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FAXA-SVX01B-EN

Installation, Operation,and Maintenance

Packaged Fresh Air Unit

For 100% Outdoor Air Applications

Models FADA and FAHA

“BO” and later design sequence

April 2003

©2003 American Standard Inc. FAXA-SVX01B-EN

generalinformation

About This Manual

Literature Change History

Use this manual for Packaged Fresh Airunits, models FADA and FAHA. This is the“B” issue of this manual, revised toinclude the total energy wheel option. Itprovides specific installation, operation,and maintenance instructions for “BO”and later design sequences.

These units have modular DDC controlsthat provide operating functions signifi-cantly different than conventional airconditioning units. Refer to the startupand test mode procedures within thismanual. Also, reference the Tranepublication, Packaged Fresh Air UnitProgramming Guide, FAXA-SVP01B-EN.For units with gas heat, also referencethe Reznor Installation Form RGM 401Installation/Operation/Service Manual.

Overview of ManualThis manual describes proper installation,startup, operation, and maintenanceprocedures for the Packaged Fresh Airunit. Carefully review the informationwithin this manual and follow theinstructions to minimize risk of improperoperation and/or component damage.

The roof curb specifically designed for thePackaged Fresh Air unit is available in14” or 24” height from Trane. The curbmust be mounted on a permanent roofstructure before attempting to install theunit. Reference the roof curb installationinstructions in the Trane publication,“Accessory Roof Curb Kit” InstallationManual, FAXA-SVN01B-EN. Dimensionaldata for use with curbs other than Trane,can be found on pages 15-32 of thismanual.

Note: One copy of this manual shipsinside the control panel of each unit.

It is important that you perform periodicmaintenance to help ensure trouble freeoperation. Should equipment failureoccur, contact a qualified Trane serviceorganization for an experienced HVACtechnician to properly diagnose andrepair this equipment.

Note: Do not release refrigerant to theatmosphere!

If adding or removing refrigerant, theservice technician must comply with allfederal, state, and local laws.

Warnings and Cautions

WARNING

Warnings indicate potential hazardoussituations, which if not avoided, can causedeath or serious injury.

CAUTION

Cautions indicate a potentially hazardoussituation, which if not avoided, may causeminor or moderate injury. Also, cautionsmay alert against unsafe practices.

CAUTIONCautions indicate a situation that maycause equipment or property-damageonly.

Examples follow below.

WARNING

Hazardous voltage!Disconnect all electrical powerincluding remote disconnects beforeservicing unit. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to do so can cause death orserious injury.

CAUTIONUse copper conductors only!Unit terminals are not designed toaccept other type conductors. Failureto use copper conductors may causeequipment damage.

Common HVAC AcronymsFor convenience, a number of acronymsand abbreviations are used throughoutthis manual. These acronyms arealphabetically listed and defined below.

BAS = building automation systems

cfm = cubic-feet-per-minuteCKT. = circuitCV = constant volumeCW = clockwiseCCW = counterclockwiseE/A = exhaust airECEM = exhaust/comparative enthalpymoduleF/A = fresh airFAU = fresh air unitGBAS = generic building automationsystemHI = human interfaceI/O = inputs/outputsIOM= installation/operation/maintenancemanualIPC = interprocessor communicationsLCI = LonTalk™ communication interfaceLH = left-handMCM = multiple compressor moduleMWU = morning warmupNSB = night setbackO/A = outside airpsig = pounds-per-square-inch, gagepressureR/A = return airRH = right-handRPM = revolutions-per-minuteRTM = rooftop moduleS/A = supply airSCM = single circuit moduleSZ = single-zone (unit airflow)TCI = Tracer communications moduleUCM = unit control modulesVAV = variable air volumeVCM = ventilation control moduleVOM = ventilation override moduleZSM = zone sensor module

Special Note on RefrigerationEmissions

World environmental scientists haveconcluded that ozone in our upperatmosphere is being reduced due to therelease of CFC fully halogenatedcompounds. Trane urges all HVACservice personnel to make every effort toprevent any refrigerant emissions whileinstalling, operating, or servicingequipment. Always conserverefrigerants for continued use and followall warnings and cautions in this manual.

FAXA-SVX01B-EN 3

contents

Cross reference to related publications:• Packaged Fresh Air Unit Programming Guide, FAXA-SVP01B-EN• Accessory Roof Curb Installation Manual, FAXA-SVN01B-EN• Reznor Installation Form RGM 401, Installation/Operation/Service for units with gas

heat

Installation ……………………………………………………………2

General Information……………………………………………2Pre-installation Considerations ………………………………8Dimensions/Weights …………………………………………15Mechanical Requirements …………………………………33Electrical Requirements………………………………………36Installation Procedure ………………………………………40Pre-Startup Requirements …………………………………51Startup …………………………………………………………52

Operation ……………………………………………………………54

General Information …………………………………………54Sequence of Operation ………………………………………62

Maintenance………………………………………………………… 67

General Information …………………………………………67Maintenance Procedures ……………………………………71Periodic Checklists ……………………………………………77

Index ………………………………………………………………… 79

Note: This document is customer propertyand must be retained by the unit’s owner foruse by maintenance personnel.

4 FAXA-SVX01B-EN

Installationgeneralinformation

Digit 1 – Unit modelF = fresh air unit

Digit 2 – Unit configurationA= air cooled

Digit 3 – Unit discharge directionD= downflowH= horizontal

Digit 4 – Development sequenceA = development sequence ‘A’

Digits 5, 6, 7 – Unit size031 = 3100 cfm040 = 4000 cfm051 = 5100 cfm066 = 6600 cfm

Digit 8 – Unit voltage3 = 230 volt/60 hz/3 ph4 = 460 volt/60 hz/3 ph6 = 208 volt/60 hz/3 ph

Digit 9 – Heating system0 = noneA= gas low rise, single bank, 2-stageB = gas low rise, single bank, 2:1

modulateC = gas high rise, single bank, 2-stageD= gas high rise, single banks, 2:1

modulateE = gas dual bank, 4-stageF = gas dual bank 4:1 modulateG= electric heat, 3-stageH= electric heat, 7-stageK = hydronic interface only

Digits 10, 11 – Design sequence** = factory assigned

Digits 12, 13, 14 – Heat input000 = none020 = 20 kW026 = 26 kW032 = 32 kW042 = 42 kW056 = 56 kW070 = 70 kW084 = 84 kW100 = 100 kW122 = 122 kW125 = 125 MBh150 = 150 MBh200 = 200 MBh250 = 250 MBh

300 = 300 MBh350 = 350 MBh400 = 400 MBh500 = 500 MBh600 = 600 MBh700 = 700 MBh800= 800 MBh

Digit 15 – Heat exchanger material0 = none1 = 409 stainless steel, 409 stainless Burner2 = 321 stainless steel, 409 stainless burner

Digit 16 – Condenser reheat coil0 = none1 = condenser hot gas reheat coil

Digit 17 – Ventilation damper type0 = parallel blade damper1 = TRAQ™ damper with air flow

measurement

Digit 18 – Energy recovery0 = none1 = total energy wheel w/occupancy

control2 = total energy wheel w/dry bulb control

Digit 19 – Return air damper0 = none1 = bottom return/reference enthalpy2 = bottom return/comparative enthalpy

Digit 20 – Supply fan type1

A= 12 - 9 centrifugal fanB = 15 - 11 centrifugal fanC = 18 - 13 centrifugal fan

Digits 21, 22, 23 – Supply fan rpm037 = 375040 = 400042 = 425045 = 450047 = 475050 = 500052 = 525055 = 550057 = 575060 = 600062 = 625065 = 650067 = 675070 = 700

072 = 725075 = 750077 = 775080 = 800082 = 825085 = 850087 = 875090 = 900092 = 925095 = 950097 = 975100 = 1000102 = 1025105 = 1050

F A D A 040 6 G A,0 0,8,4 0 1 A 0 1 A 0,5,7 0,7 A 0 0 0 E F 0 1 0,0,0 0,0 A A A A

1 2 3 4 5,6,7 8 9 10,11 12,13,141516171819 20 21,22,23 24,25 26 27 28 29 30 31 32 33 34,35,36 37,38 39 40 41 42

Packaged Fresh Air unit Model Number DescriptionFollowing is a complete description of the Packaged FAU model number. Each digit in the model number has a corresponding codethat identifies specific unit options.

Note1: The first number in this description indicates thefan wheel diameter (in.). The second numberindicates the fan wheel width.

Digits 24, 25 – Supply fan horsepower01 = 102 = 203 = 305 = 507 = 7.510 = 1015 = 15

Digit 26 – Fan motor typeA= standard efficiency ODP fan motorB = high efficiency ODP fan motor

Digit 27 – Coil protection0 = noneA= corrosion inhibiting coating

Digit 28 – Unit cabinet protection0 = standard prepainted steel finishA= corrosion inhibiting coating

Digit 29 – Filter type0 = field-provided filter1 = dirty filter switch (DFS) with field-

provided filter2 = 2” pleated media filters3 = 2” pleated media filters & DFS

Digit 30 – System controlA= supply air dehumidificationB = supply air dehimidification with zone

RH referenceE = zone dehumidification

107 = 1075110 = 1100112 = 1125115 = 1150117 = 1175120 = 1200122 = 1225125 = 1250127 = 1275130 = 1300132 = 1325135 = 1350137 = 1375140 = 1400142 = 1425145 = 1450147 = 1475150 = 1500152 = 1525155 = 1550157 = 1575

160 = 1600162 = 1625165 = 1650167 = 1675170 = 1700172 = 1725175 = 1750177 = 1775180 = 1800182 = 1825185 = 1850187 = 1875190 = 1900192 = 1925195 = 1950197 = 1975200 = 2000202 = 2025205 = 2050207 = 2075210 = 2100

FAXA-SVX01B-EN 5


F = zone dehumidification with OA RHreference

G= supply air temperature control (nodehumidification)

J = zone temperature control (nodehumidification)

Digit 31 – Control interface options0 = noneA= LonTalk® communications interface

(LCI ) (comm5)B = LCI (comm5) & generic building

automation system (GBAS) (0-5 VDC)C = LCI (comm5) & GBAS (0-5 VDC) &

ventilation override module (VOM)D= LCI (comm5) & VOME = GBAS (0-5 VDC)F = GBAS (0-5 VDC) & VOMG= VOM

Digit 32 – Miscellaneous system controloptions

0 = none1 = interface for remote human interface

Digit 33 – Exhaust option0 = none1 = exhaust interface

Digits 34, 35, 36 – Exhaust air fan rpm000 = none045 = 450047 = 475050 = 500052 = 525055 = 550057 = 575060 = 600062 = 625065 = 650067 = 675070 = 700072 = 725075 = 750077 = 775080 = 800082 = 825085 = 850087 = 875090 = 900092 = 925095 = 950097 = 975100 = 1000102 = 1025105 = 1050107 = 1075110 = 1100112 = 1125115 = 1150117 = 1175120 = 1200122 = 1225125 = 1250

Digits 37, 38 – Exhaust air fan horsepower00 = none01 = 102 = 203 = 305 = 507 = 7.510 = 10

Digit 39 – Unit connection typeA= terminal blockB = non-fused disconnect switch

Digit 40 – Convenience outlet0 = noneA= 115V, factory wiredB = 115V, field wired

Digit 41 – Extended grease lines0 = noneA= extended grease lines

Digit 42 – Agency approval0 = no agency approvalA= UL approval

Digit 43 – Roof curbA= 14” curbB = 24” curb

127 = 1275130 = 1300132 = 1325135 = 1350137 = 1375140 = 1400142 = 1425145 = 1450147 = 1475150 = 1500152 = 1525155 = 1550157 = 1575160 = 1600162 = 1625165 = 1650167 = 1675170 = 1700172 = 1725175 = 1750177 = 1775180 = 1800182 = 1825185 = 1850187 = 1875190 = 1900192 = 1925195 = 1950197 = 1975200 = 2000202 = 2025205 = 2050207 = 2075210 = 2100

6 FAXA-SVX01B-EN


Digit 1 – Parts/accessoriesP = parts/accessories

Digit 2 – Unit typeF = fresh air unit

Digit 3 – Field installed kitsK = field installed kits

Digit 4 – Development sequenceA = development sequence

Digits 5, 6, 7 – Nominal size031= 3100 cfm040= 4000 cfm051= 5100 cfm066= 6600 cfm

Digit 8 – Unit voltage3 = 230/60/34 = 460/60/36 = 208/60/3

Digit 9 – Roof curb0 = noneA = 14”B = 24”C = acousticalD = 14” curb for unit w/ERVE = 24” extended for unit w/ERVF = 24” extended, acoustical for unit w/

ERV

Digits 10, 11 – Design sequenceA0 = design sequence

Digit 12 – Filter type0 = noneA = 2” pleated mediaB = 2” cleanable

C = 2” pleated media total energy wheelonly

D = 2” cleanable total energy wheel onlyE = 2” pleated media unit & total energy

wheelF = 2” cleanable unit & total energy wheel

Digit 13 – Control interface kits0 = noneA= LonTalk® communications interface

(LCI) (comm5)B = LCI (comm5) & generic building

automation system (GBAS) (0-5 VDC)C = LCI (comm5) & GBAS (0-5 VDC) &

ventilation override module (VOM)D= LCI (comm5) & VOME = GBAS (0-5 VDC)F = GBAS (0-5 VDC) & VOMG= VOM

Digit 14 – Time clock0 = noneA = time clock

Digit 15 – Remote mounted humaninterface

0 = noneA = remote mounted human interfaceB = remote mounted human interface with

interprocessor communication bridgemodule board kit

C = interprocessor communication bridgemodule board kit

Digit 16 – Zone sensor0 = noneA = zone temperature sensor

BAYSENS017*

P F K A 031 3 A A0 B C 0 A A 0 A 0 A 0 A 0 A

1 2 3 4 5, 6, 7 8 9 10,11 12 13 14 15 16 17 18 19 20 21 22 23 24

Digit 17 – Zone sensor with timed override0 = noneA = zone temperature densor with timed

override BAYSENS013*

Digit 18 – Zone sensor with timed overrideand local setpoint adjustment

0 = noneA = zone temperature sensor with timed

override buttons and local setpointadjustment BAYSENS014*

Digit 19 – Remote minimum positionpotentiometer control

0 = noneA = remote minimum position

potentiomenter control BAYSTAT023*

Digit 20 – Dual setpoint sensor0 = noneA = dual setpoint sensor

Digit 21 – Dual setpoint sensor with systemfunction lights

0 = noneA = dual setpoint sensor with system

function lights

Digits 22 – Space relative humidity kit0 = noneA = space relative humidity kit

Digit 23 – Carbon dioxide sensor0 = noneA = carbon dioxide sensor

Digit 24 – Dry-bulb duct sensor0 = noneA = dry-bulb duct sensor

Packaged Fresh Air unit Accessory Model Number DescriptionFollowing is a complete description of the Packaged FAU accessory model number. Each digit in the model number has acorresponding code that identifies specific accessory options.

FAXA-SVX01B-EN 7


Unit Nameplate

The unit nameplate identifies the unitmodel number, appropriate serviceliterature, and wiring diagram numbers. Itis mounted on the control panel door.Reference this information when makinginquiries or ordering parts or literature forthe fresh air unit.

Figure I-GI-1. Packaged fresh air unit components

2’’ Pleated filter section withadjustable rack to 4’’

Standard protectivebird screen on inlethood

Traq® damperavailable for airflowmeasurement

Optional return airdamper for unoccupiedrecirculation

Non-corrosive IAQdrain pan sloped intwo directions

Optional condenserreheat coil withmodulating control

Quiet FC fan

1’’ Solid double-wallpanels of foamed-in-place construc-tion

Hi-rise electric(or gas) heat

Horizontal or verticaldischarge openings

Unit mounted IntelliPak®

microprocessor controlwith easy-to-read humaninterface

All ship-with items areinside this compartment

8 FAXA-SVX01B-EN

Installationpre-installationconsiderationsInstallation

Pre-Installation Considerations

ChecklistThe following checklist is provided to givean overview of the factory-recommended pre-installationconsiderations. Follow the procedures inthis section to ensure the installation iscomplete and adequate for proper unitoperation. Verify this checklist is completebefore beginning unit installation.

� Verify the unit size and tagging with theunit nameplate to ensure the correctunit is received.

� Inspect the unit for possible shippingdamage and make any necessaryclaims with the freight deliverycompany immediately.� Before installing the roof curb,

remember to allow minimumrecommended clearances for routinemaintenance and service. Refer to unitdimensions and clearances onsubmittals or in Dimensions andWeights section on page 15.� Verify the unit roof curb is installed

properly prior to beginning unitinstallation. See the Roof CurbInstallation Manual, FAXA-SVN01B-EN.� Make proper acoustic considerations

before installing unit. Do not install unitabove sound-senstive locations.� Allow adequate space for service and

operating clearances. Reference page10.� Make provisions for correct supply

power and note electrical connectionknockouts locations on the unitsubmittals or in the Dimensions andWeights section on page 15. Thisincludes main power and dual powerconnections for electric heat.

Note: Verify electric stub-out within roofcurb assembly, if using bottom electricalknockouts.

� Electrical supply power must meetspecific balance and voltagerequirements as described in the“Electrical Requirements” section onpage 36.� Units with gas heat, ensure adequate

gas service and piping is available atunit installation location.� Ensure the unit installation location is

level.

Receiving and Handling

Shipping PackagePackaged Fresh Air units ship fullyassembled.

Ship-Separate AccessoriesField-installed sensors ship separatelyinside the unit’s filter/return air section.Units with gas heat have temporarypanels in place for shipping. Thepermanent panels are located in thiscompartment and must be field-installed.Units with the total energy wheel optionhave an exhaust louver that ships insidethe exhaust compartment. Install thelouvers after installing the unit in its finalposition.

WARNING

No step surface!Do not walk on the sheet metal drainpan. Walking on the drain pan cancause the supporting metal tocollapse, causing death or seriousinjury.

FAXA-SVX01B-EN 9

Installationpre-installationconsiderations

Receiving ChecklistComplete the following checklistimmediately after receiving unitshipment to detect possible shippingdamage. If entry into the unit isnecessary, bridge between the unit’smain supports using multiple 2 x 12boards.

� Verify that the unit nameplate datacorresponds to the sales order and billof lading (including electrical data).

� Visually inspect the unit exterior forphysical signs of shipping damage ormaterial shortages.

� If a unit appears damaged, inspect itimmediately before accepting theshipment. Remove access panels andcheck for interiour componentdamage. Make specific notationsconcerning the damage on the freightbill. Do not refuse delivery.� Report concealed damage to the

freight line within the allotted timeafter delivery. Verify with the carrierwhat their allotted time is to submit aclaim.

Note: Failure to follow these proceduresmay result in no reimbursement fordamages from the freight company.

� Do not move damaged material fromthe receiving location. It is thereceiver’s responsibility to providereasonable evidence that concealeddamage did not occur after delivery.

� Do not continue unpacking theshipment if it appears damaged. Retainall packaging. Take photos of damagedmaterial if possible.

� Notify the carrier’s terminal of thedamage immediately by phone andmail. Request an immediate jointinspection of the damage by thecarrier and consignee.

� Notify your Trane representative ofthe damage and arrange for repair.Have the carrier inspect the damagebefore making any repairs to the unit.

Unit StorageIsolate all side panel service entrancesand base pan openings, such as conduitholes and supply and return air openingsfrom the ambient air until the unit is readyfor startup.

If relocating the unit is necessary after theinitial delivery, position the unit on theopen trailer so the inlet hood is facing therear of the trailer.

10 FAXA-SVX01B-EN


Service Access

Maintain adequate clearances aroundand above the fresh air unit to ensureproper unit operation and allow sufficientservice access. See Figure I-PC-1 forrecommended clearances. If installing theunit higher than the typical curb elevation,field-construct a catwalk around it toprovide safe, easy maintenance access.

WARNING!

Hazardous voltage!Disconnect electrical power sourceand remote disconnects beforeservicing unit. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to do so may cause death orinjury.

Figure I-PC-1. Top view of fresh air unit showing recommended service and code clearances.

service accessfor removal ofgas or electricheaters

unit without TE wheel

condenser airflow andcompressor maintenance

air path into unit

WARNING!

Disconnect gas supply!Before servicing unit, FIRST turn offthe gas supply. Failure to turn off thegas supply can cause death or seriousinjury.

WARNING!

Combustible materials!Maintain proper clearance betweenthe unit heat exchanger, ventsurfaces, and combustible materials.Refer to this manual for properclearances. Improper clearances cancause a fire hazard. Failure tomaintain proper clearances can causedeath, serious injury, or propertydamage.

unit with TE wheel

condenser airflow

air path into

serviceaccess forremoval of

FAXA-SVX01B-EN 11


Roof Curb

You must install the roof curb beforebeginning unit installation. Reference theRoof Curb Installation Manual, FAXA-SVN01B-EN for complete installationinstructions. For reference, installationinstructions are provided below.Reference roof curb dimensions in theDimensions and Weights section onpages 15–32.

Note: Do not tighten any of the screwsused to assemble this section until thecurb has been leveled and squared in itsinstalled location.

Roof Curb and DuctworkEnsure the unit curb encloses the entireunit base area. It is referred to as a “fullperimeter” type curb. Fabricate andinstall the supply air and return airductwork adjoining the roof curb beforethe unit is set into place. Note electricalstub-ups within the curb.

GeneralSet the roof curb and Packaged Fresh Airunit level to ensure proper operation. Ifproviding a field-fabricated roof curb, seepage 12 for roof curb details for unitswithout the total energy wheel option.See page 13 for units with the totalenergy wheel option. All installationsmust conform with local building codes,or in the absence of local codes, with theNational Fuel Gas Code ANSI Z223.1.

Note: Trane has a roof curb specificallydesigned for the Packaged Fresh Air unitavailable in the following options: 14” or24” height, and an acoustic curb. Toinstall it, reference the Accessory RoofCurb Installation Manual, FAXA-SVN01B-EN.

Roof SupportThe roof must be capable of adequatelysupporting the weight of the PackagedFresh Air unit as well as the curb. SeeFigure I-IP-1 on page 40 for approximateunit four-corner weights.

Trane Roof Curb InstallationIf the building is new, the curb may beassembled at any convenient locationand installed as soon as the roof supportmembers are in place. The curb must bemounted on the roof deck and support

provided directly below the flanges of theroof curb for further support and tominimize vibration. If the fresh air unit isto be installed on an existing building,hoist the curb shipping container to theroof, where the curb can be assembledmore conveniently.

Standard Perimeter Curb Rail AssemblyFollow the procedure below as anexample of how to field-assemble a fieldroof curb. This procedure also applies tothe Trane standard 14” roof curb.Reference pages 12 & 13 for assemblydrawings.1. Attach corner angle (7) using 4 sheet

metal screws to the end of end rail (1)adjacent to side rail (3). Place theclearance holes in the corner angletoward the top of the curb.

2. Attach end rail (1) to side rail (3) using 4sheet metal screws.

3. Align side rail (4) next to side rail (3)and attach crossmember (11)perpendicular to both side rails at thejoint using eight sheet metal screws.

4. Attach corner angle (8) using eightsheet metal screws to end rail (2) andside rail (4). Place the clearance holes inthe corner angle toward the top of thecurb.


6. Align side rail (6) next to side rail (5)and attach crossmember (11)perpendicular to both side rails at thejoint using eight sheet metal screws.


Return and Exhaust Air OpeningAssembly8. Place end rail (12) between side rail (3)

and side rail (6) with flanges positionedaway from the return air opening andattach it with two sheet metal screws ateach end. Use rails (14), (15), (16), and(17) as spacers.

9. Place side rail (14) between end rail (1)and end rail (12) with flanges positionedaway from the return air opening andattach it with two sheet metal screws ateach end.

10. Place side rail (15) between end rail(1) and end rail (12) with flangespositioned toward the return airopening and attach it with two sheetmetal screws at each end.

11. Place side rail (16) between end rail(1) and end rail (12) with flangespositioned away from side rail (15) andattach it with two sheet metal screws ateach end.

12. Place side rail (17) between end rail(1) and end rail (12) with flangespositioned away from the exhaust airopening and attach it with two sheetmetal screws at each end.

Supply Air Opening Assembly13. Place end rail (13) between side rail

(4) and side rail (5) with flangespositioned away from the supply airopening and attach it with two sheetmetal screws at each end. Use rails (18)and (19) as spacers.

14. Place side rail (18) between end rail(2) and end rail (13) with flangespositioned away from the supply airopening and attach it with two sheetmetal screws at each end.

15. Place side rail (19) between end rail(2) and end rail (13) with flangespositioned away from the supply airopening and attach it with two sheetmetal screws at each end.

Units with the Total Energy Wheel Only16. Attach corner angle (26) using five

sheet metal scres to the side of ductsupport (25) without flanges. Place theclearance holes in the corner angletoward the top of the curb.

17. Align side rail (23) next to side rail (3)and attach crossmember assembly(25) and (26) perpendicular to both siderails at the joint using ten sheet metalscrews.

12 FAXA-SVX01B-EN


1

7

20

23

15

14

17

1016

6

12

3

115

134

21

19

9

2

18

22

8

S/A

R/A

E/A

Curb legend(1) end rail (R/A end) (13) duct support end rail(2) end rail (S/A end) (14) duct support end rail (R/A end)(3) side rail (15) duct support side rail (R/A end)(4) side rail (16) duct support side rail (E/A end)(5) side rail (17) duct support side rail (E/A end)(6) side rail (18) duct support side rail (S/A end)(7) corner angle (19) duct support side rail (S/A end)(8) corner angle (20) 6” wood nailer; side(9) corner angle (21) 6” wood nailer; side(10) corner angle (22) 6” wood nailer; end(11) crossmember (23) 6” wood nailer; end(12) duct support end rail

Standard roof curb assembly,units without TE wheel option

Typical std. curb rail and crossmember assembly for units without

the total energy wheel option

Note: Center lines connectcorresponding holes in therails and crossmember. Allscrews are installed fromoutside the curb.

side rails

supply air end

return air end

crossmember

supply air end

side rail

Typical std. curb corner assembly for units

without the total energy wheel option

corner angle

end rail

Note: Center lines connectcorresponding holes in therails and crossmember. Allscrews are installed fromoutside the curb.

FAXA-SVX01B-EN 13


CURB LEGEND

Extended Height Roof Curb Component LayoutWith Total Energy Wheel

Figure 4

side rail

side rail

corner angle

duct support end rail

Typical standard roof curb assembly for units with the TE wheel

CURB LEGENGEND

Extended Height Roof Curb Component LayoutWith Total Energy Wheel

Figure 4

Standard roof curb assembly,units with the TE wheel

Curb legend

(1) end rail (R/A, E/A end) (15) duct support end rail(2) end rail (S/A end) (16) duct support side rail (R/A end)(3) side rail (17) duct support side rail (R/A end)(4) side rail (18) duct support side rail (E/A end)(5) side rail (19) duct support side rail (E/A end)(6) side rail (20) duct support side rail (S/A end)(7) corner angle (21) duct support side rail (S/A end)(8) corner angle (22) crossmember(9) corner angle (23) side rail(10) corner angle (24) side rail(11) crossmember (25) duct support end rail(12) crossmember (26) corner angle(13) crossmember (27) corner angle(14) duct support end rail

14 FAXA-SVX01B-EN

Installationpre-installationconsiderationsInstallation

Acoustic Considerations

Before determining the final unitinstallation site, remember that properunit placement is critical in reducingtransmitting sound levels to the building.The ideal time to make provisions toreduce sound transmissions is during thedesign phase. The most economicalmeans of avoiding a potential acousticalproblem is to place units in areas that arenot acoustically sensitive. Ideal locationsare over over corridors, utility rooms,toilets, or other areas where highersounds levels below the unit may beacceptable.

Follow these basic guidelines to helpminimize sound transmission through thebuilding structure:• Locate the unit’s center of gravity close

to or over a column or main supportbeam.

• If the roof structure is very light, replaceroof joists using a structural shape inthe critical areas described above.

Note: Cut applicable holes only for thesupply, exhaust, and return duct pen-etration in the roof deck. To maintainroof integrity and prevent possibleproperty damage, do not remove theroof decking from the inside perimeter ofthe curb.

Installation Preparation

Before installing the unit, perform thefollowing procedures to ensure properunit operation.

1. Verify the roof curb is level. To ensureproper unit operation, install the unitlevel (zero tolerance) in both horizontalaxes. Failure to level the unit properlycan result in condensate managementproblems, such as standing waterinside the unit. Standing water and wetsurfaces inside units can result inmicrobial growth (mold) in the drainpan that may cause unpleasant odorsand serious health-related indoor airquality problem.

2. Allow adequate service and codeclearances as recommended in“Service Access” section on page 10.

3. Position the unit and skid assembly inits final location. Test lift the unit todetermine exact unit balance andstability before hoisting it to theinstallation location. See Figure I-IP-2 onpage 41 for typical rigging procedures,including cautions and proper uses ofsuch equipment as fork lifts, spreaderbars, and hooks.

FAXA-SVX01B-EN 15

Installationdimensions& weights

Typical exterior dimensions,ft./in.

CONTROL PANELEND VIEW

outdoor side view, unit with total energy wheel

lifting hole detail A

unit size A B C D E F G H J K L M N P

without TE wheel031, 041 18' - 10" 2' - 7" 4' - 2" 3' - 10" — 3' - 2" 10" 9" 1' - 11 1/2" 1 1/4" 1' - 6 1’4" ø 2 1/2" — —051, 066 19' - 3" 3' 5' - 10" 4' - 1" — 3' - 6" 1' - 3" 10 1’4" 2' - 4 1/2" 1 1/4" 3' - 6 3/4" ø 3"with TE wheel031, 041 24' - 2" 2' - 7" 4' - 2" 3' - 10" 9 1/4" 3' - 2" 10" 9" 1' - 11 1/2" 1' 6" 1' - 6 1’4" ø 2 1/2" 7" 1' - 3/4"051, 066 24' - 7" 3' 5' - 10" 4' - 1" 8" 3' - 6" 1' - 3" 10 - 1’4" 2' - 4 1/2" 1' 8" 3' - 6 3/4" ø 3" 7" 11"

outdoor side view, unit without total energy wheel

detail B

inlet hood end viewcontrol panel end view

16 FAXA-SVX01B-EN


single & dual gas heater options

unit with TE wheel - indoor side view (electric heat version shown)

unit without TE wheel - indoor side view (electric heat version shown)

FAXA-SVX01B-EN 17


Unit base plan view, duct openings & thru-base power openings,unit sizes 031 & 040


unit with TE wheel

18 FAXA-SVX01B-EN


Unit base plan view, duct openings & thru-base power openings,unit sizes 051 & 066

unit with TE wheel


FAXA-SVX01B-EN 19


detail A

THRU-BASE MAIN POWER WIRING ENTRANCEHOLE Ø3.000’’

NOTE: DRILL OR PUNCH HOLE IN COVER PLATE FORSMALLER CONDUIT CONNECTION

3x

Fresh air unit control panel detail,all unit sizes

top view

20 FAXA-SVX01B-EN


CONDENSER FANS

HORIZONTAL DISCHARGE(OPTION)

HUMAN INTERFACEACCESS DOOR

UNIT CONTROL PANEL

24 VOLT CONTROL CIRCUIT WIRING ENTRANCE(CAN ALSO BE RUN THRU-BASE)

MAIN POWER WIRING ENTRANCE(CAN ALSO BE RUN THRU-

BASE)

MAIN CONDENSERCOIL ACCESS

PANEL (68x36)REHEAT COMPRESSOR/COIL ACCESS PANEL

(34x36)

MAIN COMPRESSOR ACCESS PANEL(40x35)

LIFTING HOLES

CONVENIENCE OUTLET (OPTION)

DUAL GAS HEAT ACCESS PANEL(EACH HEATER HAS SEPARATE PANEL)

(16x23)

GAS CONNECTION–DUAL GAS HEAT(EACH HEATER HAS SEPARATE GAS CONNECTIONS)

NATURAL GAS 250–400 MBH: �.500 NPT INTERNAL

ELECTRIC HEAT POWER WIRING ENTRANCE(ALSO CAN BE RUN THRU-BASE)

ELECTRIC HEATER ELECTRICAL PANEL (24x30)-OR-

GAS HEAT PANEL (16x23)-OR-

FIXED PANEL FOR NO-HEAT OPTIONOR HYDRONIC HEAT INTERFACE OPTION (24x47)

CONDENSATEDRAIN CONNECTION

EVAP COIL ANDCONDENSATE DRAIN PANACCESS DOOR (18x34)

INLET HOOD

SUPPLY FAN ACCESS DOOR(33X34)

Exterior features for unit sizes 031 & 040,without TE wheel

FILTER AND DAMPER ACCESS DOOR(25x39)

FAXA-SVX01B-EN 21


Exterior features, unit sizes 031 & 040with TE wheel

22 FAXA-SVX01B-EN


LIFTING HOLES

REHEAT COMPRESSOR/COIL ACCESS PANEL (40x52)

MAIN COMPRESSOR/COIL ACCESS PANEL (34x52)

CONVENIENCE OUTLET(OPTION)

MAIN COMPRESSOR/COIL ACCESS PANEL

(68x52)

MAIN POWER WIRING ENTRANCE(CAN ALSO BE RUN THRU-BASE)

24 VOLT CONTROL CIRCUIT WIRING ENTRANCE(CAN ALSO BE RUN THRU-BASE)

UNIT CONTROL PANEL

HUMAN INTERFACEACCESS DOOR

HORIZONTAL DISCHARGE(OPTION)

CONDENSER FANS

FILTER AND DAMPER ACCESS DOOR(25x59)

SUPPLY FAN ACCESS DOOR(33x54)

CONDENSATE DRAINCONNECTION

ELECTRIC HEATER ELECTRICAL PANEL (24x49)-OR-

SINGLE GAS HEAT ACCESS PANEL (16x23)-OR-

FIXED PANEL FOR NO-HEAT OPTIONOR HYDRONIC HEAT INTERFACE OPTION (24x67)

ELECTRIC HEAT POWER WIRING ENTRANCEFOR 208/230 V: 70, 84, 100, 122 kW

(CAN ALSO BE RUN THRU-BASE)

GAS CONNECTION–DUAL GAS HEAT(EACH HEATER HAS SEPARATE GAS CONNECTIONS)

DUAL GAS HEAT ACCESS PANEL(EACH HEATER HAS SEPARATE PANEL)

(16x23)

GAS CONNECTION–SINGLE GAS HEATER

EVAP COIL & CONDENSATE DRAIN PANACCESS DOOR(18x54)

INLET HOOD

Exterior features for unit sizes 051 & 066,without TE wheel

FAXA-SVX01B-EN 23


Exterior features for unit sizes 051 & 066with TE wheel

24 FAXA-SVX01B-EN


Standard curb, unit sizes 031 & 040without TE wheel

6’’ WOOD NAILER

FAXA-SVX01B-EN 25


6" WOOD NAILER

Standard roof curb, unit sizes 031 & 040with TE wheel

26 FAXA-SVX01B-EN


6’’ WOOD NAILER

Standard curb , unit sizes 051 & 66without TE wheel

FAXA-SVX01B-EN 27


Standard roof curb, unit sizes 051 & 066with TE wheel

6" WOOD NAILER

28 FAXA-SVX01B-EN


Extended height roof curb, unit sizes 031 & 040without TE wheel

6’’ WOOD NAILER

FAXA-SVX01B-EN 29


Extended height roof curb , unit sizes 031 & 040with TE wheel

6" WOOD NAILER

30 FAXA-SVX01B-EN


Extended height roof curb, unit sizes 051 & 066without TE wheel

6’’ WOOD NAILER

FAXA-SVX01B-EN 31


6" WOOD NAILER

Extended height roof curb, unit sizes 051 & 066with TE wheel

32 FAXA-SVX01B-EN


Table I-DW-2. Typical component weights

unit single gas (MBh) dual gas (MBh) electric heaters condenser hot

size 125 150 200 250 300 350 400 250 300 400 500 600 700 800 20-84 kW 100,122 kW gas reheat 2

031 201 217 247 295 295 333 — 402 434 — — — — — 60 — 150040 201 217 247 295 295 333 — 402 434 494 — — — — 60 — 150051 201 217 247 295 295 333 361 402 434 494 590 590 — — 60 100 270066 201 217 247 295 295 333 361 402 434 494 590 590 666 722 60 100 270

Unit and accessory weights

Table I-DW-1. Typical unit, unit with total energy wheel, and roof curb weights

unit base unit total energy wheel unit roof curb for unit w/o TE wheel roof curb for unit with TE wheelsize weight 1 base weight 1 low high acoustic low high031 4600 1460 282 613 1500 350 766040 4700 1520 282 613 1500 350 766051 5600 1920 282 613 1500 350 766066 6000 1970 282 613 1500 350 766

1. Base unit operating weight is for units with the condenser hot gas reheat option, return air, and no heat. Subtract condenser hot gas reheat weight for cooling only units. See TableI-DW-2 for weight.

FAXA-SVX01B-EN 33

Installationmechanicalrequirements

A MANUAL SHUTOFF VALVE WITH1/8" N.P.T. PLUGGED TAPPING,ACCESSIBLE FOR TEST GAGE CONNECTION MUST BE INSTALLEDUPSTEAM OF THE GAS SUPPLY CONNEC-TION TO THE APPLIANCE.GAS

SUPPLYLINE

GROUND JOINT UNION

TO CONTROLS

DRIP LEG

PLUGGED 1/8" N.P.T.TEST GAGE CONNECTION

3" (76 MM) MIN.

Duct Connections

Horizontal Discharge Units Only (ModelFAHA)When attaching ductwork to a horizontaldischarge unit, provide a watertightflexible connector at the unit to preventnoise transmission from the unit into theductwork. Refer to the Dimensions andWeights section on pages 13–23 for thesupply air and return air openingdimensions. All outdoor ductworkbetween the unit and the structure shouldbe weather proofed after installation iscomplete.

WARNING!

Hazardous voltage!Disconnect electrical power sourceand remote disconnects beforeservicing unit. Failure to do so maycause death or injury.

WARNING!


Ductwork ConsiderationsInstall all air ducts according to theNational Fire Protection Associationstandards for the “Installation of AirConditioning and Ventilation Systemsother than Residence Type (NFPA 90A)and Residence Type Warm Air Heatingand Air Conditioning Systems (NFPA90B).

Make duct connections to the curb with aflexible material such as heavy canvas. Ifa fire hazard exists, Trane recommendsusing Flexweave 1000, type FW30 orequivalent canvas. Use three inches forthe return duct and three inches for thedischarge duct. Keep the material looseto absorb unit vibration.

Run the ductwork as far as possiblewithout changing size or direction. Do notmake abrupt turns or transitions near theunit due to increased noise and excessive

static losses. Use elbows with splitters orturning vanes to minimize static losses.

Poorly constructed turning vanes maycause airflow generated noise. Checktotal external static pressures against fancharacteristics to be sure the requiredairflow is available throughout theductwork.

Gas Pipe Sizing

Follow the procedure below to size thegas piping to adequately provide gaspressure at the gas heater.1. Find the cu ft/hr by using the formula:

cu ft/hr = Btu/cu ft.2. Refer to Table I-MR-1. Match “Pipe Run

in Feet” with appropriate “Gas Input -Cu Ft/hr” figure. Match this figure to thepipe size at the top of the column. Forexample, requires 67 ft (20.4m) run ofgas pipe to connect a 200 MBh gas ductfurnace to a 1,000 Btu/cu ft (0.29) kW)natural gas supply.

200,000 Btu/cu ft1,000 Btu/cu ft = 200 cu ft/hr

Using Table I-MR-1, a 1” pipe is needed.Before making any connections to

Figure I-MR-1. Gas pipe connection

existing line suppling other gas appli-ances, contact the local gas company tomake sure existing line is adequate sizeto handle the combined load.

Gas Pipe Installation Procedure1. Install the gas piping in accordance with

applicable local codes.2. Check gas supply pressure. Each gas

heater must be connected to a gassupply capable of supplying its full ratedcapacity at a pressure not less than 5”w.c. (1.62 kPa) nor greater than 14” w.c.(0.5 psi) for natural gas. Size and installall gas piping in accordance with ANSIStandard Z223.1-1992 (or latest edition)National Fuel Gas Code. In Canada, gaspiping should be according to CAN/CGAB149. See Table I-MR-1 for correct gassupply piping size. If gas pressure isexcessive on natural gas applications,install a pressure regulating valve in theline upstream from the main shutoffvalve for each independent heater.

3. Adequately support the piping toprevent strain on the gas manifold andcontrols.

4. To prevent the mixing of moisture withgas, run the takeoff piping from the top,or side, of the main.

34 FAXA-SVX01B-EN


Table I-MR-1. Gas pipe sizes, at 0.5 psig (3.5 Pa) or less, 0.5” w.c. (124.4 Pa), 0.60 specific gravity gas

maximum pipe capacity for gas pressures, ft.3/hr. (m3/h)nominal internal pipe length, ft. (m)iron pipe, diameter, 10 20 30 40 50 60 70 80 90 100 125 150 175 200in. in. (mm) (3.0) (6.1) (9.1) (12.2) (15.2) (18.2) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0)1/2 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35

(16) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99)3/4 0.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

(21) (10.2) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92) (2.63) (2.38) (2.18) (2.04)1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135

(27) (19.3) (13.2) (10.6) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52) (4.96) (4.53) (4.11) (3.82)1 1/4 1.380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280

(35) (39.6) (26.9) (21.8) (18.7) (16.4) (15.0) (13.9) (13.0) (12.2) (11.3) (10.2) (9.20) (8.50) (7.93)1 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

(41) (59.5) (41.3) (33.4) (28.0) (25.5) (22.9) (21.2) (19.5) (18.4) (17.6) (15.6) (14.2) (13.0) (12.2)2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800

(53) (112) (77.9) (62.3) (53.8) (47.6) (43.0) (39.6) (36.8) (34.5) (32.6) (28.9) (26.9) (24.1) (22.7)2 1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280

(63) (178) (123) (99.7) (85.0) (75.0) (68.0) (63.7) (58.0) (55.2) (52.4) (46.7) (42.5) (38.8) (36.2)3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280

(78) (311) (218) (177) (150) (135) (122) (110) (105) (97.7) (92.0) (83.5) (75.0) (69.4) )(64.6)4 4.026 2300 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600

(102) (651) (447) (362) (309) (275) (249) (229) (212) (204) (190) (170) (156) (142) (130)

Note: 1. ft.3/hr = input / 1000. For SI, convert Btu/hr to kW. m3/hr = input (kW) x (0.0965). 2. Size natural gas select pipe directly from the table.

5. Pipe directly in to the manual shutoffvalve.

6. Install a 1/8" (3.2 mm) N.P.T. pluggedtapping, accessible for test gaugeconnection, immediately upstream ofthe gas supply connection to theappliance.

7. Provide a drip leg in the gas piping nearthe gas duct furnace.

8. Make certain that all connections havebeen adequately doped and tightened.

9. Remove temporary shipping panelsand install the permanent panels thatship in the return air section of the unit.

CAUTIONValve stress hazard!Do not overtighten the inlet gas pipinginto the valve. This may cause stressesthat would crack the valve!

Note: Use pipe joint sealant resistant tothe action of liquefied petroleum gasesregardless of gas conducted.

WARNING

Explosion hazard!Failure to follow recommended safeleak test procedures can cause deathor serious injury.

Note: Check all pipe joints for leakageusing a soap solution or other approvedmethod. The appliance and its individualshutoff valve must be disconnected fromthe gas supply piping system during anypressure testing of that system.

FAXA-SVX01B-EN 35


Condensate Drain Trapping

A fresh air unit is selected for itsdehumidifying capability. As such,condensate can be formed at anenormous rate. The Packaged Fresh AirUnit, drain pan and condensate line havebeen sized and designed accordingly. Anoften-overlooked element of propercondensate drainage is trapping. Anincorrectly designed and installed trap onthe piping exiting the drain pan canrestrict the flow of condensate or cause‘‘spitting’’ or “geysering” of thecondensate water which can dampen theinterior insulation of the air handler and/or ductwork, creating an opportunity formold infestation. The HVAC equipmentmanufacturer’s installation and trappinginstructions must be carefully followed toassure adequate condensate removalunder all operating conditions. Figure I-MR-2 shows the proper design for a p-trap design, in an air handler with a draw-through coil arrangement.

Figure I-MR-2. P-trap design for drain pan

H = (1” for each 1” of maximum negative staticpressure) + 1”J = half of HL = H + J + pipe diameter + insulation

36 FAXA-SVX01B-EN

electricalrequirements

Electrical Requirements

Follow these guidelines, referring to unitwiring diagrams and supply powerdimensional information to ensurecorrect electrical requirements at theinstallation site. Reference supply powerwiring locations on unit submittals or inthe Dimensions and Weights section onpage 13. Specific unit wiring diagramsare provided on the inside of the controlpanel door. Use these diagrams forconnections or trouble analysis.

Supply Power WiringIt is the installer’s responsibility to providepower supply wiring to the unit. Wiringshould conform to NEC and all applicablecode requirements. To ensure the unitsupply power wiring is properly sized andinstalled, follow the guidelines below:1. Verify the power supply available is

compatible with the unit nameplateratings. The supply power must bewithin 10% of the rated voltage listedon the unit nameplate.

2. Reference the electrical data in TablesI-ER-1 through I-ER-8. Protect theelectrical service from over current andshort circuit conditions in accordancewith NEC requirements. Size protectiondevices according to the electrical dateon the unit nameplate.

3. If the unit is not equipped with anoptional factory-installed disconnect,you must install a field-supplieddisconnect at or near the unit inaccordance with NEC. Do not mount afield-supplied disconnect on the unit.Reference Figures I-DW-3 and I-DW-4on pages 16–17 for the electricalservice entrance location.

4. Complete the unit power wiringconnections onto either the mainterminal block or the factory -mountednon-fused disconnect switch located inthe control panel.

5. Provide proper unit grounding inaccordance with local and nationalcodes.

Installation

Table I-ER-1. Electrical service sizing data

unit reheat comp (A) main comp 1 (B) main comp 2 (C) main comp 3 (D)size voltage tons* rla lra tons* rla lra tons* rla lra tons* rla lra031 208/60/3 4.5 15 124 9.0 35 222 14.0 48 337 — — —

230/60/3 4.5 15 124 9.0 31 251 14.0 43 376 — — —460/60/3 4.5 8 59.6 9.0 16 117 14.0 23 178 — — —

040 208/60/3 6.75 23 164 10.0 35 222 15.0 51 337 — — —230/60/3 6.75 23 164 10.0 31 251 15.0 46 376 — — —460/60/3 6.75 11 100 10.0 16 117 15.0 23 178 — — —

056 208/60/3 9.0 35 222 14.0 48 337 9.0 35 222 9.0 35 222230/60/3 9.0 31 251 14.0 43 376 9.0 31 251 9.0 31 251460/60/3 9.0 16 117 14.0 23 178 9.0 16 117 9.0 16 117

066 208/60/3 9.0 35 222 15.0 51 337 15.0 51 337 15.0 51 337230/60/3 9.0 31 251 15.0 46 376 15.0 46 376 15.0 46 376460/60/3 9.0 16 117 15.0 23 178 15.0 23 178 15.0 23 178

*tons refers to nominal R22 tonselectric heat FLA is determined at 208, 240, & 480 volts

Table I-ER-2. Supply fan motor fla

standard efficiency high efficiencyvoltage 1 hp 2 hp 3 hp 5 hp 7.5 hp 10 hp 15 hp 1 hp 2 hp 3 hp 5 hp 7.5 hp 10 hp 15 hp

208/60/3 3.1 5.9 8.7 14.0 22.2 28.2 40.7 3.1 6.1 9.3 14.9 21.3 29.0 40.7230/60/3 2.8 5.6 8.0 13.2 21.6 28.0 40.6 2.8 5.4 8.2 12.8 20.0 25.8 35.4460/60/3 1.4 2.8 4.0 6.6 10.8 14.0 20.3 1.4 2.7 4.1 6.4 10.0 12.9 17.7

Table I-ER-5. Condenser fan motors

voltage fla

208/60/3 3.8230/60/3 3.6460/60/3 1.8

Table I-ER-3. Exhaust fan motor fla

standard efficiency high efficiencyvoltage 1 hp 2 hp 3 hp 5 hp 7.5 hp 10 hp 15 hp 1 hp 2 hp 3 hp 5 hp 7.5 hp 10 hp 15 hp

208/60/3 3.1 5.9 8.7 14.0 22.2 28.2 40.7 3.1 6.1 9.3 14.9 21.3 29.0 —230/60/3 2.8 5.6 8.0 13.2 21.6 28.0 — 2.8 5.4 8.2 12.8 20.0 25.8 —460/60/3 1.4 2.8 4.0 6.6 10.8 14.0 — 1.4 2.7 4.1 6.4 10.0 12.9 —

Table I-ER-4. Energy wheel motor fla

unit size 031 040 051 066hp 1/2

1/23/4

3/4

voltage208/60/3 2.7 2.7 3.6 3.6230/60/3 2.4 2.4 3.0 3.0460/60/3 1.2 1.2 1.5 1.5

Table I-ER-6. Factory-wired convenience outlet

voltage amps

208/60/3 7.21230/60/3 6.52460/60/3 3.26

Table I-ER-7. total gas heat amps with combustion blower

voltage amps

208/60/3 2.54230/60/3 2.30460/60/3 1.15

Table I-ER-8. Control power transformer (loads greater than 1 amp)

voltage amps

208/60/3 1.20230/60/3 1.09

FAXA-SVX01B-EN 37

electricalrequirementsInstallation

Power Wire Sizing andProtection Device Equations

Each type of unit has its own set ofcalculations for MCA (minimum circuitampacity) and MOP (maximumovercurrent protection. For units withmultiple modes of operation, you mustconsider each individual field-wiredhazardous voltage circuit. Use the loadthat provides the highest value in theapplicable circuit. To correctly size theunit’s electrical service wiring, read theload definitions that follow and then findthe appropriate set of calculationsbased on your unit type.

Load DefinitionsLoad 1 = current of the largest motor

(compressor or fan motor)Load 2 = sum of the currents of all

remaining motorsLoad 3 = current of electric heatersLoad 4 = control power transformer = any other load rated at one amp or

more (gas heat, factory-wiredconvenience outlet)

Single-Source Power

Set #1: Cooling only units and coolingwith gas heat, single source power

MCA = (1.25 x load 1) + load 2 + load 4

MOP = (2.25 x load 1) + load 2 + load 4

Select an overcurrent protective devicerating equal to the MOP value. If theMOP value does not equal a standarddevice size as listed in NEC 240-6, selectthe next lower standard device rating. Ifthe selected MOP is less than the MCA,then reselect the lowest standardmaximum overcurrent protectivedevice size that is equal to or larger thanthe MCA, provided the reselecteddevice size does not exceed 800 amps.

Disconnect Switch Sizing (DSS) – if fieldprovided and installedIf the unit has a factory-installed, non-fused disconnect switch, this sizingequation is not necessary. If thedisconnect is field-provided andinstalled, use the following equation todetermine its rating:

DSS = 1.15 x (load 1 + load 2 + load 4)

Select a disconnect switch (DSS) size

equal to or larger than the DSS valuecalculated.

Set #2: Units with electric heat, singlesource power, non-concurrent loadTo arrive at the correct MCA and MOPvalues, you must perform two sets ofcalculations: one for cooling only (set #1)and one for electric heat only (set #2).Calculate the MCA and MOP values as ifthe unit were in the cooling mode (usethe equations given in set #1). Thenrepeat the calculations for MCA andMOP for the unit in the heating modeusing set #2. When determining loads,keep in mind that the compressors andcondenser fans do not run while the unitis in the heating mode.

For units using heaters:• less than 50 kW,

use the formula, MCA = 1.25 x (load 1+ load 2 + load 4) + (1.25 x load 3)

• equal to or greater than 50 kW,use the formula, MCA = 1.25 x (load 1+ load 2 + load 4) + load 3

Select the nameplate MCA value that isthe larger of the cooling (set #1) or theheating mode MCA calculated above.

MOP = (2.25 x load 1) + load 2 + load 3 +load 4

Select an overcurrent protective devicerating equal to the MOP value. If theMOP value does not equal a standarddevice size as listed in NEC 240-6, selectthe next lower standard device rating. Ifthe next lower standard rating is lessthan 125% of the current rating of theelectric heater load, select the nexthigher standard device rating. If theselected MOP is less than the MCA, thenreselect the lowest standard device sizewhich is equal to or larger than theMCA, provided the reselected devicesize does not exceed 800 amps.

Select the MOP value that is the largerof the cooling (set #1) mode MOP valueor the heating MOP value calculatedabove.

Disconnect Switch Sizing (DSS) – if fieldprovided and installedIf the unit is ordered with a factory-installed non-fused disconnect switch,this sizing equation is not necessary. Ifthe disconnect is to be field-providedand installed, use the following equationto determine its rating:

DSS = 1.15 x (load 1 + load 2 + load 3 +load 4)

Select the DSS value that is the larger ofthe cooling (set #1) mode DSS or theheating mode DSS value calculatedabove. Select a disconnect switch sizeequal to or greater than the DSS valuecalculated.

Set #3: Units with electric heat, singlesource power, concurrent loadConcurrent load = two compressors andfirst stage electric heat

Primary Heat Reheat SelectionYou may enable primary heat reheat totake advantage of the primary heatsource as supplemental reheat for thecondenser reheat. Although in mostcases, the MCA and MOP values areunaffected by the concurrent loads ofcompressors, condenser fans, and firststage of electric heat, there are a fewcircumstances where the MCA and MOPare increased when this sequence isemployed.

You must perform three sets of calcula-tions to obtain the correct MCA and MOPvalues: one for cooling (set #1) only, onefor electric heat (set #2) only, and one forwhen the unit is in the cooling mode withcompressors and electric heat onconcurrently (set #3).

For size 031 and 040 units, compressorsA (1K1) and B (1K2) can run concurrentlywith 1/3 of three-stage electric heat or 1/7of seven-stage electric heat.

For size 051 and 066 size units, compres-sors A (1K1) and D (1K4) can runconcurrently with 1/3 of three-stageelectric heat or 1/7 of seven-stage electricheat.

For units using heaters less than 50 kW:MCA = (1.25 x load 1) + load 2 + load 4 +(1.25 x load 3)

For unit using heaters equal to or greaterthan 50 kW:MCA = (1.25 X load 1) + load 2 + load 3 +load 4

Select the nameplate MCA value that isthe largest of the three sets of MCAcalculations.

MOP = (2.25 x load 1) + load 2 + load 3 +load 4

Select an overcurrent protective device

38 FAXA-SVX01B-EN

Installationelectricalrequirements

rating equal to the MOP value. If the MOPvalue does not equal a standard devicesize as listed in NEC 240-6, select thenext lower standard device rating. If thenext lower standard rating is less than125% of the current rating of the electricheater load, select the next higherstandard device rating. If the selectedMOP is less than the MCA, then reselectthe lowest standard device size which isequal to or larger than the MCA, pro-vided the reselected device size does notexceed 800 amps.

The MOP value selected should be thelargest of the three sets of MOP valuecalculations.

Disconnect Switch Sizing (DSS) – if fieldprovided and installedIf the unit is ordered with a factory-installed non-fused disconnect switch,this sizing equation is not necessary. Ifthe disconnect is to be field-provided andinstalled, use the following equation todetermine its rating:

DSS = 1.15 x (load 1 + load 2 + load 3 +load 4)

Select the DSS that is the largest of thethree sets of DSS calculations. Select adisconnect switch size equal to or greaterthan the DSS value calculated.

Set #4: Units with Electric Heat, DualSource PowerDual source power is required only onsome 208V and 230V units whenprovided with electric heat. Those unitsare:

size voltage elec ht kW

031 208V or 230V 42 kW orlarger




Dual Source Power

For units with dual source power, usetwo different sets or MCA and MOPcalculations, one for each powerconnection. MCA1 and MOP1 representthe values calculated for the operation ofthe compressors and condenser fans.

For the calculations of MCA1 and MOP1,use the instructions from set #1previously in this section.

MCA2 and MOP2 represent the valuescalculated for the operation of the unit inheating mode:

MCA2 = (1.25 x load 3) if heater kW isless than 50kW

or

(1.0 x load 3) if heater kW is 50kW orgreater, MOP2 = (1.25 x load 3)

Select an overcurrent protective devicerating for the heating circuit equal to theMOP2 value. If the MOP2 value does notequal a standard device size as listed inNEC 240-6, select the next lower stan-dard device rating. If the selected MOP2is less than the MCA2, then reselect thelowest standard device size that is equalto or larger than the MCA2, provided thereselected device size does not exceed800 amps.

Disconnect Switch Sizing (DSS) – if fieldprovided and installed:If the unit is ordered with a factory-installed non-fused disconnect switch, thissizing equation is not necessary. If thedisconnect is to be field-provided andinstalled, use the following equation todetermine its rating:

DSS2 = 1.15 x (load 3)

Select the DSS2 value that is the largestof the three sets of DSS2 calculations.Select a disconnect switch size equal to orgreater than the DSS2 value calculated.

Load Definitions

Load 1:• supply fan • exhaust fan• reheat comp (A) • condenser fan 1 (A)• main comp 1 (B) • condenser fan 2 (B)• main comp 2 (C) • condenser fan 3 (C)• main comp 3 (D) [5100/6600]• total energy wheel

Load 3:• electric heat

kW < 50kW > 50

Load 4• control power transformer (loads > 1

amp [1T1 - 208/230])• gas heat• factory-wired convenience outletthe compressors and condenser fans. For

FAXA-SVX01B-EN 39

Installationelectricalrequirements

Table I-ER-9. Electric heat FLA

unit kW kW kW kW kW kW kW kW kWsize voltage 20 26 32 42 56 70 84 100 122

031 208/60/3 55.5 72.2 88.8 116.6 155.4 — — — —230/60/3 48.1 62.5 77.0 101.0 134.7 — — — —460/60/3 24.1 31.3 38.5 50.5 67.4 — — — —

040 208/60/3 — 72.2 88.8 116.6 155.4 194.3 233.2 — —230/60/3 — 62.5 77.0 101.0 134.7 168.4 202.1 — —460/60/3 — 31.3 38.5 50.5 67.4 84.2 101.0 — —

051 208/60/3 — — 88.8 116.6 155.4 194.3 233.2 277.6 —230/60/3 — — 77.0 101.0 134.7 168.4 202.1 240.6 —460/60/3 — — 38.5 50.5 67.4 84.2 101.0 120.3 —

066 208/60/3 — — — 116.6 155.4 194.3 233.2 277.6 338.6230/60/3 — — — 101.0 134.7 168.4 202.1 240.6 293.5460/60/3 — — — 50.5 67.4 84.2 101.0 120.3 146.7

Note: Electric heat FLA is determined at 208, 240 & 480 volts.

Table I-ER-10. Dual source electric heat - customer wire gauge, AWG

unit kW kW kW kW kW kWsize voltage 42 56 70 84 100 122

031 208/60/3 1/0 2/0 — — — —230/60/3 1 1/0 — — — —

040 208/60/3 1/0 2/0 3/0 250 — —230/60/3 1 1/0 2/0 4/0 — —

051 208/60/3 — — 3/0 250 300 —230/60/3 — — 2/0 4/0 250 —

066 208/60/3 — — 3/0 250 300 500230/60/3 — — 2/0 4/0 250 350

Table I-ER-11. Voltage utilization range

utilizationvoltage range208/60/3 187-220230/60/3 208-254460/60/3 416-508

40 FAXA-SVX01B-EN

Installationinstallationprocedure

Rigging and Placement

Before Rigging and Lifting the Unit1. Verify the roof curb is installed properly

and has the prooper gaskets installedand is level and square to ensureadequate curb-to-unit seal.

2. Attach adequate strength lifting cablesto the lifting lugs. See Tables I-DW-1 & I-DW-2 on page 32 for unit & componentweights. See Figure I-PC-4 on page 32for the proper unit lifting procedure. Tolift the unit, use spreader bars to protectthe unit and ensure uniform lift. Notethat the minimum distance between thelifting hook and the top of the unitshould be seven feet.

3. Test-lift the unit at a minimum heightabove the ground to verify all rigging

Figure I-IP-1. Fresh air unit center of gravity and weight distribution

equipment operates properly and theunit is properly balanced.

4. Lift the unit and position it over the roofcurb. Align the unit base rails with theroof curb.

5. Lower the unit onto the curb. Makesure the curb gasket remains intactwhen positioning the unit.

Center of Gravity and WeightsCenter of gravity dimensions and cornerweights are approximate. Approximateunit shipping weight is the sum of the fourcorner weights. Reference unit weights inthe Dimensions and Weights section onpage 32. See Figure I-IP-1 for fresh airunit center of gravity and for cornerweights.

unit center of gravity max operational typical point loading — weight, lbs.size X (in) Y (in) weight (lbs) A B C D E F G H I J

units without total energy wheel031 90 50 4934 905 1692 1562 775040 90 50 5194 953 1781 1644 816051 100 51 6190 1392 1931 1703 1164066 100 51 6722 1512 2097 1849 1264units with total energy wheel

031 123 50 6394 1023 1023 1088 1151 1088 1023040 123 50 6718 1075 1075 1075 1142 1142 1142051 130 51 8081 1051 1212 1374 1616 1455 1455066 130 51 8663 1126 1300 1473 1819 1559 1386

D E F

C B A

unit without TE wheel optionunit with TE wheel option

G H

J I

FAXA-SVX01B-EN 41


Figure I-IP-2. Proper fresh air unit rigging and handling for units without the total

energy wheel option

Rigging Procedure1. Use spreader bars as shown in Figures

I-IP-2 and I-IP-3 to prevent upper cabinetdamage. If possible, use chains orcables at lifting locations. Do not uselifting hooks or chain hooks. Ensuredimension A is not shorter thanrecommended to prevent liftinginstability.

2. Cables used to lift the unit must becapable of supporting the entire unitweight.

3. Unit center of gravity (balance) islocated approximately at the position ofthe center of balance labels along thelength of the unit. Also, you mayreference the center of gravitylocations in Figure I-IP-1 on page 40.

Leveling the UnitThe unit must be installed level to ensureproper unit operation. The unit must belevel in both horizontal axis (max slope =1/4” per foot).

WARNING

Improper unit lift!Failure to properly lift unit can causedeath, serious injury, or equipment/property-only damage.

B

A

LIFTING POINT A MUST BEALIGNED DIRECTLY OVER UNITCENER OF BALANCE FOR ALEVEL LIFT

7 FT. MINIMUM:SHORTER LENGTHSMAY RESULT IN LESS LIFTING STABILITY

USE SPREADER BARS

EACH OF THE CABLES USED TO LIFTTHE UNIT MUST BE CAPABLE OFSUPPORTING THE ENTIRE UNIT WEIGHT

LOCATION OF CENTER OFBALANCE LABELS INDICATE APPROX. CENTER OF BALANCELOCATION ALONG THE LENGTHOF THE UNIT

USE CHAINS OR CABLESDO NOT USE HOOKS INLIFTING HOLES

7 FT. MINIMUM:SHORTER LENGTHS MAYCAUSE LIFTING INSTABILITY

B

8 FT. MINIMUMA 8 FT. MINIMUM:SHORTER LENGTHS MAY CAUSELIFTING INSTABILITY

Figure I-IP-3. Proper fresh air unit rigging and handling for units with the total energy

wheel option

A

BUSE CHAINS OR CABLES. DO NOTUSE HOOKS IN LIFTING HOLES.

LABELS INDICATE APPROX.CENTER OF BALANCE LOCATIONALONG THE LENGTH OF THE UNIT

LIFTING POINT A MUST BEALIGNED DIRECTLY OVERUNIT CENTER OF BALANCEFOR A LEVEL LIFT

42 FAXA-SVX01B-EN


Exhaust Louver Installation

Install the exhaust louvers after installingthe unit in its final position, following theprocedure below.1. Remove the temporary shipping panel

from the exhaust exit.2. Locate the shipped-with gravity

damper in the main filter compartment.A ship-with item label indicates thedoor.

3. Install the gravity damper so the thedamper blades close in a downwardmotion.

FAXA-SVX01B-EN 43


Note: Guidelines for wire sizes andlengths are shown in Table I-IP-1. Thetotal resistance of these low voltagewires must not exceed 2.5 ohms perconductor. Any resistance greater than2.5 ohms may cause the control tomalfunction due to excessive voltagedrop.

Note: Do not run low-voltage controlwiring in same conduit with high-voltage power wiring.

1. Run wires between the unit controlpanel and the zone sensor subbase. Todetermine the number of wiresrequired, refer to the unit wiringdiagrams.

2. Connect the wiring to the appropriateterminals at the unit control panel andat the zone sensor subbase. In general,zone sensor connections to the unit usethe convention of connecting zonesensor terminals to like numbered unitterminals (1 to 1, 2 to 2, etc.). Theconnection detail is shown on the unitwiring diagrams, which are located inthe unit control panel.

3. Replace the zone sensor cover backon the subbase and snap securely intoplace.

Standard Remote Sensor(BAYSENS017)When using the remote sensor,BAYSENS017, mount it in the space thatis to be controlled. Wire according to theinterconnecting wiring diagrams on theunit.

Table I-IP-1. Zone sensor maximum

lengths and wire size

distance from recommendedunit to controller wiring size0-150 feet 22 gauge151--240 feet 20 gauge241-385 feet 18 gauge386- 610 feet 16 gauge611-970 feet 14 gauge

Zone Sensor Installation forTemperature and Humidity

All remote sensor options ship in thereturn-air filter section, and require field-installation.

Mounting LocationMount the sensor on the wall in an areawith good air circulation at an averagetemperature. Avoid mounting spacetemperature sensor is areas subject tothe following conditions:• Drafts or “dead” spots behind doors or

in corners• Hot or cold air from ducts• Radiant heat from the sun or appliances• Concealed pipes and chimneys• Unheated or non-cooled surfaces

behind the sensor, such as outside walls• Airflows from adjacent zones or other

units

To mount the sensors, remove the dustcover and mount the base on a flatsurface or 2" x 4" junction box. Sensorsship with mounting screws.

Mounting the SubbaseRemove the zone sensor cover fromsubbase, and mount subbase on the wallor on a 2 x 4 junction box. Route wiresthrough the wire access hole in thesubbase. See Figures I-IP-3 and I-IP-4 onpage 44. Seal the hole in the wall behindthe subbase.

Wiring Guidelines

WARNING!

Hazardous voltage!Before servicing unit, disconnect allelectrical power including remotedisconnects. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to do so can cause death orserious injury.

44 FAXA-SVX01B-EN


Figure I-IP-4. Typical zone sensor installation.

Figure I-IP-3. Zone sensor mounting hole locations.

Junction

Mounting to Junction Box

Wall Mounting

FAXA-SVX01B-EN 45


Time Clock Option

The time clock option has aprogrammable timer that is factory wiredto the unoccupied input to provide on/offcontrol. The time clock will not allow theunit to pass through the night setback/morning warmup mode, except on unitswith optional night heat/morning warmup, or programmable night setback. SeeFigure I-IP-5.

The timeclock, a “Digi 20” by Grasslin, isinside the control panel, but accessiblewith the control panel door closed. Thissame type timer is also used for pro-grammable night setback/morning warmup.

Time Clock Installation1. Ensure operating temperature is within

4 to 131°F.2. Locate the time clock at least 5 feet

away from any large electrical contactor machinery to avoid possibleelectrical interference problems.

3. Provide a separate independent circuitfor the time clock power supply.

4. Since all electronic instruments aresensitive to voltage spikes, pay closeattention tot he following:

a. If possible, supply power to theelectronic time clock from a phasedifferent than the one supplying powerto the load.

b. Provide a suitable Varistor or RCnetwork across the INDUCTIVELOADS supply terminals to reducevoltage spikes.

c. Place a diode across the DCOPERATED INDUCTOR terminals toeliminate back EMF.

d. HIGHLY INDUCTIVE LOADS, especiallyfluorescent lights, may require a relayin which case step a. and c. apply.

The timeclock can be surface or flushmounted. Lift off the front cover andloosen the two screws on oppositecorners. Pull off the base’s plug with a leftto right rolling motion.

Time Clock Installation Checklist1. Ensure operating temperature is within

4 to 131°F.2. Locate the time clock at least 5 feet

away from any large electrical contactor machinery to avoid possibleelectrical interference problems.

3. Provide a separate independent circuitfor the time clock power supply.

4. Since all electronic instruments aresensitive to voltage spikes, pay closeattention to the following:

a. If possible, supply power to theelectronic time clock from a phasedifferent than the one supplying powerto the load

b. Provide a suitable Varistor or RCnetwork across the INDUCTIVE LOADSsupply terminals to reduce voltagespikes.

c. Place a diode across the DC OPERATEDINDUCTOR terminals to eliminate backEMF.

d. HIGHLY INDUCTIVE LOADS, especiallyfluorescent lights, may require a relayin which case (A) and (C) apply.

The Digi 20A timeclock unit can besurface or flush mounted. Lift off thefront cover and loosen the two screws onopposite corners. Pull off the base’s plugwith a left to right rolling motion.

Surface Mounting Inside PanelPlace screws through the base’s presetholes and screw to back of panel or wall.

Wire according to the instructions in thefollowing section. Depending upon thespecific installation, you may find it moreconvenient to complete wiring beforeattaching the base.

Place the terminal cover over theterminal block by aligning the two screwswith the corner holes in the base. Pushthe timer firmly onto the plug in the base.Tighten the two screws. A base for DINrail mounting is optional.

Wiring theTimeclock1. Wire 24, 120, or 220 VAC to input

terminals. Make sure to apply correctvoltage. Using incorrect voltage willvoid the warranty.

2. Connect wire to the screw terminalsaccording to the unit wiring diagrams.Use 12 to 22 AWG wire.

Figure I-IP-5. Grasslin time clock option

46 FAXA-SVX01B-EN


Figure I-IP-6. Human interface (HI) panel keypad

Remote Human InterfacePanel Installation

Human Interface (HI) PanelThe HI enables the user to communicatenecessary unit operating parameters andreceive operating status informationfrom within the occupied space.

The HI displays top level information inthe LCD window, unless the operatorinitiates other displays, for the variousunit functions. It also displays menureadouts in a clear language two line, 40character format. The 16-key keypadallows the operator to scroll through thevarious menus to set or modify theoperating parameters. See Figure I-IP-6to reference the HI keypad.

Remote Human Interface PanelThe remote human interface (RHI) panelis identical to the unit mounted HI with theexception of the “unit select” key. Thiskey allows the operator to switch fromone unit to the next to program or viewstatus information regarding a particularunit.

The RHI functions the same as the unitmounted HI with two exceptions. The firstis the “test start” function. The operatorcan view the service parameters, but canonly initiate the service test function atthe unit. The RHI door has a locking screwto deter access by unauthorized person-nel. Additionally, the RHI can control up tofour different units.

Location RecommendationsThe HI microprocessor module ismounted inside a molded plasticenclosure for surface mounting. It is notweatherproof. Therefore, it is onlyapplicable for indoor use.

Locate the RHI panel in an area that willensure the communication link betweenthe panel and the unit(s) does not exceed5,000 feet maximum or pass betweenbuildings. See Table I-IP-2.

The run length of the low voltage ACpower wiring to the remote HI must notexceed three (3) ohms/conductor. Referto Table I-IP-3.

Ambient Temperature and HumidityLimitsAmbient operating conditions• Temperature: 32 to 120°F• Relative humidity: 10 to 90%, non-

condensingAmbient storage conditions• Temperatures: -50 to 200°F• Relative humidity: 5 to 95%, non-

condensing

Table I-IP-2. Maximum communication link

wiring length

max. wire max. capacitancelength between conductors1,000 ft up to 60 pf/ft2,000 ft up to 50 pf/ft3,000 ft up to 40 pf/ft4,000 ft up to 30 pf/ft5,000 ft up to 25 pf/ftNote: pf/ft = picofarads/foot

Table I-IP-3. Wiring recommendations for

the remote HI panel

distance from unit recommendedto remote HI wire size0-460 feet 18 gage461-732 feet 16 gage733-1000 feet 14 gage

FAXA-SVX01B-EN 47


Mounting the Remote HumanInterface (RHI) Panel

The installer must provide all mountinghardware such as; hand tools, electricalboxes, conduit, screws, etc. Refer toFigure I-IP-7 on page 48 for the mountinghole and knockout locations.

ProcedureRefer to Figure I-IP-7 on page 48 andfollow the procedure below for mountingthe remote HI panel on a 4” by 4”electrical junction box. Place themicroprocessor in a clean dry locationduring the enclosure mountingprocedures to prevent damage.

1. Mount an electrical junction box in thewall so that the front edge of the boxwill be flush with the finished wallsurface.

2. Prior to mounting the panel, themicroprocessor module must becarefully removed from the enclosure.To remove the module:

a. Lay the remote panel face up on a flatsurface and remove the locking screwfrom the right hand bottom end of thepanel.

b. Remove the recessed hinge screwfrom the left hand bottom end of thepanel.

c. Unlatch the door of the enclosure as ifto open it, and slide the left hand side ofthe door upward away from the hinge.Lay it aside.

d. With the key pad visible, remove thetwo (2) screws located on the righthand side of the key pad.

e. Carefully slide the key pad plateupward from the bottom, releasing theextruded hinge pin from its socket atthe top.

f. Set the microprocessor aside untilmounting is complete.

3. Remove the junction box knockout inthe back of the enclosure.

Note: The top of the enclosure is marked“TOP.”

4. With the enclosure in the correctposition; align the mounting holesaround the knockout in the enclosurewith the screw holes in the electricalhandy box and secure with theappropriate screws.

5. Replace the microprocessor within theenclosure as follows:

a. Verify that the terminal block jumpersare connected properly.

b. Slide the extruded hinge pin at the topleft of the key pad plate into the holelocated at the top left hand side of theenclosure.

c. Slide the bottom of the plate into place,aligning the two (2) clearance holeswith the screw holes on the right. Installthe screws but do not tighten at thistime.

Note: If the two screws are not installedas called out in the previous step, holdagainst the key pad plate while installingthe door in the next step, to prevent itfrom falling out.

d. Slide the extruded hinge pin at the topleft of the door into the hole locatedunder the bottom left side of thedisplay.

e. Install and tighten the hinge screwlocated at the bottom left side of theenclosure.

Wall Mounting the RHI Panel1. Prior to mounting the panel, the

microprocessor module must beremoved from the enclosure.Complete step 2 in the previousdiscussion, “Mounting on a 4 in. x 4 in.Electrical Box,” before proceeding.

2. With the microprocessor removed,refer to Figure I-PR-7 on page 48 forthe mounting hole locations for wallmounting.

3. Place the enclosure against themounting surface and mark themounting holes.

Note: The top of the enclosure ismarked with “TOP.”

4. With the enclosure in the correctposition, remove the enclosure anddrill the necessary holes in the surfacefor the appropriate fasteners, (plasticanchors, molly bolts, screws, etc.)

5. Remove the necessary knockouts forthe wire or conduit entry beforemounting the panel.

6. Place the enclosure back onto thesurface and secure it with theappropriate screws.

7. Follow step 5 in the previous section,“Mounting on a 4” by 4” ElectricalBox,” to replace the microprocessorwithin the enclosure.

48 FAXA-SVX01B-EN


Figure I-IP-7. Remote HI mounting holes and knockout locations

FAXA-SVX01B-EN 49


Wiring the Remote HumanInterface

The remote human interface requires 24VAC + 4 volts power source and ashielded twisted pair communication linkbetween the remote panel and theinterprocessor communication bridge(ICPB) module at the self-contained unit.

Note: To prevent control malfunctions,do not run low voltage wiring (30 volts orless) in conduit with higher voltagecircuits.

Field wiring for both the low voltagepower and the shielded twisted pair mustmeet the following requirements:

1. All wiring must be in accordance withNEC and local codes.

2. Reference Table I-IP-3 on page 46 forrecommended wiring distance and size.

3. Communication link wiring must be 18AWG shielded twisted pair (Belden8760, or equivalent).

4. Communication link must not exceed5,000 feet maximum for each link. SeeTable I-IP-2 on page 35.

5. Do not run communication linkbetween buildings.

WARNING

Hazardous voltage!Before servicing unit, disconnectelectrical power source and remotedisconnects. Failure to do so maycause death or injury.

WARNING


Low Voltage (AC) Field WiringConnectionsTo access the wire entry locations, openthe RHI panel door and remove the twoscrews on the right-hand side of the keypad. Swing the keypad open, exposingboth the wire entries and the back of theHI module. Refer to Figure I-IP-7 on page48 and connect one end of the threeconductor 24 volt wires to the remotepanel terminal strip (+), (-), and (ground).

Communication Link (Shielded TwistedPair) WiringTrim the outer covering of the shieldedcable back approximately one inch. SeeFigure I-IP-8. Do not cut the bare shieldwire off. Strip approximately 1/2-inch ofinsulation from each insulated wire toconnect them to the terminal strip at theremote panel.

Connect the white lead to the positive (+)terminal, the black lead to the negative (-)terminal, and the bare shield wire to theterminal at the remote human interfacepanel.

Close the key pad plate. Install andtighten the two screws removed earlier.Close the outer door and install therecessed locking screw at the bottomright hand side of the enclosure toprevent accidental starting of the unit byunauthorized personnel while completingthe wiring at the self-contained unit.

At the fresh air unit, connect the oppositeend of the three conductor 24 volt wire tothe appropriate terminal strip as follows:

Note: Although the 24 volt power is notpolarity sensitive, do not connect eitherthe + (plus) or - (minus) terminals fromthe remote panel to ground at the freshair unit.

1. Connect the wire connected to thepositive (+) terminal at the remotepanel.

2. Connect the wire connected to thenegative (-) terminal at the remotepanel.

3. Connect the ground wire from theremote panel to the unit control panelcasing.

Interprocessor Communication BridgeModule WiringRefer to Figure I-IP-8 and trim the outercovering of the shielded cable backapproximately one inch. Cut the bareshield wire off even with the outercovering. Strip approximately 1/2-inch ofinsulation from each insulated wire inorder to connect them to the terminalstrip at the unit. Wrap tape around anyexposed foil shield and/or base shieldwire.

Note: The communication link is polaritysensitive.

Refer to the unit wiring diagram andconnect the white lead to the positive (+)terminal and the black lead to thenegative (-) terminal. (These terminalsare numbered. Reference to color is forclarification to maintain polarity).

Note: To maintain polarity, do notconnect the base shield wire to groundat the fresh air unit.

Figure I-IP-8. Dressing shielded twisted wire

50 FAXA-SVX01B-EN


Connecting to Tracer Summit™

Packaged fresh air units can operate withTrane building automation software,Tracer Summit version 14.0 or later.

Note: Tape the non-insulated end of theshield on shielded wire at the unit. Anyconnection between the shield andground will cause a malfunction. If daisy-chained in the unit, splice and tape theshields to prevent contact with ground.

Communication Wiring

Note: Communication link wiring is ashielded, twisted pair of wire and mustcomply with applicable electrical codes.

An optional communication link providesa serial communication interface (SCI)between Tracer Summit and each FreshAir unit (FAU) in the system. The FAUsystem can have a maximum of 12 FAUsper connection link to Tracer Summit. Usea single 18 AWG shielded, twisted pairwire with stranded, thinned copperconductors to establish eachcommunication link between TracerSummit and each unit.

Installation Checklist

The checklist listed below is a summaryof the steps required to successfullyinstall a Packaged Fresh Air unit. Thischecklist is intended to acquaint theinstalling personnel with what is requiredin the installation process. It does notreplace the detailed instructions detailedin the applicable sections of this manual.

General Unit Requirements�Assemble and install the roof curb and

necessary gaskets. Make sure the curbis level.�Install and secure the ductwork to the

curb or unit.�Check unit for shipping damage and

material shortage. Refer to theReceiving Checklist on page 9.�Rig the unit. Refer to Figure I-IP-2 page

41.�Place the unit on curb and check

leveling. Ensure that the unit-to-curb

seal is tight without buckles or cracks.�Install an appropriate drain line to the

evaporator condensate drainconnection. Refer to Figure I-MR-2 onpage 35.

Electrical Requirements�Verify that the electrical power supply

characteristics comply with the unitnameplate specifications.�Inspect all control components; tighten

any loose connections.�Connect properly sized and protected

power supply wiring to a field supplied/installed disconnect and unit powerterminal block, or to the optional unitmounted disconnect switch.�Properly ground the unit.

Field Installed Control Wiring (Optional)�Complete the field wiring connections.

Note: All field installed wiring mustcomply with NEC and applicable localcodes.

Gas Heat Requirements�Gas supply line properly sized,

supported, and connected to unit gastrain.�Install a 1/8-inch N.P.T. plugged tapping,

accessible for test gauge connection, iimmediately upstream of gas supplyconnection to unit.�Ground union must be installed

adjacent to the manifold for easyservicing.�Drip leg installed in the gas piping near

the unit.�Additional shutoffs are located

externally of the jacket enclosurewhere required by local code.�All gas piping joints properly sealed.�Gas piping leak checked with a soap

solution.�Main supply gas pressure adequate.�Refer to the Reznor Installation Form,

RGM 401, for additional information.

Note: All gas piping must comply withapplicable local codes.

FAXA-SVX01B-EN 51

Installationpre-startuprequirements

Pre-Startup Checklist

Complete this checklist after installing theunit to verify all recommendedinstallation procedures are completebefore unit startup. This does not replacethe detailed instructions in theappropriate sections of this manual.Always read the entire section carefullyto become familiar with the procedures.

WARNING

Hazardous voltage!Before servicing unit, disconnect allelectrical power including remotedisconnects. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to do so can cause death orserious injury.

WARNING


Receiving�Inspect unit and components for

shipping damage. File damage claimsimmediately with the delivering carrier.�Check unit for missing material. Look

for ship-with drives, filters, and sensorsthat are packaged separately andplaced inside the filter section accesspanel. See the “Receiving andHandling” section on page 9.�Check nameplate unit data so that it

matches the sales order requirements.

Unit Location�Ensure the unit location is adequate for

unit dimensions, ductwork, piping, andelectrical connections.�Ensure access and maintenance

clearances around the unit areadequate. See the “Service Access”section on page 10.

Unit Mounting�Remove shipping brackets on the

compressor assembly, exhaust, andsupply fans.

Component Overview�Verify all fan and motor sheaves are

aligned.�Check all belt tensions are properly

adjusted.�Ensure all fans rotate freely.�Tighten locking screws, bearing set

screws and sheaves.�Ensure bearing locking collars do not

wobble when rotated.�Ensure all air filters are properly

installed with consideration of size andair flow.

Ductwork�Verify that all ductwork conforms to

NFPA 90A or 90B and all applicablelocal codes.�Ensure all ductwork is properly sealed

and routed between the unit and/or roofcurb.

Unit Piping�Verify the condensate drain piping is

complete for the unit drain pan. Installand tighten the condensate “P” trapdrain plug per Figure I-MR-2 on page26.�Prevent refrigerant piping from rubbing

against other objects.

Fans�Manually rotate all fans to ensure free

movement. Verify that all of the fanmounting hardware is tight.

Outside Air Damper�Inspect all damper hinges and pins to

ensure all moving parts are secure.�Verify all damper linkages move freely

and travel from full open to full closed.

Return Air Damper�Inspect air damper and linkage.�Verify air damper has unrestricted

travel.

Total Energy Wheel�Verify the rotor rotates freely by hand.�Verify the motor rotation is correct.�Ensure the air flow orientation is

correct by referencing the identificationmarkings on the cassette.�Check that the belt is on correctly and

adjusted properly.�Verify the seals are firmly clipped to the

cassette.

52 FAXA-SVX01B-EN

Unit Startup Procedures

1. Check all electrical connections fortightness.

2. Be sure all system components areproperly set and installed.

3. Inspect all ductwork and ductconnections.

4. Remove compressor and fanassembly tie down bolts.

5. Verify the total energy wheel sealdoesn’t leak. See procedure below.

To start the unit, complete the followinglist in order:1. Apply power to the unit. Close the unit

disconnect switch(es).2. Adjust setpoints at the HI.3. Turn on the gas if unit has gas heaters

and verify all lines are purged of air.

See the Packaged Fresh Air Unit Pro-gramming Guide, FAXA-SVP01B-EN, foravailable unit operating setpoints. Referto the job specifications for propersetpoints.

Total Energy Wheel SealchecksThe total energy wheel has a neoprenebulb seal to provide an effective seal inboth the peripheral and side-to-sidesealing directions. Also, it is easilyadjustable to compensate for seal run-in,shipping misalignment, etc. The neoprenebulb is attached to a metal reinforced U-shaped neoprene grip. The metal/neoprene grip allows an expandable griprange that can be moved closer orfurther from the sealing face as needed.The peripheral bulb seals against thewheel outer band the inner bulb sealsagainst the wheel face.

Follow the procedure below:1. With the wheel stopped, move seals as

close to the sealing surface as possiblebut without exceeding grip range ofbulb seal and without pressing the bulbdown against the seal face.

2. Bump the motor. If the motor will notturn, the seal is too close. Nudge it backwhere needed. The seal will seek itsequilibrium position based on theclosest part of the sealing face.

Because the seal is meant to be anoncontact seal, small gaps may be seenbetween seal and sealing surface when itreaches the equilibrium position. Sealleakage is meant to be under 5% at one-inch of differential between supply andexhaust. Some seal run-in is commonand will result in small amounts of wearin the neoprene.

Unit Startup Checklist1. Ensure all fans rotate is in the direction

of the arrow on the fan housing. Ifrotation is incorrect, first verify theincoming power phasing is correct. If itis correct, switch wires on the fancontact so the fan is properly phased.

2. Check the fan belt condition andtension. Adjust the tension if belts arefloppy or squeal continually. Replaceworn or fraying belts in matched sets.

3. Check voltage at all compressorterminals. Actual voltage should bewithin 10% of nameplate voltage.

4. Check voltage imbalance from thesethree voltage readings, at eachcompressor. Maximum allowablevoltage imbalance, phase to phase, is2%.

startupInstallation

FAXA-SVX01B-EN 53


5. Check amp draw at compressorterminals. RLA and LRA is on the unitnameplate.

6. Measure amp draw at evaporator andexhaust fan motor terminals. FLA datais on the motor nameplate.

7. After the system has stabilized (15 – 30minutes), check and record operatingpressures and temperatures for allcircuits.

8. Check natural gas pressure and verifyno less than 5” w.c. (0.18 psi) or greaterthan 14” w.c. (0.5 psi).

9. Inspect refrigerant flow in the liquid linesight glass. Flow should be smooth andeven, with no bubbles once the systemhas stabilized.

Normal startup can occur provided thatTracer Summit is not controlling themodule outputs or the generic BAS is notkeeping the unit off.

Figure I-S-2. Compressor arrangement for

unit sizes 051 & 066

B C D

circuit 2(main)

A

circuit 1(reheat)

A

circuit 1(reheat)

circuit 2(main)

B C

Figure I-S-1. Compressor arrangement for

unit sizes 031 & 044

startup

To ensure that Tracer Summit has noaffect on unit operation, remove Tracerwiring and make required changes tosetpoint and sensor sources. See thePackaged Fresh Air Unit ProgrammingGuide, FAXA-SVP01B-EN, for moreinformation.

Unit Startup

Reference the Packaged Fresh Air UnitProgramming Guide, FAXA-SVP01B-EN,for unit operating instructions. A copyships with each unit. Also, for units withgas heat, reference the ReznorInstallation Form RGM 401 for propergas heater startup and operation.

54 FAXA-SVX01B-EN

Installation

compressorcompressor amps

L1

L2

L3

refrigerant chg (if known)

suction pressure

suction temperature

superheat

discharge pressure comp.

liquid line pressure

liquid line temp

subcooling

condenser fan motors

fan motor

fan motor amps:L1

L2

L3

Reheat coil on or off during test?

Unit Performance Log

Complete this log at unit startup.model #______________________________

serial #______________________________

date_________________________________

job name_____________________________

______________________________________

Key options:� hot gas condenser reheat� return air damper� heat = gas/electric/none� total energy recovery wheel� TRAQ™ damper

Unit line voltage: L1-L2 ______________

L2-L3 ______________

L1-L3 ______________

L1-ground __________

L2-ground __________

L3-ground __________

Visual observation of the refrigerantcircuitEvaporator coil clean?� yes �� noCondenser clean?� yes �� noAir filters clean?� yes �� noFan belts in good condition?� yes �� noBubbles in sightglass?� yes �� noDry sightglass?� yes �� noEvaporator coil frosting?� yes �� no

startup

A B C D

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

___ ___ ___ ___

2B5 2B6 2B7

� on � off

___ ___ ___

___ ___ ___

___ ___ ___

� on � off

Compressor on or off? � on � offA B C D or NA

____ ____ ____ ____ circuit 1 circuit 2

circuit 1 circuit 2

Outside air temp: Leaving air temp:DB ____________ DB ____________

WB ____________ WB ____________

Additional notes:

FAXA-SVX01B-EN 55

Installationgeneralinformationstartup

Exhaust air fanmotor nameplate hp ____________

motor nameplate FLA ____________

fan motor amps ____________

fan motor nameplate FLA:L1 ____________

L2 ____________

L3 ____________

fan wheel rpm (if known) ____________

Electric heatheater kW ____________

heater stages installed ____________

heater stages tested ____________

heater amp draw as tested:L1 ____________

L2 ____________

L3 ____________

entering air temp. as tested ____________

leaving air temp. as tested ____________

Total energy wheelmotor nameplate hp ____________




L2 ____________

L3 ____________


Supply air fanmotor nameplate hp ____________




L2 ____________

L3 ____________


Gas heatsingle or dual bank ____________

staged or modulating ____________

heater starts and runs?� yes � no

comb. blower works?� yes � no

heater capacity control works?� yes � no

burner flame good?� yes � no

entering air temp. as tested ____________

leaving air temp. as tested ____________

Additional notes:

56 FAXA-SVX01B-EN

Operationgeneralinformation

Packaged Fresh Air Units

Controlswith

We have designed the Trane PackagedFresh Air unit with the latest controltechnology. Modular DDC controls withhuman interface (HI) panel makePackaged Fresh Air units flexible andeasy to operate.

Controls are Trane-designed to work withTrane equipment for optimum efficiency.The factory installs and commissionseach control component to ensure simpleand reliable operation.

Furthermore, the DDC control’s modulardesign allows greater applicationflexibility using up to twelve differentmodules, dependent upon unit options.You can order exactly what the jobrequires as options, instead of one largecontrol package. And since unit featuresare distributed among multiple printedcircuit boards, field replacement is easy.Depending on unit options, IntelliPak™units can operate as:1) stand-alone2) interface with Trane’s Tracer Summit™

building management system3) interface with a generic (non-Trane)

building management system (via LCI-Iusing LonTalk® DAC profile).

4) interface with a generic hard-wired(non-Trane) building managementsystem via analog input and binaryoutput interface board (GBAS)

Available Input and Output Points BaseUnit (RTM module on all units)Binary inputs• emergency stop• external auto/stop• unoccupied/occupied• dirty filter• exhaust fan air provingBinary outputs• unoccupied mode indicator• alarm• exhaust fan enableAnalog input• OA damper minimum position heating

option• analog output (hydronic heat interface)

LonTalk® communication interface (LCI-I) option

Binary input• enthalpy enable unoccupied economizerBinary outputs• compressor on/off status• ventilation status• heat statusAnalog outputs• supply air pressure• supply air temperature• suction temperature of each circuit• zone temperature• supply air temperature reset signal• morning warmup sensor temperature• entering air temperatureAnalog inputs• cooling and heating setpoints• VAV discharge air temperature

setpoints• supply air pressure setpoint• cooling and heating enable/disable

• unoccupied economizer enable/disable• economizer minimum position• unit priority shutdown

Generic BAS Option (GBAS)Binary inputs• demand limit contactsBinary outputs• dirty filter relay• refrigeration fail relay• heat fail relay• supply fan fail relay• active diagnosticsAnalog inputs• occupied zone cooling setpoint• occupied zone heating setpoint• unoccupied zone cooling setpoint• unoccupied zone heating setpoint or

minimum outside air flow setpoint• supply air cooling setpoint• supply air heating setpoint• supply air static pressure setpoint

Zone Humidity Options (ECEM)Analog inputs• zone relative humidity

Traq™ Damper Option (VCM)Analog inputs• ventilation airflow

Ventilation Override Module (VOM)OptionBinary inputs• VOM mode A, unit off• VOM mode B, pressurize• VOM mode C, exhaust• VOM mode D, purge• VOM mode E, purgeBinary output• V.O. relay

FAXA-SVX01B-EN 57


Figure O-GI-1. The human interface panel on the Trane Packaged Fresh Air unit

Standard IntelliPak Unit Control Fea-tures

The human interface panel is easy toread and requires less time for buildingmaintenance personnel to learn tointeract with the unit. It features a clearlanguage display (in English, Spanish, orFrench) that shows all of the PackagedFresh Air unit control parameters,including system on/off, demand limitingtype, night setback setpoints, and manyother setpoints. All adjustments are donethrough the human interface keypad. SeeFigure O-GI-1.

Also, the human interface panel allowsyou to monitor diagnostic points such assensor failures, supply airflow loss, andinoperative refrigerant circuit. No specialtools are required for servicing the unit.Diagnostics are held in memory, evenduring power loss. This allows theoperator/servicer to diagnose the failureroot cause. All setup parameters arepreset from the factory, requiring lessstartup time.

IntelliPak Unit Features• Unit mounted human interface panel

with a two line x 40 character display inEnglish, Spanish, or French languageand a 16-function keypad that includesCUSTOM, DIAGNOSTICS, and SERVICETEST MODE menu keys

• Frostat™ coil frost protection on all units• Supply air or zone dehumidification

control• Supply air or zone temperature control• Efficient condenser hot gas reheat with

modulating capacity (optional)• Morning warmup operation• unoccupied airside economizer

(optional) when unit has return airdamper option

• supply airflow proving• supply air tempering control with

heating option• mappable sensors and setpoint sources• occupied/unoccupied switching• timed override activation

Human Interface Panel (HI)The human interface panel provides a 16-button keypad for monitoring, setting,editing and controlling. The HI panel ismounted in the unit’s main control panel,accessible through the unit’s control paneldoor.

The optional remote-mount version of thehuman interface (RHI) panel has all thefunctions of the unit-mounted version,except for the service mode. To use aRHI, the unit must be equipped with theremote HI interface option, whichincludes an interprocessor communica-tions bridge (IPCB). The RHI can belocated up to 1,000 feet (304.8 m) fromthe unit. A single RHI can be used tomonitor and control up to four fresh airunits, that have each been supplied with aRHI interface option (IPCB module).

The main menus of the human interfacepanels are:• STATUS monitors temperature,

pressure, humidity, setpoints, and inputand output status.

• CUSTOM key allows the user tocustomize a status report - consisting ofup to four screens of the data availablein the main Status menu.

• SETPOINT allows the user to edit allfactory preset default setpoints.

• DIAGNOSTICS allows the user toreview active and historical lists ofdiagnostic conditions. A total of 49

different diagnostics can be read at thehuman interface (HI) panel and the last20 diagnostics can be held in an activehistory buffer log at the HI panel.

• SETUP allows the user to edit controlparameters, sensor selections, setpointsource selections, output definitions,and numerous other points in thismenu. All points have factory presetvalues to keep unnecessary editing to aminimum.

• CONFIGURATION allows changing offactory-preset unit configurationinformation. This information can beedited only if certain options are field-installed or deleted from the unit. Forexample, if a communication interface(LCI-I) module or ventilation overridemodule (VOM) were field-installed, theunit configuration will require editing toreflect those options for proper unitoperation.

• SERVICE allows servicing ortroubleshooting the unit by selectingcomponent control outputs such ascompressors, fans, damper position,etc. This menu is accessible only at theunit-mounted human interface panel.

58 FAXA-SVX01B-EN


This zone sensor is for use withPackaged Fresh Air units to monitor CO2levels in the space.

This zone sensor module is for use withcooling/heating applications. It providesthe following features and systemcontrol functions:

• System control switch (auto/off): Allowsyou to automatically select heating orcooling as required, or turn the systemoff.

• Dual temperature setpoint levers allowyou to set different cooling (blue lever)and heating setpoints (red lever).

• Thermometer indicates temperature inthe zone.

Optional Zone Sensors

Dual setpoint, manual/automatic

changeover sensor, accessory model

number digit 20 = A

Dual setpoint, manual/automatic

changeover sensor with system function

lights, accessory model number

digit 21 = A

Carbon dioxide zone sensor, accessory

model number digit 23 = AThis wall-mounted zone sensor shipswith every Packaged Fresh Air unit thathas supply air dehumidification w/zonereference or zone dehumidification.Additional sensors are also available fororder using the accessory modelnumber and ordering the space relativehumidity kit.

This wall-mounted zone sensor shipswith every Packaged Fresh Air unit.Additional sensors are also available fororder using the accessory modelnumber. This zone sensor includes aninternal thermistor and should bemounted in the zone. This sensor isavailable for use with all zone sensoroptions to provide remote sensingcapabilities.

Standard With All Units

BAYSENS017 zone temperature sensor,

accessory model number digit 16 = A

Standard with All Units if Supply AirDehumidification w/Zone Reference orZone Dehumidification

Zone relative humidity sensor

This zone sensor is for use with cooling/heating applications. It provides thefollowing features and system controlfunctions:• System control switch to select AUTO

mode for automatic selection of heatingor cooling as required, or OFF to turnthe system off.

• Dual temperature setpoint levers forsetting cooling (blue lever) or heating(red lever).

• Thermometer to indicate temperature inthe zone.

• Function status indicator lights:SYS ON glows continuously during

normal operation, or blinks if system isin test mode.

COOL glows continuously during coolingcycles or blinks to indicate a coolingsystem failure.

HEAT glows continuously during heatingcycles or blinks to indicate a heatingsystem failure.

SERVICE blinks or glows to indicate aproblem. These signals vary dependingon the particular equipment used.

FAXA-SVX01B-EN 59


This zone sensor is for use with cooling/heating ICS™. It provides the followingfeatures and system control functions:• Remote temperature sensing in the

zone• A timed override button to move an

Integrated Comfort ™ System or abuilding management system fromunoccupied to occupied mode.

• Setpoint thumbwheel for local setpointadjustment

• Cancel button to cancel the unoccupiedoverride command.

Integrated Comfort™Systems Sensors for FAUApplications

Zone temperature sensor w/timed

override buttons and local setpoint

adjustment, accessory model number

digit 18 = A, BAYSENS014

Zone temperature sensor w/timed

override buttons, accessory model

number digit 17 = A, BAYSENS013

This zone sensor is for use with cooling/heating Integrated Comfort™ Systems(ICS). It provides the following featuresand system control functions:• Remote temperature sensing in the

zone• A timed override button to move an

ICS or building management systemfrom it unoccupied to occupied mode.

• Cancel button to cancel the unoccupiedoverride command.

60 FAXA-SVX01B-EN


Figure O-GI-4. Direct hall discharge with fan-coil or PTAC units

Figure O-GI-3. Indirect discharge to fan-

coil units

Figure O-GI-2. Direct discharge to

conditioned space

Overview

Fresh Air Unit FunctionsThe Packaged Fresh Air Unit (FAU)provides conditioned outdoor air suitablefor mechanical ventilation or make-up air.The FAU conditions outdoor air asnecessary to meet system performancerequirements by filtration, cooling,dehumidification, and/or heating. The FAUmay deliver ventilation air in a number ofways. See the System Configurationssection and Figures O-GI-2 through O-GI-4for more information.

FiltrationFiltration is necessary for the FAU tomaintain system operating efficiency, meetoccupant comfort and health needs, andprovide adequate building filtration to aidindoor air quality. The Packaged FAU offersa variety of filter options to meet mostapplication needs.

CoolingWhen the outdoor air dry-bulb temperatureis warmer than space conditions, the unitcools the outdoor air to the an appropriatesupply air dry-bulb temperature. ThePackaged FAU provides cooling using anair-cooled, direct-expansion (DX)refrigeration system with scrollcompressors.

Dehumidification (Drying)The Packaged FAU dehumidifies theoutdoor air when it is more humid than therequired space target conditions. Thishelps prevent high relative humidity levelsin the space. Occasionally, the outdoor airmay need to be sub-cooled to removeexcess moisture. When necessary, the FAUreheats discharge air to meet spacecomfort conditions. The Packaged FAUrecovers energy from the cooling processto reheat the sub-cooled air as necessary.

HeatingWhen the outdoor air dry-bulb temperatureis colder than space conditions require, theFAU heats the outdoor air to meet spacetemperature requirements. The PackagedFAU has electric or gas heat optionsavailable.

System ConfigurationsDedicated outdoor air systems can deliverconditioned outdoor air in one of thefollowing ways:1. Directly to the occupied space, with the

local terminal unit controlling the spacedry-bulb temperature. See Figure O-GI-2.

2. Directly to local terminal units, whichdeliver a mixture of the conditionedoutdoor air and (conditioned)recirculated return air to the space. SeeFigure O-GI-3.

3. Directly to a single space and control thespace temperature directly. For example,this application will provide temperaturecontrol of a hotel hallway and ventilationof the adjacent rooms. See Figure O-GI-4.

Supply Air TemperatureGive careful consideration when selectingthe FAU supply air temperature. Manycurrent system designs control the fresh airunit discharge air to a “space neutral” dry-bulb condition, typically about 75°F. Atsome operating conditions, reheating theFAU supply air will add cooling load to thespace, thus requiring the local terminalunits to “re-cool” the conditioned outdoorair to meet the space setpoint. Therefore, tohelp maintain lower energy costs, usereheat only when required to maintainoccupant comfort and space relativehumidity. The Capacity Control sectiondiscusses this issue in more detail.

Airside EconomizersOften fresh air units are sized to deliver theminimum ventilation air required for thespace it serves. However, the ventilation airis typically only a portion of the spacesupply air. Airside economizing can provideup to 100% of the space supply air comefrom outdoors when outdoor airconditions are suitable for “free cooling”capability.

Hallway

OA delivered to hallway

FAXA-SVX01B-EN 61


Subcooler

Receiver

and reheat coils. Air leaves the evaporatorcoil saturated at the preset dew pointcondition (h2) and is reheated by thereheat condenser to the preset reheattemperature setpoint (h3). The reheatevaporator transfers energy to the reheatcondenser. A liquid solenoid valveeffectively modulates the reheatcondenser capacity. The reheat outdoorcondenser rejects surplus heat. Thereheat evaporator circuit is first on andlast off, so reheat energy is available at fulland part load conditions. For thoseconditions where the reheat condensercapacity is insufficient to meet reheatdemand, optional electric or gas heat canprovide additional reheat capacity. Sinceboth the dew point setpoint anddischarge temperature setpoint are fullyadjustable, the desired supply airconditions are maintained at all loadconditions.

Cooling or HeatingConsider Figure O-GI-6. If the outdoor airdew point or zone RH is equal to or belowthe drying setpoint, the FAU will heat orcool the outdoor air to separate andadjust cooling or heating setpoints. At t1or t3, 100% outdoor air enters the FAU.The FAU filters, and cools or heats the airas it is drawn through the evaporatorsand heating section. The air leaves theFAU at the cooling or heating setpoint (t2or t4) and equal to or below the dew pointsetpoint.

Figure O-GI-7. Refrigeration system diagram with reheat

It’s important to remember that airsideeconomizer capability can be lost ifdedicated outdoor air systems are sizedfor minimum ventilation air only. Toprovide economizer capability on adedicated outdoor air system, the terminalunits must have the ability to introduce100% outdoor air during the economizer-cooling mode. The terminal unit’s outdoorair damper should modulate between fullyclosed and fully open to allow the FAU todeliver the ventilation air design volume tothe space. The terminal unit shouldenable economizing only if the outdoordry-bulb and dew point conditions aresufficiently low to justify economizing.

Packaged FAU OperationThe Packaged FAU can use either DXcooling, condenser reheat, electric or gasheat to condition the outdoor air. The unitcontrols cooling and heating capacity instages with the exception of themodulated heat options. Cooling andheating staging will result in supply airtemperature swings. The unit controls willdeliver the desired supply air conditionson a time–based, weighted average.

FAU with ReheatFigure O-GI-7 shows the Packaged FreshAir system with a DX refrigerant circuitdesign using reheat.

DehumidificationConsider Figure O-GI-5. If the outdoor airdew point is above the drying setpoint (orin the case of zone control, the zone RH isabove the RH setpoint), the FAU will:• cool the outdoor air to remove required

moisture and• reheat to meet the discharge

temperature setpoint.At h1, 100% outdoor air enters the FAU.The FAU filters, cools, and dehumidifiesthe air as it moves through the evaporator

Figure O-GI-5. Psychrometric chart with

dehumidification and reheat

Figure O-GI-6. Psychrometric chart with

cooling and heating only

h1

h3 h4

h2

Dry Bulb Temperature

Dew

po

int

Tem

per

atu

re

Wet

Bulb

Tem

perat

ure

t3t4heating

t1

t2 cooling

62 FAXA-SVX01B-EN


Evaporator 2

Evaporator 1

Circuit 2 Compressors

Circuit 1 Compressor

Subcooler

Condenser 1

Condenser 2

FAU Without ReheatFigure O-GI-10 shows the Packaged FAUDX system, using a refrigerant circuitdesign without reheat.

Dehumidification (Drying)Consider Figure O-GI-8. If the outdoor airdew point or zone RH is above the dryingsetpoint, the FAU will dehumidify theoutdoor air. 100% outdoor air enters theFAU (h1). The unit filters, cools (h2) anddehumidifies the air as it is drawn throughthe evaporator coils. Air leaves theevaporator coils saturated at a preset dewpoint setpoint (h3). Since the dew pointsetpoint is fully adjustable, the desireddew point condition is maintained at allload conditions.

Cooling or HeatingConsider Chart O-GI-9. If the outdoor airdew point is equal to or below the dewpoint setpoint, the FAU will heat or coolthe outdoor air to separate and adjustcooling or heating setpoints. 100%outdoor air enters the FAU (t1). The unitfilters and cools or heats the air as it isdrawn through the evaporators andheating section. The air leaves the FAU atthe cooling or heating setpoint and equalto or below the dew point setpoint.

FIgure O-GI-10. Refrigeration system diagram without reheat

Chart O-GI-8. Psychrometric chart with

dehumidification, no reheat

Chart O-GI-9. Psychrometric chart with

cooling and heating only


Dew

po

int

Tem

per

atu

re

Wet

Bulb

Tem

perat

ure

Dehumidification

h1h2

h3


Dew

po

int

Tem

per

atu

re

Wet

Bulb

Tem

perat

ure

t3t4heating

t1

t2 cooling

FAXA-SVX01B-EN 63


Establishing CapacityRequirementsDetermining the FAU capacityrequirements requires careful thought. Air-handling equipment is typically selectedbased on design sensible conditions. Sincelatent loads drive the need for the FAU,base the selection on design latentconditions. For more detailed informationon this subject, see the Trane PackagedFresh Air Unit catalog, MUA-PRC004-EN.

Cooling and DehumidificationSelection Criteria

Evaporator Design Entering ConditionsFor many climates the peak outdoor airenthalpy occurs at a time when theoutdoor dry-bulb temperature is not thehighest. Refer to the chapter on climaticdesign information in the ASHRAEHandbook of Fundamentals. The coolingand dehumidification design conditiondata is provided three ways:1. Design dry-bulb temperature with mean

coincident wet bulb temperature2. Design wet-bulb temperature with mean

coincident dry-bulb temperature3. Design dew point temperature with

mean coincident dry-bulb temperature

The design wet-bulb condition typicallyrepresents a significantly higher outdoor airenthalpy than the design dry-bulbcondition. Use the condition thatrepresents the highest enthalpy as theentering evaporator selection condition.

Evaporator Design Leaving ConditionsDue to the uncertainty of the local terminalunit’s latent capacity at part load, it isusually most straightforward to size theFAU to handle the entire latent load on thesystem, both indoor and outdoor. With thisdesign approach, the terminal units may dosome latent cooling (dehumidification)during periods of higher sensible load. Atthese times, the space will run slightly drierthan the design RH limit. This is why itmakes sense to select the FAU to limit thespace RH to a maximum allowable level forthose conditions when the terminal unitsare providing no space latent cooling.ASHRAE Standards 62.1 and 55recommend using 60% RH design limit forcomfort cooling. Using lower design limitsmay result in an unnecessary increase insystem operating energy use.

64 FAXA-SVX01B-EN

Operationsequence ofoperation

Figure O-SO-2. Dry-bulb control in a neutral DB/dry DP

application

Air to Air Energy Recovery

Energy recovery can significantlyreduce HVAC system first-cost andoperating energy costs. You can userecovered energy for two purposes:1. to temper or reheat supply air for

independent control of sensible andlatent capacity, or

2. to precondition outdoor air as itenters the building for ventilation.

The Packaged FAU offers refrigerantheat recovery for reheating the supplyair. To precondition the outdoor air, usethe total energy wheel option torecover energy from building exhaust.

Controlling an Energy RecoveryVentilatorOne way to control an energy recoverydevice is to turn it on and off with theFAU system exhaust fan. In this case,the total energy wheel enables whenthe unit is in occupied mode and theexhaust fan is running. While thiscontrol method is certainly simple andeffective in some applications, it maynot provide the expected energysaving benefit, particularly when cold

air (vs. neutral air) is supplied to thebuilding.

Another more effective approach is touse the outdoor air dry-bulb to deter-mine when to energize or de-energizethe energy recovery device. See FigureAC-7 for an example of this simplifiedversion of energy recovery. In additionto being more effective from a controlstandpoint, it’s also a very simplecontrol method because the totalenergy wheel (only) enables when all ofthe following are true:• unit is in occupied mode• exhaust fan is enabled• outside air temperature is above the

upper limit setpoint (default setpoint80°F) or below the lower limit setpoint(default setpoint 45°F)

• outside air temperature is above thefrost protection setpoint (defaultsetpoint 12°F).

Set the upper limit setpoint to theanticipated return air dry-bulb tempera-ture. Set the lower limit setpoint to 10°Fless than the supply air dry-bulbsetpoint. This control strategy prevents

Figure O-SO-1. Dry-bulb control in a cold DB/dry DP

application

the energy recovery device frompotentially adding to the load seen bythe cooling and/or heating system ofthe unit, but rather utilizing the deviceonly at those times when it providestrue operating energy savings.

If using the FAU to deliver cold, dryconditioned air to the building (outdoorair is cooled to a low dew point but notreheated), use the dry-bulb controloption.

Cross LeakageAll energy wheels have some crossleakage. Therefore, do not use energywheels in applications involving toxic orhazaradous air streams. Thepercentage of cross leakage dependson the pressure differentials across thewheel section. With Trane PackagedFAU energy wheels, the exhaust airtransfer ratios are typically low (<4%).

FAXA-SVX01B-EN 65


Supply Air DehumidificationUnit

1

Occupied SequenceDuring occupied mode, the primaryfunction of the unit is to provideventilation air to the space. Upon enteringthe occupied mode, the outside airdamper is opened and the supply air fanwill start.

Drying ModeThe unit will enter the drying mode whenthe OA dew point exceeds the SA dryingsetpoint (dew point). The SA dryingsetpoint can be reset down based on OAdew point conditions. Drying functionswill have priority over cooling mode.Upon entering drying mode, the firstcompressor will stage up. While in dryingmode, the first compressor stage willalways remain active. This allowscondenser reheat (when ordered) to beavailable as required during dryingoperation. Additional compressors will besequenced to match unit capacity to thelatent load.

Reheat will be controlled to meet a supplyair reheat setpoint that is a minimum of3°F greater than the supply air dryingsetpoint. The supply air reheat setpointcan be reset up based on OA or zonetemperature conditions. When available,condenser reheat will be cycled toachieve a time-weighted average of thereheat setpoint. If primary heat reheat isuser-enabled, additional reheat capacitywill be made available to match sensibleload.

Cooling SequenceWhen not in drying mode, the unit willstage cooling capacity to maintain thesupply air cooling setpoint. The supply aircooling setpoint can be reset down basedon HI selectable parameters (OA sensor,zone sensor if installed).

Heating SequenceWhen not in drying mode, the unit willstage heating capacity to maintain thesupply air heating setpoint. The supply airheating setpoint can be reset up based onHI selectable parameters (OA sensor,zone sensor if installed). The supply airheating setpoint must be lower than thesupply air cooling setpoint.

2

Unoccupied SequenceIn unoccupied mode, the fan is stoppedand the OA damper is closed.

Supply Air Dehumidificationwith Zone RH Reference Unit

1


Drying ModeThe unit will enter the drying mode whenthe OA dew point exceeds the SA dryingsetpoint (dew point). The SA dryingsetpoint can be reset down based onzone relative humidity conditions or OAdew point conditions. Drying functionswill have priority over cooling mode.Upon entering drying mode, the firstcompressor will stage up. While in dryingmode, the first compressor stage willalways remain active. This allowscondenser reheat (when ordered) to beavailable as required during dryingoperation. Additional compressors will besequenced to match unit capacity to thelatent load.

Reheat will be controlled to meet a supplyair reheat setpoint that is a minimum of3°F greater than the supply air dryingsetpoint. The supply air reheat setpointcan be reset up based on OA or zonetemperature conditions. When available,condenser reheat will be cycled toachieve a time-weighted average of thereheat setpoint. If primary heat reheat isuser-enabled, additional reheat capacitywill be made available to match sensibleload.

Cooling SequenceWhen not in drying mode, the unit willstage cooling capacity to maintain thesupply air cooling setpoint. The supply aircooling setpoint can be reset down basedon HI selectable parameters (OA sensor,Zone sensor if installed).

Heating SequenceWhen not in drying mode, the unit willstage heating capacity to maintain the

supply air heating setpoint. The supply airheating setpoint can be reset up based onHI selectable parameters (OA sensor,zone sensor if installed). The supply airheating setpoint must be lower than thesupply air cooling setpoint.

2

Unoccupied SequenceWhen the return air damper option isinstalled and a request for unoccupiedoperation is received, the fan, cooling,and heating capacity will be cycled in arecirculating mode to maintain zonerequirements. See below for a detaileddescription of the operating modes.

If no return air damper is installed, the fanis stopped and the OA damper is closedin unoccupied mode.

Drying ModeDuring unoccupied mode (with return airdamper option installed), the unit willenter the drying mode when the zone RHexceeds the unoccupied zone RHsetpoint. In the drying mode, capacity willbe cycled to maintain the supply airdrying (dew point) setpoint. The SAdrying setpoint can be reset down basedon zone relative humidity conditions andwill be based on the unoccupied zone RHsetpoint.

Supply air reheat functions will be activeto maintain the supply air reheat setpoint.Supply air reheat reset functions will beactive and reset based on unoccupiedzone setpoints. Exhaust fan operationcontrol will be cycled off during unoccu-pied modes unless unoccupied econo-mizer operations are active.

Cooling ModeDuring unoccupied cooling mode, the fan,economizer and mechanical cooling cycleto control zone temperature. Economizerfunctions will be enabled when thedifference in the enthalpy of the OA andzone is adequate. Mechanical cooling willsupplement economizer capacity asrequired.

Heating ModeDuring unoccupied heating mode, fanand heating capacity are cycled tomaintain the unoccupied zone heatingsetpoint.

66 FAXA-SVX01B-EN


Zone Dehumidification UnitSequence of Operation

1


Drying ModeThe unit enters the drying mode whenthe zone relative humidity exceeds thezone relative humidity setpoint (%RH). Inthe drying mode, the capacity iscontrolled to meet the default supply airdrying setpoint (dewpoint). The SA dryingsetpoint can be reset down based onzone relative humidity conditions. Dryingfunctions have priority over coolingmode. Upon entering drying mode, thefirst compressor stages up. While indrying mode, the first compressor stagealways remains active. This allowscondenser reheat option (if ordered) to beavailable as required during the dryingoperation. Additional compressors willsequence to match unit capacity to thelatent load.

Reheat is controlled to meet a supply airreheat setpoint that is a minimum of 3°Fgreater than the supply air dryingsetpoint. The supply air reheat setpointcan be reset up based on OA or zonetemperature conditions. When available,condenser reheat will cycle to achieve atime-weighted average of the reheatsetpoint. If primary heat reheat is user-enabled, additional reheat capacity ismade available to match the sensibleload.

Drying mode stops when the zonerelative humidity falls below the operatoradjustable setpoint for leaving dryingmode.

Cooling SequenceWhen not in drying mode, the unit stagescooling capacity to maintain the supplyair cooling setpoint. The supply air coolingsetpoint can be reset down based on HIselectable parameters (OA sensor, zonesensor if installed).

Heating SequenceWhen not in drying mode, the unit willstage heating capacity to maintain thesupply air heating setpoint. The supply airheating setpoint can be reset up based onHI selectable parameters (OA sensor,zone sensor if installed). The supply airheating setpoint must be lower than thesupply air cooling setpoint.

2

Unoccupied SequenceIn unoccupied mode, the fan is stoppedand the OA damper is closed.

Drying ModeDuring unoccupied mode (with return airdamper option installed), the unit entersthe drying mode when the zone RHexceeds the unoccupied zone RHsetpoint. In the drying mode, capacitycycles to maintain the supply air drying(dew point) setpoint. The SA dryingsetpoint can be reset down based onzone relative humidity conditions and willbe based on the unoccupied zone RHsetpoint.

Supply air reheat functions are active tomaintain the supply air reheat setpoint.Supply air reheat reset functions areactive and reset based on unoccupiedzone setpoints. Exhaust fan operationcontrol cycles off during unoccupiedmodes unless unoccupied economizeroperations are active.

Cooling ModeDuring unoccupied cooling mode, the fan,economizer, and mechanical cooling cycleto control zone temperature. Economizerfunctions enable when the difference inthe enthalpy of the OA and zone isadequate. Mechanical coolingsupplements economizer capacity asrequired.

Heating ModeDuring unoccupied heating mode, fanand heating capacity cycle to maintainthe unoccupied zone heating setpoint.

Zone Dehumidification withOutside Air RH Reference Unit

1

Occupied SequenceDuring occupied mode, the primaryfunction of the unit is to provide

ventilation air to the space. Upon enteringthe occupied mode, the outside airdamper opens and the supply air fanstarts.

Drying ModeThe unit enters the drying mode whenthe zone relatiave humidity exceeds thezone relative humidity setpoint (%RH). Inthe drying mode, capacity is controlled tomeet the default supply air dryingsetpoint (dew point). The SA dryingsetpoint can be reset down based onzone relative humidity conditions or OAdew point conditions. Drying functionswill have priority over cooling mode.Upon entering drying mode, the firstcompressor stages up. While in dryingmode, the first compressor stage alwaysremains active. This allows condenserreheat (when ordered) to be available asrequired during drying operation.Additional compressors will sequence tomatch unit capacity to the latent load.

Reheat is controlled to meet a supply airreheat setpoint that is a minimum of 3°Fgreater than the supply air dryingsetpoint. The supply air reheat setpointcan be reset up based on OA or zonetemperature conditions. When available,condenser reheat will cycle to achieve atime-weighted average of the reheatsetpoint. If primary heat reheat is user-enabled, additional reheat capacity ismade available to match sensible load.

Drying mode stops when the zonerelative humidity falls below the opera-tor-adjustable setpoint for leaving dryingmode.

Cooling SequenceWhen not in drying mode, the unit stagescooling capacity to maintain the supplyair cooling setpoint. The supply air coolingsetpoint can be reset down based on HIselectable parameters (OA sensor, zonesensor if installed).

Heating SequenceWhen not in drying mode, the unit stagesheating capacity to maintain the supplyair heating setpoint. The supply airheating setpoint can be reset up based onHI selectable parameters (OA sensor,zone sensor if installed). The supply airheating setpoint must be lower than thesupply air cooling setpoint.

FAXA-SVX01B-EN 67


2

Unoccupied SequenceWhen the return air damper option isinstalled and a request for unoccupiedoperation is received, the fan and cooling/heating capacity cycle in a recirculatingmode to maintain zone requirements.See below for a detailed description ofthe operating modes.

If no return air damper is installed, the fanstops and the OA damper closes inunoccupied mode.

Drying ModeDuring unoccupied mode (with return airdamper option installed), the unit entersthe drying mode when the zone RHexceeds the unoccupied zone RHsetpoint. In the drying mode, capacitycycles to maintain the supply air drying(dew point) setpoint. The SA dryingsetpoint can be reset down based onzone relative humidity conditions and willbe based on the unoccupied zone RHsetpoint.

Supply air reheat functions are active tomaintain the supply air reheat setpoint.Supply air reheat reset functions areactive and reset based on unoccupiedzone setpoints. Exhaust fan operationcontrol will cycle off during unoccupiedmodes unless unoccupied economizeroperations are active.

Cooling ModeDuring unoccupied cooling mode, the fan,economizer, and mechanical cooling cycleto control zone temperature. Economizerfunctions will enable when the differencein the enthalpy of the OA and zone isadequate. Mechanical coolingsupplements economizer capacity asrequired.

Heating ModeDuring unoccupied heating mode, fanand heating capacity cycle to maintainthe unoccupied zone heating setpoint.

Supply Air Temp Control (NoDehumidification) Unit

1

Occupied SequenceDuring occupied mode, the primaryfunction of the unit is to provideventilation air to the space. Upon entering

the occupied mode, the outside airdamper opens and the supply air fanstarts.

Cooling SequenceThe unit stages cooling capacity tomaintain the supply air cooling setpoint.The supply air cooling setpoint can bereset down based on HI selectableparameters (OA sensor, zone sensor ifinstalled).

Heating SequenceThe unit stages heating capacity tomaintain the supply air heating setpoint.The supply air heating setpoint can bereset up based on HI selectableparameters (OA sensor, zone sensor ifinstalled). The supply air heating setpointmust be lower than the supply air coolingsetpoint.

2

Unoccupied SequenceIn unoccupied mode, the fan stops andthe OA damper closes.

Zone Temp Control (NoDehumidification) Unit

1

Occupied SequenceDuring occupied mode, the primaryfunction of the unit is to provideventilation air to the space. Upon enteringthe occupied mode, the outside airdamper opens and the supply air fanstarts.

Cooling SequenceThe unit stages cooling capacity tomaintain the supply air cooling setpoint.The supply air cooling setpoint can bereset down based on HI selectableparameters (OA sensor, zone sensor ifinstalled).

Heating SequenceThe unit stages heating capacity tomaintain the supply air heating setpoint.The supply air heating setpoint can bereset up based on HI selectableparameters (OA sensor, zone sensor ifinstalled). The supply air heating setpointmust be lower than the supply air coolingsetpoint.

2

Unoccupied SequenceIn unoccupied mode, the fan stops andthe OA damper closes.

Control Sequences ofOperation

Morning WarmupThis feature is available on all types offactory-installed heat units and on unitswith no heat. This function may still beselected to support systems with heatsources not provided by the fresh air unit.At the conclusion of unoccupied mode,the selected zone is heated to the user-defined morning warmup setpoint. Theunit is then released to occupied mode.There are two types of morning warmup:full capacity or cycling capacity.

• Full capacity morning warmup (MWU)Full capacity morning warmup uses fullheating capacity to heat the zone asquickly as possible. Full heating capacityis provided until the morning warmupsetpoint is met. At this point, the unit isreleased to daytime mode.

• Cycling capacity morning warmup(MWU)Cycling capacity morning warmupprovides gradual heating to overcome“building sink” as the zone is heated.Normal zone temperature control withvarying capacity raises the zonetemperature to the MWU zonetemperature setpoint. Cycling capacityMWU will operate until MWU setpoint isreached or for 60 minutes. Then the unitswitches to occupied mode. Cooling willsuspend until building load conditionsexceed the MWU setpoint of 3°F (1.7°C),which is field adjustable.

Ventilation Override (VOM) OptionThe user can customize up to fivedifferent override sequences forpurposes of ventilation override control. Ifmore than one VOM sequence isrequested, the sequence with the highestpriority initiates first. Priority schedule isthat sequence “A” (unit off) is first, withsequence “E” (purge sequence) last.

68 FAXA-SVX01B-EN


UNIT OFF sequence “A”When complete system shut down isrequired, the following sequence is used.• supply fan – off• outside air dampers – closed• heat – all stages – off, modulating heat

output at 0 vdc• occupied/unoccupied output –

deenergized• VO relay –energized• exhaust fan (field-installed) – off• exhaust damper (field-installed) – closed

PRESSURIZE sequence “B”This override sequence is for use when apositively pressured space is desiredinstead of a negatively pressurized space.• supply fan – on• outside air dampers – open• heat – all stages – off, modulating heat

output at 0 vdc• occupied/ unoccupied output – energized• VO relay – energized• exhaust fan (field-installed) – Off• exhaust damper (field-installed) – closed

EXHAUST sequence “C”With the building’s exhaust fans runningand the unit’s supply fan off, theconditioned space becomes negativelypressurized. This is desirable for clearingthe area of smoke when necessary (i.e.,from an extinguished fire, to keep smokeout of areas that were not damaged).• supply fan – off• outside air dampers – closed• heat – all stages – off, modulating heat

output at 0 vdc• occupied/unoccupied output –

deenergized• VO relay – energized• exhaust fan (field-installed) – on• exhaust damper (field-installed) – open

PURGE sequence “D”This sequence is for purging air out of abuilding before coming out of unoccupiedmode of operation. Also, it can purgesmoke or stale air.• supply fan on• outside air damper – open• heat: all stages off, modulating heat

output at 0 vdc• occupied/unoccupied output energized• VO relay energized• exhaust fan (field-installed) on• exhaust damper (field-installed) open

PURGE sequence “E”This sequence uses supply air control forsmoke control.• supply fan on• outside air dampers open• heat: all stages off, modulating heat

output at 0 vdc• occupied/unoccupied output energized• VO relay energized• exhaust fan (field-installed) on• exhaust damper (field-installed) open

Note: Each system (cooling, exhaust,supply air, etc.) within the unit can beredefined in the field for each of the fivesequences, if required. Also the defini-tions of any or all of the five sequencesmay be locked into the software bysimple key strokes at the human inter-face panel.

Generic Building Automation SystemModule (GBAS) OptionThe generic building automation systemmodule (GBAS) provides broad controlcapabilities for building automationsystems other than a Tracer Summitsystem. Use a field providedpotentiometer or a 0-5 vdc signal to anyof the GBAS inputs, to access thefollowing inputs and outputs listed in theparagraphs below.

GBAS analog inputsThese four analog inputs can beconfigured to any of the following:(1) occupied zone cooling(2) unoccupied zone cooling(3) uccupied zone heating(4) unoccupied zone heating(5) SA cooling setpoint(6) SA heating setpoint(7) space static pressure setpoint(8) SA static pressure setpoint

GBAS binary outputsEach of the five (5) relay outputs can bemapped to any/all of the availablediagnostics.

Demand limiting binary inputThis function is operational on units with aGBAS and reduces electricalconsumption at peak load times. Thereare two types of demand limiting, 50%and 100%. When demand limiting isneeded, mechanical cooling and heatingoperation are either partially (50%), orcompletely disabled (100%) to save

energy. The demand limit definition isuser definable at the human interfacepanel. Demand limit binary input acceptsa field supplied switch or contact closure.When the need for demand limitingdiscontinues, the unit’s cooling/heatingfunctions will (again) fully enable.

Evaporator Coil Frost ProtectionFrostat™A temperature sensor on the evaporatordetermines if the coil is getting close to afreezing condition. Mechanical coolingcapacity is shed as necessary to preventicing.

The Frostat™ system eliminates theneed for hot gas bypass and adds asuction line surface temperature sensormounted near the TXV bulb location toshut off cooling when coil frostingconditions occur. The supply fan does notshut off and will de-ice the coil. Timersprevent the compressors from rapidcycling.

Occupied/Unoccupied SwitchingThere are four ways to switch occupied/unoccupied:(1) programmable night setback sensor(2) field-supplied contact closure

(hardwired binary input to RTM)(3) Tracer Summit or other BAS (via LCI-I

with LonTalk DAC profile)(4) factory-mounted time clock

Field supplied occupied/unoccupied inputon the RTMThis input accepts a field supplied switchor contacts closure such as a time clock.

Tracer SystemThe Tracer system can control theoccupied/unoccupied status of the freshair unit.

Factory Mounted Time ClockA time clock can control theoccupied/unoccupied status of thefresh air unit.

Timed Override Activation - ICSThis function is operational whenever theunit’s RTM module board is used as thezone temperature sensor source, whichcan be set at the human interface panel.Initiate this function by pressing theoverride button on the zone sensor, toswitch the unit to the occupied mode. Unitoperation (occupied mode) during timedoverride will terminate by a signal fromTracer.

FAXA-SVX01B-EN 69


Timed Override Activation - Non-ICSThis function is active whenever the userselects the unit’s RTM module board asthe zone temperature source (can be setat the human interface panel). Initiate thisfunction by pressing the override buttonon the zone sensor, which will switch theunit to the occupied mode. Automaticcancellation of the timed override modeoccurs after three hours of operation.

Low Ambient Compressor LockoutThis function will lock out the compressorif the outdoor air temperature is belowthe low ambient compressor lock-outtemperature setpoint when using a field-installed outside air sensor. This setpointis adjustable at the human interfacepanel. Compressors will lock out whenoutdoor air temperature falls below thatselected temperature and will start againwhen the temperature rises 5°F abovethe setpoint.

Comparative Enthalpy Control ofUnoccupied Economizer OperationAn optional comparative enthalpysystem controls the economizeroperation and measures the temperatureand humidity of both return air andoutside air to determine which sourcehas lower enthalpy. This system allowstrue comparison of outdoor air and returnair enthalpy by measurement of outdoorand return air temperature and humidity.The comparative enthalpy option shouldalways be ordered with a return airdamper.

Note: If the unit does not have compara-tive enthalpy, the Packaged Fresh Air unitcompares outdoor air enthalpy with afixed reference enthalpy, set through thehuman interface panel. If ordering thereference enthalpy option, you shouldalso order a return air damper. Also,either supply air dehumidification withzone RH reference or zone dehumidifica-tion with OA RH reference must beordered to utilize either comparativeenthalpy or reference enthalpy control.

Emergency Stop InputA binary input is provided on the unit’sRTM module board for installation of a

field-provided switch or contacts toimmediately shutdown all unit functions.

Total Energy Wheel with OccupancyControlThe optional total energy wheel recoversenergy from the exhaust airstream andpreconditions the outdoor air. The totalenergy wheel enables when the unit is inoccupied mode and the exhaust fan isrunning. The wheel disables duringunoccupied mode or any time that theexhaust fan is not running. This includesthe unoccupied economizer mode whenthe wheel disables, but the exhaust fanenables. The wheel also disables via afactory-installed thermostat at any time afrost condition occurs (default setpoint12°F). This frost protection thermostatutilizes a setpoint range of -30 to 100°F.

Total Energy Wheel with Dry-BulbControlThe optional total energy wheel recoversenergy from the exhaust airstream andpreconditions the outdoor air. The totalenergy wheel enables when all of thefollowing are true:• unit is in occupied mode• exhaust fan is enabled• outside air temperature is above the

upper limit setpoint (default setpoint80°F) or below the lower limit setpoint(default setpoint 45°F)

• outside air temperature is above thefrost protection setpoint (defaultsetpoint 12°F)

Always set the upper limit setpoint to theanticipated return air dry-bulb tempera-ture. Set the lower limit setpoint to 10°Fless than the unit supply air dry-bulbsetpoint. The wheel will disable duringunoccupied mode or when the exhaustfan is not running. This includes theunoccupied economizer mode when thewheel will disable, but the exhaust fan willenable. The wheel also disables via afactory installed thermostat when a frostcondition occurs. This frost protectionthermostat utilizes a setpoint range of -30to 100°F.

70 FAXA-SVX01B-EN

Maintenancegeneralinformation

Component arrangementunit size 031 & 040


unit with TE wheel

FAXA-SVX01B-EN 71



Component arrangementunit size 051 & 066

unit with TE wheel

72 FAXA-SVX01B-EN


Total energy wheel cassette locations,typical indoor side views

unit size 031

unit size 040

unit size 051

unit size 066

FAXA-SVX01B-EN 73


Table M-GI-1. Maintenace general data

Unit size 031 040 051 066

nominal cfm 3100 4000 5100 6600maximum design cfm 3100 4000 5100 6600minimum design cfm 1800 2200 2900 3600

Compressor datareheat circuit (nom. tons R134a) 3.0T 4.5T 6.2T 6.2Tmain circuit (nom. tons R134a) 6.2T + 9.3T 6.7T + 10.0T 6.2T + 6.2T + 9.3T 10.0T + 10.0T + 10.0Tunit cooling capacity steps % 100-66-50-16 100-69-53-21 100-67-45-22 100-72-45-17Supply fan data, FC fan 1/FC fan 2

quantity 1/1 1/1 1/1 1/1size (diameter-width), in. 12-9/15-11 12-9/15-11 15-11/18-13 15-11/18-13maximum hp 7.5/15 7.5/15 15/13.76 15/13.76maximum rpm 2115/1760 2115/1760 1760/1515 1760/1515Condenser fan dataquantity/fan diameter, in.-type 1/24;2/26-prop 3/26-prop 3/26-prop 3/26-propcfm (reheat, main) 2900, 8500 4000, 10500 5500, 12000 5500, 13000number of motors/hp each 3/1.0 3/1.0 3/1.0 3/1.0Evaporator coil - main

size, ft2 6.67 8.33 11.11 14.06rows/fin s series 4/168 4/168 4/168 4/168tube diameter, in./surface 0.5/enhanced 0.5/enhanced 0.5/enhanced 0.5/enhanced

Evaporator coil - reheatsize, ft2 6.67 8.33 11.11 14.06rows/fin series 2/168 2/168 2/168 2/168tube diameter, in./surface 0.5/enhanced 0.5/enhanced 0.5/enhanced 0.5/enhancedCondenser coil - main

size, ft2 15.62 17.71 23.43 28.13rows/fin series 2/168 2/168 2/168 2/168tube diameter, in./surface 0.5/enhanced 0.5/enhanced 0.5/enhanced 0.5/enhanced

Condenser coil - reheat outdoorsize, ft2 5.35 7.29 9.38 9.38rows/fin series 2/168 2/168 2/168 2/168tube diameter, in./surface 0.5/enhanced 0.5/enhanced 0.5/enhanced 0.5/enhancedCondenser coil - reheat indoor

size, ft2 6.67 8.33 11.11 14.06rows/fin series 2/168 2/168 2/168 2/168tube diameter, in./surface 0.5/enhanced 0.5/enhanced 0.5/enhanced 0.5/enhanced

Heating datagas heat input, MBh 125-350 125-400 125-600 150-800elec. heat input, kW 20-56 26-84 32-100 42-122Refrigerant operating charge, lbs., R-134a main circuit(circuit 2) 25 28 34 48reheat circuit (circuit 1) 29 32 50 52cooling only (circuit 1) 9 13 18 20

Compressor oil data

main circuit POE oil type OIL00078 OIL00078 OIL00078 OIL00078 reheat circuit POE oil type Mobil Artic EAL22CC Mobil Artic EAL22CC OIL00078 OIL0007 main circuit, # pints 7/11.5 7/11.5 7/7/11.5 11.5/11.5/11.5 reheat circuit, # pints 4.13 3.75 7 7Filters

number-size, in. 4 - 16x20x2 4 - 16x20x2 4 - 24x24x2 4 - 24x24x2face area, ft2 8.4 8.4 15.2 15.2

Total energy (TE) wheel

wheel diameter (in) 42 48 54 60 wheel drive motor hp 1/2

1/23/4

3/4

exhaust fan

quantity 1 1 1 1 size (dia-width in.) 12-9 12-9 15-11 15-11 maximum hp 7.5 7.5 15 15 maximum rpm 2115 2115 1760 1760 outdoor air filters

number/size (in.) 4 - 16x20x2 4 - 16x20x2 4 - 20x25x2 4 - 20x25x2 face area (ft2) 8.4 8.4 13.3 13.3 exhaust air filters

number/size (in.) 4 - 16x20x2 4 - 16x20x2 4 - 16x25x2 4 - 16x25x2 face area (ft2) 8.4 8.4 10.5 10.5

74 FAXA-SVX01B-EN

Maintenancemaintenanceprocedures

Maintenance Procedures

Before beginning any maintenanceprocedures heed all warnings andcautions.

WARNING


WARNING


Periodic Maintenance Checklist� Inspect optional coil guard for debris

that may be blocking louvers. Clean asrequired.� Inspect coil surface for cleanliness.

Clean as required. Refer to “ CoilCleaning” under “MaintenanceProcedures.”� Manually rotate fan blades to insure

proper orifice clearance. Inspect fanorifices for debris and obstructions.Clean as required.

Annual Maintenance Checklist� Perform all monthly maintenance

inspections.� Perform seasonal start up checks.� Leak test refrigerant circuits. Inspect

contacts of fan motor contactors andrelays. Replace all worn contacts.� Clean condenser fans. Check fan

assemblies for proper orifice clearance,abnormal end play, and excessivevibration or noise. Fan motor bearingsare permanently lubricated and do notrequire lubrication.� Clean and repaint any corroded

surface.

Periodic Maintenance ProceduresThis section describes specificmaintenance procedures that must bepreformed as a part of the normalmaintenance program for this unit. Becertain to disconnect electrical power tothe unit before performing theseprocedures.

Note: the following coil cleaning proce-dures apply only to the outdoor condens-ers. Do not use these procedures for thereheat or evaporator coils.

Cleaning the Condenser CoilsClean the coil at least once each year ormore frequently if located in a dirtyenvironment, to help maintain proper unitoperating efficiency. High dischargepressures are a good indication that thecoil needs cleaning. Follow the detergentmanufacturer instructions as closely aspossible to avoid potential damage to thecoil.

WARNING

Hazardous chemicals!Coil cleaning agents can be eitheracidic or highly alkaline. Handlechemical carefully. Ensure properhandling by wearing goggles or faceshield, chemical resistant gloves,boots, and apron or suit as required.For personal safety refer to thecleaning agent manufacturer’smaterials safety data sheet and followall recommended safe handlingpractices. Failure to follow all safetyinstructions can cause death orserious injury.

To clean the refrigerant coil, use a softbrush and sprayer, such as a gardenpump or high pressure type, with aquality detergent; like SPREX AC, OAKITE161, OAKITE 166, or COILOX.

Note: If detergent is strongly alkaline (i.e.has a pH value greater that 8.5 ) aftermixing, an aluminum corrosion inhibitormust be added.

Coil Cleaning Procedure1. Turn off gas supply to the gas heaters

and disconnect power to the unit.2. Remove enough panels and

components from the unit to gainaccess to the coil.

3. Use a soft brush to remove loose dirtand debris form both sides of the coil.

4. Straighten coil fins with fin comb asrequired.

5. Mix the detergent with wateraccording to the manufacturersinstructions.

Observe all recommendations of thecleanser manufacturer. The coil cleansermanufacturer’s recommendations,warnings and cautions will at all timestake precedence to these instructions.

WARNING

Hazardous pressure!Coils contain refrigerant underpressure. When cleaning coils,maintain coil cleaning solutiontemperature under 150°F to avoidexcessive pressure in the coil. Failureto follow these safety precautions cancause coil bursting, which can result indeath or serious injury.

1. Place solution in the sprayer. Be sure tofollow these guidelines if using a high-pressure sprayer:

a) Minimum nozzle spray angle is 15°.b) Spray solution at 90° to the coil face.c) Keep sprayer nozzle at least six inches

form the coil.d) Sprayer pressure must not exceed

600 psi.2. Spray leaving air side of the coil first

then spray the entering air side of thecoil. Allow the detergent and watersolution to stand on the coil for fiveminutes.

3. Rinse both sides of the coil with cool,clean water.

4. Inspect the coil. If it still appears dirty,repeat the cleaning procedure.

5. Reinstall all unit components andpanels, and restore electrical powerand gas supply to the unit.

FAXA-SVX01B-EN 75


Total Energy WheelProtect the total energy wheel by using a30% filter to keep dust and dirt from theheat transfer surface. The wheel issomewhat self cleaning through itsnormal action of rotating in and out ofcounter-current airflow streams. If thewheel becomes dirty, clean it by blowingout the unit with compressed air, 20 psigmaximum.

Cleaning the Total Energy WheelTrane total energy wheels are self-cleaning with respect to dry particles.Smaller particles pass through the wheel.Larger particles land on the surface andare blown clear as the wheel turns intothe opposite airflow path. For this reason,the primary cleaning required for thetotal energy wheel is to remove the oil-based aerosol film that collect on thesurface. Such films can close off micron-sized pores at the surface of the desiccantmaterial, reducing its ability to absorb anddesorb moisture. Periodically record theair temperatures entering and leavingthe energy wheel to detect changes inperformance.

In a reasonably clean indoor environ-ment, such as a school or office building,experience shows that reductions ofairflow or loss of sensible effectivenessmay not occur for ten or more years.Where there is moderate tobacco smokeor within cooking facilities, reduction ineffectiveness can occur much faster. Inapplications experiencing high levels of

smoke, the energy transfer surfaces mayrequire cleaning as often as every sixmonths. Similar washing cycles may alsobe appropriate for industrial applications,such as welding or machining operations,involving ventilation of high levels ofsmoke or oil-based aerosols.

Proper cleaning of the energy wheelshould restore latent effectiveness tonear original performance.

Clean the total energy wheel as neces-sary to maintain optimum airflow. Whenwashing/cleaning the wheel, take carenot to allow water or detergent to comeinto contact with any of the electricalcomponents. Drain holes in the wheelrack are capped and can be removedduring cleaning. Replace caps to avoid airbypass. The single draw hole locatedupstream of the outside air filters shouldbe utilized for draining, during cleaning.Ensure no water, moisture, or excessdetergent is left in the energy wheelcompartment. Use a wet-vac vauumcleaner to remove water/moisture asneeded.

Air Filter ReplacementFilter access doors are on both sides ofthe unit. To replace filters, remove thedirty elements and install new filters(ASHRAE 30% or higher) with the filterdirectional arrows pointing toward thefan. Verify that no air bypasses the filters.

Inspecting and Cleaning the Drain PanCheck the condensate drain pan anddrain line to ensure that the condensatedrains properly at least every six monthsor as dictated by operating experience.

If evidence of standing water or conden-sate overflow exists, take steps to identifyand remedy the cause immediately.Refer to the trouble shooting section ofthis manual for possible causes andsolutions. If microbial growth is evident inthe drain pan, remove and clean itimmediately. Clean drain pans using thefollowing procedure:1. Disconnect all electrical power to the

unit.2. Don the appropriate personal

protective equipment (PPE).3. Remove all standing water.4. Use a plastic scraper or other tools to

remove any solid matter. Remove solidmatter with a vacuum device thatutilizes high efficiency particulatearrestance (HEPA) filters with aminimum efficiency of 99.97% at 0.3micron particle size.

5. Thoroughly clean the contaminatedarea(s) with an EPA-approved sanitizerspecifically designed for HVAC use.Carefully follow the sanitizermanufacturer’s instructions regardingproduct use.

6. Immediately rinse the drain panthoroughly with fresh water to preventpotential corrosion from the cleaningsolution.

7. Allow the unit to dry thoroughly before

Figure M-MP-1. Filter placement three racks

with return

Figure M-MP-2. Filter placement two racks

without return

Table M-MP-1. Filter sizes, in.

unit size OA EA main unit

031 20 x 16 20 x 16 20 x 16040 20 x 16 20 x 16 20 x 16051 25 x 20 25 x 16 24 x 24066 25 x 20 20 x 16 20 x 16

Note: Filters are ASHRAE 30% or higher.

OAOA

EAEA

UNIT

FILTER

76 FAXA-SVX01B-EN


Fan and DrivePerform the following proceduresaccording to the “Periodic MaintenanceCheck List”. Reference Figure M-MP-3 forproper fan shaft and motor alignment.

WARNING


1. Rotate the fan wheel to be sure it turnsfreely in the proper direction and is notrubbing on the fan housing, inlet, or inletguide vanes. If necessary, center thefan wheel again.

2. Check the position of both shafts. Fanand motor shafts should operate

parallel to each other for maximum beltand bearing life. Shim as necessaryunder the motor or fan bearings toobtain proper alignment.

3. Check the fan motor sheave alignmentwith straight edge or a tightly pulledstring. For sheaves of different widths,place a string in the center groove ofeach sheave and pull it tight for a centerline.

4. Once the sheaves are properly aligned,tighten sheave set screws to propertorque.

5. Check belt tension.6. If required, adjust belt to the minimum

recommended tension.7. Retighten bearing set screws to the

proper torques after aligning thesheaves.

8. Check the fan bearing locking collarsfor tightness on the shaft. To tighten thelocking collar, loosen the set screw andslide the collar into its proper positionover the extended end of the innercase. Tighten the set screw.

9. During air balancing, verify the sheavealignment, belt tension, and that theshaft is parallel.

Figure M-MP-3. Fan shaft and motor sheave alignment

putting the system back into service.8. Determine and correct the cause of

any microbial contamination.9. Be careful that the contaminated

material does not contact other areasof the unit or building. Properly disposeof all contaminated materials andcleaning solution.

Inspecting and Cleaning the FansInspect the fan section every six monthsor more frequently if operatingexperience dictates. Clean accumulateddirt and organic matter on the fan interiorsurfaces following the procedure below:1. Disconnect gas supply and all electrical

power to the unit.2. Don the appropriate personal

protective equipment (PPE).3. Use a portable vacuum with HEPA

filtration to remove the loose dirt andorganic matter. The filter should be99.97% efficient at 0.3 micron particlesize.

4. If no microbial growth (mold) exists,thoroughly clean the fan andassociated components with anindustrial cleaning solution. Carefullyfollow the cleaning solutionmanufacturer’s instructions regardingpersonal protection and ventilationwhen using their product.

5. If microbial growth is present, removethe contamination (Step 2) andthoroughly clean the affected area withan EPA-approved sanitizer specificallydesigned for HVAC use. Carefullyfollow the sanitizer manufacturer’sinstructions regarding the productusage.

6. Rinse the affected surfaces thoroughlywith fresh water and a fresh sponge toprevent potential corrosion of metalsurfaces.

7. Allow the unit to dry completely beforeputting it back into service.

8. Ensure that contaminated materialdoes not contact other areas of the unitor building. Properly dispose of allcontaminated materials and cleaningsolution.

Determine the cause of any microbialgrowth (mold) and take action to ensure itdoes not reoccur.

FAXA-SVX01B-EN 77


Figure M-MP-6. Fan belt adjustment

Figure M-MP-4. Belt tension gauge

Adjusting Fan Belt TensionTo adjust the fan belt tension, refer toFigure M-MP-6, following the procedurebelow.1. Loosen bolts on both sides of the

sliding motor base.2. Loosen nuts (as required for motor

horsepower) to slide the motor on itsmounting plate in the proper directionto add or relieve belt tension.

3. Adjust nuts and bolt. Do not stretch thebelts over the sheaves.

4. Retighten all nuts and bolts.5. Verify tension is adjusted properly.

CAUTIONBelt tension!Do not over-tension belts. Excessivetension will reduce fan and motorbearing life, accelerate belt wear, andpossibly cause shaft failure.

Recommended belt tension range valuesare on the unit fan scroll. To access thefan scroll, face the right-hand side of the

deflection = belt span/64

unit and open the supply fan access door.The belt tension label is on the top right-hand corner of the fan scroll. The correctoperation tension for a V-belt drive isthelowest tension at which the belt willnot slip under the peak load conditions. Itmay be necessary to increase the tensionof some drives to reduce flopping orexcessive startup squealing.

Figure M-MP-5. Fresh air unit fan plate

WARNING

Rotating components!Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to disconnect power beforeservicing can cause death or seriousinjury.

78 FAXA-SVX01B-EN


environment, our customers, and the airconditioning industry. All technicians whohandle refrigerants must be certified. TheFederal Clean Air Act (Section 608) setsforth the requirements for handling,reclaiming, recovering and recycling ofcertain refrigerants and the equipmentthat is used in these service procedures.In addition, some states or municipalitiesmay have additional requirements thatmust also be adhered to for responsiblemanagement of refrigerants. Know theapplicable laws and follow them.

Also, pay specific attention to the follow-ing recommendations.• Whenever removing refrigerant from

air conditioning equipment, recover itand reuse, recycle, reprocess (reclaim),or properly destroy.

• Always determine possible refrigerantrecycling or reclaiming requirementsbefore beginning recovery. Questionsabout recovered refrigerants andacceptable refrigerant qualitystandards are addressed in ARIStandard 700.

• Use approved containment vessels andsafety standards. Comply with allapplicable transportation standardswhen shipping refrigerant containers.

• Use recycling equipment to minimizeemissions while recovering refrigerant.

• Always attempt to use methods that pullthe lowest possible system vacuumwhile recovering and condensingrefrigerant into containment.

• When leak checking, be aware of anynew leak test methods that eliminaterefrigerant as a trace gas.

• Do not use refrigerant or solvents thathave ozone depletion factors to cleansystem components and parts. Tranerecommends clean up methods usingfilters and dryers. Properly dispose ofused materials.

• Take extra care to properly maintain allservice equipment directly supportingrefrigerant service work such asgauges, hoses, vacuum pumps, andrecycling equipment.

• Stay aware of unit enhancements,conversion refrigerants, compatibleparts, and manufacturer’srecommendations that will reducerefrigerant emissions and increaseequipment operating efficiencies.Follow specific manufacturer’s

Refrigerant System

Follow these Trane recommendedprocedures to ensure refrigerantconservation and emission reduction.

WARNING

Explosion hazard and deadlygases!Never solder, braze, or weldrefrigerant lines or any unitcomponents that are aboveatmospheric pressure or whererefrigerant may be present. Alwaysremove refrigerant by following theguidelines established by the EPAFederal Clean Air Act or other stateor local codes as appropriate. Afterremoving refrigerant, use drynitrogen to bring the system back toatmospheric pressure before openingfor repairs. Refrigerant mixtures andair under pressure may becomecombustible in the presence of anignition source leading to anexplosion. Excessive heat fromsoldering, brazing, or welding withrefrigerant vapors present can formhighly toxic gases and extremelycorrosive acids. Failure to follow allproper safe refrigerant handlingpractices can cause death or seriousinjury.

Important Environmental ConcernsScientific research has shown thatcertain man-made chemicals can affectthe earth’s naturally occurringstratospheric ozone layer when releasedto the atmosphere. In particular, severalof the identified chmeicals that mayaffect the ozone layer are refrigerantsthat contain chlorine, fluorine, and carbon(HCFCs). Not all refrigerants containingthese compounds have the samepotential impact to the environment.Trane advocates the responsiblehandling of all refrigerants, includingindustry replacements for CFCs, such asHCFCs and HFCs.

Responsible Refrigerant PracticesTrane believes that responsiblerefrigerant practices are important to the

guidelines to convert existing systems.• To help reduce power generation

emissions, always attempt to improveequipment performance with improvedmaintenance and operations thatconserve energy resources.

Refrigerant Leak Testing

WARNING

Confined space hazard!Do not work in confined spaces wheresufficient quantities of refrigerant orother hazardous, toxic, orflammmable gas may be leaking.Refrigerant or other gases candisplace available oxygen, causingpossible asphyxiation or other serioushealth risks. Some gases may beflammable and or explosive. Evacuatethe area immediately and contact theproper rescue or response authority.Failure to take appropriateprecautions or to react properly to apotential hazard can cause death orserious injury.

WARNING

Explosion hazard!Use only dry nitrogen with a pressureregulator to pressurize units for leaktesting. Do not use acetylene, oxygen,compressed air, or any mixture of ahydrogen-containing refrigerant andair above atmostpheric pressurebecause they may become flammableand cause an explosion. Failure toproperly regulate pressure can causea violet explosion that can causedeath, serious injury, or equipment/property-only damage.

In the event of required system repair,leak test the liquid line, evaporator coil,and suction line at pressures dictated bylocal codes, and using the followingguidelines.

FAXA-SVX01B-EN 79


1. Charge enough refrigerant and drynitrogen into the system to raise thepressure to 100 psig.

2. Use a halogen leak detector, halidetorch, or soap bubbles to check forleaks. Check interconnecting pipingjoints, the evaporator coil connections,and all accessory connections.

3. If a leak is detected, release the testpressure, break the connections andreassemble it as a new joint, usingproper brazing techniques.

4. If no leak is detected, use nitrogen toincrease the test pressure to 150 psigand repeat the leak test. Also, use soapbubbles to check for leaks whennitrogen is added. Never pressurize theunit above 200 psig.

5. Retest the system to make sure newconnections are solid.

6. If a leak is suspected after the system isfully charged with refrigerant, use ahalogen leak detector, halide torch, orsoap bubbles to check for leaks.

Refrigerant EvacuationFor field evacuation, use a rotary stylevacuum pump capable of pulling avacuum of 100 microns or less.

When connecting the vacuum pump to arefrigeration system, it is important tomanifold the pump to both the high andlow side of the system. Follow the pumpmanufacturer’s directions.

CAUTIONMotor winding damage!Do not use a Meg ohm meter or applypower to the winding of a compressorwhile it is under a deep vacuum. Thismay damage the motor windings.

WARNING

Hazardous pressures!If using a heat source to raise the tankpressure when removing refrigerant,use only warm water or heat blanketsto raise the tank temperature. Do notexceed 150°F. Do not, under anycircumstances, apply direct flame toany portion of the refrigerant cylinder.Failure to follow these safetyprecautions can cause a violetexplosion that can cause death orserious injury.

Charging the Refrigerant System

CAUTION

Freezing temperatures!Do not allow liquid refrigerant tocontact skin. If it does, treat the injurysimilar to frostbite. Slowly warm theafffected area with lukewarm waterand seek immediate medicalattention. Direct contact with liquidrefrigerant may cause minor ormoderate injury.

To completely charge the system, chargegaseous refrigerant into the suction lineshrader valve with the unit running.However, make sure that somerefrigerant is present in each circuitbefore starting the compressors. Therefrigerant container should be upright sothat gaseous refrigerant is drawn off thetop.

Note: Charge each circuit with R134a.See Table M-GI-1 on page 70.

CAUTIONMotor winding damage!Do not use a megohm meter or applyvoltage greater than 50 DVC to acompressor motor winding while it isunder a deep vacuum. Voltage sparkovermay damage the motor windings.

Note: Refer to Table M-GI-1 on page 70for POE, oil type. Oil type is different forTrane compressors vs. Copelandcompressors. Failure to comply maycause premature compressor failure andvoid compressor warranty.

CAUTIONCompressor damage!Never manually or automatically pumpdown system below 7 psig. This willcause the compressor to operate in avacuum and result in compressordamage.

80 FAXA-SVX01B-EN

Maintenanceperiodicchecklists

Periodic MaintenanceChecklists

Monthly ChecklistThe following checklist provides therecommended maintenance schedule tokeep the unit running efficiently.

WARNING


WARNING!


1. Inspect unit air filters. Clean or replaceif airflow is blocked or if filters are dirty.

2. Inspect coils for icing. Icing on the coilsmay indicate low airflow supply,restricted airflow from dirty fins,evaporator frost protection sensorproblems, or a shortage of refrigerantflowing through the coil.

3. Check the condition and tension of fanbelt. Adjust tension if belt is floppy orsqueals continually.

4. Verify the total energy wheel sealshave not become worn or damaged.Replace as necessary.

Note: Check and adjust belt tension atleast twice daily the first days of newbelt operation. Belt tension will rapidlydecrease until the belts are run in.

5. Check and record operating pressures6. Inspect and clean total energy wheel as

needed.

Semi-Annual Maintenance1. Verify the fan motor is properly aligned

and bolted tight to the motor frame.2. Lubricate fan bearings with any of the

following types grease:• NLGI N°3• Mobil - Mobilux EP3• ESSO - Beacon 3• Shell - Alvania FET3• Fina - Marson HTL3

3. With power disconnected, manuallyrotate the fan wheel to check forobstructions in the housing orinterference with fan blades or inletguide vane option. Removeobstructions and debris. Center the fanwheel if necessary.

4. Check the fan assembly sheavealignment. Tighten set screws to theirproper torques.

5. Check the total energy wheel linkagebelt tightness. Adjust as necessary.

Note: Perform this procedure monthly ifthe unit is in a coastal or corrosiveenvironment.

Annual MaintenanceCheck and tighten all set screws, bolts,locking collars and sheaves.1. Inspect, clean, and tighten all electrical

connections.2. Visually inspect the entire unit casing

for chips or corrosion. Remove rust orcorrosion and repaint surfaces.

3. Visually check for leaks in refrigerantpiping.

4. Inspect fan, motor, and control contacts.Replace badly worn or eroded contacts.

5. Inspect the thermal expansion valvesensing bulbs for cleanliness, goodcontact with the suction line, andadequate insulation from ambient air.

Note: For units with gas heat, refer tothe Reznor Installation Form RGM 401for proper maintenance procedures ofgas heaters.

FAXA-SVX01B-EN 81


Table M-MP-1. Common unit problems and solutions

problem possible cause remedy

drain pan is overflowing plugged drain line clean drain lineunit not level level unit

standing water in drain pan unit not level level unitplugged drain line clean drain line

wet interior insulation coil face velocity too high reduce fan speedimproper trap design design trap per unit installation

instructions drain pan leaks/overflowing repair Leakscondensation on surfaces insulate surfaces

excess dirt in unit missing filters replace filtersfilter bypass reduce filter bypass

System Checks

Before proceeding with technical troublecharts or controls checkout, complete thefollow system analysis:1. Measure actual supply voltage at the

compressor and at motor terminalswith the unit running. Voltage must bewithin the range listed on the motornameplate. Phase imbalance must beless than 2.0% between phases.

2. Check all wiring and connections to besure that they are intact, secure andproperly routed. The as wired systemdiagrams are provided in the unitcontrol panel.

3. Check that all fuses are installed andproperly sized.

4. Inspect air filters and coils to ensureairflow to the unit is not restricted.

5. Check the zone thermostat settings, ifapplicable.

6. Ensure the fan is rotating in the properdirection. If phasing is wrong at themain power terminal block, the fan andcompressors will not run.

7. Inspect ductwork and duct connectionsfor tightness.

8. Verify all applicable settings on thehuman interface (HI).

WARNING

Live electrical components!During installation, testing, servicing,and troubleshooting this equipment, itmay be necessary to work with liveelectrical components. Have aqualified licensed electrician or otherproperly trained individual performthese tasks. Failure to follow allelectrical safety precautions whenexposed to live electrical componentscan cause death or serious injury.

Operating ProceduresInstall pressure gauges on the dischargeand suction line access valves. When theunit has stabilized (after operatingapproximately 15 minutes at full load),record suction and discharge pressures.System malfunctions such as low airflow,line restrictions, incorrect refrigerantcharge, malfunctioning of expansionvalves, damaged compressors, and soon— will result in pressure variationswhich are outside the normal range.

Note: If phasing at the main incomingpower terminal is incorrect, switch twoof the three incoming power leads. If acompressor has been replaced and thephase is changed at the compressor, itwill run backwards and dischargepressure will be very low. To resolveincorrect compressor wire phasing,change phasing at the compressor.

It is important that pressures be mea-sured under stable and constant condi-tions in order for the readings to beuseful.

Voltage ImbalanceVoltage imbalance on three-phase

systems can cause motor overheatingand premature failure. Maximumallowable imbalance is 2.0% and thereadings used to determine it must bemeasured at the compressor terminals.

Voltage imbalance is defined as 100times the sum of the division of the threevoltages from the average voltage. If, forexample, the three measured voltagesare 221, 230, 227, the average would be:

(221+230+227) = 226 volts 3

The percentage of voltage imbalance isthen:

100*(226-221) = 2.2% 226

In this example, 2.2% imbalance of morethan 2.0% exists, be sure to check thevoltage at the unit disconnect andterminal block switch. If an imbalance atthe unit disconnect switch does notexceed 2.0%, the imbalance is caused byfaulty wiring within the unit. Be sure toconduct a thorough inspection of the unitelectrical wiring connections to locate thefault, and make any repairs necessary.

82 FAXA-SVX01B-EN

A

about this manual 2acoustic considerations 14acronyms 2adjusting fan belt tension 74air filters 72airside economizers 58annual maintenance 77annual maintenance checklist 71

C

cautions 47center of gravity and weights 41cleaning the coil 71cleaning the drain pan 72coil cleaning procedure 71communication link 49communication wiring 50condensate drain trapping 35cooling 58cooling or heating 59, 60

D

dehumidification 58, 59duct connections 33ductwork considerations 33

E

electrical requirements 36, 50establishing capacity requirements

61

F

FAU without reheat 60field installed control wiring 50filtration 58fresh air unit functions 58

G

gas heat requirements 50gas pipe installation procedure 33gas pipe sizing 33general unit requirements 50

H

heating 58human interface (HI) panel 46, 49

I

installation checklist 50interprocessor communication bridge

49

L

leveling the unit 41literature change history 2low voltage (AC) field wiring 49

M

maintenace general data 70maintenance periodic checklists 77maintenance procedures 71monthly checklist 77mounting the remote human inter-

face (RHI) panel 47

O

operating procedures 78overview of manual 2

P

packaged FAU operation 59periodic maintenance checklist 71periodic maintenance procedures 71pre-installation checklist 8pre-startup checklist 51

R

receiving and handling 8receiving checklist 9refrigerant evacuation 75refrigerant system 75refrigeration emissions 2remote human interface panel 46remote human interface panel

installation 46rigging and handling 40rigging procedure 41roof curb and ductwork 11

roof curb installation 11roof support 11

S

service access 10, 11ship-separate accessories 8shipping package 8skid removal 8standard remote sensor

(BAYSENS017) 43startup log 53supply air temperature 58supply fan and drive 73supply power wiring 36system checks 78system configurations 58

T

time clock option 45Tracer Summit 50

U

unit handling procedure 40unit nameplate 7, 8, 52unit startup procedures 52unit startup checklist 52unit storage 9

V

voltage imbalance 78

W

warnings and cautions 2wiring guidelines 43wiring the remote human interface

49

Z

zone sensor installation 43

index

a business of American Standard Inc.www.trane.com

For more information contactyour local office or [email protected]

Literature Order Number

File Number

Supersedes

Stocking Location

Trane has a policy of continuous product improvement and reserves the right to change design and specifica-tions without notice. Only qualified technicians should install and service equipment.

FAXA-SVX01B-EN

PL-AH-FAXA-SVX01B-EN 0403

FAXA-SVX01A-EN 1201

LaCrosse - Inland

USC

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