Installation Operation Maintenance Ductable water unit FWD 08-12 - 20-30 - 45
General Information Foreword These installation, operation and maintenance instructions are given as a guide to good practice in the installation, putting into service, operation and periodic maintenance by the user of FWD units. They do not contain full service procedures necessary for the continued successful operation of this equipment. The services of a qualified service technician should be employed through the medium of a maintenance contract with a reputable service company. Warranty Warranty is based on the general terms and conditions of the constructor. The warranty is void if the equipment is modified or repaired without the written approval of the constructor, if the operating limits are exceeded, or if the control system or the electrical wiring is modified. Damage due to misuse, lack of maintenance, or failure to comply with the manufacturer's instructions, is not covered by the warranty obligation. If the user does not conform to the rules of chapter "Maintenance", it may entail cancellation of warranty and liabilities by the constructor. Reception When the unit arrives on site, check it has not been damaged in any way during transport. If damage is observed, or even merely suspected, notify the carrier within 24 hours by registered letter. Notify the local Trane Sales office at the same time. The unit should be totally inspected within 3 days of delivery. If damage is observed, notify the last carrier by registered letter and notify the local sales office. Warnings and cautions Warnings and Cautions appear at appropriate places in this instruction manual. Your personal safety and the proper operation of this machine require that you follow them carefully. Trane assumes no liability for installations or servicing performed by unqualified personnel. 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, may result in minor or moderate injury. It may also be used to alert against unsafe practices or for equipment or property-damageonly accidents. 2013 Trane 2
General Information Safety recommendations To avoid accidents and damage, the following recommendations should be observed during maintenance and service visits: 1. The maximum allowable pressures for system leak testing on low and high pressure side are given in the chapter Installation. Always provide a pressure regulator. 2. Disconnect the main supply before any servicing on the unit. 3. Service work on the refrigeration system and the electrical system should be carried out only by qualified and experienced personnel. Maintenance contract It is strongly recommended that you sign a maintenance contract with your local Service Agency. This contract provides regular maintenance of your installation by a specialist in our equipment. Regular maintenance ensures that any malfunction is detected and corrected in good time and minimizes the possibility that serious damage will occur. Finally, regular maintenance ensures the maximum operating life of your equipment. We would remind you that failure to respect these installation and maintenance instructions may result in immediate cancellation of the warranty. Training The equipment described in this manual is the result of many years of research and continuous development. To assist you in obtaining the best use of it and maintaining it in perfect operating condition over a long period of time, the manufacturer has at your disposal a refrigeration and air conditioning service school. The principal aim of this is to give operators and technicians a better knowledge of the equipment they are using, or that is under their charge. Emphasis is particularly given to the importance of periodic checks on the unit operating parameters as well as on preventive maintenance, which reduces the cost of owning the unit by avoiding serious and costly breakdown. 3
Contents General Information 2 Foreword 2 Warranty 2 Reception 2 Warnings and cautions 2 Safety recommendations 3 Maintenance contract 3 Training 3 Installation 5 Introduction 5 Technical data 6 Ceiling installation 7 Installation on the ground 7 Condensate drainage 8 Electrical connections 8 Main power supply 9 Duct connections 10 Diagrams 9 Operation / Maintenance 16 Choice of fan speed 16 Initial checks 16 Maintenance recommendations 16 Maintenance 17 Removal of the fan motor 17 Troubleshooting 18 4
Installation Introduction Caution. Read this manual carefully before starting to install the system. Components supplied with the unit - 2 corner brackets to suspend the unit from the ceiling Electrical connections - The electrical wiring and connections must comply with local electricity legislation. - Check the electrical characteristics on the name plate correspond to the grid s characteristics. Figure 1 : Description Warning. Never open the electrical panel without first disconnecting the power supply. There is a risk of electrocution! Handling the unit Warning! Wear protection gloves when handling the unit. When removing the unit from its pallet, do not handle it by pipes, spigots, valves, drain pan or control panel. Take precaution to not damage the unit. Description of the unit The FWD unit is a slim discharge cabinet unit for installation in false ceilings, lofts and ventilation spaces. It is designed for horizontal installation with discharge via a duct (see selection catalogue for the available static pressure). The unit s structure consists of unpainted completely insulated galvanised steel panels. ➀ ➁ ➂ ➀ Hot water coil ➁ Fan unit ➂ Control / power cabinet ➃Water inlet and outlet screw-in connections ➃ 5
Installation TECHNICAL DATA FWD 08 12 20 30 45 Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kw) 5,2 8,3 15 18,8 30,1 Heating capacity on water (2) (kw) 6,3 11,9 18,9 20,9 38,2 Fan motor (type) 2 x direct drive centrifugal Fan power input (3) (kw) 0,23 0,46 0,65 1,04 1,51 Current amps(3) (A) 1,1 2,2 3,1 4,7 5,5 Start-up amps (A) 3,2 5,5 9,3 14,1 16,5 Rated Input Power (W) 246 516 707 1100 1815 Airflow minimum (m3/h) 490 980 1400 1800 2700 nominal (m3/h) 820 1650 2300 3000 4500 maximum (m3/h) 980 1970 2600 3600 5400 Main coil Water entering/leaving connections (type) ISO R7 rotating female (Dia) 3/4" 3/4" 1"1/2 1"1/2 1"1/2 Hot water coil (accessory for blower only) Heating capacity (4) (kw) 6,3 12 17,4 22,4 34,5 G2 filter (filter box accessory) Quantity 2 2 2 2 2 Dimensions ( LxWxth) (mm) 386x221x8 486x271x8 586x321x8 586x421x8 586x621x8 G4 filter (filter box accessory) Quantity - 2 2 2 2 2 Dimensions ( LxWxth) (mm) - 486x264x48 586x314x48 586x414x48 586x614x48 Condensate pump (accessory) (type) Centrifugal Water flow - lift height (l/h - mm) 24-500 Not available for FWD30 and FWD45 Sound level (L/M/H speed) Sound pressure level (5) (db(a)) 36/40/43 38/41/44 46/50/53 47/52/57 47/52/58 Sound power level (5) (db(a)) 46/50/53 48/51/54 56/60/63 57/62/67 57/62/68 Unit dimensions Width x Depth (mm) 890 x 600 1090 x 710 1290 x 820 1290 x 970 1290 x 1090 Height (mm) 250 300 350 450 650 Shipped unit dimensions Width x Depth (mm) 933 x 644 1133 x 754 1333 x 864 1333 x 1008 1333 x 1133 Height (mm) 260 310 360 460 660 Weight (kg) 32 46 61 76 118 Colour galvanised steel Recommended fuse size Unit alone (am/gi) (A) 8/16 8/16 8/16 8/25 8/25 (1) Conditions: Water entering/leaving temperature: 7/12 C, Air inlet temperature 27/19 C DB/WB - Nominal air flow (2) Conditions: Water entering/leaving temperature: 50/45 C,,Air inlet temperature 20 C DB - Nominal air flow (3) At high speed with nominal air flow. (4) Water entering/leaving temperature 90/70 C, air inlet temperature 20 C DB, Nominal air flow. (5) A rectangular glass wool duct 1m50 long is placed on the blower.the measurement is taken in the room containing the blower unit. Heat exchanger operating limits: FWD : - Water temperature: max 100 C - Absolute service pressure: min 1 bar / max 11 bars Accessories - Hot water coil: - Water temperature: min. +2 C / max. 100 C - Absolute service pressure: min 1 bar / max 11 bars 6
Installation Ceiling installation Preparation of the ceiling and installation of the unit A template for drilling into the ceiling to fix the threaded rods is printed on the cover of the unit s packaging. The angle brackets can also be used to determine the drilling hole distances. Access must be provided on the water connection end to facilitate installation, maintenance and access to the cabinet. Four 8 mm diam. threaded rods must be securely fixed into the building s slab or structure. Screw a nut A (Figure 2) sufficiently high onto each threaded rod. Put the angle brackets B in place by holding them using a second nut C. Make sure the angle brackets are level in both directions using the bottom nuts C. Once they are perfectly level insert the FWD unit and let the angle brackets support it. Use the top nuts A to tighten the unit against the corner brackets. It is possible to avoid using the 2 angle brackets B supplied with the unit and mount it using just the threaded rods D and the 2 shaped bars E. In both cases isolators can be installed between the nuts C and the angle brackets B or shaped bars E, to reduce transmission of vibrations to the building s structure. Warning. Since the condensate tray is sloped to facilitate flow of condensates, the unit must be positioned absolutely level in both directions. Installation on the ground The unit can be installed on the ground, but make sure the condensate can be drained properly. Ensure it is installed on vibration isolators and that it is level in both directions. Figure 2 : Angle brackets B A Hydraulic connections It is easy to remove the electric cabinet to facilitate access to the hydraulic connections. Operating limits of pressure must not exceed 1.5MPa. Installation procedure - Define the layout of the lines so that they are as short as possible. - Limit pressure losses in the lines caused by pinching, too many bends and bending radii that are too small. - Connection of water inlet and outlet lines: The coil is connected by means of 3/4 female ISO R7 connectors. Warning. Limit the tightening torque applied to the connector nuts to prevent deformation of the piping and seals (risk of leaks). ➀ ➀ Figure 3 : Recommended clearances 7
Installation Condensate drainage The unit must be perfectly horizontal in both directions. Connect the condensate tray outlet (outer diam. 20 mm). To ensure satisfactory condensate drainage, the drainage tube must be sloped 10. There must not be a condensate trap anywhere on the line. However a siphon can be provided to prevent outside air being drawn in by the indoor unit. If the pipe passes through a room, insulate it to prevent damage caused by condensation. We recommend polyethylene foam (6 mm thick). Condensate pump (accessory) If it is not possible to drain the condensates by gravity, a condensate pump can be installed as an accessory. Figure 4 : Connection of the condensate drain It can lift the condensates a maximum of 500 mm. For installation and connection of the condensate pump, refer to the submittals supplied with this accessory. Electrical connections If access to the electric cabinet is problematic, it can be moved a maximum distance of 500 mm. All wiring and earthing must comply with local standards. Caution a) Check the electrical characteristics on the unit s name plate. Make sure the wiring corresponds to the manufacturer s electrical diagram and local standards. b) Power up the units using one or more lines protected by a disconnect switch and fuses. c) Earth each unit. d) The wires must not touch the refrigerant lines, the motors or other moving parts. e) The manufacturer does not assume any liability for problems caused by modifications to the unit s internal wiring. f) Tighten the terminals securely. Figure 5 : Moving the electric cabinet 8
Installation Main power supply It is the installer's responsibility to ensure that units are protected by an electrical disconnect device such as a fuse or circuit breaker. Standard units are supplied without any protection. The recommended fuse size is given in the Technical data table. For electrical connections of options or accessories, refer to following diagrams which are supplied with corresponding option/accessory: Motorized water valve for FWD sizes 08-20: 44053756 Valve (Hot water coil): 44053759 Automatic change over kit: 23090607 Lift pump control kit: 44053753 Motor connections for FWD sizes 8-20: 23078700 Motor connections for FWD sizes 30-45: 23090686 Interconnections diagram: 23090605 Motorized water valve for FWD sizes 30-45: 44054611 All electrical connections must be made on the terminal blocks of the main electrical control box. WARNING! Disconnect the power supply before making electrical connections. Failure to do so may cause serious injuries as well as irreversible damage to certain electrical components. WARNING! Use copper conductors only. Unit terminals are not designed to accept other types of wiring. Aluminium or other materials could lead to galvanic corrosion or overheating at the contact point thus damaging the unit. The customer's electrical connections must comply with current standards. FWD units manufactured by Trane comply with CEI regulations. All power supply wiring must be sized and selected in accordance with local code and regulation. Fast-acting circuit breaker, which is sensitive to very low levels of current leakage to ground (max 30mA) must be installed as a general line protection. Only copper conductors (Min. 1.5mm 2 - Max 4.0mm 2 ) must be used as unit terminals are not designed to accept other types of wiring. 9
Installation Duct connections FWD units can be fitted directly with rectangular discharge and intake ducts. DIMENSIONS OF DUCT CONNECTIONS (INTAKE AND DISCHARGE) Sizes 08 12 20 30 45 Length 748 948 1148 1148 1148 Width 198 248 298 598 598 Warning.The pressure loss caused by the duct network and accessories must not exceed the unit s available static pressure (see selection chart). The air intake can be located at the back of the unit ➀ or underneath it ➁. Filtering: vital to ensure the unit runs smoothly. No filters are supplied with the unit, but they can be ordered as accessories: - Filter box with EU2 filters to fix to the unit s intake. (behind or underneath). Figure 6 : Connection of ducts ➀ ➁ 10
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Operation / Maintenance Choice of fan speed The FWD unit is delivered from the factory unwired. Please refer to the selection chart to select the static pressure according to the flowrate. Once the fan rotation speed has been determined, wire up the fan motor to the required speed using the supplied electrical diagrams. For use of temperature control, refer to the guide supplied with the thermostat. Initial checks - Check the electrical connections and water pipes are fixed securely. - Rotate the fan blades by hand to make sure it rotates freely. - Check that all nuts and bolts are tightened correctly. - Make sure the chilled water piping and the condensate drainage tube are properly insulated to avoid problems with condensation water flow. Maintenance recommendations (regular use) Failure to follow these instructions may cause damage to the unit. The frequency of maintenance will depend on the conditions of use of the unit and will be determined by regular inspections. When servicing the units, make sure also that the air passage through the coils (both internal and external) is clean, and free of dirt or debris. a) Clean the air filter by beating it and drawing air through it in the opposite direction to the passage of air. b) Check the condensate tubes are not obstructed. c) Rotate the fan blades and make sure they are not damaged. Clean them if necessary and check they are correctly aligned. d) Motor - check the wiring, and make sure the switches operate correctly. Replace any damaged components. e) Safety disconnection and electrical components - check they operate correctly. f) Water circuit - check there are no leaks. g) Tighten all the nuts and bolts. 16
Maintenance Figure 7 : Removal of the fan motor ➂ ➄ ➅ ➇ ➄ ➀ ➂ ➆ ➀ ➁ ➇ ➈ ➉ ➈ ➀ ➁ Unscrew the 4 screws fixing the panel and remove the panel. ➂➃ Unscrew the 4 screws fixing the intake support bracket and remove it. ➄ Unscrew the 4 screws fixing the base of the electrical cabinet by one turn. N.B.. The motor cables must be disconnected in the electrical cabinet. ➅ Push the cabinet upwards and move it enough to access the screws fixing the fan motor. ➆ Loosen the 4 screws fixing the condensate tray by a few turns. ➇ Unscrew the 2 x 2 screws (08) or 2 x 3 screws (12-20-30-45) fixing the fan motor while holding it up. ➈ ➉ Take out the fan motor assembly, by pushing outwards on the bottom of the 2 side panels, taking care not to damage the insulation material. 17
Maintenance Troubleshooting Symptom The unit is not powered up. The unit does not operate The fan motors do not operate. Room temperature too high Room temperature too low No airflow Possible cause A)The electric cabinet is not connected. B) The control circuit is not powered up. A) The thermostat is not controlling the unit. A) The electric motors are not powered up. B)The thermal protection of the motors has been cut. A) The unit is not operating. B) The thermostat settings are incorrect. C) Insufficient air flow D) Insufficient chilled water flow E) Chilled water temperature too high. F) The thermostat is not operating correctly. G) Heat load is greater than expected. A) Clogged filters. B) The fans are rotating the wrong way C) The air flow is obstructed. Solution Check the unit s general disconnect switch is closed. Check the control circuit s fuse. Check the thermostat is plugged in (also refer to the thermostat s instruction manual). Check the fan motors are powered up and the fan circuit-breakers are reset. Check the motor winding resistance after resetting. Check the power supply voltage and the input current. See The unit is not operating. Check the set point. See No air flow Checked the chilled water flow. Check the gate valves and the water circuit. Check the unit s chilled water production. Refer to the thermostat s instruction manual. Check the zone s heat load (too much fresh air). Check the extent of infiltration of outside air. Clean or replace the recycling filters. Check and correct 18
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