Trane IntelliPak Modular Series User Manual

Installation, Owner, andDiagnostic ManualJuly 2000SCXG-SVX01B-ENIntelliPak®Commercial Self-ContainedModular Series, 20-35 TonModels“BO” and later Desi

10 SCXG-SVX01B-ENInstallationPre-InstallationConsiderationsInstallation PreparationBefore installing the unit, performthe following procedures toensur

100 SCXG-SVX01B-ENFigure O-M-2. Fan Belt Adjustment.Figure O-M-3. Belt Tension Gauge.Fan BearingsThe opposite drive end bearing is aspecial bearing wi

SCXG-SVX01B-EN 101Owner MaintenanceFigure O-M-5. Fan assembly.Figure O-M-6 . Fan motor adjustment points.

102 SCXG-SVX01B-ENFollow specific manufacturer’sguidelines for conversion of existingsystems.• To assist in reducing power generationemissions, always

SCXG-SVX01B-EN 103refrigerant service work such asgauges, hoses, vacuum pumps, andrecycling equipment.• Stay aware of unit enhancements,conversion ref

104 SCXG-SVX01B-ENDo not exceed 200 psig whenleak testing the system. Damageto the unit could result, or anexplosion may occur causinginjury or death.

SCXG-SVX01B-EN 105Figure O-M-7. Typical water-cooled (SXWG) compressor section components.MaintenanceOwner

106 SCXG-SVX01B-ENInlet Guide VanesPerform the following procedure everysix months for proper inlet guide vaneoperation:1. Spray all parts of guide va

SCXG-SVX01B-EN 107Coil Fin and External CleaningKeep coils clean to maintain maximumperformance. For operation at its highestefficiency, clean the ref

108 SCXG-SVX01B-ENMaintenanceAlso, a drain plug is at the bottom of theinlet condenser manifold and in the outletpipe near the unit’s left side. Remov

SCXG-SVX01B-EN 109Piping ComponentsWater ValvesWater valves have a stern packing nut. Ifthere is evidence of water leakage at thevalve stem, proceed a

SCXG-SVX01B-EN 11denser and fan motor access panels aresecured with quick-acting fasteners.Access panels for evaporator coils,expansion and water valv

110 SCXG-SVX01B-ENPeriodic MaintenanceChecklistsMonthly ChecklistThe following check list provides therecommended maintenance schedule tokeep the unit

SCXG-SVX01B-EN 111Table D-T-1. Common Unit Problems and SolutionsProblem Possible Cause RemedyDrain pan is overflowing Plugged drain line Clean drain

112 SCXG-SVX01B-ENDiagnosticTroubleshootingDiagnosticsRefer to the IntelliPak® Self-ContainedProgramming Guide, PKG-SVP01B-EN,for specific unit progra

SCXG-SVX01B-EN 113DiagnosticTroubleshooting DiagnosticsReset Required: (PAR) An automatic resetoccurs after communication has beenrestored.Emergency S

114 SCXG-SVX01B-ENDiagnosticTroubleshooting Diagnosticsthis input (temp < -55 F or temp > 209 F).UCM’s Reaction: The functions thatdesignated th

SCXG-SVX01B-EN 115DiagnosticTroubleshooting DiagnosticsUCM’s Reaction: The system modereverts to the default (HI set) systemmode.Reset Required: (INFO

116 SCXG-SVX01B-ENDiagnosticTroubleshooting Diagnosticsits allowable range continuously for 10seconds.RTM Aux. Temp. Sensor FailureProblem: The RTM au

SCXG-SVX01B-EN 117DiagnosticTroubleshooting Diagnosticsrange for 10 continuous seconds, or aftera different SA pressure setpoint source isuser-defined

118 SCXG-SVX01B-ENDiagnosticTroubleshooting DiagnosticsReason for Diagnostic: The TCI has lostcommunications with Tracer Summit® for> 15 minutes.UC

SCXG-SVX01B-EN 119DiagnosticTroubleshooting DiagnosticsWWSM Communications FailProblem: The RTM has lostcommunication with the WSM.Check: Field/unit w

12 SCXG-SVX01B-ENFigure I-PC-6. Split-apart unit gravity block location.Figure I-PC-5. Assembled unit gravity block location.Table I-PC-2. Gravity Blo

120 SCXG-SVX01B-ENIndexA“After-Shipment” Accessory ModelNumber 8Air Filters 98Air-Cooled Condensers 88Airside Economizer Installation 48Airside Ec

SCXG-SVX01B-EN 121IndexSensor Fail 113Heat Module Comm Failure 114HI 58, 80HI Location Recommendations 58High Duct Static Switch 90High Duct Temp

122 SCXG-SVX01B-ENReturn Air Humidity Sensor Failure115Return Air Temp Sensor Failure 115Return Air Temperature Sensor 90RHI 58, 80Rigging and Hand

SCXG-SVX01B-EN 123Water Temperature Requirements 35Water Valves 109Water-Cooled Condensers 84Water-Cooled Unit Piping 63Waterside Components 84Wa

The Trane CompanyA Division of American Standard Inc.www.trane.comFor more information contactyour local district office ore-mail us at comfort@trane.

SCXG-SVX01B-EN 13Pre-InstallationConsiderationsRigging and HandlingUnit Shipping1. Position rigging sling under woodshipping skid.2. Use spreader bars

14 SCXG-SVX01B-ENSplit-Apart Unit Assembly1. Ensure the tagging information on thefan section nameplate matches that onthe compressor nameplate.2. Rem

SCXG-SVX01B-EN 15Pre-InstallationConsiderationsInstallationFigure I-PC-9 How to assemble the split apart modular unit.Figure I-PC-10 Modular unit pane

16 SCXG-SVX01B-ENPre-InstallationConsiderationsSkid RemovalThe unit ships on skids to provide forkliftlocations from the front or rear. The skidallows

SCXG-SVX01B-EN 17Dimensionsand WeightsInstallationSCWG/SIWG Unit —English - (inches)ON PAGE 20ON PAGE 21ON PAGE 21ON PAGE 21ON PAGE 21

18 SCXG-SVX01B-ENDimensionsand WeightsInstallationSCWG/SIWG Unit —Metric- (mm)ON PAGE 21ON PAGE 21ON PAGE 21ON PAGE 21ON PAGE 21

SCXG-SVX01B-EN 19Dimensionsand WeightsInstallationSCRG/SIRG Unit —English - (inches)ON PAGE 21ON PAGE 21ON PAGE 21

©American Standard Inc. 2000 SCXG-SVX01B-ENGeneralInformationAbout This ManualLiterature Change HistoryUse this manual for commercial self-contained

20 SCXG-SVX01B-ENDimensionsand WeightsInstallationSCRG/SIRG Unit —Metric - (mm)ON PAGE 21ON PAGE 21ON PAGE 21

SCXG-SVX01B-EN 21Dimensionsand WeightsInstallationUnit Dimensions - English, (inches)Unit Tons A B C D E FSCWG/SCRG 20 20 10 3/458 1/25 1/813 1/411

22 SCXG-SVX01B-ENDimensionsand WeightsInstallationHot Water CoilHot Water Coil Dimensions - English - (inches)Unit Ton A B C D E F G H J20 - 35 37 1/4

SCXG-SVX01B-EN 23Dimensionsand WeightsInstallationSteam Coil Dimensions - English - (inches)Unit Ton A B C D E K L M N P Q R20 - 35 37 1/453 3/416 5/8

24 SCXG-SVX01B-ENDimensionsand WeightsInstallationElectric Heat Coil

SCXG-SVX01B-EN 25Dimensionsand WeightsInstallationWaterside Economizer

26 SCXG-SVX01B-ENDimensionsand WeightsInstallationAirside Economizer Dimensions - English - (inches) Unit Size A B C D E F (1) F (2) G (1) G (2) H (1)

SCXG-SVX01B-EN 27Detail “A”Detail “B”Dimensionsand Weights(Factoryprovidedfor fieldinstallation)

28 SCXG-SVX01B-ENDimensionsand WeightsInstallationVariable Frequency DriveVariable Frequency Drive Dimensions - English - (inches)Motor HP Voltage A B

SCXG-SVX01B-EN 29Dimensionsand WeightsInstallationVariable FrequencyDrive with Bypass

SCXG-SVX01B-EN 3ContentsCross reference to related publications/information:IntelliPak® Self-Contained Programming Guide, PKG-SVP01B-ENRemote Air-Cool

30 SCXG-SVX01B-ENVariable Frequency Drive With Bypass Dimensions - English - (inches)Motor HP Voltage A B C D E F G H J K L M Weight7.5 200V 19 1/217

SCXG-SVX01B-EN 31Dimensionsand WeightsFlexible Horizontal Discharge Plenum Dimensions - English - (inches)20-35 Tons A B CLow Height 35 17 1/486 1/2St

32 SCXG-SVX01B-ENTable I-DW-1. Unit Weights, English - SCWG/SCRG/SIWG/SIRG2-Row 4-RowUnit Base Airside Waterside Waterside HeatingSize Weight Economiz

SCXG-SVX01B-EN 33MechanicalRequirementsDuct ConnectionsDisconnect electrical powersource before servicing the unit.Failure to do so may result ininjur

34 SCXG-SVX01B-ENMechanicalRequirementsWater PipingNote: To prevent water damage, install allpiping drain and vent plugs.Condenser ConnectionsCondense

SCXG-SVX01B-EN 35Figure I-MR-3. Condenser water piping components for cooling tower system.MechanicalRequirementsFigure I-MR-4. Typical water piping f

36 SCXG-SVX01B-ENRefrigerant Piping (Air-CooledUnits Only)The maximum line pressure design ofeach refrigerant circuit is 3 psig. Includethe following

SCXG-SVX01B-EN 37ElectricalRequirementsUnit Wiring DiagramsSpecific unit wiring diagrams areprovided on the inside of the controlpanel door. Use these

38 SCXG-SVX01B-ENElectricalRequirementsSelection ProceduresRLA = Rated Load AmpsCompressor LRA = Locked Rotor AmpsFan Motor LRA = Locked Rotor Amps,N.

SCXG-SVX01B-EN 39Pre-StartupRequirementsPre-Startup ProceduresBefore starting up units perform thefollowing procedures to ensure properunit operation.

4 SCXG-SVX01B-ENFigure I-GI-1. IntelliPak® commercial self-contained Modular Series unit.InstallationModular Series Self-ContainedUnit ComponentsComme

40 SCXG-SVX01B-ENUnit Vibration Isolator OptionVibration isolation is not necessary for theunit since the factory internally isolatesthe fan and compr

SCXG-SVX01B-EN 41Pre-StartupRequirementsPlenumBefore installing the plenum attach theinsulation strip that ships with the plenum.See Figure I-PR-4 for

42 SCXG-SVX01B-ENPre-StartupRequirementsInstallationFigure I-PR-5. Installing the waterside economizer.Waterside EconomizerInstallation Procedure1. Lo

SCXG-SVX01B-EN 43Pre-StartupRequirementsInstallationFigure I-PR-7. Waterside economizer with left-hand factory piping tubing assemblyItem Part Descrip

44 SCXG-SVX01B-ENPre-StartupRequirementsInstallationFigure I-PR-8. Waterside economizer with right-hand factory piping tubing assembly.Item Part Descr

SCXG-SVX01B-EN 45Pre-StartupRequirementsInstallationHydronic Coil InstallationThese instructions are for steam and hotwater coil installation. The hyd

46 SCXG-SVX01B-ENDisconnect electrical powersource before wiring electric heatto unit to prevent risk of injury ordeath from electrical shock.2. Punch

SCXG-SVX01B-EN 47Variable Frequency DriveOption (VFD)The variable frequency drive (VFD)option can only be used with IntelliPakunits. The VFD and VFD w

48 SCXG-SVX01B-ENPre-StartupRequirementsAirside Economizer InstallationUnit Handling1. Hoist the damper cabinet to theinstallation location with strap

SCXG-SVX01B-EN 49Pre-StartupRequirementsStatic Pressure TransducerInstallation (VAV units only)Supply air static pressure controls theinlet guide vane

SCXG-SVX01B-EN 5InstallationControl OptionsUnits can have either a thermostatcontrol or IntelliPak® UCM controlnetwork.IntelliPak® Unit ControlsStanda

50 SCXG-SVX01B-ENPre-StartupRequirementsInstallationRemote Mounted ThermostatOptionMount the thermostat in the largestspace occupied by the most peopl

SCXG-SVX01B-EN 51Pre-StartupRequirementsFigure I-PR-15. BAYSENS017Zone Temperature Sensor OnlyStandard with All UnitsRemote Zone Sensor OptionsZone se

52 SCXG-SVX01B-ENPre-StartupRequirementsFigure I-PR-20. BAYSENS013Zone temperature sensor w/timed override ,Accessory Model Number Digit 6 = BFigure I

SCXG-SVX01B-EN 53Note: Guidelines for wire sizes andlengths are shown in Table I-PR-7. The totalresistance of these low voltage wiresmust not exceed 2

54 SCXG-SVX01B-ENFigure I-PR-23. Typical zone sensor installation.Pre-StartupRequirementsFigure I-PR-22. Zone sensor mounting hole locations.Mounting

SCXG-SVX01B-EN 55Pre-StartupRequirementsConstant Volume Zone SensorBAYSENS019 DescriptionThis seven day programmable sensorwith night setback has four

56 SCXG-SVX01B-EN6. Pull the zone sensor module wiresthrough the subbase as shown in FigureI-PR-31.7. Loosely secure subbase to the wallwith the mount

SCXG-SVX01B-EN 57Pre-StartupRequirementsTime Clock OptionThe time clock option has aprogrammable timer that is factory wiredto the unoccupied input to

58 SCXG-SVX01B-ENPre-StartupRequirementsFigure I-PR-31. Human Interface (HI) Panel KeypadInstalling the Remote HumanInterface PanelHuman Interface (HI

SCXG-SVX01B-EN 59Pre-StartupRequirementsMounting the Remote HumanInterface (RHI) PanelThe installer must provide all mountinghardware such as; hand to

6 SCXG-SVX01B-ENInstallationGeneralInformationS C W G N 20 4 2 BO A B 2 10 065 B A 1 0 1

60 SCXG-SVX01B-ENPre-StartupRequirementsFigure I-PR-32. Remote HI mounting holes and knockout locations.Installation

SCXG-SVX01B-EN 61Wiring the Remote HumanInterfaceThe remote human interface requires 24VAC + 4 volts power source and ashielded twisted pair communica

62 SCXG-SVX01B-ENConnecting to Tracer Summit®IntelliPak® self-contained units operatewith Trane building automation software,Tracer Summit® version 10

SCXG-SVX01B-EN 63Pre-StartupRequirementsInstallationPre-Startup ChecklistComplete this checklist after installing theunit to verify all recommendedins

64 SCXG-SVX01B-ENProgrammingInstallationFigure I-P-1. BAYSENS019 Keypad and display configuration.BAYSENS019 Keypad and DisplayExplanation1. Up and Do

SCXG-SVX01B-EN 65ProgrammingInstallationFigure I-P-2. BAYSENS020 Keypad and display configuration.BAYSENS020 Keypad and DisplayExplanation1. Up and Do

66 SCXG-SVX01B-ENto the program menu. See Figure I-P-2.Before toggling to the program menu,use the mode button to select the typesetpoints to review o

SCXG-SVX01B-EN 67a temporary manual override menu. SeeFigure I-P-3.This mode overrides any number ofprogrammed setpoints through any ofthe 28 programm

68 SCXG-SVX01B-ENTemporary Override Run ModeThe temporary override run mode sendssetpoint data to the Unit Control Module(UCM) from the setpoint data

SCXG-SVX01B-EN 69Table I-P-1. Zone Sensor BAYSENS019 Option Menu Settings.Option # Description Value Factory Setting1 Morning Warmup 0 = Disabled 01 =

SCXG-SVX01B-EN 7P S W G S A 1 1 0 AO1 2 3 4 5 6 7 8 9 10 11 Self-Contained Ship-With Accessory Model Number DescriptionInstallationGeneralInformatio

70 SCXG-SVX01B-ENProgrammingInstallationTable I-P-2. Zone Sensor BAYSENS020 Option Menu Settings.Option # Description Value Factory Setting1 Morning W

SCXG-SVX01B-EN 71ProgrammingInstallationIcon DescriptionsBAYSENS019 Icon DescriptionsRefer to Figure I-P-9 for a pictorial view ofthe written descript

72 SCXG-SVX01B-ENProgrammingInstallationFigure I-P-10. BAYSENS020 complete icon display.BAYSEN020 Icon DescriptionsRefer to Figure I-P-10 for a picto

SCXG-SVX01B-EN 73Programming the Time ClockOptionSetting the TimeImportant: Depress reset key beforebeginning to set time and program.1. Select milita

74 SCXG-SVX01B-ENUnit Startup Procedures1. Check all electrical connections fortightness.2. For water-cooled units: gain access tothe liquid line serv

SCXG-SVX01B-EN 75InstallationStartup LogComplete this log at unit start-up.Unit: ____________________________ Unit Location: ___________________

76 SCXG-SVX01B-ENInstallationStartupWater Cooled Units:Circuit A:Entering Water Temperature - F: __________ Leaving Water Temperature - F: __________

SCXG-SVX01B-EN 77Owner GeneralInformationPoints ListRTM Module:Binary inputs• Emergency stop• External auto/stop• Unoccupied/occupied• Dirty filter• V

78 SCXG-SVX01B-ENUnit Control ComponentsThe Modular Series IntelliPak® self-contained unit is controlled by amicroelectronic control system thatconsis

SCXG-SVX01B-EN 79Table O-GI-2. RTM Sensor Resistance vs. TemperatureTemperature (F) Resistance (ohms) Temperature (F) Resistance (ohms)-40 346.1 71 1

8 SCXG-SVX01B-ENInstallation“After-Shipment” Accessory Model NumberS C W F N 20 4 2 AO A B 2 10 065 B

80 SCXG-SVX01B-ENCompressor Module (SCM andMCM - Standard on All UnitsThe compressor module, (single circuitand multiple circuit) energizes theappropr

SCXG-SVX01B-EN 81Figure O-GI-2. Velocity Pressure Trans-ducer/Solenoid Assembly.• VO relay – energized• Exhaust fan (field-installed) - on• Exhaust d

82 SCXG-SVX01B-ENGeneric Building AutomationSystem Module OptionThe generic building automation systemmodule (GBAS) provides broad controlcapabilities

SCXG-SVX01B-EN 83Table O-GI-6. GBAS Analog Input SetpointsControl Parameter Signal Range Setpoint RangeOccupied Zone Cooling Setpoint 0.5 to 4.5 vdc 5

84 SCXG-SVX01B-ENtemperature is less than 58 F (15 C). Thisoption allows the compressor to operatewith entering fluid temperature down to35 F (2 C). T

SCXG-SVX01B-EN 85OwnerCondenser 1Condenser 2V2Condenser 1Condenser 2V1EconomizerCondenser 1Condenser 2V2Figure O-GI-3. Basic water piping configu-rati

86 SCXG-SVX01B-ENOwnerUnit Airside ComponentsThe unit’s air delivery system consists ofcondensers, dampers, enthalpy switchoption, airside economizer

SCXG-SVX01B-EN 87Ownermode at the HI panel. When in bypassmode, VAV boxes need to be fully open.The self-contained unit will controlheating and coolin

88 SCXG-SVX01B-ENTable O-GI-10. Remote Air-Cooled Condenser Refrigerant Connection Sizes - Englishinches (Metric, mm)Unit Circuit 1 Circuit 1 Circuit

SCXG-SVX01B-EN 89Input Devices and SystemFunctionsFollowing are basic input device andsystem function descriptions used withinthe UCM network on Intel

SCXG-SVX01B-EN 9InstallationReceiving and HandlingShipping PackageCommercial self-contained units shipassembled on skids with protectivecoverings over

90 SCXG-SVX01B-ENcondenser water temperature exceeds58 F.Low Ambient Control (Air-Cooled UnitsOnly)The low ambient modulating output onthe compressor

SCXG-SVX01B-EN 91OwnerControl Sequences ofOperationOccupied/Unoccupied SwitchingThere are four ways to switch occupied/unoccupied:(1) Night setback zo

92 SCXG-SVX01B-ENOwnerSequence ofOperationTimed Override Activation - ICS™This function is operational whenever theunit’s RTM module is used as the zo

SCXG-SVX01B-EN 93OwnerSequence ofOperationOccupied Sequence OfOperationAll setpoints can be adjusted using the HIpanel. Also, cooling/heating setpoint

94 SCXG-SVX01B-ENOwnerSequence ofOperationcontrol setting, only mechanical coolingwill function and outside air dampers willremain at their minimum po

SCXG-SVX01B-EN 95Table O-SO-1. Compressor Stages.Unit Refrigerant Compressor HP Standard Lead/Lag

96 SCXG-SVX01B-ENOwnerSequence ofOperationCompressor Safety DevicesThe compressors have motortemperature cutout switches in the motorwindings. These

SCXG-SVX01B-EN 97OwnerSequence ofOperationFigure O-SO-2. Typical pulldown curve for unit operating properly within control band.Figure O-SO-3. Typical

98 SCXG-SVX01B-ENMaintenance ProceduresAir FiltersFilter access doors are on the same sideof the unit as the water pipingconnections. To replace throw

SCXG-SVX01B-EN 99Supply FanFan DrivePerform the following proceduresaccording to the “Periodic MaintenanceCheck List” on page 110.Disconnect electrica