Trane Intellipak 2 Service Manual
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Installation RT-SVX24K-EN91 Figure 59. Typical field wiring diagram for 90 to 162 ton VAV control options
Installation 92RT-SVX24K-EN Figure 60. Typical field wiring diagram notes for 90 to 162 ton VAV and CV control options
Installation RT-SVX24K-EN93 Figure 61. Typical GBAS analog input wiring diagram for 90 to 162 ton CV and VAV control options Note:See Figure 64, p. 101
Installation 94RT-SVX24K-EN Table 35. GBAS voltage vs. setpoint SetpointGBAS 0-5 VDCGBAS 0-10 VDCValid Range Occ Zone Cooling Setpoint(CV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 90°F Unocc Zone Cooling Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F Occ Zone Heating Setpoint(CV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 90°F Unocc Zone Heating Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F SA Cooling Setpoint (VAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 90°F SA Cooling Setpoint (SZVAV only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 40 to 70°F Zone Cooling Setpoint (SZVAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 80°F Zone/Return Critical Temperature Setpoint (RR only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 75 to 95°F SA Heating Setpoint (VAV only)0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 180°F SA Heating Setpoint (SZVAV only) 0.5 to 4.5 VDC 0.5 to 9.5 VDC 65 to 95°F Space Static Pressure Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC-0.20 to 0.30 IWC SA Static Pressure Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 0.7 to 5.1 IWC Min OA Flow Setpoint 10.5 to 4.5 VDC0.5 to 9.5 VDC0 to Unit Max Flow MWU Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 50 to 90°F Econ Dry Bulb Enable Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC50 to 140°F SA_Reheat_Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 60 to 90°F Minimum Position Setpoint 30.5 to 4.5 VDC0.5 to 9.5 VDC0 to 100% Occ Dehumidification Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 40 to 65% Unocc Dehumidification Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC40 to 65% Occ Humidification Setpoint 0.5 to 4.5 VDC 0.5 to 9.5 VDC 20 to 50% Unocc Humidification Setpoint0.5 to 4.5 VDC0.5 to 9.5 VDC20 to 50% Notes: 1. If DCV is enabled this is used for Design Minimum OA Flow Setpoint 2. If DCV is enabled, this is used for Design Minimum OA Damper Position Setpoint Table 36. GBAS 0-10 VDC output range SetpointGBAS 0-10 VDCValid Range Outdoor Air Temperature0.5 to 9.5 VDC-40 to 200°F Zone Temperature 0.5 to 9.5 VDC -40 to 200°F Supply Air Temperature (VAV only)0.5 to 9.5 VDC-40 to 200°F Supply Air Pressure (VAV only) 0.5 to 9.5 VDC 0.0 to 7.91 wc Space Pressure0.5 to 9.5 VDC-0.67-0.67 wc Space RH 0.5 to 9.5 VDC 0-100% OA RH0.5 to 9.5 VDC0-100% Space CO2 Level 0.5 to 9.5 VDC 50-2000 PPM Cooling Capacity %0.5 to 9.5 VDC0-100% Heating Capacity % 0.5 to 9.5 VDC 0-100% Outdoor Air Damper Position0.5 to 9.5 VDC0-100% Outdoor Airflow 0.5 to 9.5 VDC 0 to 65,000 CFM
Installation Checklist RT-SVX24K-EN95 Installation Checklist General Checklist (applies to all units) Unit checked for shipping damage and material shortage Verify that the installation location of the unit will provide the required clearance for proper operation Roof curb assembled and installed Roof curb level and square Ductwork secured to curb, or unit Corners of duct adapters sealed on units with horizontal supply or return Horizontal supply or return ductwork is self supporting Pitch pocket installed for units with power supply through building roof Unit set on curb and checked level Unit-to-curb seal checked to ensure it is tight and without buckles or cracks Condensate drain lines installed to each evaporator drain connection Verify that all access doors open 100% and are not obstructed by drain lines etc. Shipping hardware removed from each compressor assembly Shipping hold-down bolts and shipping channels removed from the supply and exhaust/return fans with spring isolators Supply and exhaust/return fans spring isolators checked for proper adjustment Plastic coverings (paint shields) removed from all compressors (if present) Verify all discharge, suction, and liquid line service valves are back seated Compressor crankcase heaters energized for a minimum of 12 hours prior to unit refrigeration system startup Verify that unit literature (IOM, PTG) are left inside control box for startup Unit Rigging and Placement (Two-Piece— addition to General Checklist) First, rig and set the low side unit on the roof curb (aligned with return end) Remove the rail connector splice brackets and install the brackets on the low side unit base rails Take off the side panels (these are labeled) and the top cover of the high side unit and set aside to be assembled later Rig and set the high side unit on roof curb pedestal Lift the unit and position it over the pedestal Use the rail splice bracket as an alignment aid to connect the Low and high side units. The Low and high side unit rails should be butted together with a maximum 2 (preferably 1) separation Remove the left upper and lower louvered panels of the high side unit as well as the corner panels on each side to aid in tubing and wiring connections Close refrigeration shut off valves as indicated in this manual—Liquid, discharge, hot gas bypass (if present), and hot gas reheat (if present). For Evaporative Condensers Recover/transfer charge from tubing between shut valves and stub point. For 2 and 3 piece Air-Cooled condensers add field charge per nameplate. Braze refrigerant piping connections and leak test Low side and high side evacuated to 500 microns Standing vacuum does not rise over 200 microns in 15 minutes Open service valves to allow refrigerant flow Refrigerant released from discharge to suction until suction pressure is approximately 60 PSIG Power wires connected in connection box Control wires connected in connection box Seal air gaps around wiring and refrigerant tubing through bulkhead Side panels and top cover assembled between high and low side Verify line dampening weights are installed on each discharge line. Unit Rigging and Placement (Three-piece unit) (in addition to Two-piece unit rigging and placement) Rail guide attached to evaporator section base rails Evaporator section rigged and set onto roof curb, aligned with supply end Removed and discarded shipping protection panels and top blockoffs from evaporator section Removed side panels and roof cap from evaporator section Applied gasket and butyl tape as indicated in the IOM Removed and discarded shipping protection panels and top block off from outside air section Rigged and set outside air section onto roof curb to within 2 of evaporator section
Installation Checklist 96RT-SVX24K-EN Using 0.75 x 24 threaded rod pull and secure evaporator section and outside air section together Using .375 bolts, nuts and washers pull and secure the roof rails together Installed roof splice plate Added bullwrap to electrical wiring between evaporator and outside air section Connected power and control wiring between evaporator and outside air section Gasket applied and side panels installed on unit split Butyl tape applied on top of unit split along roof seam and roof cap installed Field Installed Control Wiring—Complete the field wiring connections for constant volume or variable air volume controls as applicable. Refer to “Field Installed Control Wiring” for guidelines Electric Heat Units Inspect the heater junction box and control panel; tighten any loose connections Check electric heat circuits for continuity Two and Three piece units only) Route power wiring to high side junction box Gas Heat Units Gas supply line properly sized and connected to the unit gas train All gas piping joints properly sealed Drip leg Installed in the gas piping near the unit Gas piping leak checked with a soap solution. If piping connections to the unit are complete, do not pressurize piping in excess of 0.50 psig or 14 W.C. to prevent component failure Main supply gas pressure between 7 and 14 W.C. Flue Tubes clear of any obstructions Factory-supplied flue assembly installed on the unit Connect the 3/4 CPVC furnace drain stub-out to a proper condensate drain Install field provided heat tape to furnace drain line Hot Water Heat Route properly sized water piping through the base of the unit into the heating section Install the factory-supplied, 3-way modulating valve Complete the valve actuator wiring Steam Heat Route properly sized steam piping through the base of the unit into the heating section Install the factory-supplied, 2-way modulating valve Complete the valve actuator wiring Install 1/2, 15-degree swing check vacuum breaker(s) at the top of each coil section. Vent breaker(s) to the atmosphere or merge with return main at discharge side of steam trap Position the steam trap discharge at least 12 below the outlet connection on the coil Use float and thermostatic traps in the system, as required by the application. O/A Pressure Sensor and Tubing Installation (All VAV units and CV units with return fan or StatiTrac) O/A pressure sensor mounted to the roof bracket Factory supplied pneumatic tubing installed between the O/A pressure sensor and the connector on the vertical support (Units with StatiTrac) Field supplied pneumatic tubing connected to the proper fitting on the space pressure transducer located in the filter section, and the other end routed to a suitable sensing location within the controlled space Electrical Verify that the power supply to the unit complies with the unit nameplate specification Properly ground the unit Inspect all control panel components and tighten any loose connections Connect properly sized and protected power supply wiring to a field supplied/installed disconnect and the unit (copper wiring only to the unit) Verify that phasing to the unit is correct (ABC) Turn the 1S2 toggle switch off to prevent accidental unit operation Turn on power to the unit Press the STOP button on the Human Interface (1U2) Verify that all compressor crankcase heaters are energized for at least 12 hours prior to unit startup Evaporative Condenser Remove fan bracket Hookup inlet and drain piping Install Heat tape if needed Setup drain hold or drain on power loss Setup Mechanical Float Setup drain time Setup water quality management (3rd party or Trane factory-installed Dolphin Water Care System) Options setup Calibrate Conductivity Controller Setup blowdown set points on the conductivity sensor
Installation Checklist RT-SVX24K-EN97 Energy Recovery Wheel Verify that the wheel turns freely though a full rotation Confirm that all wheel segments are fully engaged in the wheel frame and that the segment retainers are completely fastened Confirm the seal adjustment and proper belt tracking on the wheel rim
98RT-SVX24K-EN Unit Startup Sequence of Operation Cooling Sequence of Operation Time delays are built into the controls to increase reliability and performance by protecting the compressors and maximizing unit efficiency. SZVAV Cooling Sequence of Operation Single Zone VAV units will be equipped with a VFD controlled supply fan which will be controlled via the 0- 10VDC RTM VFD output and the RTM Supply Fan output. With the RTM Supply Fan output energized and the RTM VFD output at 0Vdc the fan speed output is 37% (22Hz) from the VFD motor, by default, and at 10VDC the Fan Speed output is 100% (60Hz). The control scales the 0- 10Vdc VFD output from the RTM linearly to control between the 37%-100% controllable range. If the RTM determines that there is a need for active cooling capacity in order to meet the calculated Temperature Setpoint (Tset), the unit will begin to stage compressors accordingly once supply fan proving has been made. Note that the compressor staging order will be based on unit configuration and compressor lead/lag status. Once theTset calculation has reached its bottom limit (Tset Lower Limit Setpoint) and compressors are being utilized to meet the demand, theTset value continues to calculate below theTset Lower Limit Setpoint and the algorithm will begin to ramp the Supply Fan Speed up toward 100%. Note that the supply fan speed will remain at the compressor stage’s associated minimum value (as described below) until the Tset value is calculated below the Tset Lower Limit Setpoint. As the cooling load in the zone decreases the zone cooling algorithm will reduce the speed of the fan down to minimum per compressor stage and control the compressor outputs accordingly. As the compressors begin to de-energize, the Supply Fan speed will fall back to the Cooling Stage’s associated minimum fan speed, but not below. As the load in the zone continues to drop cooling capacity will be reduced in order to maintain the discharge air within the ± ½ Tset deadband. Cooling Stages Minimum Fan Speed As the unit begins to stage compressors to meet thecooling demand, the following minimum Supply Fan Speeds will be utilized for each corresponding Cooling Stage. Note that the Supply Fan Speed will be allowed to ramp up beyond 37% as determined by the active Tset calculation; the speeds below are only the minimum speeds per cooling stage. Note that when transitioning between active cooling stages, compressors may energize prior to the supply fan reaching the minimum speed for the associated step. 1. 2-Stage DX Cooling -The minimum fan speed for units with 2 stages of DX Cooling will be 37% of the unit’s full airflow capacity. At Stage 1 of DX Cooling the minimum Fan Speed will be 37% and at Stage 2 of DX Cooling the Fan Speed will be at a minimum of 67%. 2. 3-Stage DX Cooling - There are no IntelliPakapplications with 3 stages of DX Cooling. 3. 4-Stage DX Cooling -The minimum fan speed for units with 4 stages of DX Cooling will be 37% of the unit’s total airflow. At Stage 1 the minimum Supply Fan Speed will be 37%, at Stage 2 the minimum Supply Fan Speed will be 58%, and at Stages 3 & 4 the minimum Supply Fan Speed will be 67%. Rapid Restart This feature will occur after every power cycle. Once power is restored (e.g., via a backup generator), the RTM will maximize cooling capacity within 3-5 minutes. Once the space has returned to its Zone Temperature Setpoint, the RTM controls the load using normal capacity control algorithms. The supply fan will be turned on immediately after a power cycle, module initialization, or after the Unit Start Delay has timed out. The supply fan proving switch input must be closed prior to continuing with Rapid Restart. Once the supply fan proving switch input has closed, the unit will consider the outside air temperature to determine whether economizing or DX mechanical cooling will be utilized to provide the necessary cooling. If the outside air temperature is less than 50°F and economizing is enabled, the outside air damper will be utilized. If the outside air temperature is above 50°F, the outside air damper will remain closed and DX mechanical cooling will occur for the duration of Rapid Restart. Compressor Sequence of Operation Each compressor is equipped with a crankcase heater and is controlled by a 600 volt auxiliary switch on the compressor contactor. The proper operation of the crankcase heater is important to maintain an elevated compressor oil temperature during the “Off” cycle to reduce oil foaming during compressor starts. When the compressor starts, the sudden reduction in crankcase pressure causes the liquid refrigerant to boil rapidly causing the oil to foam. This condition could damage compressor bearings due to reduced lubrication and could cause compressor mechanical failures. NOTICE: Compressors Failure! Unit must be powered and crankcase heaters energized at least 8 hours BEFORE compressors are started. This will protect the compressors from premature failure.
Unit Startup RT-SVX24K-EN99 Low Ambient Compressor Operation Certain applications require compressor operation at lower ambient conditions than standard units. Low ambient compressor operation is a factory configured option that allows units to operate down to -10°F by extending the low ambient compressor lockout setpoint range. Standard configuration units are limited to a minimum low ambient compressor lockout setpoint of 40° F. In conditions below 40°F the low-pressure cutout (LPC) switch can open in the first few minutes of initial compressor operation due to refrigerant circulation characteristics. To prevent nuisance LPC events at startup in these conditions the unit controller will bypass LPC processing for a varying period of time as defined below: – For ambient temps below 20°F LPC events will bebypassed for the first 170 seconds of compressor operation. For ambient temps between 20° and 40°F the bypass time reduces linearly from 170 seconds at 20°F to 0 seconds at 40°F. LPC events are not bypassed at initial compressor start in ambient conditions above 40°F. – An open LPC switch detected at compressor startwill result in a manual-reset compressor lockout condition. – 4 consecutive LPC trip occurrences after the bypass time expires without a minimum of 3 minutes of compressor operation between trips will result in a manual-reset compressor lockout. In addition to alternate LPC event processing, the second compressor to start on each refrigerant circuit will be disabled for 40 minutes each time a circuit starts in ambient conditions less than 40°F. To properly maintain head pressure control in low ambient conditions one condenser fan on each refrigerant circuit will be controlled by a Variable-frequency motor drive (VFD). This fan will always be the first fan active. The VFD will control fan speed at all times compressors are active to the HI-adjustable Low Ambient Control Point. If head pressure control requires additional condenser fan stages to maintain proper Saturated CondenserTemperature within limits they will be activated as necessary according to the standard head pressure control fan-staging algorithm. Units with Evaporative Condenser Sequence of Operation Upon a power up without water in the sump, the condenser sump drain will be controlled to allow the sump to hold water.The fill relay will be energized if there is a call for mechanical cooling and if the outdoor air temperature is greater than 10°F on units with a sump heater installed or greater than 40°F on units without sump heat. Once the fill solenoid is energized, the sump will begin to fill. The minimum water level switch will close and the fill relay will be de-energized. The sump water temperature sensor is invalid unless the minimum water level switch is closed. If the sump water temperature is less than the setpoint (default is 38°F), the sump heater will be energized until the water temperature reaches the setpoint plus 5 degrees (43°F for default).The fill solenoid will remain closed for 20 minutes or until the water temperature is greater than 35°F. Once a water temperature of 35°F or greater is achieved, the fill solenoid is energized, the sump will continue to fill, and a five minute timer is started. When the timer expires, the compressor lockout will be released and mechanical cooling will be allowed. Head pressure control will be regulated by a variable speed fan until the liquid line pressure from either circuit reaches the upper limit, which is set on the Human Interface under the setup menu 120°F default. The liquid line pressure is converted to a temperature for display at the Human Interface. When the temperature exceeds the upper limit, the condenser sump pump will be energized. When the sump pump is energized, water is pumped from the sump and sprayed over the condenser coil. If the liquid line pressure from either circuit falls below the lower limit the sump pump will be de-energized. When the sump pump is energized or de-energized a change in state is observed from an auxiliary contactor to ensure proper sump pump operation. A change in states must be observed by the auxiliary contactor within 6 seconds of the command to change states or mechanical cooling will be locked out on a sump pump failure causing a manual reset diagnostic to be set. The fill solenoid will remain energized and the water level will be controlled by the mechanical float valve. If the maximum level float ever closes, an information-only diagnostic is set and the fill solenoid is de-energized. This is an indication that the mechanical float is not adjusted properly or a failure of the mechanical float valve has occurred. If the maximum level input is open for two continuous minutes, the diagnostic will be cleared and the fill solenoid will be energized. If the sump water temperature ever drops below 35°F, the drain actuator will be controlled in order to drain the water from the sump. If there is a call for mechanical cooling and the outdoor air temp is greater than 10°F on units with sump heat installed or greater than 40°F on units without sump heat, the unit will be allowed to refill the sump. 00F20F40F 170 Outdoor Air Temp(° F) LPC Bypass Time (sec)
Unit Startup 10 0RT-SVX24K-EN The drain control can be configured via the Human Interface, and by the drain actuator installation, to hold or drain water on power loss; the default is set to drain. Periodic purge is a cyclic opening of the drain to remove debris and buildup from the sump and add additional fresh water to the sump. Periodic purge has an adjustable interval from the setup menu on the Human Interface with a range of 1-12 hours or can be set to disabled - the default position if periodic purge is not required. The duration of the blowdown, or the time that the drain valve is opened, is adjustable to a range of 5 - 255 seconds, with 120 seconds being the default. The optional conductivity controller also uses this timer to open the drain, when required, based on water quality. During this purge, the fill solenoid will remain energized to provide fresh water to the sump to replace water being released during the blowdown. Water treatment blowdown is provided by shorting the designated input on the customer-supplied terminal strip. This gives the customer more flexibility in determining water conditions via external controls. Once the input is detected closed, the drain valve will be opened for a time equal to the Human Interface adjustable periodic purge duration. Once the duration timer expires, or if the minimum level switch opens, the drain valve will be closed and the water treatment blowdown input will be ignored for 15 minutes. During this blowdown the fill relay will remain open to provide fresh water to the sump. The adjustable duration time period should be set so that during drain operation 1 inch of water is drained from the sump with the fill solenoid valve closed. If the minimum water level switch opens during a blowdown cycle, the unit will de-energize the sump pump in order to protect the compressors and sump heater from insufficient water levels. Once the water level reaches the minimum level input and this input closes for 10 seconds, the compressors and sump heater operations will be allowed to restart.Evaporative Condenser Drain Valve Setup The drain valve is shipped to “Drain During Unit PowerLoss Conditions.” This means that when the unit disconnect is turned off, the 1S2 toggle switch is turned off, or the unit loses power, the drain will open. The valve is spring loaded and will travel from fully closed to fully open in approximately 25 seconds. This is desirable in cold climates where a risk of freezing exists. In milder climates it may be desirable to keep the water in the sump when unit power is off to avoid unnecessarily wasting water whenever the unit disconnect is turned off. To convert the unit to “Hold During Unit Power Loss Conditions”: 1. Remove power from the unit. 2. Remove the weather shield cover (Figure 62, p.10 0). 3. Loosen the shaft set screw (Figure 62, p.10 0), remove the locking clip, remove the shaft adapter ( Figure63, p. 101 ). 4. Lift the drain valve actuator and rotate it to the “hold during power loss” position. (Figure 64, p.101) 5. Reinstall the shaft adapter and locking clip and reinstall the actuator onto the base. Make sure the arrow on the shaft adapter is set to 0°. 6. Make sure the valve is in the fully closed position, then tighten the shaft set screw. 7. Reinstall the weather shield cover. 8. Restore power to the unit. 9. At the Human Interface, press SETUP, NEXT until Head P ressure Control Setup Submenu” is seen. Press ENTER. 10. Change the “Sump Drain Valve Relay Control” from Drain to Hold. Figure 62. Drain valve actuator with weather shield Weather Shield Shaft Set ScrewDrain Valve Actuator