Installation Manual Rental Services Air Handling Units July 2008 CHS-SVN01A-EN
Copyright 2008 Trane All rights reserved This document and the information in it are the property of Trane and may not be used or reproduced in whole or in part, without the written permission of Trane. Trane reserves the right to revise this publication at any time and to make changes to its content without obligation to notify any person of such revision or change. Trademarks Trane, Rover, the Trane logo, are trademarks of Trane in the United States and other countries. All other brands and products referenced in this document are acknowledged to be the trademarks or registered trademarks of their respective holders. Warnings and Cautions. Notice that warnings and cautions appear at appropriate intervals throughout this manual. Warnings are provided to alert installing parties of potential hazards that could result in personal injury or death, while cautions are designed to alert personnel to conditions that could result in equipment damage. Your personal safety and the proper operation of the Trane Rental Services temporary chilled water system depend upon the strict observation of these precautions. Please refer to the Installation Operation Manual (IOM) for all appropriate Warning and Cautions. 2 Rental Services Air Handling Unit CHS-SVN01A-EN Trane All rights reserved
Contents Introduction................................................4 General Information.........................................5 10,000 cfm Air Handling Unit (nom. 25 tons).....................6 10,000 cfm Air Handling Unit Fan Curve....................7 10,000 cfm Air Handling Unit Drawing.....................8 25,000 cfm Air Handling Unit w/vfd............................9 25,000 cfm Air Handling Unit Fan Curve...................10 25,000 cfm Air Handling Unit Drawing....................11 Electrical Information.......................................12 Piping Connection Configuration..............................12 10,000 cfm Unit Piping Manifold.........................12 25,000 cfm Unit Piping Manifold.........................13 Duct Configuration Information...............................15 Controls Information........................................15 Rigging Guidelines.........................................17 Installation/Startup Guidelines................................18 Maintenance Guidelines.....................................19 Decommissioning Guidelines................................19 CHS-SVN01A-EN Rental Services Air Handling Unit 3
Air Handling Units Introduction This engineering bulletin covers the rental air handling units (AHU) available to rent from Trane Rental Services for temporary cooling solutions. This includes AHU technical information, start-up information, and unit maintenance. The information contained in this bulletin is provided to ensure the safe installation and operation of the equipment and its surroundings. The information provided in this Engineering Bulletin is to be used as a reference for each AHU to aid in determining unit size, power requirements, or lifting requirements. If additional information regarding a particular unit is required, please contact Trane Rental Services. Contact Trane Rental Services Marketing for availability of equipment (including ancillary items: pumps, flexible hose, flexible duct) prior to obtaining a purchase order from the customer. Equipment is available on a first-come, first-serve basis, but can be reserved with a signed rental agreement. Call Rental Services 24 x 7 at (800) 755-5115 for specific questions.! WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. Important: All air handlers should be installed per the National Electric Code (NEC) and/or applicable state and local codes. Note: All information contained in this document is for reference only. 4 Rental Services Air Handling Unit CHS-SVN01A-EN
Air Handling Units General Information Our rental air handling units are custom Trane air handlers that have been modified for use as rental units. The majority of the modifications are related to framing for rigging purposes, connection of chilled water piping, and temporary duct connection. These air handling units contain only chilled water coils and do not have heating capability. Each unit has been selected for use with 100% outside air. Return plenums are available if required. An MP580 controller with touch screen display and wireless zone sensor is included with each unit. In addition, each unit includes a Trane TR1 variable frequency drive (VFD) that can control the fan motor. For additional information on the unit controls see Controls Information on page 15. CHS-SVN01A-EN Rental Services Air Handling Unit 5
10,000 cfm Air Handling Unit General RSAU0025F0 Model Number....................................................TCCA Nominal Tonnage.................................................25 tons Water Connection Size..................................... 2.5 in. Victaulic Ambient Operating Conditions1................................... 25 115 F Supply Motor..................................................... 20 Hp Fused Disconnect....................................................Yes Number of Electrical Circuits.............................................1 Discharge Configuration........................................ Horizontal Flex Duct Connection Size......................................19 in round Number of Discharge Air Connections.................................... 2 Max Discharge Static Pressure................................. 5.82 in. ESP Filter Rack (Quantity and size)2..................... (4) 24 x 24, (2) 24 x 12 Nominal Air Flow (cfm)............................................ 10,000 Min/Max Air Flow (cfm)....................................... 8,000/15,000 Insurance Value................................................. $35,000 Selection is required for actual AHU performance. 1 For ambient conditions below 40 F, glycol is recommended. 2 Unit provided with standard 2 filters. Filter rack will accept up to 95% efficient MERV 14 filters. Electrical Data Voltage.................................................... 460V 3-phase Frequency........................................................ 60 Hz Lug(s) can accept wire up to3.................................. #3 AWG wire Minimum Circuit Ampacity (MCA)................................ 42.5 amps Maximum Overcurrent Protection (MOP)............................ 60 amps 3 Depending on unit MCA and wire used, multiple wires per phase may be required. For additional electrical information contact Trane Rental Services. Total Cooling Capacity Entering Chilled Water Temperature (F) Outdoor Ambient Temperature (F) 84 db / 77 wb 44 909.85 MBh Contact Trane Rental Services for specific selection information. Water Flow Rates Minimum Standard Maximum Coil Flow 70 gpm 151 gpm 400 gpm Pressure Drop 4.61 ft H 2 0 Dimensions and Weights Length Width 4 Height Weight Maximum water side pressure is 150psi (2.31 H20 = 1 psi) 16 ft 0 in 7 ft 4 in 7 ft 6 in 6,000 lbs 4Width includes permanently mounted piping manifold. Lifting Device: Fork Lift or Crane 6 Rental Services Air Handling Unit CHS-SVN01A-EN
10,000 cfm Air Handling Unit (nom. 25-tons) 10,000 cfm Air Handling Unit Fan Curve CHS-SVN01A-EN Rental Services Air Handling Unit 7
10,000 CFM Air Handling Units 10,000 cfm Air Handling Unit Drawing Note: Drawing should be used for information only as drawing depicts factory unit without rental modifications. 8 Rental Services Air Handling Unit CHS-SVN01A-EN
25,000 CFM Air Handling Units General RSAU0062F0 Model Number....................................................TCCA Nominal Tonnage...............................................62.5 tons Water Connection Size........................................4 in. Victaulic Ambient Operating Conditions 1...................................25-115 F Supply Motor.....................................................50 Hp Fused Disconnect....................................................Yes Number of Electrical Circuits............................................1 Discharge Configuration........................................Horizontal Flex Duct Connection Size.....................................19 in. round Number of Discharge Air Connections....................................4 Max Discharge Static Pressure..................................6.00 in. ESP Filter Rack (Quantity and size) 2..........(9) 24 x 24, (3) 24 x 12, (3) 12 x 24 Nominal Air Flow (cfm)............................................ 25,000 Min/Max Air Flow (cfm)......................................15,000/35,000 Insurance Value................................................. $45,000 Selection is required for actual AHU performance. 1 For ambient conditions below 40 F, glycol is recommended. 2 Unit provided with standard 2 filters. Filter rack will accept up to 95% efficient MERV 14 filters. Electrical Data Voltage..................................................... 460V 3-phase Frequency......................................................... 60 Hz Lug(s) can accept wire up to 3....................................1/0 AWG wire Minimum Circuit Ampacity (MCA)................................... 91 amps Maximum Overcurrent Protection (MOP)............................ 100 amps 3 Depending on unit MCA and wire used, multiple wires per phase may be required. For additional electrical information contact Trane Rental Services. Total Cooling Capacity Entering Chilled Water Temperature (F) Outdoor Ambient Temperature (F) 84 db / 77 wb 44 2274.6 MBh Contact Trane Rental Services for specific selection information. Water Flow Rates Minimum Standard Maximum Coil Flow 110 gpm 378 gpm 820 gpm Pressure Drop 12.26 ft H 2 0 Maximum water side pressure is 150psi (2.31 H20 = 1 psi) Dimensions and Weights Length Width 4 Height Weight 18 ft 2 in 8 ft 6 in 10 ft 1 in 10,500 lbs 4Width does not include field installed piping manifold. Lifting Device: Fork Lift or Crane CHS-SVN01A-EN Rental Services Air Handling Unit 9
25,000 CFM Air Handling Units 25,000 cfm Air Handling Unit Fan Curve 10 Rental Services Air Handling Unit CHS-SVN01A-EN
25,000 CFM Air Handling Units 25,000 cfm Air Handling Unit Drawing Note: Drawing should be used for information only as drawing depicts factory unit without rental modifications. CHS-PRB009-EN Rental Services Air Handling Unit 11
Air Handling Units Electrical Information FIGURE 1 Disconnect FIGURE 2 Emergency stop FIGURE 3 Circuit breaker Each air handling unit (AHU) has an external fused disconnect as shown in Figure 1. In addition to the external fused disconnect each unit has an external start/stop button on the outside of the control cabinet access door (Figure 2) and a circuit breaker inside the control cabinet (Figure 3). Each 10,000cfm unit is provided with a minimum of 50-ft of #8/4 600V electrical cable connected to the external fused disconnect. Each 25,000cfm unit is provided with a minimum of 50-ft of #4/4 600V electrical cable connected to the external fused disconnect. Piping Connection Configuration 10,000 cfm Air Handling Unit (RSAU0025F0 ) Each 10,000 cfm AHU has two 2.5-in threaded inlet chilled water connections and two 2.5-in threaded outlet chilled water connections. Piping Manifold To provide a single chilled water connection point for each 10,000 cfm air handling unit, a piping manifold has been made to connect each unit s chilled water coils. Each 10,000 cfm unit has a manifold that is permanently installed on the unit for flex hose connection (Figure 4). The contents of the drop down kit for the 10,000 cfm units are listed in the bill of material below. The manifold kit will ship in the mixed air chamber and can be accessed through the filter access door. 12 Rental Services Air Handling Unit CHS-SVN01A-EN
Air Handling Units Bill of Material for 10,000 cfm Air Handling Unit Piping Manifold QUANTITY DESCRIPTION OF ITEMS 8 2.5 Victaulic quick-snap couplings 2 2.5 30 pipe section 4 2.5 Victaulic 90 degree elbows FIGURE 4 10,000 cfm unit piping manifold 25,000 cfm Air Handling Unit (RSAU0062F0 ) Each 25,000 cfm AHU has four 2.5-in threaded inlet chilled water connections and four 2.5-in threaded outlet chilled water connections. Piping Manifold To provide a single chilled water connection point for each 25,000 cfm air handling unit, a piping manifold has been made to connect each unit s chilled water coils. Each 25,000 cfm unit has a manifold that must be field installed on each unit for flex hose connection (Figure 5). The contents of the piping manifold kit for the 25,000 cfm units are listed in the bill of material below. The manifold kit will ship in the mixed air chamber and can be accessed through the filter access door. CHS-SVN01A-EN Rental Services Air Handling Unit 13
Air Handling Units Bill of Material for 25,000 cfm Air Handling Unit Piping Manifold QUANTITY DESCRIPTION OF ITEMS 2 4 Manifold pipe section 2 4 Victaulic blank off 8 4 Victaulic quick-snap couplings 24 2.5 Victaulic quick-snap couplings 4 2.5 x 3 flex hose section 2 2.5 x 6 pipe section 8 2.5 Victaulic 90 degree elbows 2 4 x 6 Victaulic reducers 2 4 x 43 pipe section 4 4 Victaulic 90 degree elbows FIGURE 5 25,000 cfm unit piping manifold Reference the Rental Services hose engineering bulletin, CHS-PRB007-EN, for further information. 14 Rental Services Air Handling Unit CHS-SVN01A-EN
Air Handling Units Duct Connection Configuration 10,000 cfm Air Handling Unit (RSAU0025F0 ) Each 10,000 cfm AHU has two 19-in diameter discharge air connections. Each discharge air connection has a manual damper to control air flow. Each connection was made to accept one 20-in diameter flexible duct. 25,000 cfm Air Handling Unit (RSAU0062F0 ) Each 25,000 cfm AHU has four 19-in diameter discharge air connections. Each discharge air connection has a manual damper to control air flow. Each connection was made to accept one 20-in diameter flexible duct. FIGURE 6 Flex Duct Connection Reference the Rental Services flex duct engineering bulletin, CHS-PRB004-EN, for further information. Controls Information All 10,000 cfm and 25,000 cfm rental air handling units come equipped with a Trane MP-580 controller (Figure 7) and Trane TR-1 VFD (Figure 8) mounted in a control cabinet inside the unit. The controller is accessed by opening the external control cabinet door with an emergency stop button. In order for the unit to run using the MP-580 controller and default controls program, the VFD selector switch must be in VFD mode (Figure 9). The unit control program can be accessed using a laptop computer with the Rover service tool software or the unit-mounted stand alone display. The stand alone display is mounted in a sealed cabinet on the front of the unit next to the external disconnect (Figure 10). The operator display touch screen is an intuitive operator interface for monitoring and changing building control functions. With the operator display you can: CHS-SVN01A-EN Rental Services Air Handling Unit 15
Air Handling Units FIGURE 7 MP-580 controller FIGURE 8 TR1 VFD FIGURE 9 VFD Selector Switch Choose between constant volume or VAV. Choose specific air flow within specified range. Monitor space temperature, air flow, filter status, etc. Identify and troubleshoot problems. View and reset controller alarms. FIGURE 10 Unit Mounted Display FIGURE 11 Typical Status Screen The operator display includes a 7-day time clock that allows for time-of-day scheduling with two on/off times per day and up to 20 exception schedules per year. Both the 10,000 cfm and 25,000 cfm units can be configured to run based on a specified air flow (CV) or be controlled by space temperature (VAV) using the Rover service tool or the stand alone display. If the unit is configured as CV (or constant volume) the unit air flow can be specified within a certain air flow range. See chart below for air flow range per unit. Unit Nominal Air Flow (cfm) Min Air Flow (cfm) Max Air Flow (cfm) 10,000 8,000 15,000 25,000 15,000 35,000 If the unit is configured as VAV the unit will be controlled by the zone set-point using the wireless zone sensor that is provided with each unit. The wireless zone sensor can be found inside the control cabinet and is strapped in place for shipment. (See BAS- SVX04A-EN for additional information on wireless zone sensor.) 16 Rental Services Air Handling Unit CHS-SVN01A-EN
Air Handling Units Rigging Guidelines Each air handling unit has forklift pockets and an overhead lifting frame (Figure 12). Refer to page 5 and page 7 for unit dimensions and weights.! WARNING Heavy Objects! Use a forklift/crane of suitable capacity to move the unit. Failure to properly lift unit could result in death or serious injury or possible equipment or property-only damage. FIGURE 12 10,000 cfm Unit in Frame CHS-SVN01A-EN Rental Services Air Handling Unit 17
Air Handling Units Installation and Startup Guidelines In addition to the startup guidelines below, please refer to startup information contained in the Custom Climate Changer Installation, Operation and Maintenance Manual (CAH-SVX01A-EN), TR1 Series VFD Installation and Operation Manual (TR1- SVX10A-EN), and Wireless Zone Sensor Installation, Operation and Maintenance Manual (BAS-SVX04A-EN). [ ] Install piping manifold supplied with unit and ensure all temporary piping is properly secured. See piping configuration information on page 12. [ ] To avoid flooding of unit interior install the P-trap supplied with unit. The unit P-trap is located in a bin in the mixed air chamber that is accessed through the filter access door. [ ] Close all coil drains. [ ] Install all temporary ductwork and open manual supply dampers. See duct connection configuration information on page 15. [ ] Connect electrical cable supplied with unit to power supply. See electrical information on page 12. [ ] Turn the fused disconnect switch located on the front of the unit to the ON position. [ ] Open the control cabinet door and turn the VFD selector switch to the VFD position. [ ] Make sure all access doors are properly closed. [ ] Using the unit mounted stand alone touch screen display select either CV or VAV. See page 16 for display location and explanation of the CV and VAV options. Note: Power must be supplied to the unit to operate the touch screen display. [ ] If the VAV option is selected remove the wireless zone sensor that is shipped inside the unit control cabinet and locate in the conditioned space. [ ] Pull the red Start/Stop button on the unit control cabinet door to start the unit fan. 18 Rental Services Air Handling Unit CHS-SVN01A-EN
Air Handling Units Maintenance Guidelines Please refer to the Custom Climate Changer Installation, Operation and Maintenance Manual (CAH-SVX01A-EN) and Wireless Zone Sensor Installation, Operation and Maintenance Manual (BAS-SVX04A-EN) for any regular unit maintenance. [ ] Monitor differential pressure across the unit filters using the pressure gauge mounted on the outside of the filter access door and change the filters as necessary (see pages 6 and 9 for unit filter rack quantities). Filter status can also be monitored using the stand alone touch screen display mounted in a cabinet on the front of the unit. Decommissioning Guidelines Reference the following guidelines for decommissioning rental AHUs prior to their return at the end of a rental job. Please contact Trane Rental Services at 800-755-5115 for any additional information. [ ] Press the red Start/Stop button on the unit control cabinet door. Allow enough time for the supply fan to come to a complete stop before opening any unit access doors. [ ] Turn the fused disconnect located on the front of the unit to the OFF position. [ ] Open the control cabinet door and turn the VFD selector switch to the OFF position. [ ] Drain solution from the system. If the system has glycol or other anti-freeze solution, flush hoses, manifold, and coil with water. Note: Local codes and regulations apply for disposal of glycol or anti-freeze solutions. [ ] Remove all external piping, temporary manifold pieces (see piping configuration section on page 12), and P-trap. Return P-trap and temporary manifold pieces to the bin located in the mixed air chamber that is accessed through the filter access door. [ ] Open all coil drains. [ ] Remove all temporary ductwork and close manual supply dampers. [ ] Disconnect electrical cable supplied with the unit from the power supply. [ ] Make sure all access doors are properly closed. [ ] Return additional hose, fittings, or cable (if furnished by Trane Rental Services) to appropriate containers for return shipment. [ ] Notify Trane Rental Services (800-755-5115) if unit needs repair or has damage. CHS-SVN01A-EN Rental Services Air Handling Unit 19
www.trane.com For more information, contact your local Trane office or e-mail us at comfort@trane.com Literature Order Number CHS-SVN01A-EN Date July 2008 Supersedes Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. New