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Installation, Operation, and Maintenance
Oxbox Light Commercial
Rooftops
Cooling and Gas/Electric
7.5 to 12.5 Tons, 60 Hz
Model Numbers:
PRG*090-150
PRC*090-150
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. 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 on the tags, stickers, and labels that are attached to the equipment.
October 2023
SAFETY WARNING
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Related Manuals for Trane OXBOX PRG 090 Series
Summary of Contents for Trane OXBOX PRG 090 Series
- Page 1 Installation, Operation, and Maintenance Oxbox Light Commercial Rooftops Cooling and Gas/Electric 7.5 to 12.5 Tons, 60 Hz Model Numbers: PRG*090-150 PRC*090-150 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.
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Page 2: Warnings, Cautions, And Notices
Introduction Read this manual thoroughly before operating or servicing WARNING this unit. Proper Field Wiring and Grounding And keep in a safe place for future reference by a Required! serviceman. Failure to follow code could result in death or serious Category I, the combustion system is fan-assisted. - Page 3 Introduction Overview of Manual WARNING Follow EHS Policies! One copy of this document ships inside the control panel of each unit and is customer property. It must be retained by Failure to follow instructions below could result in the unit’s maintenance personnel.. death or serious injury.
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Page 4: Table Of Contents
Table of Contents Model Number Description ....5 Cooling without an Economizer ..23 Evaporator Fan Operation (for Gas General Information . -
Page 5: Model Number Description
Model Number Description Digit 1 — Oxbox Brand Digit 14 —Version Number J = Oxbox Brand A = Minor Design Sequence Digit 2 — Refrigerant 4 = R410A 5 = R454B Digit 3 — Product Family PR = Packaged Rooftop Digit 5 —... -
Page 6: General Information
General Information Unit Inspection WARNING Fiberglass Wool! To protect against loss due to damage incurred in transit, perform inspection immediately upon receipt of the unit. Exposure to glass wool fibers without all necessary Check carefully for shipping damage. If any damage is PPE equipment could result in cancer, respiratory, found, report it immediately, and file a claim against the skin or eye irritation, which could result in death or... -
Page 7: Unit Description
General Information Note: Do not use the unit’s heater for temporary heat a field supplied contact installed in parallel with the Frost without first completing the start-up. Control. The manufacturer will not assume any responsibility for If this circuit is open before the compressor is started, the equipment damage resulting from condensate compressor will not be allowed to operate. -
Page 8: Dimensional Data
Dimensional Data Below figure illustrates the minimum operating and service Providing less than the recommended clearances may clearances for either a single or multiple unit installation. result in condenser coil starvation, “short-circuiting” of These clearances are the minimum distances necessary to exhaust and economizer airflows, or recirculation of hot assure adequate serviceability, cataloged unit capacity, and condenser air. - Page 9 Dimensional Data Figure 2. Gas units — overview Electric units — overview CONDENSATE CONDENSATE GAS CONNECTION DRAIN DRAIN INSIDE CONNECTION CONNECTION Figure 3. Gas units — front and side views (in inches) Ø2 Ø1-3/8” Ø2 Ø1-3/8” Ø7/8” 2-5/16” 7-3/4” 23-3/4” 7-3/4”...
- Page 10 Dimensional Data Figure 4. Oxbox units — bottom view (in inches) 88-7/16” 25-5/8” 29-5/8” 14” 3-7/16” 36-7/16” 3-7/16” NOTES: 1.THROUGH THE BASE GAS AND ELECTRICAL IS NOT STANDARD ON ALL UNITS. 2.VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. Figure 5.
- Page 11 Dimensional Data Figure 6. Roof curb (in inches) 15 1/2” 3.000 84 13/16” 54 9/16” 32 1/4” 19 3/8” SUPPLY 3.000 45 1/8” 15 13/16” 37 15/16” RETURN 3 9/16” 14.000 1 3/4” 54 9/16” 84 13/16” Figure 7. Downflow unit clearance (in inches) CLEARANCE 68”...
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Page 12: Weights
Weights Table 1. Maximum unit and corner weights (lb) and center of gravity dimensions (in.) Weights (lb) Corner Weights Center of Gravity (in.) Tons Unit Model No. Shipping Length Width PRG4090A 1087 1012 45.0 34.0 PRG4102A 1111 1036 44.0 36.0 PRG4120A 1133 1058... - Page 13 Weights Figure 9. Rigging and center of gravity data CENTER OF GRAVITY CENTER OF GRAVITY WIDTH LENGTH...
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Page 14: Installation
Installation Unit Foundation Ductwork WARNING Elbows with turning vanes or splitters are recommended to minimize air noise due to turbulence and to reduce static Risk of Roof Collapsing! pressure. Failure to ensure proper structural roof support could When attaching the ductwork to the unit, provide a cause the roof to collapse, which could result in death watertight flexible connector at the unit to prevent operating or serious injury and property damage. -
Page 15: Requirements
Installation ☐ Fabricate and install ductwork; secure ductwork to Figure 10. Vent hood installation curb. ☐ Rigging the unit. ☐ Set the unit onto the curb; check for levelness. ☐ Ensure unit-to-curb seal is tight and without buckles or cracks. ☐... -
Page 16: Main Unit Power
Installation Note: All field installed wiring must conform to NEC • A field supplied disconnect switch must be installed at guidelines as well as state and Local codes. or near the unit in accordance with the National Electrical Code (NEC latest edition). Verify that the power supply available is compatible with the unit’s nameplate ratings. - Page 17 Installation Table 2. Electromechanical thermostat 24V AC conductors with electromechanical unit (continued) Distance from Unit to Control Recommended Wire Size 14 gauge 126 - 200 feet 38.4 - 60.9 m 2.0 mm^2 Figure 11. Conventional thermostat field wiring diagram...
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Page 18: Gas Heat Data
Installation Gas Heat Data Table 3. Gas heater operating data Heating Input Rate 125,000 180,000 225,000 250,000 —Btu/h Minimum Supply Gas Pressure Natural/LP 4.5/11.0 4.5/11.0 4.5/11.0 4.5/11.0 Manifold Gas Pressure Combustion Blower Suction Pressure (1 Stage) -1.3 to -1.7 -1.3 to -1.7 -1.1 to -1.5 -1.1 to -1.5 Combustion Blower Suction Pressure (2... -
Page 19: Voltage Imbalance
Installation Electrical Phasing (Three Phase Motors) Figure 13. Typical unit gas train configuration The compressor motor(s) and the supply fan motor are internally connected for the proper rotation when the incoming power supply is phased as A, B, C. Proper electrical supply phasing can be quickly determined and corrected before starting the unit by using an instrument such as an Associated Research Model 45 Phase Sequence Indicator and following the steps below:... -
Page 20: Checklist
Installation Checklist Important: All phases of this installation must comply with NATIONAL, STATE, and LOCAL CODES. In Use the following checklist in conjunction with the general addition to local codes, the installation must checklist (“General Unit Requirements,” p. 15) to ensure comply with National Electric Code - ANSI/ that the unit is properly installed and ready for operation. -
Page 21: Through The Base Gas Utility Option
Installation Through the Base Gas Utility 2. The gas piping assembly ships inside this section and includes the shut-off valve, a pressure tap for testing, Option and the necessary unions for field connection. For through the base access, remove the factory-provided This section contains the instructions for making field cap from the base pan opening. -
Page 22: Pre Start
Pre Start Verifying Proper Air Flow (Units Electromechanical Controls – with Belt Drive Indoor Fan) Test Procedure Much of the systems performance and reliability is closely Fan Test and Minimum Ventilation. Connect the short associated with, and dependent upon having the proper circuit between R and G. -
Page 23: Start Up
Start Up Electromechanical Controls - When the thermostat fan selection switch is set to the "On" position, the thermostat keeps the indoor fan relay coil (F) Sequence Of Operation energized for continuous fan motor operation. These units are offered with electromechanical controls. Economizer Set-Up - Standard Cooling without an Economizer Economizer... -
Page 24: Heating Operation (For Gas Units) - Standard Economizer
Start Up When the W2 contacts close, the second stage electric Table 8. Ignition module diagnostics (continued) heat contactor (BH or BH and DH) is energized, if Flame Rollout Switch open. Six blinks applicable. The thermostat cycles both the first and second stages of heat "On"... -
Page 25: High Pressure Cutout And Temperature
Start Up High Pressure Cutout and Temperature Figure 15. Compressor terminal box Discharge Limit The high pressure controls and temperature discharge limit are wired in series between the compressor outputs on the LTB and the compressor contactors. If the high pressure safety or temperature discharge limit opens, the compressor on the affected circuit is turned off. -
Page 26: Heating Start-Up
Start Up Final System Set Up 5. To stop the SERVICE TEST, turn the main power disconnect switch to the “Off” position or proceed to the After completing all of the pre-start and startup procedures next component start-up procedure. Remove outlined in the previous sections (i.e., operating the unit in electromechanical test mode connections (if each of its modes through all available stages of cooling... -
Page 27: Maintenance
Maintenance WARNING b. Divide the distance measured in Step 1a by 64; the resulting value represents the amount of belt Electrical Shock, Fire, or Explosion deflection that corresponds to the proper belt Hazard! tension. Failure to follow these instructions could result in 2. -
Page 28: Monthly Maintenance
Maintenance Table 11. Belt tension measurement and deflection ranges (in/lb) Deflection Force (lb) Small P.D Range Belts Cross Super Gripbelts (in) Gripnotch (in) Steel Cable Gripbelts (in) (in) Section Min. Max. Min. Min. Max. 3.0–3.6 3.00 4.50 3.87 5.50 3.25 4.00 3.8–4.8 3.50... -
Page 29: Heating Season
Maintenance Coil Cleaning NOTICE Equipment Damage! Regular coil maintenance, including annual cleaning enhances the unit’s operating efficiency by minimizing the Forcibly turning the motor shaft can damage the following: gear train and motor beyond repair. • Compressor head pressure and amperage draw Never turn the motor shaft by hand or with a wrench. - Page 30 Maintenance Final Process no greater than 600 psi. To minimize the risk of coil damage, approach the cleaning of the coil with the For future reference, record the unit data below in the pressure washer aimed perpendicular to the face of the coil blanks provided.
- Page 31 Maintenance...
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Page 32: Troubleshooting
Troubleshooting WARNING verify operation of all outputs, controls, and modes. Refer to the sequence of operations for each mode, to Hazardous Service Procedures! assist in verifying proper operation. Make the Failure to follow all precautions in this manual and on necessary repairs and proceed to Step 6 and Step 7. -
Page 33: Method 2
Troubleshooting Method 2 To reset the system at the unit, cycle the unit power by turning the disconnect switch “Off” and then “On”. Table 15. Troubleshooting chart Symptom Remedy Possible Cause Check for correct voltage at compressor contactor in control box Power off or loose electrical connection Thermostat out of calibration-set too high Reset... - Page 34 Troubleshooting Table 15. Troubleshooting chart (continued) Symptom Remedy Possible Cause Low evaporator airflow Increase speed of blower or reduce restriction - replace air filter Low vapor - cool compressor - iced evaporator coil Recover refrigerant - evacuate & recharge - add filter drier Moisture in system Excessive load Recheck load calculation...
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Page 35: Wiring Diagrams
Wiring Diagrams Table 16. Wiring diagrams Type of Airflow Schematic Type Voltage Description Multi-Speed Fans Power and Control 208–230 PRG*090-150, 60Hz, 2-Stage Gas Heat w/VFD... -
Page 36: Exclusions And Limitations
Wiring Diagrams Table 17. Wiring diagrams Type of Airflow Schematic Type Voltage Description Multi-Speed Fans Power and Control PRG*090-150, 60Hz, 2-Stage Gas Heat w/VFD 2 4 V YELLOW CN10 CN13 BLACK BROWN GRAY BROWN BLACK GRAY GRAY GRAY BROWN BROWN BLACK BLACK BROWN... -
Page 37: Horizontal Duct Conversion Instruction
Horizontal Duct Conversion instruction WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Oxbox or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. - Page 38 Notes...
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