duct work installation by such organizations as SMACNA (Sheet Metal and Air Figure 38. Field-supplied duct connection to air handler bottom supply/return air opening Typical Trane air handler base Field-supplied Typical Trane...
Component Installation Requirements Fan Discharge Connections Figure 42. Typical section with duct flat/flange To ensure the highest fan efficiency, duct turns and connection - uninsulated or externally transitions must be made carefully, minimizing air friction insulated losses and turbulence. Proper ductwork installation, as outlined by such organizations as Sheet Metal and Air Conditioning Contractors National Association, Inc.
Component Installation Requirements have a framed opening that can be used to secure the duct to the bell mouth fitting. Attachment to the casing requires to the frames. If the duct is lined, it is important the the round duct diameter to be sized two inches larger than insulation does not obstruct the opening of the section.
Pitch the connection lines operational damage: horizontal or downward toward an open drain. Trane recommends installing a plug to facilitate cleaning of the • Support all piping independently of the coils.
Piping and Connections Figure 47. Drain pan trapping for negative and positive pressure applications Section under negative pressure Section under positive pressure L = H + J + pipe diameter where: L = H + J + pipe diameter where: H = 1 inch for each inch of negative H = 1/2 inch (minimum) pressure plus 1 inch with loaded filters...
Page 39
25 psig or higher. damage. Note: Trane steam coils require a minimum of 2 psi of pressure to assure even heat distribution. To prevent coil damage, complete the following recommendations: 2.
Piping and Connections Water Coil Piping Figure 49. Typical piping for one-row water coil Figure 49 Figure 50 illustrate typical water coil piping configurations. Water supply main Water coils are self-venting only if the water velocity Water exceeds 1.5 feet per second (fps) in the coil tubes. See the return main unit submittals for coil water velocity.
Piping and Connections Refrigerant Coil Piping Figure 51 illustrates an example of a split-system component arrangement. Use it to determine the proper, relative sequence of the components in the refrigerant Note: Refer to for information on handling refrigerants. lines that connect the condensing unit to an evaporator coil.
Venturi type distributor refrigerant from the evaporator during the off cycles. Trim solenoids cannot be used with MCHE. Note: Trane condensing units with MCHE no longer Coil employ pump-down, but isolation solenoids are required. The suggested solenoid uses a 120-volt...
Components Trane now has many years of experience in the successful Installing the suction line requires field installation of use of equipment without hot gas bypass in commercial these components: a filter, access port, and a Frostat™...
For NOTICE specific handling concerns with R-410A, please contact your local Trane representative. Compressor Damage! POE oil is hygroscopic – it absorbs water directly from Every part of an existing split system needs to be analyzed the air.
Piping and Connections Field-Installed Evaporator Piping Examples Figure 53. Single-circuit condensing unit: evaporator coil with one distributor Evaporator Coil with Standard Circuiting Suction line Liquid line Sight glass Thermal Solenoid Filter drier expansion valve valve (TXV) Distributor 1. Pitch the liquid line slightly—1 inch/10 feet —so that the refrigerant drains toward the evaporator.
Page 46
Piping and Connections Figure 54. Single-circuit condensing unit: evaporator coil with two distributors 1. Pitch the liquid line slightly—1 inch/10 feet —so Evaporator Coil with Horizontal-Split the refrigerant drains toward the evaporator. Suction line (Standard) Circuiting 2. Provide one expansion valve per distributor. “Trim”...
Page 47
Piping and Connections Figure 55. Single-circuit condensing unit: evaporator coil with four distributors 1. Pitch the liquid line slightly—1 inch/10 feet —so Evaporator Coil with Horizontal-Split that the refrigerant drains toward the (Standard) Circuiting evaporator. Suction line Thermal expansion valves (TXV) 2.
Page 48
Piping and Connections Figure 56. Dual-circuit condensing unit: evaporator coil with two distributors Evaporator Coil Suction line with Horizontal-Split (Standard) Circuiting (circuit 2) Liquid line (circuit 2) Sight glass Solenoid Distributor valve Suction line (circuit 1) Liquid line (circuit 1) Thermal Filter drier expansion...
Page 49
Piping and Connections Figure 57. Dual-circuit condensing unit: evaporator coil with four distributors 1. Pitch the liquid line slightly—1 inch/10 feet —so Evaporator Coil that the refrigerant drains toward the with Horizontal-Split (Standard) Circuiting evaporator. Suction line (circuit 2) Liquid line Thermal expansion 2.
Page 50
Piping and Connections Figure 58. Dual-circuit condensing unit: evaporator coil with eight distributors 1. Pitch the liquid line slightly—1 inch/10 feet —so Evaporator Coil that the refrigerant drains toward the with Horizontal-Split (Standard) Circuiting Suction line evaporator. Thermal expansion valves (TXV) 2.
Report any shortages immediately. If accessories have 1-in. air gap Drain Inactive tubes been damaged in transit, notify Trane and file claim with Elevation view F&T trap the transportation company. If your order covers more than one package, segregate complete assembly.
For variable frequency drives All units with starters or variable-frequency drives (VFDs) or other energy storing components provided by Trane that have direct-digital controllers (DDCs) are provided or others, refer to the appropriate manufacturer’s...
Rotate all fan wheels manually to confirm they turn inadvertently energized. For variable frequency drives freely in the proper direction. or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s • Check fan shaft bearings, fan wheel, and drive sheave...
For example, if the three measured voltages are 221, 230 and 227, the average Note: For motor warranty needs, contact your local Trane voltage would be 226 volts. The percent of voltage sales office.
Start-Up Tension the Fan Belt Figure 62. Belt tensioner NOTICE: Belt Tension! Do not over-tension belts. Excessive belt tension will reduce fan and motor bearing life, accelerate belt wear Force scale and possibly cause shaft failure. Under tensioning belts Small O-ring is the primary cause of premature belt failure.
Start-Up Table 2. Typical sheave diameter and deflection force Belt Deflection Force (lbs) Super gripbelts and Gripnotch belts and Smallest sheave unnotched gripbands notched gripbands Cross diameter range Speed (rpm) section (in.) range Used belt New belt Used belt New belt 1,000–2,500 3.70 5.50...
Start-Up Align Fan and Motor Sheaves Figure 64. Proper drive alignment Align the fan and motor sheaves using a straightedge. The straightedge must be long enough to span the distance Center line between the outside edges of the sheaves. When the Lines must must coincide be parallel...
Page 58
Start-Up Figure 66. Traq damper terminal connections volts 2 – Airflow = k (cfm @ 10V) ------------------------------ volts 2 – Airflow = k (L/s @ 10V) ------------------------------ For example, if the VCM on a size 30 air handler at sea level (k=1) has a 10-volt signal, it would represent 24,492 cfm (11,559 L/s) through the Traq damper.
Trane’s system determines airflow using a static pressure differential. Trane air handlers use a 0-5 inch, 0-20 inch, or 0-30 inch w.g. range transmitter as standard. To sufficiently cover Note: This type of system is different than a total pressure VAV turndown on the smallest fans with the above range, or thermal dispersion system.
74,233.52 90,279.75 110,113.94 total airflow for the system. As a result, the factor should be adjusted as follows: Table 7. Constant K-Factors for Trane SDDP™ Fans Trane SDDP Fans K Factor K = N * K-Factor from Table 6 Table 10.50 AF stacked direct-drive plenum...
Field-obtained factors can provide maximum accuracy. To Exceeding the recommended airflow can result in obtain the factor in the field, measure the differential damage to equipment. Trane is not responsible for pressure output from the transmitter while measuring the equipment damage resulting from exceeding airflow through the system.
Start-Up Figure 69. Confirm proper belt tracking on the wheel WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Routine Maintenance WARNING WARNING Hazardous Service Procedures! Rotating Components! The maintenance and troubleshooting procedures The following procedure involves working with recommended in this manual could result in exposure rotating components. Disconnect all electric power, to electrical, mechanical or other potential safety including remote disconnects before servicing.
Routine Maintenance Air-to-Air Plate Heat Exchangers 8. Repeat steps 6 and 7 as necessary. 9. Straighten any plate fins that may have been damaged during the cleaning process. WARNING 10. Confirm the drain line is open following the cleaning process. Hazardous Voltage! 11.
Routine Maintenance Note: If the detergent is strongly alkaline after mixing (PH 8.5 or higher), it must contain an inhibitor. Follow WARNING the cleaning solution manufacturer’s instructions regarding the use of the product. Hazardous Chemicals! 5. Place the mixed solution in a garden pump-up sprayer Coil cleaning agents can be either acidic or highly or high-pressure sprayer.
Trane recommends flushing the coil with glycol if coils will there until the air warms sufficiently to re-evaporate it. be exposed to temperatures below 35 degrees.
Routine Maintenance Drain Pans 6. Repeat steps 4 and 5 as necessary. 7. Confirm the drain line is open following the cleaning process. 8. Allow the unit to dry thoroughly before putting it back WARNING into service. Hazardous Chemicals! 9. Replace all panels and parts and restore electrical Coil cleaning agents can be either acidic or highly power to the unit.
Routine Maintenance 8. Be careful any contaminated material does not contact from one side and vacuum up water from the other other areas of the unit or building. Properly dispose of side with a wet vacuum. all contaminated materials and cleaning solution. 5.
Routine Maintenance CDQ Drive Belt Tension Figure 71. Remove short posts first The drive belt is a link stretch belt designed to provide tension throughout the life of the belt. Inspect the belt annually for proper tracking and tension. A properly tensioned belt will turn the wheel immediately, with no visible slippage, when power is applied.
Page 70
Routine Maintenance 6. Remove the shaft bolt. Figure 76. Remove snap ring Figure 74. Remove shaft bolt 7. Remove the post. 9. Remove shaft bolt, post and snap ring from opposite Figure 75. Remove post side using the same procedure. Remove shaft, being careful not to damage it.
Page 71
Routine Maintenance Figure 77. Remove old bearing by tapping from the back. Gently tap around the race. Repeat on Figure 78. Tap outer race of new bearing, alternating opposite side. sides 11. Clean the hub and new bearing races before installing 12.
Page 72
Routine Maintenance Figure 79. Exploded view of internal bearing and shaft Figure 81. Remove cover plate assembly (no hub shown) 4. Remove the bolt and washer from the end of the shaft. Figure 82. Remove bolt and washer from shaft. 20.
Page 73
Routine Maintenance 6. Remove the bolts securing the bearing to the cassette. Figure 86. Typical flange bearing, shaft and hub assembly Figure 84. Remove bolts securing bearing Set screw requires Loctite 7. Remove the bearing. Use a bearing puller if necessary. 8.
Page 74
Routine Maintenance CDQ Belt Tension 5. Remove one link. 6. Reconnect the belt as shown in Figure 1. Disconnect all power to the desiccant wheel. a. Push tab through 2. Slip belt off of drive pulley. b. Align belt 3. Hold the belt with tabs facing outward as shown in Figure 88, twist tab and push through one link.
1. Disconnect all electrical power. energy wheel. Increased pressure drop can result in 2. Remove the belt from the pulley and temporarily permanent damage to the energy wheel. Trane is not responsible for equipment-only-damage caused by position it around the wheel rim.
Routine Maintenance Energy Wheel Drive Belt Adjustment 5. Retighten the adjusting screws and recheck the clearance with the paper feeler gauge. The drive belt is a urethane stretch belt designed to Energy Wheel Drive Motor and Pulley provide constant tension throughout the life of the belt. No periodic adjustment is required.
Routine Maintenance Fans Figure 94. Alignment WARNING Rotating Components! The following procedure involves working with rotating components. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Secure rotor to ensure rotor cannot freewheel.
2 1/2 - 2 15/16 Bag and cartridge filters must have an airtight seal to prevent air bypass. If using other than Trane-supplied • Fan bearings without lubrication lines are sealed filters, apply foam gasketing to the vertical edges of the bearings.
Routine Maintenance Front Load Filters Cartridge or Bag Side-Load Filters Most filters in custom units are installed in unitary sheet To replace cartridge or bag filters: metal frames. Filters are secured with a metal clip. There 1. Disconnect all electrical power to the unit. are several different styles.
Routine Maintenance Ultraviolet (UV) Light 6. Attach the loom to the lamp by firmly pushing the four- port connector onto the four pins on the lamp end. Maintenance Note: Connection must be snug to avoid potential arcing. The intensity of the ultraviolet energy emitted from the Replacing the Bulbs ultraviolet bulbs is dependent on the cleanliness and age Ultraviolet bulbs should be replaced annually if operated...
Troubleshooting This section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact your local Trane service representative. WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety hazards.
Page 82
Troubleshooting Table 11. Air handler troubleshooting recommendations Symptom Probable Cause Recommended Action Worn sheaves Replace sheaves. Misaligned belt Realign drive with MVP sheave set at mean pitch diameter. Short belt life Grease or oil on belts Check for leaky bearings. Clean belts and sheaves. Belt slipping Improper belt tension.
Page 83
Troubleshooting Table 11. Air handler troubleshooting recommendations Symptom Probable Cause Recommended Action The fuse or circuit breaker may be blown or open. Check the breaker/fuse box and replace. There may be a loss of incoming power. Attempt to trace the power loss back to its source and correct.
Page 84
Ingersoll Rand (NYSE:IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency.