Trane Intellipak 2 Service Manual

							Unit Startup
RT-SVX24K-EN171
Final Unit Checkout
After completing all of the checkout and startup
procedures outlined in the previous sections (i.e.,
operating the unit in each of its Modes through all
available stages of cooling and heating), perform these
final checks before leaving the unit:
[ ] Close the disconnect switch or circuit protector
switch that provides the supply power to the unit
terminal block or the unit mounted disconnect switch.
HIGH VOLTAGE IS PRESENT AT TERMINAL BLOCK OR
UNIT DISCONNECT SWITCH. [ ] Turn the 115 volt control circuit switch “Off”.
[ ] Turn the 24 volt control circuit switch to the “On”
position.
[ ] At the Human Interface Module, press the “SETUP”
key. The LCD screen will display various preset
“parameters of operation” based on the unit type, size, and the installed options. Compare the factory preset
information to the specified application requirements.
If adjustments are required, follow the step-by-step instructions provided in the appropriate programming
manual for CV or VAV applications.
[ ] Program the Night Setback (NSB) panel (if
applicable) for proper unoccupied operation. Refer to
the programming instructions for the specific panel.
[ ] Verify that the Remote panel “System” selection
switch, “Fan” selection switch, and “Zone
Temperature” settings for constant volume systems are correct.
[ ] Verify that the Remote panel “System” selection
switch and the “Supply Air Temperature” settings for
variable air volume systems are correct.
[ ] Inspect the unit for misplaced tools, hardware, and
debris.
[ ] Turn the 115 volt control circuit switch “On”.
[ ] Press the “AUTO” key at the Human Interface
Module to begin system operation. The system will
start automatically once the dampers modulate and a
request for either heating or cooling has been given.
[ ] Verify that all exterior panels including the control
panel doors and condenser grilles are secured in place.
Multi-piece Unit—Trane Startup
Once the IntelliPak II multi-piece unit has been installed, all
shipped with items have been installed, all utilities and
drain pipes have been connected, the refrigeration piping
has been reconnected and refrigerant charge has been
adequately distributed throughout the system, and all
ductwork has been attached to the unit,Trane will provide
unit startup.
Trane startup of multi-piece units will review the overall unit for exterior damage (dents, bends, missing panels,
doors work properly), verify that the unit interior is free
from debris/obstructions, ensure that the panels and
doors are secured properly and verify that all wiring
connections are tight.
The overall installation will be reviewed to ensure the unit clearances are adequate to avoid air recirculation and all
unit drain lines and traps are properly installed.
The unit main power will be reviewed to ensure the unit is properly grounded, the main power feed wire gauge is
adequately sized, the correct voltage is supplied to unit
and electric heaters, and the incoming voltage is phase
balanced. Verification will be performed to ensure that all
field installed control wiring is applied to the correct
terminals, all automation and remote controls installed/
wired and control wiring for CV, SZVAV and VAV controls
is completed.
The refrigeration system will be reviewed to ensure the coil fins are straightened, the removal of shipping
hardware and plastic covers for compressors, proper oil
level in the compressors, crankcase heaters have been
operational for at least 12 hours time prior toTrane startup
being performed. The proper compressor voltage and
amperage, correct position of service valves prior to
Figure 120. 850-1100 MBH
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. 
						

							Unit Startup
172RT-SVX24K-EN
startup and proper system subcooling and superheat will
be verified.
The unit fans will be checked to ensure that the condenser fan blade set-screws to the motor shaft are tight, that the
hold down bolts and channels from fan sections have been
removed, proper adjustment of fan section spring
isolators, proper fan belts tension, adequate fan bearings
grease, alignment of fan sheaves, adequate tightness of
supply and exhaust fan pulley bolts, proper fan rotation,
and proper fan motor amperage.
A check will be made to ensure both piping to the condenser and air handler side of the system have been
completed and interconnecting refrigerant tubing has
been evacuated by the contractor prior to Trane
performing the startup. All damper linkages will be
checked for proper adjustment, and proper damper
operation and outside air pressure sensors verified.
Units equipped with electric heaters will be checked to
ensure that the heating system matches the unit
nameplate and for correct voltage supply to the heaters.
Units equipped with gas heaters will be checked to ensure
that the flue assembly is secure and properly installed,
sufficient gas pressure exists according to pipe size, no
leaks exist in gas supply line, the gas heat piping includes
a drip leg, condensate line and the combustion air CO2 and
O2 levels are normal. Units equipped with hot water heat will be checked to
ensure that the hot water pipes are properly routed, sized
and leak free; for the presence of swing joints or flexible
connectors next to the hot water coil; proper gate valve
installation in the supply and return branch line; proper
three way modulating valve installation, and proper coil
venting will be verified.
Units equipped with steam heat will be checked to ensure
that the hot water pipes are properly routed, sized and leak
free; proper swing check vacuum breaker installation;
proper 2-way modulating valve installation; proper steam
trap installation.
Units equipped with energy recovery wheels will be
checked to ensure proper rotation and operation of the
wheel. The service test guide will be used to check proper
component operation.
Finally, the program set points for proper unit operation
will be validated through human interface module. Once
the IntelliPak II multi-piece unit has been started, a
communication will be provided of startup activities and
the associated operating log. 
						

							Unit Startup
RT-SVX24K-EN173
Table 49. Trane startup checklist
Important: This checklist is not intended as a substitution for the contractor’s installation instruction.
This checklist is intended to be a guide for the Trane technician just prior to unit startup. Many of the recommended checks and actions could expose the technician to electrical and mechanical hazards. Refer to the appropriate sections
in the this manual for appropriate procedures, component specifications and safety instructions.
Job Name Serial #
Job Location Model #
Sales Order # Ship Date
Unit DL # (special units) Date
Starting Sales Office Technician
Important: Except where noted, it is implied that theTrane technician is to use this checklist for inspection/verification
of prior tasks completed by the general contractor at installation. Use the line item content to also record
the associated values onto the Trane unitary packaged equipment log.
Complete
1. Crankcase heaters working for 8 hours prior to arrival of Trane technician performing startup
2. Correct voltage supplied to unit and electric heaters
3. Unit exterior inspected
4. Disconnect all power, Unit interior free from debris/obstructions etc.
5. Open all access doors to verify all open and close fully without any binding
6. All wiring connections tight
7. Unit properly grounded
8. Copper power wiring meets sizing requirement
9. All field control wiring for CV, SZVAV or VAV controls completed
10. All automation and remote controls installed/wired
11. Unit clearances adequate for service and to avoid air recirculation etc.
12. All unit drain lines and traps proper
13. All coil fins inspected and straightened
14. Shipping hardware for compressors removed
15. Hold down bolts and channels from fan sections removed
16. Fan section spring isolators checked/adjusted
17. Damper linkages tight/adjusted
18. Rail connector splice brackets installed on low side base rail
Where applicable: Evaporative condenser
19. Verify incoming water pressure is between 35-60psig, dynamic pressure (measured with valve open) for min flow rate of 30 GPM
20. Verify fan shipping brackets between fans and mist eliminators above spray distribution system have been removed
21. Verify water treatment system has been installed and approved - discontinue start-up if proof of active water treatment does not exist
Continued on next page
22. Verify conductivity controller calibration has been documented
23. Verify conductivity controller min and max setpoints have been setup
24. Verify all water and drain connections are complete
25. Verify the sump fills to within 1 of the overflow
26. Verify drain valve is set to drain during power loss or hold during power loss per job specification
Where applicable: Electric Heat
27. Electric heat circuits have continuity
Where applicable: Gas Heat
28. Gas heat piping includes drip leg previously installed by controlling contractor
29. Gas heat flue assembly fully installed 
						

							Unit Startup
174RT-SVX24K-EN
30. Gas heat condensate line + heat tape installed where applicable
Where applicable: HW/Steam Heat
31. Modulating valve and actuator (HW and Steam) installed/wired
32. Steam heat swing check vacuum breakers installed per IOM direction
33. Steam heat condensate trap provided
34. O/A pressure sensor installed and piped
35. High side to low side piping to be completed prior to Trane technician arriving for startup
36. Space sensor and pneumatic tubing installed properly
Complete
37. Compressor discharge service valves, oil valves and liquid lines valves open/back seated (excludes Schrader valves)
38. Compressor oil levels (½ -¾ high in glass) proper
39. Verify power wires are connected in the high voltage power box
40. Verify field installed control wiring landed on correct terminals
41. All fan belts tensioned and bearings greased
42. Heat wheel rotates freely by hand
43. Reenergize power. Phase sequence (A-B-C) proper for compressor rotation
44. Incoming voltage balanced
45. All panels/doors secured prior to startup
Start unit
46. Service test guide used to operate unit components
47. Fan amperages within nameplate specs
48. Verify system airflow
49. Dampers open and close properly
50. Adjust outside air damper travel
51. On evaporative condenser models: Verify the sump fills to within 1.5” below the overflow, which is within the slot on the max float
bracket (see Figure 114, p. 164 )
52. Compressor operation normal and within amperage rating
53. Superheat (14-18°F) and subcooling (14-22°F) normal for air-cooled units
54. Electric, hot water and steam heating operation checked
55. Gas heating startup sequence of operation per IOM has been followed
56. Gas heat operation has been verified with combustion analyzer
57. Incoming gas pressure does not drop below 7 water column when burner is on high fire
58. Operating log completed
Table 49. Trane startup checklist (continued) 
						

							RT-SVX24K-EN175
Service and Maintenance
WARNING
Hazardous Voltage and Exposure to
Ultraviolet Radiation!
This product contains components that emit high- intensity ultraviolet (UV-C) radiation which can be
harmful to unprotected eyes and skin. To avoid injury,
disconnect all electrical power, including remote
disconnects, and make sure the UV lights are off 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 burns or electrocution which could result in
death or serious injury.
Trane does not recommend field installation of ultraviolet lights in its equipment for the intended
purpose of improving indoor air quality. High intensity
C-band ultraviolet light is known to severely damage
polymer (plastic) materials and poses a personal safety
risk to anyone exposed to the light without proper
personal protective equipment. Polymer materials
commonly found in HVAC equipment that could be
susceptible include insulation on electrical wiring, fan
belts, thermal insulation, various fasteners and
bushings. Degradation of these materials can result in
serious damage to the equipment.
Trane accepts no responsibility for the performance or operation of our equipment in which ultraviolet devices
were installed outside of the Trane factory or its
approved suppliers.
Table 50. Control Settings and Time Delays
Control Description Elec. DesignationContacts Open Contacts Closed
Combustion Airflow Switch   
(Gas Heat Only) 4S25see note 10.1 - 0.25 wc rise in press diff
Supply Airflow Switch   
(Gas Heat Only) 4S380.03 - 0.12 wc  0.15 + 0.05 wc rise in press diff
Freezestat   
(Hydronic Heat Only) 4S12(N.O.) Auto Reset 40 F
Gas Heat Units
Prepurge Timer: Honeywell 4U18internal timing function 2 Stage 850/1100 MBH 60—seconds/
All other configurations—30 seconds
Sequencing Time Delay Relay 4DL6N.C. - timed to close 60 seconds 
+ 20%
Notes: The combustion airflow switch (4S25) differential is 0.02 - 0.08 wc\
. 
						

							Service and Maintenance
176RT-SVX24K-EN
Table 51. Gas Heat—High Limit
UNIT
TONS 2500 MBH HIGH LIMIT 
CONTACTS CONTACTS
FAN SIZE  (IN) CONFIG. OPEN CLOSE
120-162 40 DF 195 155
40 HZ 240 200
32 DF & HORZ 220 180
 1800 MBH HIGH LIMIT 
 120-162
32 &40 DF 240 200
32 &40 HZ 220 180
90-118 32 DF & HZ 240 200
36 DF & HZ 240 200
36 HZ 240 310
25 DF 240 200
25 HZ 220 180
 1100 MBH HIGH LIMIT 
 120-162
32 DF 240 200
32 HZ 200 160
40 DF & HZ 240 200
90-118 32 DF 240 200
32 HZ 200 160
25 &36 DF & HZ 220 180
850 MBH HIGH LIMIT 
 90-118 25 &36 DF & HZ 240 200
Table 52. Electric Heat—Selection Limits
TonsIndoor Fan 
Option Electric Heat Option Supply 
Discharge Linear Limit - 
Open Temp. Fan Fail Limit - 
Open Temp.
120-162 Ton High (40) High (300 kW) Downflow 185F185F
Hz (right) 185F185F
Low (140 kW) Downflow 150F185F
Hz (right) 150F185F
Low (32) High (300 kW) Downflow 205F185F
Hz (right) 185F185F
Low (140 kW) Downflow 150F185F
Hz (right) 150F185F
105/118 Ton High (36) High (262.5 kW) Downflow 195F155F
Hz (right) 195F155F
Low (90 kW) Downflow150F175F
Hz (right) 150F175F
Low (32) High (262.5 kW) Downflow 225F185F
Hz (right) 205F185F
Low (90 kW) Downflow150F175F
Hz (right) 150F175F
90/105 Ton High (36) High (262.5 kW) Downflow 195F155F
Hz (right) 195F155F
Low (90 kW) Downflow150F175F 
						

							Service and Maintenance
RT-SVX24K-EN177
Hz (right)150F175F
Low (25) High (262.5 kW) Downflow 215F155F
Hz (right) 235F155F
Low (90 kW) Downflow150F175F
Hz (right) 150F175F
Table 52. Electric Heat—Selection Limits
Table 53. Compressor Circuit Breaker Electrical Characteristics
460V 575V380V
Unit Size Compressor 
Designator Compressor 
Size Must 
Hold Must 
Trip Must 
Hold Must 
Trip Must 
Hold Must 
Trip
90/105 1A, 2A CSHN250 41.5 47.7 33.2 38.2 41.4 47.6
1B, 2B CSHN250 41.5 47.7 33.2 38.2 41.4 47.6
105/118 1A, 2A CSHN250 41.5 47.7 33.2 38.2 41.4 47.6 1B, 2B CSHN315 54.4 62.6 43.6 50.1 54.3 62.4
120/128 1A, 2A CSHN315 57.7 66.4 46.3 53.2 57.3 66 1B, 2B CSHN315 54.4 62.6 43.6 50.1 54.3 62.4
130/140 1A, 2A CSHN315 57.7 66.4 46.3 53.2 57.3 66 1B, 2B CSHN374 63.4 72.9 50.0 57.5 63.3 72.8
150/162 1A, 2A CSHN374 66.7 76.7 52.7 60.6 66.4 76.3 1B, 2B CSHN374 63.4 72.9 50.0 57.5 63.3 72.8 
						

							Service and Maintenance
178RT-SVX24K-EN
Note:**See fuse replacement table on VFD panel for VFD
power fuses (F40, F41, F42).
Table 54. Unit Internal Fuse Replacement Data & VFD
Factory Settings 
						

							Service and Maintenance
RT-SVX24K-EN179
Table 55. Filter Data
Filters
Unit 
Model  (AC/ EC) Standard 2 High Eff 
Throwaways 90-95% Bag Filters 
with Prefilters 90-95% Cartridge Filters 
with Prefilters 90-95% Low Pressure Drop 
Cartridge Filters
Qty Size of 
Each Face 
Area 
(ft2) Pre-filters Bag Filters Prefilters Cartridge Filters Prefilters Low PD Filters
Qty Size Qty Size Face 
Area 
(ft2) Qty Size Qty Size Face 
Area 
(ft2) Qty Size Qty Size  Face 
Area 
(ft2)
90/100 21 20x24x2
8021 20x24x2 21 20x24x19
8021 20x24x2 21 20x24x12
8021 20x24x2 21 20x24x12
80
5 15x24x2 5 12x24x2 5 12x24x19 5 12x24x2 5 12x24x12 5 12x24x2 5 12x24x12
105/ 118 21 20x24x2
8021 20x24x2 21 20x24x19
8021 20x24x2 21 20x24x12
8021 20x24x2 21 20x24x12
80
5 15x24x2 5 12x24x2 5 12x24x19 5 12x24x2 5 12x24x125 12x24x2 5 12x24x12
120/ 128 28 20x24x2 93 21 20x24x2 21 20x24x19
8021 20x24x2 21 20x24x12
8021 20x24x2 21 20x24x12
80
5 12x24x2 5 12x24x19 5 12x24x2 5 12x24x125 12x24x2 5 12x24x12
130/ 140 28 20x24x2 93 21 20x24x2 21 20x24x19
8021 20x24x2 21 20x24x12
8021 20x24x2 21 20x24x12
80
5 12x24x2 5 12x24x19 5 12x24x2 5 12x24x125 12x24x2 5 12x24x12
150/ 162 28 20x24x2 93 21 20x24x2 21 20x24x19
8021 20x24x2 21 20x24x12
8021 20x24x2 21 20x24x12
80
5 12x24x2 5 12x24x19 5 12x24x2 5 12x24x125 12x24x2 5 12x24x12 
						

							Service and Maintenance
180RT-SVX24K-EN
Table 56. Final Filter Data
Final Filters
Unit Model  (AC/EC) 90-95% Low Pressure Drop Cartridge Filters 90-95% Bag Filters with Prefilters 90-95% Cartridge Filters with Prefilters
Pre-filters Low PD Cartridge Filters Prefilters Bag Filters Prefilters Cartridge Filters
Qty Size Qty Size Face Area (ft2) Qty Size Qty  Size Face Area (ft2) Qty Size Qty Size  Face Area (ft2)
90/100 15 24x24x4 15 24x24x12 74 15 24x24x2 15 24x24x19 74 15 24x24x2 15 24x24x12 74
7 12x24x4 7 12x24x12 7 12x24x2 7 12x24x19 7 12x24x2 7 12x24x12
105/118 15 24x24x4 15 24x24x12 74 15 24x24x2 15 24x24x19 74 15 24x24x2 15 24x24x12 74
7 12x24x4 7 12x24x12 7 12x24x2 7 12x24x19 7 12x24x2 7 12x24x12
120/128 15 24x24x4 15 24x24x12 74 15 24x24x2 15 24x24x19 74 15 24x24x2 15 24x24x12 74
7 12x24x4 7 12x24x12 7 12x24x2 7 12x24x19 7 12x24x2 7 12x24x12
130/140 15 24x24x4 15 24x24x12 74 15 24x24x2 15 24x24x19 74 15 24x24x2 15 24x24x12 74
7 12x24x4 7 12x24x12 7 12x24x2 7 12x24x19 7 12x24x2 7 12x24x12
150/162 15 24x24x4 15 24x24x12 74 15 24x24x2 15 24x24x19 74 15 24x24x2 15 24x24x12 74
7 12x24x4 7 12x24x12 7 12x24x2 7 12x24x19 7 12x24x2 7 12x24x12Unit Model  (AC/EC) 90-95% High Temp Cartridge Filters 
with Prefilters HEPA Filters with Prefilters High Temp HEPA Filters with Prefilters
Pre-filters High Temp Cartridge Filters Prefilters HEPA Filters Prefilters High HEPA Temp Filters
Qty Size Qty Size Face Area (ft
2) Qty Size Qty  Size Face Area (ft
2) Qty Size Qty Size  Face Area (ft
2)
90/100 15 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
74
7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12
105/118 15 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
74
7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12
120/128 15 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
74
7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12
130/140 15 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
74
7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12
150/162 15 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
7415 24x24x2 15 24x24x12
74
7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12 7 12x24x2 7 12x24x12