Installation
Operation
Maintenance
Custom
Climate Changer™
Air Handlers
Part No. X39640745010
July 2005 CAH-SVX01A-EN
NOTICE:
Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.
WARNING
...indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
...indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
CAUTION
...indicates a situation that may result in equipment or property-damage-only accidents.
© 2005 American Standard All rights reserved CAH-SVX01A-EN
Introduction
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.
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.
Each unit is provided with a
nameplate. This nameplate includes
unit model number, serial number
and electrical data.
The fans are internally isolated. To
insure fan stability, the unit ships
with a minimum of four lock-down
devices that prevent the fan from
shifting during shipment and
installation. These spacers must be
removed prior to fan operation to
assure 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. These can be use as
stand-alone devices or operate with a
complete controls system. End devices
include factory-mounted starters and
variable speed drives.
Custom Climate Changer™ air
handlers ship as complete
assemblies or in sections. Some
jobsite assembly is required when
the units ship in sections.
Protecting the
Environment
World environmental scientists have
concluded, based on the best
currently available evidence, that
ozone in our upper atmosphere is
being reduced due to the release of
CFC (chlorofluorocarbon) fully
halogenated compounds.
Trane urges that all HVAC servicers
working on Trane equipment, or any
manufacturer’s products, make
every effort to eliminate, if possible,
or vigorously reduce the emission of
CFC, HCFC (halocarbon that contains
fluorine, chlorine, carbon, and
hydrogen), and HFC (halocarbon
that contains only fluorine, carbon,
and hydrogen) refrigerants to the
atmosphere resulting from
installation, operation, routine
maintenance, or major service on
this equipment. Always act in a
responsible manner to conserve
refrigerants for continued use even
when acceptable alternatives are
available.
Refrigerant used in any type of airconditioning or refrigerating
equipment should be recovered for
reuse, recovered and/or recycled for
reuse, reprocessed (reclaimed), or
properly destroyed, whenever it is
removed from equipment. Never
release it to the atmosphere!
CAH-SVX01A-EN 3
Contents
Introduction .........................................................................3
Unit Description .................................................................................. 3
Protecting the Environment ................................................................ 3
Contents ............................................................................... 4
General Information ............................................................ 5
Operating Environment ....................................................................... 5
Controls ............................................................................................... 5
Ultraviolet (UV) Germicidal Irradiation Lights (optional) ....................... 6
Pre-Installation Requirements ...........................................7
Receiving Checklist ............................................................................. 7
Resolving Shipping Damage ............................................................... 7
Job Site Storage Recommendations ................................................... 7
Preparing the Unit Site ........................................................................ 8
Roof Curb Installation .......................................................................... 9
Installation ......................................................................... 10
Lifting and Rigging .............................................................................10
Unit Assembly ....................................................................................11
TCP Model Assembly Instructions .................................................... 12
TCC Model Assembly Instructions .....................................................17
Duct Connections ............................................................................. 24
Component Installation Requirements ............................................. 24
Coil Piping and Connections ............................................................. 28
Wiring ................................................................................................ 41
External Insulating Requirements ..................................................... 42
Startup ............................................................................... 43
Pre-Startup Checklist ......................................................................... 43
Unit Operation................................................................................... 44
Determine Fan Speed ....................................................................... 47
Sheave Alignment ............................................................................. 47
Multibelt Check ................................................................................. 47
Routine Maintenance ........................................................48
Air Filters ........................................................................................... 49
Drain Pans ......................................................................................... 50
Fans ................................................................................................... 50
Coils .................................................................................................. 52
Moisture Purge Cycle ........................................................................ 53
Internal Insulation .............................................................................. 54
Ultraviolet (UV) Germicidal Irradiation Lights ..................................... 55
Troubleshooting ................................................................56
4 CAH-SVX01A-EN
General
Information
Operating
Environment
When considering the placement of
the Custom Climate Changer 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: The customer should provide
adequate freeze protection for the
coils.
Controls
Wiring Sizes and
Connections
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 module
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.
Factory-Mounted Controls
Small items that cannot be factory
mounted will ship inside the control
enclosures. Larger items may ship
inside the fan module.
Note: All control valves ship directly
to the “ship-to address” from the
vendor unless another address is
given on the Trane sales order.
Depending on job requirements, the
customer may need to provide
120 Vac 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.
For a more in-depth understanding
of controls, refer to the following
manuals:
• For factory-configured AH540/
AH541 controllers,
CNT-SVX05B-EN
• For programmable MP580
controllers, CNT-SVP01A-EN
• For hardware installation,
CNT-SVN01A-EN
• For Danfoss VFD,
TR1-SVX10A-EN
• For universal programmable
control modules (UPCMs):
–EMTX-PG-5
– EMTX-IN-22A
Custom air handlers and/or fieldinstalled 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 noncondensing. Electrical components are
not moisture-tolerant.
Note: The warranty will not cover
damage to the unit or controls due
to negligence during storage. A
controlled indoor environment is
recommended for proper storage.
For further storage considerations,
refer to “Job Site Storage
Recommendations” on page 7.
CAH-SVX01A-EN 5
General Information
Ultraviolet (UV)
Germicidal
Irradiation Lights
(optional)
The United States Environmental
Protection Agency (EPA) believes
that molds and bacteria inside
buildings have the potential to cause
health problems in sensitive
individuals
provides ultraviolet lights (UV-C) as
a factory-engineered and installed
option in select commercial air
handling products.
When UV lights are factory provided,
polymer materials that are
susceptible to deterioration by the
UV-C light will be substituted or
shielded from direct exposure to the
light.
In addition, UV-C radiation can
damage human tissue, namely eyes
and skin. To reduce the potential for
inadvertent exposure to the lights by
operating and maintenance
personnel, electrical interlocks that
automatically disconnect power to
the lights are provided at all unit
entry points to equipment where
lights are located.
1.United Sates Environmental Protection Agency; A
Brief Guide to Mold, Moisture and your Home;
Brochure EPA 402-K-02-003.
(1)
. If specified, Trane
WARNING
Equipment Damage From
Ultraviolet (UV) Lights!
Trane does not recommend field
installation of ultraviolet lights in its
air handling equipment for the
intended purpose of improving
indoor air quality. High intensity Cband 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 (can cause
damage to eyes and skin). Polymer
materials commonly found in HVAC
equipment that may be susceptible
include insulation on electrical
wiring, fan belts, thermal insulation,
various fasteners and bushings.
Degradation of these materials can
result in serious damage to the
equipment.
Trane accepts no responsibility for
the performance or operation of our
air handling equipment in which
ultraviolet devices were installed
outside of the Trane factory.
6 CAH-SVX01A-EN
Pre-Installation
Requirements
Receiving Checklist
Based on customer requirements,
Custom Climate Changer air
handlers can ship as complete units
or as individual sections to be field
assembled.
Upon receipt of the unit(s) and prior
to unloading, remove any shipping
material and inspect the unit for
damage and verify that the shipment
is complete.
Note: Delivery cannot be refused.
Trane is not responsible for shipping
damage.
1 Visually inspect components for
any damage that may have
occurred during shipment.
2 Check all access doors to confirm
that the latches and hinges are
not damaged.
3 Inspect the interior of each
section for any internal damage.
Note: Concealed damage must be
reported within 15 days of receipt.
4 Inspect the coils for damage to
the fin surface and/or coil
connections.
5 If the unit was ordered with
factory-mounted controls, locate
all sensors.
Note: Items that cannot be factorymounted should ship inside the
control enclosures or should be
packaged inside the fan module or
mixing box module.
6 Check all devices attached to the
unit exterior and confirm that
they are not damaged.
7 Manually rotate the fan wheel to
ensure free movement of the
shaft, bearings, and drive.
Inspect the fan housing for any
foreign objects.
8 Locate assembly hardware.
9 Inspect and test all piping for
possible shipping damage.
Nipples may be installed on coils
at the factory but should always
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: Trane will not be responsible
for any leak at the field connections.
Coils have been factory pressure
tested before shipping.
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 occurred to the unit
during shipment, follow these
instructions:
Note: Trane is not responsible for
shipping damage.
1 Make specific notation,
describing the damage, on the
freight bill. Take photos of the
damaged material, if possible.
2 Report all claims of shipping
damage to the delivering carrier
immediately and coordinate
carrier inspection, if necessary.
Note: Do not attempt to 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.
Job Site Storage
Recommendations
Custom units 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.
CAUTION
Use Canvas Only!
Use only canvas tarps to cover air
handlers. Plastic tarps cause
condensation to form in and on the
equipment, which can result in
corrosion damage or wet storage
stains.
CAH-SVX01A-EN 7
Pre-Installation Requirements
General Storage
The unit controller and all other
electrical/electronic 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.
• Every six months, check fan shaft
bearings and grease lines. Add
grease using a manual grease
gun following the lubrications
recommendations in “Fan
Bearing Lubrication” on page 51.
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 container for
protection and ease of handling.
1 Select a well-drained area,
preferably a concrete pad or
blacktop surface.
2 Place the unit on a dry surface or
raised off the ground to assure
adequate air circulation beneath
the unit and to assure no portion
of the unit will contact standing
water at any time.
3 Loosen the belt tension on the
drive belts.
4 Cover the unit securely with a
canvas tarp.
5 Do not stack units.
6 Do not pile other material on the
unit.
Preparing the Unit
Site
1 Ensure the installation site can
support the total weight of the
unit. The building roof must be
able to support the entire weight
of the unit, roof curb and
accessories. Refer to the unit
submittals for weights.
2 Allow sufficient space to allow
adequate free air and necessary
service access. Refer to
submittals for specific
minimums.
3 Allow room for supply and
return piping, ductwork,
electrical connections, and coil
removal.
4 Ensure there is adequate height
for condensate drain
requirements. See “Drain Pan
Trapping” on page 29.
Note: 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.
WARNING
Level Foundation!
The floor 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 air-handling units could result
in microbial growth, which may
cause unpleasant odors, serious
health problems, or death.
5 Confirm the foundation of the
mounting platform is level and
large enough to include the unit
dimensions (refer to the unit
submittals for specific
dimensions).
6 Provide adequate lighting for
maintenance personnel to
perform maintenance duties.
7 Provide permanent power
outlets in close proximity to the
unit for installation and
maintenance.
8 Depending upon job
requirements, the customer may
need to provide 120 Vac power to
the unit controller. Refer to
submittals for more information.
A dedicated 15-amp circuit is
recommended.
9 Wiring for Custom units must be
provided by the installer and
must comply with all national
and local electrical codes.
10 Rooftop curb mounted units
must be sealed tightly to the
curb. Use proper sealants 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.
8 CAH-SVX01A-EN
Pre-Installation Requirements
Roof Curb
Installation
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)
Figure 1. Cross section of typical curb installation on new construction
Typical Curb Installation
Checklist
• Verify that the roof structure can
adequately support the
combined weight of the unit and
curb assembly.
• Ensure that the selected
installation location provides
sufficient service and operational
clearances.
• Remove any twist within the curb
due to roof supports and square
the curb.
• Level the curb.
• Secure the curb to the roof
support members.
• Install 2-inch thick boards or rigid
insulation around the curb.
• Install cant strips around the
curb.
• Bring field supplied roofing felt
up to the top of the curb nailing
strips. ail felt into place.
• Install field supplied flashing
under the lip of the curb flanges
and over the felt.
•
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
.
CAH-SVX01A-EN 9
Installation
Lifting and Rigging
WARNI NG
Lifting and Rigging!
Do not lift, rig, or ceiling-suspend
from the top of the unit. Lift from
lifting lugs only, located at the
bottom of the unit. Use all lifting
lugs provided.
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 supporting the
entire weight of the unit. Lifting
cables (chains or slings) may not be
of the same length. Adjust as
necessary for even unit lift.
Do not use a fork lift for handling
units. This may result in equipment
damage. Trane is not responsible for
equipment damage resulting from
improper forklifting practices.
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.
Always place, assemble, and
suspend sections one at a time.
Failure to follow instructions could
result in death or serious injury or
equipment damage.
Figure 2. Recommended attachment to
lifting lugs.
Figure 3. Use proper lifting and rigging methods
Per job requirements, air handlers
will ship as a complete assembly or
in sections.
Trane recommends that the
contractor use spreader bars and
slings to rig units and
subassemblies.
Before preparing the unit for lifting,
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.
General Lifting
Considerations
• Always rig subassemblies or
• Always assemble unit at the
• Make the loop of the sling
• Each of the cables used to lift the
• When hoisting the unit into
sections as they ship from the
factory. See the unit submittal
drawings for correct placement
of sections.
installation site. Never bolt
sections together before rigging.
parallel to the direction of
airflow, if possible.
unit must be capable of
supporting the entire weight of
the unit.
position, use the proper rigging
method, such as straps, slings,
spreader bars, or lifting lugs for
protection and safety.
Note: Never lift units in windy
conditions.
10 CAH-SVX01A-EN
Installation
• Personnel should be positioned
overhead and on the ground to
guide the crane or helicopter
operator in positioning the
sections.
• The air handler is not designed
to be lifted, rigged or ceiling
suspended from the top of the
unit.
• 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.
Unit Assembly
Note: If the unit is shipped as a
complete assembly, go to “Coil
Piping and Connections” on
page 28.
Prior to unit assembly, refer to the
unit submittal drawings and unit
tagging for correct 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.
Units may be mounted on the roof
with a roof curb or pier mount. Units
may be mounted indoors on
housekeeping pads. Refer to
submittals for unit dimensions and
openings.
Note: For proper operation, the unit
must be supported around the entire
unit base perimeter. If the unit is
shipped in sections, the entire
section perimeter must be
supported, as well as at the base
channels of the unit splits.
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
support the entire weight of the unit,
roof curb and accessories. See
submittals for approximate unit
weights.
• Preparation of the roof curb or
pier mount and roof openings
should be completed prior to
lifting the unit to the roof.
• Check that the gasketing or
sealant on the roof curb is intact
and provides an airtight seal with
the unit base.
• Complete all ductwork, piping
and electrical connections only
after mounting the unit.
Assembly Hardware
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 one of the sections. If space
inside a section is not adequate, a
crate or pallet will be loaded onto
the bed of the truck. Check the Parts
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. The number of sections to
be assembled often makes it
necessary to use more than one
section to ship the material. Please
check all sections thoroughly before
contacting your local Trane sales
engineer to report missing
hardware.
CAH-SVX01A-EN 11
Installation
TCP Model
Assembly
Instructions
If your nameplate model number
begins with TCP, use the assembly
instructions below.
Joining Sections Edge-toEdge
Units must be installed level for
proper drainage of condensate 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.
two sections should be within 12
inches to reduce the amount of
dragging required.
6 Remove lifting lugs on mating
section as required.
7 Insert threaded rods through
each hole of each mating
connecting plate (see Figure 4).
Bring each connecting surface
together uniformly until
gasketing is contacted.
Note: Use field provided threaded
rods inserted in all holes of each
connecting plate to prevent damage
and distortion of the sections as they
are joined. Tighten all rods in
sequence. Do not try to join sections
by tightening only some of the rods.
Figure 4. Insert threaded rods through each hole of mating connecting plate.
Note: Failure to compress the
gasketing may result in air leakage.
8 Secure the unit sections at the
base using the field provided
bolts, nuts and washers at the
connecting plates.
9 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.
2 Place one section of the air
handler into the desired position.
Verify each section is level and
properly supported prior to
proceeding with assembly. Each
unit must be level side-to-side
and front to back. Check
squareness measuring the
critical dimensions given.
3 When the unit is positioned and
squareness is assured within 1/8inch, remove all lifting lugs
located along the split plane.
4 Install 4-inch x 1/4-inch neoprene
gasket to all mating surfaces of
the section, including the internal
walls. This gasket must be
applied to the full perimeter of
the section split of both sections
to be joined.
5 Move the next mating section
into alignment with the
positioned section. Alignment of
sections must be completed
before gasket surfaces meet. The
12 CAH-SVX01A-EN
Installation
TCP Base Section
Assembly (Typical)
Note: Failure to completely
compress the gasketing may result
in air leakage.
1 Join the two units and secure
with field provided 5/8-inch flat
washers and 5/8-inch X 2-1/2-inch
grade 9 bolts though each of the
six holes.
2 Caulk the overlapping flange
along the length of each split to
maintain a seal.
Note: Use a polyurethane or
equivalent caulk.
Figure 5. TCP base assembly
3 Apply the 3-inch X 1/8-inch
gasket evenly across the two
joined edges of the splits.
4 Before installing the pre-cut 4-
inch 18 gauge joining strip over
the gasket, 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.
5 Apply the 4-inch joining strip
over the gasket and uniformly
straddle the splits. Secure with
number 14 sheet-metal screws at
12-inch centers.
WITH 7/32"
JOIN WITH
5/8" FLAT WASHER
5/8" X 2 1/2" GRADE 9 BOLTS
A
BASE ASSEMBLY.
PREDRILL HOLES
DRILL BIT.
3" X 1/8" GASKET
A
SPLIT
18 GAUGE JOINING STRIP
SECURE W/#14 S.M. SCREWS
@ 12" CTR'S.
4"
ADD CAULKING BEFORE
ADDING JOINING STRIPS.
SPLIT
4" X 1/4" GASKET.
CAH-SVX01A-EN 13
Installation
TCP Wall Section Assembly
(Typical)
1 Apply the walls and join at the
inside angles with number 14
sheet-metal screws on 12-inch
centers along the length of the
angles.
2 Apply the 1/8-inch gasket evenly
to the exterior of the walls across
the two joined edges of the
splits.
3 Before installing the pre-cut
joining strip over the gasket, predrill holes in the wall using the
strip as a guide with a number 29
drill bit at 12-inch centers.
Figure 6. TCP outdoor roof assembly
4 Apply the joining strip over the
gasket and uniformly straddling
the splits. Secure with number 10
sheet metal 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 number
8 sheet metal screws. Fill the top
and bottom openings with caulk
as moisture seal. Pre drill holes
with a number 29 bit.
TCP Outdoor Roof Section
Assembly (Typical)
1 Align the roof splits and join the
interior section trim with number
14 sheet metal screws on 12 inch
centers.
INSTALLING J-CAP
2 Add a bead of caulk along the
length of the roof seams. Install
the pre-cut J-cap over the seam
and secure with number 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 predrill to prevent
separation when drilling with
screws.
3 Apply caulk to the end cap
interior surface. Secure the end
cap on the J-cap with one
number 10 screw.
SPLIT
4" X 1/4" GASKET
SECURE J-CAP
W/#14 S.M. SCREWS.
SPLIT
SECTION TRIM ACTS AS
AS JOINING ANGLE
SECURE w/#14 S.M.
@ 12" CENTERS.
APPLY CAULKING TO END CAPS
THEN SECURE END CAPS
TO THE ENDS OF J CAP.
J-CAP
END CAP
14 CAH-SVX01A-EN
Installation
TCP Indoor Roof Section
Assembly (Typical)
1 Align the walls and join the
inside angles with number 14
sheet metal screws on 12-inch
centers along the length of the
angles.
2 Apply a bead of caulk along the
length of the roof seam joint.
3 Apply the 1/8-inch gasket on the
exterior of the roof evenly across
the roof split.
Figure 7. TCP indoor roof assembly
PREDRILL HOLES
WITH #29
SECURE HUB CAP W/#8
S.M. SCREWS.
DRILL BIT.
4 Before installing the pre-cut
joining strip over the gasket, predrill holes in the roof using the
strip as a guide with a number 29
drill bit at 12-inch centers.
5 Apply the joining strip over the
gasket and uniformly straddling
the splits. Secure with #10 sheet
metal screws.
6 Fit the pre-cut hub cap and
secure it to the roof with #8 sheet
metal screws. Fill the end
openings with caulk as moisture
seal. Note: Pre drill the screw
holes with a number 29 bit.
3" JOINING STRIP
SECURE WITH #10 S.M. SCREWS.
3" X 1/8" THICK GASKET
(2) 1 1/4" X 6" GALVANIZED ANGLE
4" X 1/4" GASKET
SECURED W/ #14 S.M. SCREWS
@ 12" CENTERS
INDOOR
CAH-SVX01A-EN 15
ROOF ASSEMBLY COMPLETE
SPLIT
Installation
TCP Base to Interior Wall
Section Assembly (Typical)
Note: Failure to completely
compress the gasketing may result
in air leakage.
1 Join the two units and secure
with field provided 5/8-inch flat
washers and 5/8-inch X 2-1/2-inch
grade 9 bolts though each of the
six holes.
Figure 8. TCP base to interior wall sections
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 the adjoining
section. See Illustration below.
Note: Use a polyurethane or
equivalent caulk.
3 Secure the 2-inch X 2-inch angle
to the adjoining wall with
number 14 sheet-metal crews on
12-inch centers along the length
of the angle and wall.
INTERIOR
WALL
4" X 1/4" GASKET
SECURE 2" X 2" ANGLE TO WALL
W/#14 S.M. SCREWS @ 12" CTR'S
CAULK
SPLIT
INTERIOR
WALL
SPLIT
CAULK
CAULK
SPLIT
SPLIT
BASE TO WALL ASSEMBLY COMPLETE
16 CAH-SVX01A-EN
Installation
TCC Model
Assembly
Instructions
If your nameplate model number
begins with TCC, use the assembly
instructions below.
Joining sections - Edge to
Edge
Units must be installed level for
proper drainage of condensate from
the drain pan and for squareness of
the sections during installation. In
addition, each section in a multisection unit must be properly
supported.
Note: Leveling each section,
beginning with the first section, is
critical. Failure to level and align the
sections immediately creates greater
misalignment or even structural
damage afterward.
• Remove all wooden blocks under
the unit and shipping protection
from adjoining surfaces (see
Figure 9).
• Place the first section of the air
handler on the end of the roof
curb or the housekeeping pad.
The section must be level from
side-to-side and front to back.
Section squareness should be
within 1/8-inch. Remove the
bottom bolts from lifting lugs
located at the shipping split (see
Figure 10).
Figure 9. Remove shipping blocks
Figure 10. Remove lifting lug bolts
CAH-SVX01A-EN 17
Installation
• Apply 1.25-inch x 0.33-inch
ribbed butyl tape to the shipping
split channel and shipping split
plates (see Figure 11).
• Verify the section is level prior to
proceeding with the next section
of the unit.
Figure 11. Apply butyl tape to shipping splits
• Move the next unit section as
close as possible from the
previous section. The two
sections should be close enough
to reduce the amount of
dragging required. This is
particularly important when
mounting on a roof curb to
minimize damage to the sealant
on the roof curb. Alignment of
sections must be completed
before drawing sections
together.
• Remove the bottom bolts from
the shipping split lifting lugs (see
Figure 12).
Figure 12. Remove bottom bolts from
lifting lugs
18 CAH-SVX01A-EN