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Custom Climate Changer air handlers
User Manual
60 pgs8 Mb1
Brochure
4 pgs879.37 Kb0

Trane Custom Climate Changer Air Handlers Installation and Maintenance Manual

Installation Operation Maintenance
Custom Climate Changer™ Air Handlers
July 20 10
X-code - X39640745010
CAH-SVX01B-EN
Warnings, Cautions and Notices
Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at
appropriate intervals throughout this manual. Warnings are provide to alert inst alling contractors to potential hazards that could result in personal injury or death. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that may result in equipment or property-damage-only accidents.
Y our personal safety and the proper operation of this mac hine depend upon the strict observance of these precautions.
ATTENTION: Warnings, Cautions and Notices appear at appropriat e secti ons th roug hout
this literature. 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, could
result in minor or moderate injury . It could also be used to aler t against unsafe practices.
NOTICE: Indicates a situation that may result in equipment or property-damage only
accidents.
Important Environmental Concerns!
Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In part icular , several of the identified chemicals that may af fect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containin g Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.
Responsible Refrigerant Practices!
Trane believes that responsible refrigerant pra ctices 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 (Section 608) sets forth the req uiremen ts for handli ng , reclaiming, recovering and recycling of certai n refrigerants and the equipment th at is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.
WARNING
Refrigerant warning information!
System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.
Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or r efrigerant additives could r esult in death o r serious injury or equipment damage.
Warnings, Cautions and Notices
WARNING
Hazard of Explosion!
Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxyg en or compr essed air or mixtur es containing them f or pressu re t esting. Do not use mixtur es of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a tr ace gas should only be mixed with dry nitrogen for pressurizing units. Failure to follow these recommendations could result in death or serious injury or equipment or property-only damage.
Ultraviolet (UV) Germicidal Irradiation Lights
The United States Environmental Protection Agency (EP A) 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 pow er to the lights are pro vided at all unit en try points to equipment where lights are located.
WARNING
Equipment Damage From Ultraviolet (UV) Lights!
Trane does not recommend field-installation of ultr aviolet lig hts in its air handling equip ment for the intended pur pose 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 e y es and skin ). Polymer materials commonly found in HVA C equipment that may be susceptible include insulation on el ectrical wiring, fan belts, thermal insulation, various fasteners and bushings. Degradation of these materi als can result in serious damage to the equipmen t.
Trane accepts no responsib ili ty for the performance or operation of our air handling equipment in which ultraviolet devices were installed outside of the Trane factory.
CAH-SVX01B-EN 3
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Factory-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Receiving Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Resolving Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparing the Unit Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Roof Curb Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TCP Model Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TCC Model Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outdoor Storage Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Suggested Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TCP Standard Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TCP Structural Roof Curb and I-Beam Dunnage . . . . . . . . . . . . . . . . . . . . 19
TCP Flat Concrete Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TCP Roof Curbs for Large Units with Shipping Splits . . . . . . . . . . . . . . . 21
TCP Joining Sections Edge-to-Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TCP Base Section Assembly with Flat Floor . . . . . . . . . . . . . . . . . . . . . . . 23
TCP Base Section Assembly with Turned-Up Floor . . . . . . . . . . . . . . . . . 24
TCP Wall Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TCP Outdoor Roof Assembly - Single Span . . . . . . . . . . . . . . . . . . . . . . . 26
TCP Outdoor Roof Assembly - Multiple Span . . . . . . . . . . . . . . . . . . . . . . 27
TCP Indoor Roof Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . 28
TCP Indoor Roof Assembly - Multiple Span . . . . . . . . . . . . . . . . . . . . . . . 29
TCP Base-to-Interior Wall Section Assembly . . . . . . . . . . . . . . . . . . . . . . 30
TCP Stacked Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TCC Overhang Base on Common Roof Curb . . . . . . . . . . . . . . . . . . . . . . 32
TCC Flat Base to Steel Dunnage or Concrete Pad . . . . . . . . . . . . . . . . . . 32
TCC Joining Sections - Edge-to-Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TCC Internal Shipping Split Frame Assembly (Typical) . . . . . . . . . . . . . . 36
TCC Wall Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TCC Indoor Roof Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . . . 37
TCC Outdoor Roof Section Assembly (Typical) . . . . . . . . . . . . . . . . . . . . 38
TCC Stacking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TCC Energy Wheel and CDQ Wheel Assembly . . . . . . . . . . . . . . . . . . . . . 42
Pipe Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bottom Opening Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Component Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Isolator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Magnahelic Air Filter Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Outdoor Unit Weather Hood(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Coil Piping and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General Coil Piping Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drain Pan Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Steam Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Water Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Refrigerant Coil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Suction Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Examples of Field-Installed Evaporator Piping . . . . . . . . . . . . . . . . . . . . . . . . 63
Single-Circuit Condensing Unit: Evaporator Coil with One Distributor . 63 Single-Circuit Condensing Unit: Evaporator Coil with Two Distributors 64 Single-Circuit Condensing Unit: Evaporator Coil with Four Distributors 65 Dual-Circuit Condensing Unit: Evaporator Coil with Two Distributors) . 66 Dual-Circuit Condensing Unit: Evaporator Coil with Four Distributors . 67 Dual-Circuit Condensing Unit: Evaporator Coil with Eight Distributors . 68
Installation - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Quick Connects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Setting Up the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Calibrating the Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjusting Brightness and Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
External Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pre-Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fan-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CAH-SVX01B-EN 5
Coil-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Motor-Related Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Calculate Motor Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tension the Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Determine Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Align Fan and Motor Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Check Multiple Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Traq™ Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fan Inlet Airflow Measuring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transmitter Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transmitter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Constant Factor K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
External Insulating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Throwaway Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Permanent Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Front Load Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Side Load Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Inspecting and Cleaning Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Bearing Set Screw Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motor Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fan Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Steam and Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cleanable Cooling Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Refrigerant Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Coil Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Chilled Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cleanable Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Moisture Purge Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Internal Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Multiple Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Ultraviolet (UV) Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cleaning the Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Disposal of Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CAH-SVX01B-EN 7
General Info rmation
Use this manual to install, startup, operate, and maintain the Custom Climate Changer™ air handler. Carefully review the procedures discussed in this manual to minimize installation and startup difficulties.
Each Trane air handler section is provided with a nameplate which identifies the type of section, customer tagging information, the section serial number, the section position, the service model number, and electrical data.
Note: This information is required when ordering parts or requesting service for a Trane air
handler.
Operating Environment
When considering the placement of the air handler, it is important to consider the operating environment. The acceptable ambient temperature range for unit operation is -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).
For the units furnished with gas furnaces, the heating demands require a special motor to withstand the higher temperatures. These motors are furnished with Class “H” insulation to withstand this rigorous duty.
Note: Units with UL approval have a maximum ambient temperature requirement of 104ºF. The
customer should provide adequate freeze protectio n for the coils. See “Coil Wint erization”
on page 93 for more information.
Unit Description
Custom Climate Changer™ air handlers are designed for a variety of controlled-air applications. The basic unit consists of a fan, heating and/or cooling coils, filters, and dampers. See the unit submittal drawings for detailed descriptions.
The fans are internally isolated. To insure fan stability, the unit ships with a minimum of four lock­down devices that prevent the fan from shifting during shipment and installation. These spacers must be removed prior to fan operation to ensure proper vibration isolation. Retain these spacers for use in adjusting fan isolators if required.
The units are available with factory mounted controls for climate and humidity control. Th ese can be use as stand-alone devices or operate with a complete controls system. End devices include factory-mounted star ters and variable speed drives.
Custom Climate Changer™ air handlers ship as complete assemblies or in sections. Some jobs ite assembly is required when the units ship in sections.
Factory-Mounted Contr ols
Trane air handlers are 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.
Small items that cannot be factory-mounted, such as space temperature sensors, 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 terminal 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 50/60 Hz control power. A dedicated 15-amp circuit is recommended.
Factory-mounted control systems ordered with factory-mounted starters or VFDs are supplied with line to 24 Vac control transformers. No additional power wiring is required.
General Information
Wiring
For a more in-depth understanding of controls, refer to the following manuals:
• Tracer MP580/581 Programmable Controllers catalog, CNT-PRC002-EN
• Tracer MP581 Programmable Controllers Hardware Installation, CNT-SVN01C-EN
• Variable Frequency Drives TR200 Series, BAS-SLB026-EN Custom air handlers and/or field-installed accessories that must be stored for a period of time prior
to being installed must be protected from the elements. All controllers and electrical/electronic components should be stored in conditions of -20 to 120°F and 5- to 95-percent relative humidity non-condensing. Electrical components are not moisture-tolerant.
Note: The warranty will not cover damage to the unit or controls due to negligen ce during storage.
A controlled indoor environment is recommended for proper storage. For further storage considerations, refer to “Storage Recommendations” on page 11.
WARNING
Grounding Requir ed!
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.
On outdoor units, entrances are provided for field-installation of high and lo w voltage wiring through a pipe/nipple connection in the base of the unit. As a standard, there are no penetrations into the Custom air handler for any field-provided wiring or device. Before installation, consider overall unit serviceability and accessibility before mounting, running wires (power), making cabinet penetrations, or mounting any components to the cabinet.
Wiring to the unit must be provided by the installer and must comply with all national and local electrical codes. The fan motor nameplate includes a wiring diagram. If there are any questions concerning the wiring of the motor, be sure to write down the information from the motor nameplate and contact your local fan motor manufacturer representative for assistance.
CAH-SVX01B-EN 9
Pre-Installation Requirements
Receiving Checklist
Based on customer requirements, Trane air handlers can ship as complete units or as individual sections to be field assembled.
Upon receipt of the air handler(s), a thorough inspection should be performed to note any shipping damage that may have occurred and that the shipment is complete. All factory shipping protection should be removed immediately to allow complete access for the inspection.
Note: The shipping protection provided by the factory is for transit protection only and should not
be used as a jobsite storage cover.
Note: Delivery cannot be refused. Trane is not responsible for shipping damage.
• Check all access doors to confirm that the latches and hinges are not damaged.
• Inspect the interior of each section for any internal damage.
Note: 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 contro ls, lo cate al l sensors.
Note: 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 that 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.
• If the unit is shipped in sub-assemblies, locate the assembly hardware, which should be packaged and shipped inside the fan or mixing box section.
• Inspect and test all piping for possible ship ping d amage. Nippl es may be i nstalled o n coi ls at the factory but should alwa ys be tightened and tested before any connections are made. Rough handling during shipping, in addition to other factors can cause pipe connections to become loose.
Note: T rane will not be responsible for any leak at the field connections. Coils have been factory
pressure tested before shipping.
Assembly Hardware
T rane air handlers ship with all necessary assembly hardware and gasket material. This hardware is packaged in either a clear plastic envelope or cardboard box and can be found inside the fan, mixing box, or access section. If there is not enough space inside the section, a crate or pallet will be loaded onto the bed of the truc k. Chec k the par ts list on the field assembly drawing against the contents of the crate. Do not proceed with unit assembly until verification that all materials are present. Sometimes it is necessary to use more than one section to ship hardware. Please check all sections thoroughly before contacting your local Trane sales engi neer to report missing hardware.
Resolving Shipping Damage
Trane air handlers ship free-on-board (FOB), meaning that the unit belongs to the customer the moment the delivery truck leaves the factory. If damage has occur red to the unit during shipment, follow these instructions:
Note: Trane is no t r esponsible for shipping damage.
1 . Make specific notation, describing the damage, on the freight bill. T ake photos of the da maged
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 repair the unit without consulting the delivering carrier.
3. Notify your Trane sales representative of the damage and arrange for repair.
Note: Do not attempt to repair the unit without consulting the Trane sales representative.
4. Keep the damaged material in the same location as it was received.
Note: It is the receiver's responsibility to provide reasonable evidence that concealed damage was
not incurred after delivery.
Storage Recommendations
Air handlers and/or field-installed accessories that must be stored for a period of time before installation must be protected from the elements. A controlled indoor environment is recommended for proper storage.
Note: The warranty does not cover damage to the unit or controls due to negligence during
storage.
Pre-Installation Requirements
NOTICE
Use Canvas Only!
All factory shipping protection should be removed. This wrapping is for transit protection only and should not be used for jobsite storage. Use only canvas tarps to cover air handlers. Plastic tarps can cause condensation to form in and on the equipment, which could result in corrosion damage or wet storage stains.
General Storage
The unit controller and all other electrical/electroni c components should be stored in conditions of
-20ºF to 120°F and 5 to 95 percent relative humidity, non-condensing. Electrical components are
not moisture-tolerant. Factory protective coverings should be removed prior to storage.
Long-Term Storage
For longer periods of storage, allow proper clearance around the unit to perform periodic inspection and maintenance of the equipment.
While the unit is in storage:
• Every two weeks, rotate the fan and motor shaft 30 revolutions by hand. Chec k for free rotation.
• Every six months, chec k fan shaft bearings and grease lines. Add grease using a manual grease
• Check the motor lubrication; remove and clean grease plugs and check for the presence of
gun following the lubrications recommendations in “Fan Bearing Lubrication” on page 89.
moisture in the grease. If moisture is present, remove the motor and send it to an authorized repair shop for bearing inspection/replacement. If no moisture if present, refer to the motor manufacturer’s lubrication reco mm end ation for pro per lu bricatio n
CAH-SVX01B-EN 11
Pre-Installation Requirements
Outdoor Storage Considerations
Outdoor storage is not recommended; however, when outdoor storage is necessary, several things must be done to prevent damage:
Note: Keep the equipment in the original shipping co ntainer for protection and ease of hand ling.
• Select a well-drained area, preferably a concrete pad or blacktop surface.
• Place the unit on a dry surface or raised off the ground to ensure adequate air circulation beneath the unit and to ensure no portion of the unit will contact standing water at any time.
• Loosen the belt tension on the drive belts.
• Cover the unit securely with a canvas tarp.
• Do not stack units.
• Do not pile other material on the unit.
Preparing the Unit Site
NOTICE Microbial Growth!
The roof curb or foundation must be level and the condensate drain at the proper height for proper coil drainage 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 materials.
NOTICE Level Foundation!
A level foundation is critical to proper unit and door alignment, operation, and sealing. Failure to level and align sections properly can lead to structural damage.
• Ensure the installation site can support the total weight of the unit. Refer to the unit submit tals for weights.
• Allow sufficient space for adequate free air and necessary service access. Refer to submittals for specific minimums.
• Allow room for supply and return piping, ductwork, electrical connections, and coil removal.
• Ensure there is adequate height for condensate drain requirements. See “Drain Pan T rap ping”
on page 54.
Note: If unit is installed in a mechanical room on a pad, inadequate height may necessitate core-
drilling the floor to attain proper trap height. Insufficient height could inhibit condensate drainage and result in flooding the unit and/or equipment room.
• Confirm the roof curb or foundation of the mounting platform is level and large enough to accommodate the unit. Refer to the unit submittals for specific dimensions.
• Provide adequate lighting for maintenance personnel to perform maintenance duties.
• Provide permanent power outlets in close proximity to the unit for installation and maintenance.
• Depending upon job requirements, the customer may n eed to provide 120 Vac p ower to the unit controller. Refer to submittals for more information. A dedicated 15-amp circuit is recommended.
• Wiring for units must be provided by the installer and must comply with all national and local electrical codes.
• Rooftop curb mo un ted u ni ts m ust be sealed tightly to the curb. Use proper sealan ts and roof to curb sealing techniques to prevent water and air leakage.
Note: Preparation of the roof curb or pier mount and roof openings should be completed prior to
lifting the unit to the roof.
Roof Curb Installation Checklist
It is recommended that the curb be installed directly on the support members and fastened to the supports using tack welds or other equivalent methods. Properly supported decking should be installed inside the air handler section of the curb when this method is used. See Figure 1.
NOTICE
Roof Curb Structurally Sound
Check with curb manufacturer and job engineer to ensure the roof curb is structurally sufficient to support the weight of the unit. The curb should be checked to ensure it is level and square. Curb bowing, buckling, or sagging can lead to unit assembly and operation pr oblems up to complete failure.
Pre-Installation Requirements
Figure 1. Cross section of typical curb installation on new construction
CAH-SVX01B-EN 13
Pre-Installation Requirements
1 . V erify that the roof structure can adequately support the combined weight of the unit and curb
assembly.
2. Ensure that the selected installation location provides sufficient service and operational clearances.
3. Remove any twist within the curb due to roof supports and square the curb.
4. Level the curb.
5. Secure the curb to the roof support members.
6. Install 2-inch thick boards or rigid insulation around the curb.
7. Install cant strips around the curb.
8. Bring field supplied roofing felt up to the top of the curb nailing strips. Nail felt into place.
9. Install field supplied flashing under the lip of the curb flanges and over the felt.
10. Apply sealant to the four corners. Caulk all joints between the curb and the roof. Attach the gasket material to the curb’ s top flanges (entire perimeter) and to the supply and return air duct opening panel flanges
Suggested Tools
• T wo chain come-alongs. These have the pulling power to bring the shipping splits together, one on each side of the u nit. Cable come-alo ngs are not strong enough and n ormally will fai l. The chain versions work well.
• Two long drift pins to keep holes aligned as the sections come together.
• One half-inch or 3/4-inch electric impact gun. These are very effective to tighten the bolts at the base once it’s close enough together to get the bolts in.
• Caulk guns.
• Standard battery impact gun or bat tery drill for installation of screw in joint strips, hubcaps, and inlet or exhaust hoods.
• Nut setters for battery impact gun - 3/8-inch and 5/16-inch.
• Utility knives for cutting section-to-section gasket.
• A couple of large pry bars.
• Proper size soc kets and wrenches to remove lifting lugs when in p ositions. Multiple size sockets. Must have 15/16-inch and 1 1/16-inch sockets.
Installation - Mechanical
Lifting and Rigging
WARNING
Heavy Objects!
Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of suppor ting the enti r e w eight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or property-only damage. Failure to properly lift unit could result in death or serious injury. See details below.
WARNING
Heavy Objects!
Always place, assemble, and suspend sections/subassemblies one at a time. Do not lift units in windy conditions. Do not raise units o verhead with personnel below unit. F ailur e to f ollo w thes e instructions could result in death, serious injury, or equipmen t dam age.
WARNING
Installation - Mechanical
WARNING
Improper Unit Lift!
Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level. Failure to properly lift unit could result in death or serious injury or possible equipment or property-only damage.
NOTICE Equipment Damage!
Do not use a fork lift on air handlers or subassemblies. Improper use of fork lifts on units may result in equipment damage. Trane is not responsible for equipment damage resulting from improper forklifting practices.
Preparation of the roof curb or pier mount and roof openings should be completed before liftin g unit to the roof. Per job requirements, air handlers will ship as a complete assembly or in sections. T rane recommends that the contractor use spreader bars and slings to rig units and sub-assemblies (sections).
CAH-SVX01B-EN 15
Installation - Mechanical
Lifting Considerations
.
Figure 2. Recommended
attachment to lifting lugs.
Figure 3. Use proper lifting and rigging methods • Make the loop of the sling parallel to
• Before lifting the unit, estimate the approximate center of gravity for lifting safety. Because of the placement of internal components, the unit weight may be unevenly distributed, with more weight in the coil and fan areas. Refer to the unit submittals for section weights. Test the unit for proper balance and rigging before lifting.
• Always assemble unit at the installation site. Never bolt sections together before rigging.
• Always rig subassemblies or sections as they ship from the factory. See the unit submittal drawings for correct placement of sections.
• Lift all sections individually using all lifting lugs provided. See Figure2. See specific instructions for handling the pipe cabinet (see “TCC Wall Section
Assembly (Typical)” on page 37) and inlet and exhaust hoods (see “Outdoor Unit Weather Hood(s)” on page 52).
the direction of airflow whenever possible.
• Each of the cables used to lif t the unit must be capable of supporting the entire weight of the unit.
• When hoisting the unit into position, use the proper rigging method, such as straps, slings, spreader bars, or lifting lugs for protection and safety. See Figure 3.
• The air handler is not designed to be lifted, rigged or ceiling sus pend ed from the top of the unit.
• Never lift units in windy conditions. Personnel should be positioned overhead and on the ground to guide the crane or helicopter operator in positioning the sections.
• Never stack the pipe cabinet and inlet hoods on the unit as the unit is being lifted.
• Do not attach the intake/exhaust hoods to the unit prior to lifting the unit. Doing so may damage the equipment. Attach the hoods to the unit only after all sections are in place.
• Remove all wooden blocks before installing the unit to the roof curb.
Unit Assembly
All Trane air handlers ar e identified by a multiple-character model number that identifies each section. It is located on the panel on the inside of the supply fan section access door. Be sure to refer to the information on the nameplate when ordering replacement parts or requesting servic e.
Note: If the unit is shipped as a complete assembly, go to “Coil Piping and Connections” on
Prior to unit assembly , refer to th e unit submit tal drawings and un it tagging for cor rect placement of sections. Failure to review the submittal drawings could result in performance or assembly problems. If there are any discrepancies, contact your local Trane sales representative before proceeding.
All shipping supports and crating on the face of the sections must be removed and discarded to permit proper fit-up and sealing of the surfaces.
Outdoor units may be mounted on the roof with a roof curb or pier mount. Indoor units may be mounted on housekeeping pads. Refer to submittals for unit dimensions and openings.
Note: For proper operation, the unit must be suppor ted aro und the entire unit base perime ter. If
Provide clearance around the unit to allow adequate free air and necessary service access. Also, allow room for supply and return piping, ductwork, electrical connections, and coil removal.
The building roof must be able to suppor t the entire weight of the unit, roof curb and accessories. See submittals for approximate unit weights.
• Prepare the roof curb or pier mount and roof openings before lifting the unit to the roof.
• Check that the gasketing or sealant on the roof curb is intact and provides an air tight seal with
• Complete all ductwork, piping and electrical connections only after mounting the unit.
Installation - Mechanical
page 53.
the unit is shipped in sections, the entire section perimeter must be suppor ted, as well as at the base channels of the unit splits.
the unit base.
CAH-SVX01B-EN 17
Installation - Mechanical
TCP Model Assembly Instructions
If the model number on the nameplate begins with TCP, use the assembly instructions below. The TCP base is constructed for specific installation requirements such as standard roof curbs, structural support curbs, steel I-beam dunnage support, and pier mounting.
NOTICE
Roof Curb Structurally Sound
Check with curb manufacturer and job engineer to ensure the roof curb is structurally sufficient to support the weight of the unit. The curb should be checked to ensure it is level and square. Curb bowing, buckling, or sagging can lead to unit assembly and operation pr oblems up to complete failure.
TCP Standard Roof Curb
Figure 4. Standard roof curb The TCP unit exterior base channel is
constructed to overhang the roof curb. Unit support is provide by a square tube channel locate inside of exterior base channel. See
Figure 4. The standard curb should be designed
to properly support the unit’s weight without bow and sized to fit within the perimeter base channel.
For large units shipped in sections, see additional requirements in “TCP R oof Curbs for
Large Units with Shipping Splits” on page 21.
Air handler
base structure
Roof curb
Insulation
Installation - Mechanical
Air handler
basic structure
Structural
steel curb
Air handler base structure
Dunnage
TCP Structural Roof Curb and I-Beam Dunnage
The TCP base for structural roof curbs (see Figure 5) and I-beam dunnage (see Figure 6) are designed to sit directly onto unit support with no overhang. The structure should be designed to properly support unit weight without bow an d siz ed to the unit’s perimeter exterior base channel.
For large units shipped in sections, see additional requirements in “TCP Roof Curbs for Large Units
with Shipping Splits” on page 21.
Figure 5. Structural roof curb Figure 6. I-beam dunnage mount
CAH-SVX01B-EN 19
Installation - Mechanical
Air handler
base structure
Concrete
pad
TCP Flat Concrete Pad
The TCP base for concrete is designed to sit flat on the concrete with full perimeter contact. Concrete pads should be perfectly level, flat, and sized to the minimum exterior base channel measurements. See Figure 7.
Figure 7. Flat concrete pad mo un t
TCP Roof Curbs for Large Units with Shipping Splits
Larger units with shipping splits may require full-width intermedi ate support. With any raised type roof support such as curbs or dunnage, provisions must be made to carry the weight of the base cross members at the sectional splits. Since these unit bases are designed with lifting l ugs between the sections, temporary support must be pro v ided so additional sections can be set down with a 12-inch gap to allow for working room between sections and lug removal.The use of field-provided outriggers has proven to be a successful way to accomplish this, as shown in Figure 8.
.
Figure 8. Large units with shipping splits may require intermediate support. Field-supplied
outriggers may be a useful tool in making this field joint.
Installation - Mechanical
CAH-SVX01B-EN 21
Installation - Mechanical
TCP Joining Sections Edge-to-Edge
Units must be installed level for proper drainage of conden sate from the drain pan. In addition, each section in a multi-section unit must be properly supported.
Note: Leveling each section, beginning with the first, is critical. Failure to level and align the
sections immediately creates greater misalignment or even structural damage afterward.
1. Remove all crating and wrapping from the surfaces to be joined.
2. Place one section of the air handler into the desired position. Verify section is installed level front to back and side to side. Verify section is square to support structure, this is critical to insure proper alignment for next adjoining sections.
3. Chec k squareness measuring the critical dimensions given. Use preselected method to anchor first piece in place. This is necessary so movement will not affect pulling next sections into alignment.
4. When th e unit i s positioned and squ areness is ensured with in 1/8-inch, remove all lifting lugs located along the split plane.
5. Af ter assuring positionin g is correct, anc hor in place either by welding unit base to the cu rb or by mechanical fasteners. The first section will be used to pull remaining sections up tight so it’ s critical that first section be secured.
6. Install 4-i nch x 1/4-inch neoprene gasket to all mating surfaces of the section, including an y internal walls. This gasket must be applied to the full perimeter of the section split on both sections to be joined.
7. Move the next mating section into alignment with the positioned section. Alignment o f sections must be completed before gasket surfaces meet. The two sections should be within 12 inches to reduce the amount of dragging required.
8. Remove lifting lugs on mating section as required.
Figure 9. Insert supplied bolts through each hole of
mating connecting plate.
9. Pulling sections together on a flat surface can be done by using chain come-alongs hooked onto the welded square tubes located on each si de of the shipping split. These square tubes are designed to fully support the stress of pulling sections together. Sections should be pulled together until mating gaskets make contact and factory-supplied bolts can be installed in connecting plate.
10. When sections are close enough to allow full threading of the factory-supplied nut onto the bolt, chain come-alongs can be removed. The use of an electric impact gun to tighten bolts in a sequential manner will allow the additional section to be pulled into the final position.
1 1 . Check overall u nit length to assure proper joint compression.
Note: Failure to compress the gasketing may result in air
leakage.
12. Once the sections are pulled together, install the assembly hardware as applicable for the walls, roof, and the base as demonstrated in the following assembly sections.
TCP Base Section Assembly with Flat Floor
#14 SMS screw
Joining strip
3-in. x 1/8-in. gasket
4-in. x 1/4-in. gasket
Joining trim
Top floor
Add caulking before installing J strip
Trim gasket after strips are installed
Add caulking after trimming gasket
Note: Failure to completely compress the gasketing may result in air leakage.
1. Join the two units and secure with factory -pro vided 5/8-inch flat washers and 5/8-inch X 2-1/2­inch grade 9 bolts though each of the six holes. See Figure 10.
2. Caulk the overlapping flange along the length of each split to maintain a seal.
Note: Use a polyurethane or equivalent caulk.
3. Before installing the pre-cut 4- inch 1 8-gauge joining strips, pre-drill holes in the floor using the 4-inch strip as a guide with a 7/32-inch drill bit at 12-inch centers.
4. Af ter holes are pre-drilled, apply an ample bead of caulk to the joint then install 4-inch strip with #14 sheet metal screws uniformly straddling the split.
5. In cases of tread plate floor , some job specifications may call for the seam to be welded. In those cases make sure the sections are pulled together tightly then weld with appropriate method. The floor construction in those cases will be suc h that the heat from welding will not aff ect the insulation.
Figure 10. TCP base assembly with flat floor
Installation - Mechanical
CAH-SVX01B-EN 23
Installation - Mechanical
Cap
Caulk
Floor
Cap
Caulk
Floor
Floor
Floor
Gasket
Gasket
TCP Base Section Assembly with Turned-Up Floor
1. See Figure 11. Apply 4-inch x ¼-inc h neoprene gasket to the full perimeter face of eac h shipping split section.
2. Join the two sections and secure with field-provided 5/8-inch flat washers and 5/8-inch x 2 ½­inch grade 9 bolts through each of the six holes.
3. Apply a heavy bead of caulk to the inside of the U-channel.
4. P ress U-channel down over upturned flanges with moderate pressure to ensure it is fully seated onto upturned flanges. The caulk w ill cur e and act as an adhe sive to hold U-channel in place, no fasteners are required.
Figure 11. Upturned floor assembly
TCP Wall Section Assembly
Exterior Wall Assembly (Typical)
1. See Figure 12. Ensure shipping split sections are aligned and pulled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec 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. Fill the top and bottom openings with caulk as a moisture seal. Screw holes can be pre-drilled with a #29 bit.
Interior Wall and Roof Joint Assembly (Typical)
1. See Figure 12. Ensure shipping split sections are aligned and pulled together properly.
2. Pre-drill interior joining strip screw holes using #29 drill bit.
3. Apply a bead of caulk the full height of interior wall joint.
4. Install joining strips using #10 sheet metal screws.
Figure 12. Wall section assembly
Installation - Mechanical
#8 x 1-in. Phillips zip screw
2 3/4-in. wide joining strip
Add caulking before installing J strip
3-in. x 1/8-in. neoprene gasket is applied to metal joining strip. Apply gasket to metal strip before installation.
#8 x 1-in. Phillips zip screw
4-in. x 1/4-in. gasket
Wall split
Wall panel section split
2 3/4-in. wide joining strip
Trim cap
#10 x 1-in. self tapping screw
Add caulking after installing J strip
CAH-SVX01B-EN 25
Installation - Mechanical
Add caulking before installing J cap
Joining cap
4-in. x 1/4-in. gasket
#10 x 1-in. self-tapping screw
Roof panel section split
2 3/4-in. wide joining strip
#8 x 1-in. Phillips zip screw
3-in. x 1/8-in. neoprene gasket is applied to metal joining strip. Apply gasket to metal strip before installation.
Roof split outdoor unit
TCP Outdoor Roof Assembly - Single Span
1. Ensure shipping split sections are aligned and pulled together properly . See Figure 13.
2. Add a bead of caulk al ong the length of the roof seams. Install the pre-cut J-cap over the seam and secure with #14 sheet metal screws on 12-inch centers.
Note: Use a polyurethane or equivalent caulk. It may be necessary to clamp the joint together or
pre-drill to prevent separation when drilling with screws.
3. Apply caulk to end of J-cap to seal thoroughly.
Figure 13. TCP outdoor roof assembly - single span
TCP Outdoor Roof Assembly - Multiple Span
6-inch trim cap
#10 sheet metal screw
CaulkCap and
gasket
Standing seam
10 ga. galv
#14 sheet metal screw
on 10-inch centers
18 ga. galv
Zip screws
Follow instructions in Figure 13 for installation of J-Caps.
4. The multiple roof split requires and additional cap that covers the center T-shaped seam running parallel to air flow.
5. Install #14 self drilling screws on 10-inch centers on underside of center split as shown in
Figure 14.
Figure 14. TCP outdoor roof assembly - multiple span
Installation - Mechanical
CAH-SVX01B-EN 27
6. Apply 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 in pre-punched holes.
9. Apply a bead of caulk over the butt joint where roof caps meet.
10. Install roof cap trim piece at joint of each roof cap using #10 sheet metal screws.
Installation - Mechanical
18 ga. strip
18 ga. trim cap
No greater than 6 inch spacing on all fasteners
18 ga. trim cap
Gasket
#10 SMS
“Zip” screw
18 ga. strip
18 ga. trim cap
18 ga. strip
Interior of unit
TCP Indoor Roof Section Assembly (Typical)
1. Ensure shipping split sections are alig ned an d pu lled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec 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 bot tom openings with caulk as a moisture seal. S crew holes can be pre-drilled with a #29 bit.
7. Apply a bead of caulk over top corner of cap seam.
8. Using #10 sheet metal screws, attach corner seam trip cap as shown in Figure 15.
Figure 15. TCP indoor wall and roof assembly - trim cap
TCP Indoor Roof Assembly - Multiple Span
6-inch trim cap
#10 sheet metal screw
CaulkCap and
gasket
Standing seam
10 ga. galv
#14 sheet metal screw
on 10-inch centers
18 ga. galv
Zip screws
1. Ensure shipping split sections are alig ned an d pu lled together properly.
2. Apply a bead of caulk to full height of wall joint.
3. Apply 3-inch x 1/8-inch adhesive-backed foam gasket to inner joining strip.
4. Install inner joining strip using #14 x 1.5-inch gasketed tec 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 bot tom openings with caulk as a moisture seal. S crew holes can be pre-drilled with a #29 bit.
7. Apply a bead of caulk over top corner of cap seam.
8. Using #10 sheet metal screws, attach corner seam trip cap as shown in Figure 16.
Figure 16. TCP indoor roof assembly - multiple span
Installation - Mechanical
CAH-SVX01B-EN 29
Installation - Mechanical
Interior
wall
4-in. x 1/4-in. gasket
Secure 2-in. x 2-in. angle to wall with #14 SM screws at 12-in. centers
Caulk
Split
Split
Interior
wall
Caulk
Caulk
Split
Split
Base-to-Wall Assembly Complete
TCP Base-to-Interior Wall Section Assembly
Note: Failure to completely compress the gasketing may result in air leakage.
1 . Join the two units and secure with field provided 5/8-inc h flat washers and 5/8-inch X 2-1/2-inch
grade 9 bolts though each of the six holes.
2. Apply caulk th e leng th of t he base betwe en th e 2-inch X 2-inch angle on the one base section and the wall on the adjoining section. See Figure 17 below. Note: Use a polyurethane or equivalent caulk.
3. Secure the 2-inch X 2-inch angle to the adjoining wall with #14 sheet-metal crews on 12-inch centers along the length of the angle and wall.
Figure 17. TCP base-to-interior wall sections
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