Installation Instructions

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

• 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.

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.

Important 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 according to local rules. For the USA, 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.

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.
• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.
• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

Installation – FIAPWRX*01/02*

Hazardous Voltage w/Capacitors! Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Pre-Installation

1. Open and lock unit disconnect before attempting to install this accessory.
2. Remove the filter access panel from front side of the unit.
3. Remove the compressor access panel from front side of the unit.
4. Remove the return air panel from back side of the unit.

Standard Economizer

Use the template for the return air panel provided in the hardware kit to locate positions to drill holes and cut required new opening. Note: Use template that corresponds to unit/return panel size. Do not cut a hole for units that have a low leak economizer installed.

Recommended Procedure

Place the template into position for drilling and cutting, and secure it with pieces of duct tape (field supplied).

Alignment of the template is critical. Instructions for alignment and cutting are printed on the template.

1. Drill three 1/8-inch holes in the template and panel for engagement holes. Refer to template.

Figure 1: Power exhaust hood installation for standard economizer

Diagram shows the power exhaust hood being attached to the ductwork. Key elements include: partially installed screws with a 1/8-inch clearance between the heat and duct cover, an installed bushing, and an installed edge protector on the down-facing top edge of the cutout. The power exhaust hood is shown connected.

Figure 2: Duct block-off

Diagram illustrates the removal of a return duct block-off.

Remove the return duct block-off.

8. Install duct cover back on unit.
9. Apply gasket to face of power exhaust assembly. See Figure 3.

Figure 3: Gasket to power exhaust assembly

Diagram shows a gasket being applied to the power exhaust assembly. The top edge of the gasket is aligned with the bottom edge of a slotted hole.

Figure 4: Wire harness routing

Diagram illustrates routing the wire harness along the top edge of the economizer and securing it with pop-in wire ties. The top view shows the power exhaust assembly and the economizer.

Figure 5 & 6: Return control box location and view

Diagrams show the location and internal view of the return control box within the unit.

Hazardous Voltage w/Capacitors! Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Low Leak Economizer

Figure 7: Low leak install

Diagram illustrates the configuration for a low leak economizer installation.

Figure 8: Gear side of the economizer

Diagram shows the gear side of the economizer, highlighting a 1-inch hole for wire routing.

Figure 9: Power exhaust

Diagram shows the power exhaust assembly being attached. It indicates dimples for power exhaust screws and shows the routing of the wire.

1. Remove aluminum barometric relief hood blade (if installed) and discard.
2. Open 1-inch hole near the gear side of the economizer and install 1-inch grommet. (Note: Grommet in economizer parts bag.)
3. Partially insert self-drilling screws in three dimples above power exhaust opening and just below top economizer hood. See Figure 9. Note: Do not re-use barometric relief damper holes.
4. Install gasketing around perimeter of power exhaust assembly.
5. Route the power exhaust wire harness through the 1-inch hole near the gear side of the economizer.
6. Hang power exhaust on three partially inserted screws and remove the slack in wire harness.
7. Attach power exhaust with self-drilling screws. See Figure 9.
8. Verify wire harness is clear of gears, doors, and any sharp edges of metal.
9. Route the wires for the power exhaust to the return control box location at the return portion of the unit. Refer to Figure 5.

Wiring Installation – FIAPWRX*01/02*

Proper Field Wiring and Grounding Required! Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

Wire Damage! Failure to follow instructions below could result in damaged wires. Use provided wire ties to make sure wires are secured and protected from sharp edges and hot surfaces.

Figure 10: Wiring

POWER WIRING: Diagram shows electrical connections involving PPF89 (BR wire), CFX, XFR, and XFM with various colored wires (ORG, RED, BRN, PUR, BLK, G/Y) connected to a motor symbol. Notes indicate PPF89 mating connector is in the return enclosure panel and voltage is 460V/575V.

CONTROL WIRING: Diagram shows connections to a FRESH AIR MODULE with terminals P6, J6, BK, and R, and an XFR relay.

Symbio™ Controls Wiring

Hazardous Voltage w/Capacitors! Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Refer to controls wiring diagram (Figure 10) for connections.

1. Route controls wiring (black and red) and connector J6 along the top of the return control box and down the right side and enter enclosure through the top hole for Precedent B/C/D cabinets or hole towards rear of enclosure for Precedent A cabinet.
2. Connect wire connector J6 to P6 on the fresh air options module in the return control box (brown connector). Secure wiring with pop-in wire ties. See Figure 6, p. 7.
3. After installation is complete, the Symbio™ 700 UC configuration will need to be updated to enable this installed feature.

Power Wiring

Hazardous Voltage w/Capacitors! Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Use provided wire ties to secure and protect wires from sharp edges, rotating parts, and hot surfaces.

1. Route the high voltage wiring (brown and orange) and purple connector (PPF89) along the top of the return control box and down the right side and enter enclosure through the bottom wire hole for Precedent B/C/D cabinets or hole closest to front of enclosure for Precedent A cabinet.
2. Connect PPF89 to PPM89 (purple connector) and secure the wires with pop-in wire ties.

Close Out

Hazardous Voltage w/Capacitors! Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

1. Open and lock unit disconnect.
2. Replace the filter access panel.
3. Place the 1-inch x 3-inch label (power exhaust installed) next to the main unit wiring diagram inside the compressor access panel.
4. Check all seams on the power exhaust and confirm they are all sealed water-tight with provided silicone rubber sealant.
5. Close the unit disconnect switch.

Installation – FIAPWRX*03*

Parts List

Figure 11: Major power exhaust components

Diagram shows an exploded view of major power exhaust components, numbered 2, 4, 5, 7, 8, 9, 10, 11, and 12.

Components not shown

• 1/4 x 20 x 5/8, Screws
• #10 x 14 x 3/4, Screws
• 7.78-in. Wire Tie
• 11.0-in. Wire Tie
• 0.94-in. ID; Bushing
• 0.56-in. ID; Bushing
• 1-in. x 3-in. power exhaust installed label

Hazardous Service Procedures! Failure to follow instructions could result in death or serious injury. The procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

1. Open and lock unit disconnect before attempting to install this accessory.
2. Remove the filter access panel from front side of the unit.
3. Remove the horizontal duct cover.
4. Remove the economizer duct block-off.

Internal Block-off Gasket Seals

The following are two types of economizers:

1. Standard economizer: Attach one gasket (9) to the base, aligned with the economizer return air damper (RAD) bracket. See Figure 12.

Figure 12: Attach gasket to base and block-off panel

Diagram shows gasket (9) attached to the base and aligned with the RAD bracket (4).

2. Low leak economizer: Align gasket with the return air damper flange. See Figure 13.

Figure 13: Align gasket with RAD flange

Diagram shows gasket alignment with the RAD flange.

Cut one piece of gasket (9) to a length of 4.3-inch and attach to (4) leaving a gap of 0.5-inch from face A. See Figure 12.

Comparative Enthalpy Install

1. Install humidity and temperature sensors as required. See Figure 14.

Figure 14: Install comparative enthalpy and bushing

Diagram shows the installation of humidity and temperature sensors (RAT Sensor, RAH Sensor) and bushings within the internal block-off panel.

2. Install bushing in internal block-off panel. See Figure 14.
3. Connect wires to humidity sensor and route wires through bushing. Wire tie leads to block-off to provide strain relief. (Wires to be routed with power exhaust leads back to the fresh air options module as described in later steps).

Block-off Assembly

1. Install internal base duct block-off using two screws.

Figure 15: Install base duct block-off panel

Diagram shows the internal base duct block-off being installed on the return duct opening.

Figure 16: Block-off assembly

Diagram shows internal block-offs (4, 5, and 7) being attached using screws.

Figure 17: Secure internal block-off assembly

Diagram shows the internal block-off assembly being secured to the side flanges of the return opening with screws.

Power Exhaust Assembly

1. Remove center screw at bottom of rear panel duct opening.
2. Attach gasket (11) to unit back panel. Start gasket below the return horizontal duct opening, centered on the opening and aligned with the flange at the base rail. Route gasket to cover holes and dimples along sides and top of the duct opening. Gasket should be one continuous piece overlapping 1-inch at bottom center.

Figure 18: Remove screw and attach gasket

Diagram illustrates removing a screw and attaching the gasket (11) to the unit back panel.

Figure 19: Install support and alignment bracket

Diagram shows the support and alignment bracket (12) being installed to the base rail below the return duct opening with screws.

Figure 20: Standard economizer wire routing

Diagram shows wire routing along the economizer support channel for a standard economizer.

Figure 21: Low leak economizer wire routing

Diagram shows wire routing along the bottom of the return air damper for a low leak economizer.

Figure 22: Attach power exhaust to side of unit

Diagram shows the power exhaust being attached to the side of the unit using screws.

4. Set power exhaust housing adjacent to return duct opening.
5. Uncoil wires and route through grommet in internal block-off. (Feed terminals through bushing one at a time).
6. Standard economizer: Insert wire tie into closest hole in the economizer support channel and secure the power and control wires. See Figure 20.
7. Low leak economizer: Route wiring along the bottom of the return air damper and secure the power and control wire. See Figure 21.
8. Attach power exhaust to side of unit using 10 screws.
9. Using 10 screws, attach horizontal return block-off to unit rear panel.

The following are two types of economizers:

10. Standard economizer: Continue to route two power and two control wires (with comparative enthalpy sensor wiring if present) along economizer support channel and secure with four pop-in wire ties. See Figure 24, p. 15.

Figure 24: Route wires along standard economizer support bracket

Diagram shows wires being routed along the standard economizer support bracket.

Figure 25: Route wires along economizer support bracket

Diagram shows wires being routed along the economizer support bracket for a low leak economizer, secured with pop-in wire ties.

Wiring Installation – FIAPWRX*03*

Hazardous Voltage with Capacitors! Failure to follow instructions below could result in death or serious injury. Disconnect all electric power, including remote disconnects and wait for DC capacitors to discharge before servicing. Refer to the manufacturer's recommendations for proper discharge time as DC bus capacitors retain hazardous voltages after input power has been disconnected. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. Verify with a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged before touching any internal components.

Use provided wire ties to secure and protect wires from sharp edges, rotating parts, and hot surfaces.

Power Wiring

1. See Figure 26, route the high voltage wiring (brown and orange wires) and connector PPF89 (purple connector) along the top of the return control box and down the right side and enter enclosure through bottom wire hole. Connect PPF89 to PPM89 (purple connector) on the fresh air options module and secure wires with pop-in wire ties.
2. Confirm that all wires are protected from damage by moving parts. Secure the wires with wire ties (provided).
3. After installation is complete, the Symbio™ 700 UC configuration will need to be updated to enable this installed feature.

Figure 26: Power connection to return control box - all units

Diagram shows the power connection routing to the return control box, illustrating the connection of PPF89 to PPM89.

Control Wiring

Units with Standard and Low Leak Economizer

Note: Refer to Figure 27, p. 17 for connections.

Connect power exhaust wire connector J6 to P6 on the fresh air options module in the return control box (brown connector).

1. Route controls wiring (black and red wires) and connector J6 along the top of the return control box and down the right side and enter enclosure through top hole for Precedent B/C/D cabinets or hole towards the back of the enclosure for Precedent A cabinet.
2. Connect wire connector J6 to P6 on the fresh air options module in the return control box (brown connector). Secure wiring with pop-in wire ties. See Figure 26.
3. After installation is complete, the Symbio™ 700 UC configuration will need to be updated to enable this installed feature.

Figure 27: Control wiring diagram

Diagram shows the control wiring connections for the Fresh Air Module, including terminals P6, J6, and connections to XFR and BK wires.

Power Exhaust Settings with Single Zone VAV and Multi-Speed Units

Set power exhaust setpoint with the fan at maximum speed. Maximum speed can be obtained in full cooling or any heating modes.

Weights and Dimensions

Table 3. Weights and dimensions

Diagram: Unit Dimensions

Diagram shows a rectangular unit with labels for Length (L), Width (W), and Height (H).