PART-SVN109A-EN Installation - Desert Mountain Trane

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© 2008 Trane All rights reservedJune 2008 PART-SVN109A-EN Installation Thermal Expansion Valve Upgrade Kit for Precedent™ Packaged Rooftops Models: THC(036-120*)…
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© 2008 Trane All rights reservedJune 2008 PART-SVN109A-EN Installation Thermal Expansion Valve Upgrade Kit for Precedent™ Packaged Rooftops Models: THC(036-120*) TSC(036-120) YHC(036-120*) YSC(036-120) *033, 043 and 063 are excluded 2 PART-SVN109A-EN Introduction Important Environmental Concerns! Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs. Responsible Refrigerant Practices! Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.  WARNING Contains Refrigerant! System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage. ATTENTION: Warnings and Cautions appear at appropriate sections throughout this literature. Read these carefully.  WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION – Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices. NOTICE – Indicates a situation that could result in equipment or property-damage only accidents. PART-SVN109A-EN 3  WARNING Hazard of Explosion and Deadly Gases! Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids. Failure to follow all proper safe refrigerant handling practices could result in death or serious injury. General Information This information documents the process of removing the short orifice headers from a Precedent™ packaged rooftop unit and then installing R-22 thermal expansion valve(s) for use as the refrigerant metering device. The thermal expansion valve kits are not for use on Precedent units that are heat pumps or use R-410A for the refrigerant. For help selecting the correct kit, see Table 1 or the latest version of the selection guide, PART-SVB20A-EN, in e-Library. Table 1. Kit contents and refrigerant charge KIT Unit Type TXV Tube Assembly Bulb Clip (Quantity) Copper Coupler- Reducer for Liquid line Refrigerant Charge(a) (lb) (a) If the unit nameplate has different information, recharge to the unit nameplate information. Circuit 1 Circuit 2 KIT15166 (T/Y)HC036 TUB11170 CLP00223 X17030023000 5.3 N/A KIT15167 (T/Y)HC048 TUB11171 CLP00223 X17030023000 7.7 N/A KIT15168 (T/Y)(H/S)C060 TUB11182 CLP00181 X17030023000 8.4 N/A KIT15169 (T/Y)HC072 TUB10478 CLP00292 X17030023000 10.7 N/A KIT15170 (T/Y)HC092 TUB10482 (CKT 1) CLP00181 (2) X17030023000 (2) 6.4 6.2 TUB10483 (CKT 2) KIT15171 (T/Y)HC102 TUB10486 (CKT 1) CLP00181 (2) X17030023000 (2) 7.4 7.1 TUB10487 (CKT 2) KIT15172 (T/Y)HC120 TUB10491 (CKT 1) CLP00181 (2) X17030023000 (2) 11 7.3 TUB10490 (CKT 2) KIT15173 (T/Y)SC036 TUB11180 CLP00223 X17030023000 3.8 N/A KIT15174 (T/Y)SC048 TUB11181 CLP00223 X17030023000 3.8 N/A KIT15175 (T/Y)SC072 TUB10477 CLP00292 X17030023000 7.1 N/A KIT15176 (T/Y)SC090 TUB10479 CLP00292 X17030023000 11.5 N/A KIT15177 (T/Y)SC092 TUB10480 (CKT 1) CLP00181 (2) X17030023000 (2) 6.2 3.4 TUB10481 (CKT 2) KIT15178 (T/Y)SC102 TUB10484 (CKT 1) CLP00181 (2) X17030023000 (2) 7.9 4.0 TUB10485 (CKT 2) KIT15179 (T/Y)SC120 TUB10496 (CKT 1) CLP00181 (2) X17030023000 (2) 7.2 5.3 TUB10489 (CKT 2) Note: Each kit also includes a piece of insulation for use around the TXV sensing bulb. 4 PART-SVN109A-EN For each TXV tube assembly, there should be a tag on one of the distribution tubes with a 12-digit identification number (see Table 2). Note: The following installation procedure also calls for existing filter-drier(s) to be replaced. Due to variances in sizes of filter driers used, they are not included in the upgrade kit. Correct filter driers can be identified using the unit model number and the WebCATS parts identification system. Installation Procedure 1. Check the contents of the kit and confirm that all parts are present. Note: Refer to PART-SVB20A-EN for a list of kit parts. 2. Before removing or opening the access panels, disconnect the electrical power.  WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. 3. Remove the blower compartment access panels, the narrow support panel between the access panels (left-hand side of unit), and the compressor access panel (see Figure 1). Table 2. Cross-reference: kit number to TXV tube assembly number Tube Assembly Mnemonic ID Number Tube Assembly Mnemonic ID Number TUB11170 436632500210 TUB11180 436632500110 TUB11171 436632500310 TUB11181 436632500410 TUB11182 436632500510 TUB10477 436621500110 TUB10478 436621500210 TUB10479 436621500310 TUB10482 436621500510 TUB10480 436621500410 TUB10483 436621510210 TUB10481 436621510110 TUB10486 436621500710 TUB10484 436621500610 TUB10487 436621510410 TUB10485 436621510310 TUB10491 436621500910 TUB10496 436623620110 TUB10490 436621510610 TUB10489 436621510510 Figure 1. Access panels PART-SVN109A-EN 5 4. Recover the refrigerant.  WARNING Contains Refrigerant! System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage. 5. Each circuit can now be cut away (see Figure 2 and Figure 3). a. Cut the liquid line before the header tube so that the valve will be positioned roughly in the middle of the evaporator coil. b. After cutting, un-braze the joint on the existing liquid line for later connection. Note: The final bend in the liquid line of the valve assembly may need to be cut off. Figure 2. Determining placement for circuit 2 Figure 3. Determining placement for circuit 1 6 PART-SVN109A-EN 6. Cut each orifice tube about 1-1/2 inch from the header tube (see Figure 4). Note: The orifice is located internal to this tube section. If the unit has two circuits, mark the tubes for later identification. 7. Reshape the tubes to round that were cut using a needle nose pliers or other tool (see Figure 5). 8. Cut the ends off of the distributor tubes with a tube cutter so that they will fit inside of the tubes that were cut in Step 6. Use an awl or similar tool to widen the ends of the distributor tubes after cutting. Figure 4. Cutting tubes just below the existing orifice Figure 5. Bringing tubes back to round Figure 6. Ends of distributor tubes to be cut off PART-SVN109A-EN 7 9. Attach the TXV assembly to the liquid tube. Note: It may be necessary to use the 5/16-inch to 3/8-inch adapter provided in the kit to connect the liquid lines (see Figure 7).  WARNING Hazard of Explosion and Deadly Gases! Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids. Failure to follow all proper safe refrigerant handling practices could result in death or serious injury. 10. Route and bend the individual feeder tubes to the cut tubes feeding the evaporator coil circuits. Check to make sure the connections are not cross-circuited. The TXV feeder tubes are 3/16-inch diameter and should be inserted about 1 inch into the existing circuit tubes. The 3/8-inch existing tubes will require some crimping (see Figure 8) for a neat braze joint. Braze the feeder tube connections using the nitrogen purge (see Figure 9, p. 8). Figure 7. Liquid line connected Figure 8. Distribution tubes crimped into place 8 PART-SVN109A-EN 11. Connect the equalizer line to the suction line.  CAUTION Safety Glasses Required! The nitrogen purge pressure inside the suction line is between 50 to 100 psig. When drilling a hole in the line, some copper chips could be blown to the outside of the tube as a result of this pressure. To avoid injury you MUST wear safety glasses while performing this operation. Failure to do so could result in minor to moderate injury. NOTICE: Equipment Damage! When drilling a hole in the suction line, make sure no copper chips fall inside the tubing. If copper chips fall inside the tubing, they could result in equipment damage when unit is operating. a. First, drill a 1/8-inch diameter hole near the upper portion of the suction line. Leave room to the right of the hole for the sensing bulb to be attached later. Figure 9. Brazing distribution tubes PART-SVN109A-EN 9 NOTICE: Frozen Coil and Compressor Damage! Take care not to cross-circuit the equalizer lines when inserting them into the suction lines. Failure to follow this precaution could result in equipment damage including frozen coil and compressor damage. b. Remove or cut off the black plastic coating that is covering the end of the equalizer line, and then insert the equalizer line just far enough into the suction line so that it can be brazed into place (see Figure 10). Note: If the nitrogen purge pressure inside the suction line is between 50 to 100 psig, the copper chips will be blown to the outside of the tube. Do not allow copper chips to fall inside the tubing. Take care not to cross-circuit the equalizer lines. 12. If the unit has two refrigerant circuits, repeat Step 6 through Step 11 for the other circuit. 13. The TXV sensing bulbs are to be located just to the right of the equalizer line connections on the suction line. a. Secure the bulbs at the 10:00 o’clock position. b. Pull the suction line insulation back into position and make sure the sensing bulb is insulated using the additional insulation material provided. Note: Equalizer line just out of frame to the left of the sensing bulb. Figure 10. Inserting the equalizer line into the drilled hole 1. Equalizer line 2. Drilled hole (see Step 11a, p. 8) Figure 3. TXV sensing bulb clipped into place 2 1 10 PART-SVN109A-EN 14. Replace the existing filter-drier(s). Note: Due to variances in sizes of filter driers used, they are not included in the upgrade kit. Correct filter driers can be identified using the unit model number and the WebCATS parts identification system. 15. With all weld joints complete, leak-test all the new connections. 16. The system is now ready for evacuating and recharging. Recharging with new refrigerant is recommended. Refrigerant charge information is shown in Table 1, p. 3. Note: If the unit nameplate has different information, recharge to the unit nameplate information. 17. Use the charts in the “Refrigeration Data” section of the Service Facts literature to adjust the charge if necessary. Table 3, p. 11 lists Service Facts literature numbers by model number. Note: Literature can be accessed via e-Library. 18. Reinstall the access panels, and then re-connect the electrical power. PART-SVN109A-EN 11 Table 3. Service Facts literature numbers Model Type Service Facts Literature # Model Type Service Facts Literature # YSC036 YSC036-SF-2A TSC036 TSC036-SF-1A YSC036-SF-1A TSC036-SF-2A YSC048 YSC048-SF-1A TSC048 TSC048-SF-1A YSC048-SF-2A TSC048-SF-2A YSC060 YSC060-SF-1A TSC060 TSC060-SF-1A YSC060-SF-2A TSC060-SF-2A YSC060-SF-3 TSC060-SF-3 YSC072 YSC072-SF-1 TSC072 TSC072-SF-1 YSC072-SF-2 TSC072-SF-2 YSC090 YSC090-SF-1 TSC090 TSC090-SF-1 YSC090-SF-2 TSC090-SF-2 YSC090-SF-3 TSC092 TSC092-SF-1 YSC092 YSC092-SF-1 TSC102 TSC102-SF-1 YSC092-SF-2 TSC102-SF-2 YSC102 YSC102-SF-1 TSC120 TSC120-SF-1 YSC102-SF-2 TSC120-SF-2 YSC120 YSC120-SF-1 THC036 THC036-SF-1A YSC120-SF-2 THC036-SF-2A YSC120-SF-3 THC048 THC048-SF-1A YHC036 YHC036-SF-1A THC048-SF-2A YHC036-SF-2A THC060 TCH060-SF-1A YHC048 YHC048-SF-1A TCH060-SF-2A YHC048-SF-2A TCH060-SF-2B YHC060 YHC060-SF-1A THC072 THC072-SF-1 YHC060-SF-2A THC092 THC092-SF-1 YHC072 YHC072-SF-1 THC102 THC102-SF-1 YHC092 YHC092-SF-1 THC120 THC120-SF-1 YHC102 YHC102-SF-1 YHC120 YCH120-SF-1 www.trane.com For more information, contact your local Trane office or e-mail us at comfort@trane.com Literature Order Number PART-SVN109A-EN Date June 2008 Supersedes New Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.
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