Trane 2/4TGB3F42A Assembly instructions

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service informa-
tion pack upon completion of work.
HAZARDOUS VOLTAGE - DISCONNECT POWER BEFORE SERVICING
WARNING:
Installer’s Guide
© 2008 Trane
A. GENERAL INFORMATION
▲WARNING
!
THIS INFORMATION IS FOR USE BY INDIVIDUALS
HAVING ADEQUATE BACKGROUNDS OF ELECTRICAL
AND MECHANICAL EXPERIENCE. ANY ATTEMPT TO
REPAIR A CENTRAL AIR CONDITIONING PROD-
UCT MAY RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE. THE MANUFACTURER OR
SELLER CANNOT BE RESPONSIBLE FOR THE IN-
TERPRETATION OF THIS INFORMATION, NOR CAN
IT ASSUME ANY LIABILITY IN CONNECTION WITH
ITS USE.
▲CAUTION
!
To prevent shortening its service life, the air
handler should not be used during the finishing
phases of construction. The low return air tem-
peratures can lead to the formation of conden-
sate. Condensate in the presence of chlorides and
fluorides from paint, varnish, stains, adhesives,
cleaning compounds, and cement creates a corro-
sive condition which may cause rapid deteriora-
tion of the cabinet and internal components.
These instructions do not cover all variations in sys-
tems or provide for every possible contingency. Should
further information be desired or particular problems
arise which are not covered sufficiently by this manu-
al, contact your local distributor or the manufacturer
as listed on the air handler nameplate.
These Air Handlers are vertical upflow and horizontal
left configuration only. Refer to Section B beginning on
page 2 for additional information.
INSPECTION
Check carefully for any shipping damage. This must be
reported to and claims made against the transporta-
tion company immediately. Check to be sure all major
components are in the unit. Any missing parts should
be reported to your supplier at once, and replaced with
authorized parts only.
3-1/2 – 4 Ton Air Handlers
Upflow / Horizontal Left
2/4TGB3F42A 2/4TGB3F48A
CONTENTS
General Information............................................... 1
Installation Limitations & Recommendations............................. 1
Unit Installation ...................................................... 2
Vertical Upflow .......................................................................... 2
Horizontal Left ........................................................................... 3
Refrigerant Piping .................................................. 3
Condensate Drain Piping ...................................... 4
Electrical - Wiring ................................................... 5
Hook Up Diagrams .................................................. 5
Outline Drawings .................................................... 7
Checkout Procedures ............................................. 8
INSTALLATION LIMITATIONS & RECOMMENDATIONS
The general location of the air handler is normally se-
lected by the architect, contractor and/or home owner
for the most effective application and satisfaction.
These air handlers are suitable for installation in a
closet, alcove or utility room with free, non-ducted, air
return, using the area space as a return air plenum.
With ducted supply air, if the minimum clearances to
combustible materials and service access are observed,
the above installations are suitable.
NOTE: Condensation may occur on the
surface of the air handler when installed in
an unconditioned location. When units are
installed in unconditioned spaces, verify
that all electrical and refrigerant line pen-
etrations on the air handler are sealed com-
pletely.
This area may also be used for other purposes, includ-
ing an electric hot water heater - but in no case shall
a fossil fuel device be installed and/or operated
in the same closet, alcove or utility room.
18-GD07D1-5

2 18-GD07D1-5
Installer’s Guide
applicable local codes may limit this air handler to
installation only in a single story residence & with-
in conditioned space.
10. If the outdoor unit is to be installed later, or by
others, then installation of the air handler must be
made to allow access for refrigerant lines, or attach
refrigerant lines to air handler when installing.
11. Make sure there are provisions for installing con-
densate drain lines.
12. Route refrigerant & condensate drain lines away
from air handler so they do not interfere with ac-
cess panels and filters.
13. When external accessories are used, the additional
height and width requirements must be considered
in the overall space needed.
14. These units are not approved for outdoor installa-
tion.
15. These units are approved for draw-through appli-
cation only.
B. UNIT INSTALLATION
UPFLOW
a. For maximum efficiency, the horizontal drip
tray should be removed. Tray removal requires
that the coil be removed by sliding the coil out
on the coil channel supports. The tray is de-
tached by removing the two screws at the drain
pan and the two screws holding the two brackets
at the top of the coil.
b. Openings where field wiring enters the
cabinet must be completely sealed. The Re-
frigerant lines must be sealed and Electrical in-
lets need to be sealed both the low and the high
voltage. Location of power entry is shown on the
Outline Drawing.
c. Remove the factory installed baffle assembly
from the apex of the coil by removing the 5/16"
hex head screws.
Replace this baffle with the factory supplied nar-
row coil baffle using the screws removed previ-
ously (See Figure 1).
In addition, these air handlers are suitable for instal-
lation in an attic, garage or crawl space with ducted
supply and return air.
This equipment (for models TGB3F42, 48A only) has
been evaluated in accordance with the Code of Federal
Regulations, Chapter XX, Part 3280 or the equivalent.
“SUITABLE FOR MOBILE HOME USE”
For proper installation the following items must be con-
sidered:
1. If adequate power is available and correct accord-
ing to nameplate specifications.
2. Pursuant to Florida Building Code 13-610.2.A.2.1,
this unit meets the criteria for a factory sealed air
handler.
3. Insulate all ducts, particularly if unit is located
outside of the conditioned space.
4. To ensure maximum efficiency and system
performance, the existing supply and return duct
system static pressures must not exceed the total
available static pressure of the air handler. Refer-
ence ACCA Manual D, Manual S and Manual RS
along with the air handler Product Data and Ser-
vice Facts for additional information.
5. It is recommended that the outline drawing
be studied and dimensions properly noted and
checked against selected installation site. By not-
ing in advance which knockouts are to be used,
proper clearance allowances can be made for in-
stallation and possible future service.
6. The Refrigerant lines must be sealed and Electri-
cal inlets need to be sealed at both the low and the
high voltage.
7. If supplementary heat is to be added, power supply
must be sufficient to carry the load. In addition,
minimum air flow settings, unit and duct clearanc-
es to combustible material must be maintained as
stated on the air handler rating nameplate.
▲
CAUTION
!
For air handlers not equipped with a factory in-
stalled electric heater, a field installed heater is
available from the manufacturer. Only manufac-
turer-built heaters are approved for use in the air
handler. These heaters have been designed and
tested in accordance with UL standards to provide
safe and reliable operation. A list of approved heat-
ers is provided on the air handler rating name-
plate. Heaters that are not factory approved could
cause damage and are not covered under equip-
ment warranty.
8. If field installed electric heaters are applied, mini-
mum air flow settings, unit and duct clearances to
combustibles must be maintained as stated on the
air handler rating nameplate.
9. If the unit is installed without a return air duct,
For Maximum Efficiency on
Upflow
Remove
and
Discard
Replace
with
Narrow
Baffle
Figure 1

18-GD07D1-5 3
Installer’s Guide
d. Position unit on Pedestal or other suitable foun-
dation. If Pedestal is not used, a frame strong
enough to support the total weight must be pro-
vided. Provide a minimum height of 14 inches
for proper unrestricted airflow.
e. If a return air duct is connected to the air han-
dler, it must be the same dimensions as shown
in the outline drawing.
f. Pedestal and unit should be isolated from the
foundation using a suitable isolating material.
HORIZONTAL LEFT
a. For maximum efficiency and Customer
ease of filter maintenance, it is recommended
that a properly sized remote filter and grille
be installed for horizontal applications. Airflow
should not exceed the face velocity of the fil-
ter being used. The factory installed filter
should then be removed from the unit.
b. The unit is shipped from the factory in the hori-
zontal left airflow position.
c. Openings where field wiring enters the
cabinet must be completely sealed . The Re-
frigerant lines must be sealed and Electrical in-
lets need to be sealed both the low and the high
voltage.Location of power entry is shown on the
Outline Drawing.
d. The unit may be suspended as long as the unit
is supported from both ends as well as the mid-
dle to prevent sagging and service access is not
obstructed.
e. If the unit is not suspended it must be isolated
carefully to prevent sound transmission. Vibra-
tion isolators (purchased locally) must be placed
under the unit.
f. It is always recommended that an auxiliary
drain pan be installed under a horizontal air
handler (See Condensate Drain Piping) to pre-
vent possible damage to ceilings.
g. Isolate the auxiliary drain pan from the unit or
from the structure.
h. Connect the auxiliary drain line to a separate
drain line (no trap is needed in this line) and
terminate according to local codes.
i. If a return duct is connected to the Air Handler,
it must be the same dimensions as the return
opening shown in the outline drawings.
C. DUCT CONNECTIONS
The supply and return air ducts should be connected
to the unit with flame retardant duct connectors.
Convertible duct flanges are provided to make a “flush
fit” for ¾” or 1-1/2” ductboard applications. Three are
located in the accessory kit shipped with the unit and
one is installed on the discharge opening. If the duct
flanges are not needed, the installed flange must be
removed. See the Outline drawing for sizes of the dis-
charge opening. After ductwork is secured, seal the
ductwork per local and national codes to prevent air
loss/infiltration.
D. REFRIGERANT PIPING
IMPORTANT:
Refrigerant piping must be routed to maintain service ac-
cess to blower compartment and provide easy removal of
filter access panel and filter.
1. Refrigerant connections are made outside the cabinet.
NOTE:
TXV bulb MUST be protected (wrap a wet rag around
the suction line between the TXV bulb and the braze
joint) or removed, while brazing the tubing. Overheat-
ing of the sensing bulb will affect the functional char-
acteristics and performance of the air handler.
2. If changing the Thermostatic valve (TEV/TXV), be
sure to use a wrench and backup wrench to tight-
en the mechanical fittings 1/6 turn past finger
tight upon installation.
3. Installation of refrigerant lines is covered in the in-
stallation instructions packaged with the outdoor
unit. Evacuation, leak testing and brazing pro-
cedures are included in those instructions. Read
those instructions before starting installation of
refrigerant lines.
NOTE:
TXV Equipped is Non-Bleed, and may require a start kit
on the outdoor unit.
NOTE:
Refrigerant line openings must be sealed along with
field wiring.
E. BRAZING TO EVAPORATOR SECTION
IMPORTANT:
Do NOT unseal refrigerant tubing until ready to cut and
fit refrigerant lines.
1. Remove the sealing caps from indoor coil field con-
nections.
2. Field supplied tubing should be cut squared-off,
ensuring the tube is still round and free of burrs
at the connecting end. Clean the tubing to prevent
contaminants from entering the system.
3. Run refrigerant tubing into the stub sockets of in-
door unit coil. Refrigerant line openings must
be completely sealed.
4. Braze and evacuate according to indoor and out-
door installation instructions.
NOTE:
Painted areas of unit must be shielded during brazing.

4 18-GD07D1-5
Installer’s Guide
F. CONDENSATE DRAIN PIPING
NOTE:
Make certain that the unit has been installed in a level
position to ensure proper draining.
The indoor blower is downstream of the evaporator coil
which creates a negative pressure at the condensate
drain connections during operation. The condensate
drain connections in front of the indoor coil are 3/4"
NPT. The lower connection is the primary drain. See
Figure 3.
Two secondary drain connections are provided for the
different orientations (See Figure 3). The lower of the
two should be connected as a backup to prevent con-
densate overflow by a blocked primary drain. The weep
hole in center of drain coupling area should be sealed
with caulk or RTV.
For proper drainage of condensate, the following steps
should be followed:
1. The primary drain line must be trapped with a
minimum of 2" water seal as shown in Figure 4 &
Figure 5.
2.Do not use preformed 3/4" PVC running
traps.
The use of Field fabricated or manufactured traps
as shown in Figures 4 & 5 is acceptable. The man-
ufactured trap shown in Figure 4 allows for a float
switch option to be added. Refer to the manufac-
turers data and instructions for details.
3. The trap must be located within 4 feet of the
air handler drain outlet connection.
4. It is recommended that a clean-out tee or cross be
installed in the primary drain line for future main-
tenance (See Figure 4 & 5).
5. Do not use reducing fittings in the condensate
drain lines.
6. Slope the drain lines downward a minimum of 1/4"
per foot.
7. Insulate the primary drain to prevent sweating.
Field fabricated trap
2" MIN.
2" MIN.
CAP OR PLUG
Trap must be within 4'
of air handler condensate
drain connection.
Close as possible
Figure 5
2" MINIMUM
2" MINIMUM
Manufactured traps
EZT-105 Figure 4
8. Provide means for drainage to prevent win-
ter freeze-up of condensate line.
9. Do not connect the drain line to a closed drain sys-
tem.
10. Use Teflon®tape on the air handler drain line con-
nections! Do Not Use pipe joint compound or PVC/
CPVC cement!
It is always recommended that an auxiliary drain pan
be installed under a horizontally installed air handler.
Connect the auxiliary drain line to a separate drain
line (no trap is needed in this line) and terminate ac-
cording to local codes.
NOTE:
DO NOT use a torch or flame near the plastic drain pan
coupling.
NOTE:
DO NOT tighten the drain pipe excessively. Support the
condensate piping and traps outside the unit to pre-
vent strain on the drain coupling.
▲WARNING
!
TO PREVENT INJURY OR DEATH DUE TO ELECTRICAL
SHOCK OR CONTACT WITH MOVING PARTS, LOCK
UNIT DISCONNECT SWITCH IN OPEN POSITION
BEFORE SERVICING UNIT.
Figure 3
3/4" NPT
Primary
drain
connection
3/4" NPT
Secondary
drain con-
nection
Seal weep
hole
Convertible duct flanges are provided to make a “flush fit” for ¾” or 1-1/2” ductboard applications. 3 are located in the accessory kit shipped
with the unit and 1 is installed on the discharge opening. If the duct flanges are not needed, the installed flange must be removed. See the Outline
drawing for sizes of the discharge opening. After ductwork is secured, seal the ductwork per local and national codes to prevent air loss/infiltra-
tion.

18-GD07D1-5 5
Installer’s Guide
G. ELECTRICAL — POWER WIRING
1. These Air Handlers are shipped from the factory
wired for 230 volts. The units may be wired for 208
volts. Follow instructions on unit wiring diagram
located on blower housing and in the Service Facts
document included with the unit.
2. The selection of wire and fuse sizes should be made
according to the Minimum Branch Circuit Ampac-
ity and the Maximum Overcurrent Device listed on
the unit nameplate.
3. Field wiring diagrams for electric heaters and unit
accessories are shipped with the accessory.
4. Wiring must conform to National and Local codes.
Ground unit per Local codes with good safety pro-
cedures.
If an electric heater is not installed, the Knockout Plate
provided in the Accessory Kit MUST be installed on the air
handler and the conduit terminated to it. The electrical
connections are made using the two power leads and ground
wire connections which are located near the discharge of the
blower.
2/4TGB AIR HANDLERS WITH SINGLE STAGE COOLING, 1 STAGE HEAT
NOTE:
If air handler is used with or without a heater, the
7/8" electrical entry hole as well as any other cabi-
net penetrations must be sealed air tight.
H. CONTROL WIRING
1. Connect wiring between indoor unit, outdoor unit
and thermostat. The use of color-coded low-voltage
wires is recommended.
2. Field wiring diagrams are provided which show the
low voltage wiring hookup for a single speed cool-
ing only system (with supplementary heaters) and
a heat pump system (with supplementary heaters).
Plug in type electrical connectors are provided for
use with supplementary heaters.
IMPORTANT:
When supplementary heaters are installed, inspect to in-
sure that all packaging material has been removed.
NOTE:
Direct drive motors have bearings which are per-
manently lubricated and under normal use lubri-
cation is not recommended.
Convertible duct flanges are provided to make a “flush fit” for ¾” or 1-1/2” ductboard applications. 3 are located in the accessory kit shipped
with the unit and 1 is installed on the discharge opening. If the duct flanges are not needed, the installed flange must be removed. See the Outline
drawing for sizes of the discharge opening. After ductwork is secured, seal the ductwork per local and national codes to prevent air loss/infiltra-
tion.

6 18-GD07D1-5
Installer’s Guide
2/4TGB AIR HANDLERS WITH SINGLE STAGE COOLING AND TWO STAGE HEATING
2/4TGB AIR HANDLERS WITH SINGLE SPEED HEAT PUMP
From Dwg. B801081 Rev. 2

18-GD07D1-5 7
Installer’s Guide
OUTLINE DRAWING FOR 2/4TGB3F42,48A
From Drawing D810126P01 Rev 2

1/09
The manufacturer has a policy of continuous product and product data improvement, and it reserves the right
to change design and specifications without notice.
6200 Troup Highway
Tyler, Texas 75707
For more information contact
your local dealer (distributor)
CHECKOUT PROCEDURES
After installation has been completed, it is recommended that the Air Handler be checked against the following
checklist.
1.Make sure power is “OFF” at power disconnect
switch...............................................................................
.................................................................................... [ ]
2.Check all field wiring for tight connections. See that
grounding of unit is in accord with code .................. [ ]
3.Make sure unit suspension (if used) is secure
and that there are no tools or loose debris in,
around or on top of the unit...................................... [ ]
4.Check all duct outlets; they must be open
and unrestricted........................................................ [ ]
5.Check drain lines and be sure all joints are tight [ ]
6.Make sure secondary drain pan is installed......... [ ]
7.Check power supply for correct requirements
per unit nameplate.................................................... [ ]
8.Check filters for proper size. Inform owner of
proper procedure for removal and reinstallation .... [ ]
9.Energize the system and carefully observe its opera-
tion; make any necessary adjustment...................... [ ]
10.Instruct owner, engineer (if possible) on proper
operating procedure and leave Use and Care
Manual with owner................................................... [ ]
SUPPLEMENTARY HEATERS CHECKOUT PROCEDURES
IF a heater is USED, see "limitations and recommendations"
to determine if the heater requires a SPECIAL CIRCUIT.
1. Be sure the disconnect switch is “OFF”, and safety label (if any) is attached ............................ [ ]
2. Check on field wiring for tight connections and grounding according to codes .......................... [ ]
3. Check circuit protection for proper size per nameplate specifications ........................................ [ ]
4. Check control box panel — in place and secured.......................................................................... [ ]
NOTE:
OPERATION OF HEATERS MUST BE CHECKED DURING THE OPERATIONAL CHECK OF THE TOTAL SYSTEM.
I. CHECKOUT PROCEDURE
1. Check the Air Handler installation in accordance with this instruction.
2. “Operational Procedure” for the system installation can be found in the outdoor unit installer guide and will be
compatible with this Air Handler.