Trane Voyager PKGP-PRC001-EN User manual

Packaged Heat Pumps
Voyager™
12½ to 20Tons — 60 Hz
PKGP-PRC001-EN
September 2004

PKGP-PRC001-EN© 2004 American Standard Inc. All rights reserved
Introduction
Packaged Rooftop
Air Conditioners
Through the years,Trane has designed
and developed the most complete line of
Packaged Rooftop products available in
the market today.Trane was the first to
introduce the Micro—microelectronic
unit controls—and has continued to
improve and revolutionalize this design
concept.
The ReliaTel control platform offers the
same great features and functionality as
the original Micro, with additional
benefits for greater application flexibility.
Voyager continues to provide the highest
standards in quality and reliability,
comfort, ease of service, and the
performance of Trane light commercial
products.
Trane customers demand products that
provide exceptional reliability, meet
stringent performance requirements, and
are competitively priced. Trane delivers
with Voyager.
Voyager features cutting edge
technologies: reliable compressors,Trane
engineered ReliaTel controls, computer-
aided run testing, and Integrated
Comfort™ Systems. So, whether you’re
the contractor, the engineer, or the owner
you can be certain Voyager Products are
built to meet your needs.
It’s HardTo Stop ATrane.®

3
PKGP-PRC001-EN
Introduction
Features and Benefits
Application Considerations
Selection Procedure
Model Number Description
General Data
Performance Data
Cooling Performance
Fan Performance
Heating Performance
Controls
Electric Power
Dimension and Weights
Mechanical Specifications
2
4
9
10
11
12
14
17
14
22
26
27
38
48
Contents

4PKGP-PRC001-EN
Features and
Benefits
Factory Installed Options
• Black Epoxy Pre-Coated Coils
• High Efficiency Motors
• High Pressure Cutout
• Hinged Access Doors
• Powered or Unpowered Convenience
Outlet
• Supply and/or Return Air Smoke
Detector
• Through the Base Electrical with Circuit
Breaker
• Through the Base Electrical With
Disconnect Switch
• Through the Base Utilities Access
• Two-Inch Pleated Filters
Factory or Field Installed Options
•Clogged Filter/Fan Failure Switch
•Differential Pressure Switches
•Discharge Air Sensing Kit
•Downflow – Economizer
•Electric Heaters
•Frostat
•LonTalk® Communications Interface
•Oversized Motors
•Reference or Comparative Enthalpy
•Tool-less Hail Guards
•Trane Communications Interface (TCI)
Field Installed Options
•CO2Sensing
•Digital Display Zone Sensor
•DualThermistor Remote Zone Sensor
•High Static Drive
•Manual Outside Air Damper
•Motorized Outside Air Dampers
•Powered Exhaust
•Downflow – Roof Curb
•Horizontal – Economizer
•Remote Potentiometer
•Ventilation Override Accessory
•Zone Sensors

PKGP-PRC001-EN 5
Features and
Benefits
Easy to Install, Service and
Maintain
Because today’s owners are very cost-
conscious when it comes to service and
maintenance, theTrane Voyager was
designed with direct input from service
contractors.This valuable information
helped to design a product that would get
the serviceman off the job quicker and
save the owner money. Voyager does
this by offering:
Quality and Reliability
ReliaTel™ Controls (LCI-R)
ReliaTel controls provide unit control for
heating, cooling and ventilating utilizing
input from sensors that measure outdoor
and indoor temperature.
Quality and Reliability are enhanced
through ReliaTel control and logic:
—prevents the unit from short cycling,
considerably improving
compressor life.
—ensures that the compressor will run
for a specific amount of time which
allows oil to return for better
lubrication, enhancing the reliability of
the compressor.
Voyager with ReliaTel reduces the
number of components required to
operate the unit, thereby reducing
possibilities for component failure.
ReliaTel Makes Installing and
Servicing Easy
ReliaTel eliminates the need for field
installed anti-shortcycle timer and time
delay relays. ReliaTel controls provide
these functions as an integral part of the
unit.The contractor no longer has to
purchase these controls as options and
pay to install them.
The wiring of the low voltage connections
to the unit and the zone sensors is as
easy as 1-1, 2-2, and 3-3.This simplified
system makes wiring easier for the
installer.
ReliaTel MakesTesting Easy
ReliaTel requires no special tools to run
the Voyager unit through its paces.
Simply place a jumper betweenTest 1
andTest 2 terminals on the Low Voltage
Terminal Board and the unit will walk
through its operational steps
automatically.
—The unit automatically returns
control to the zone sensor after
stepping through the test mode a
single time, even if the jumper is
left on the unit.
As long as the unit has power and the
“system on” LED is lit, ReliaTel is
operational.The light indicates that the
controls are functioning properly.
ReliaTel features expanded diagnostic
capabilities when utilized withTrane
Integrated Comfort™ Systems.
Some zone sensor options have central
control panel lights which indicate the
mode the unit is in and possible
diagnostic information (dirty filters for
example).
Other ReliaTel Benefits
The ReliaTel built-in anti-shortcycle timer,
time delay relay and minimum “on” time
control functions are factory tested to
assure proper operation.
ReliaTel softens electrical “spikes” by
staging on fans, compressors and
heaters.
Intelligent Fallback is a benefit to the
building occupant. If a component goes
astray, the unit will continue to operate at
predetermined temperature setpoint.
Intelligent Anticipation is a standard
ReliaTel feature. It functions continuously
as ReliaTel and zone sensor(s) work
together in harmony to provide much
tighter comfort control than conventional
electro-mechanical thermostats.
The same ReliaTel Board fits all Voyager
Packaged Gas/Electrics, Cooling with
Electric Heat, and Heat Pump models.
This provides standardization of parts for
contractors. Less money is tied up in
inventory with ReliaTel.
ReliaTel™

6PKGP-PRC001-EN
Features and
Benefits
Black Epoxy Pre-Coated Coils
The pre-coated coils are an economical
option for protection in mildly corrosive
environments.
Cabinet Integrity
For added water integrity, Voyager has a
raised 11/8" lip around the supply and
return of the downflow units to prevent
water from blowing into the ductwork.
Clogged Filter/Fan Failure Switch
A dedicated differential pressure switch is
available to achieve active fan failure
indication and/or clogged filter indication.
CO2Sensing
The CO2sensor has the ability to monitor
space occupancy levels within the
building by measuring the parts per
million of CO2(Carbon Dioxide) in the air.
As the CO2levels increase, the outside air
damper modulates to meet the CO2
space ventilation requirements.The CO2
sensor kit is available as a field installed
accessory.
Colored And NumberedWiring
Save time and money tracing wires and
diagnosing the unit.
Compressors
Voyager contains the best compressor
technology available to achieve the
highest possible performance. Dual
compressors are outstanding for
humidity control, light load cooling
conditions and system back-up
applications. Dual compressors are
available on all models.
Outstanding Standard and
Optional Components
Condenser Coil
Voyager boasts a patent-pending 1+1+1
condenser coil, permanently gapped for
easy cleaning.
Digital Display Zone Sensor
The Digital LCD (Liquid Crystal Display)
zone sensor has the look and functionality
of standard zone sensors. This sensor
should be utilized with ReliaTel™ controls.
Discharge Air Sensing Kit
Provides true discharge air sensing in
heating models. The kit is functional only
with the ReliaTel Options Module.
Downflow And Horizontal Economizers
The economizers come with three control
options — dry bulb is standard, enthalpy
and differential enthalpy are optional.
DualThermistor Remote Zone Sensor
This sensor will reduce the total number
of remote sensors to obtain space
temperature averaging. This sensor
should be utilized with ReliaTel controls.
Factory Built Roof Curbs
Available for downflow units. Only two
roof curbs for the entire Voyager line
simplifies curb selection.
Fresh Air
0 - 25% manual or 0 - 50% motorized
outside air hoods are available.
High Static Drive Accessory
Available on many models, this high
static drive accessory extends the
capability of the standard motor. Avoid
expensive motors and operating costs by
installing this optimized sheave
accessory.
Hinged Access Doors
These doors permit easy access to the
filter, fan/heat, and compressor/control
sections. They reduce the potential roof
damage from screws or sharp access
door corners.
LonTalk® Communications Interface
The LonTalk communications interface
allows the unit to communicate as a
Tracer™LCI-V device or directly with
generic LonTalk Network Building
Automation System Controls.
Power Exhaust Option
This option is available on downflow units
and provides exhaust of the return air,
when using a downflow economizer, to
maintain proper building pressurization.
Great for relieving most building
overpressurization problems.
Quick-Access Panels
Remove three or fewer screws for
access to the standardized internal
components and wiring.
Quick-Adjust Idler Arm
With the Quick-Adjust Idler Arm, the belt
and sheaves can be quickly adjusted
without moving the mounted fan motor.
The result is a major savings in time and
money.

PKGP-PRC001-EN 7
Features and
Benefits
Reference or Comparative Enthalpy
Measures and communicates humidity
while maximizing comfort control.
Sloped Drain Pans
Standard on every unit.
Standardized Components
Components are placed in the same
location on all Voyager units. Familiarize
yourself with one Voyager and you are
familiar with every Voyager.
Due to standardized components
throughout the Voyager line, contractors/
owners can stock fewer parts.
Supply and/or Return Air Smoke
Detector
With this option installed, if smoke is
detected, all unit
operation will be shut
down. Reset will be
manual at the unit.
Return Air Smoke
Detectors require
minimum allowable
airflow when used
with certain models.
Tool-less Hail Guards
Tool-less, hail
protection quality coil
guards shall be either
factory or field-installed for condenser
coil protection.This option protects the
condenser coil from vandalism and/or
hail damage.
Trane Communication Interface (TCI)
Available factory or field installed.This
module when applied with the ReliaTel™
easily interfaces withTrane’s Integrated
ComfortTM System.
VariTrac
WhenTrane’s changeover VAV System
for light commercial applications is
coupled with Voyager, it provides the
latest in technological advances for
comfort management systems and can
allow thermostat control in every zone
served by VariTrac.
Ventilation Override Accessory
With the Ventilation Override Accessory
installed, the unit can be set to transition
to up to 3 different pre-programmed
sequences for Smoke Purge,
Pressurization, and Exhaust.The
transition occurs when a binary input on
the RTOM is closed (shorted).This would
typically be a hard wired relay output
from a smoke detector or fire control
panel.The ventilation override kit is
available as a field installed accessory.
Zone Sensors
Available in programmable, automatic
and manual styles.
Rigorous Testing
The fan and idler arm assembly designs
have been tested to over 300,000 cycles
each. Our combined cycle testing is now
over 7,000,000 cycles.
All of Voyager’s designs were rigorously
rain tested at the factory to ensure water
integrity.
Actual shipping tests were performed to
determine packaging requirements. Units
were test shipped around the country to
determine the best packaging. Factory
shake and drop tests were used as part
of the package design process to help
assure that the unit arrives at the job site
in top condition.
Rigging tests include lifting a unit into the
air and letting it drop one foot, assuring
that the lifting lugs and rails hold up under
stress.
We perform a 100% coil leak test at the
factory.The evaporator and condenser
coils are leak tested at 200 psig and
pressure tested to 450 psig.
All parts are inspected at the point of final
assembly. Sub-standard parts are
identified and rejected immediately.
Every unit receives a 100% unit run test
before leaving the production line to
make sure it lives up to rigorousTrane
requirements.
Voyager units incorporate either a one
piece top or theTrane-Tite-Top (T3). Each
part of the top (either two or three pieces)
overlaps in such a way that water cannot
leak into the unit.These overlapped edges
are gasketed and sealed to ensure
superior water integrity.
VariTrac™

8PKGP-PRC001-EN
Features and
Benefits
Easy to Install and Service
Conversionless Units
The dedicated design units (either
downflow or horizontal) require no panel
removal or alteration time to convert in
the field — a major cost savings during
installation.
Horizontal units come complete with duct
flanges so the contractor doesn’t have to
field fabricate them.These duct flanges
are a time and cost saver.
Easy Access Low Voltage Terminal Board
Voyager’s Low VoltageTerminal Board is
external to the electrical control cabinet. It
is extremely easy to locate and attach the
thermostat wire.This is another cost and
time saving installation feature.
Low Voltage Connections
The wiring of the low voltage connections
to the unit and the zone sensors is as
simple as 1-1, 2-2, and 3-3.This simplified
system makes it easy for the installer to
wire.
Electric Heaters
Electric heat modules are available within
the basic unit. If ordering theThrough the
Base Electrical option with an Electrical
Heater, the heater must be factory
installed.
Powered or Unpowered Convenience
Outlet
This option is a GFCI, 120v/15amp, 2 plug,
convenience outlet, either powered or
unpowered.This option can only be
ordered when theThrough the Base
Electrical with either the Disconnect
Switch, or Circuit Breaker, option is
ordered.This option is available on all
downflow models.
Single Point Power
A single electrical connection powers the
unit.
Single Side Service
Single side service is standard on all
units.
Through the Base Electrical with Circuit
Breaker
This option is a factory installed thermal
magnetic, molded case, HACR Circuit
Breaker with provisions for through the
base electrical connections. This option is
available on all downflow models.
Through the Base Electrical with
Disconnect Switch
Factory installed 3-pole, molded case,
disconnect switch with provisions for
through the base electrical connections
are available. This option is available on
all downflow models.
Through the Base Utilities Access
An electrical service entrance shall be
provided allowing electrical access for
both control and main power connections
inside the curb and through the base of
the unit. Option will allow for field
installation of liquid-tight conduit and an
external field installed disconnect switch.
Factory Installed Options
A wide variety of Factory Installed
Options (FIOPs) are available.
Added Efficiency
Airflow
Airflow is outstanding.The Voyager can
replace an older machine with old
ductwork and, in many cases, improve
the comfort through better air
distribution.
High Efficiency Motors
This option is available with efficiency
ratings from 86.5 up to 91.0. It is not
available for all models.
U-shaped Airflow
U-shaped airflow allows for improved
static capabilities.
Low Ambient Cooling
Cooling capabilities down to 0°F as
standard.
Oversized Motors
Factory or field installed oversized
motors available for high static
applications.
One of our Finest Assets:
Trane Sales Representatives are a
Support group that can assist you with:
— Product
— Application
— Service
— Training
— Special Applications
— Specifications
— Computer Programs and much more
Voyager has the features and benefits
that make it first class in the light
commercial rooftop market. Designed
with input from field contractors and
engineers, its U-shaped airflow
performance is outstanding.

PKGP-PRC001-EN 9
Application of this product should be
within the cataloged airflow and cooling
considerations.
Low Ambient Cooling
This Voyager line features, as standard,
low ambient cooling down to 0°F. Contact
your localTrane Representative for more
assistance with low ambient cooling
applications.
Barometric Relief
This product line offers an optional
barometric relief damper included in the
downflow economizer accessory.This
accessory consists of gravity dampers
which open with increased pressure. As
the building air pressure increases, the
pressure in the unit return air section also
increases, opening the dampers and
relieving the conditioned space.
NOTE:THE EFFECTIVENESS OF
BAROMETRIC RELIEF DAMPER DURING
ECONOMIZING OPERATION IS SYSTEM
RELATED.
PRESSURE DROP OFTHE RETURN AIR
SYSTEM SHOULD BE CONSIDEREDTO
CONTROL BUILDING PRESSURIZATION.
Power Exhaust Accessory
The power exhaust accessory is
available on all downflow units.This
accessory can be field installed and will
assist in relieving building pressurization.
Condensate Trap
The evaporator is a draw-thru
configuration. A trap must be field
provided prior to start-up on the cooling
cycle.
Clearance Requirements
The recommended clearances identified
with unit dimensions should be
maintained to assure adequate
serviceability, maximum capacity and
peak operating efficiency. Actual
clearances which appear inadequate
should be reviewed with the localTrane
sales personnel.
Unit Pitch
These units have sloped condensate
drain pans. Units must be installed level,
any unit slope must be toward access
side of unit.
Application
Considerations

10 PKGP-PRC001-EN
Selection
Procedures
Cooling Capacity
Step 1
Calculate the building’s total and sensible
cooling loads at design conditions. Use
theTranecalculation form or any other
standard accepted method.
Step 2
Given the following building
requirements:
A
Electrical Characteristics: 460/60/3
B
Summer Design Conditions:
Entering Evaporator Coil: 80 DB/ 67 WB
Outdoor Ambient: 95 DB
C
Total Cooling Load: 172 MBh
D
Sensible Cooling Load: 122 MBh
E
Airflow: 6000 cfm
F
External Static Pressure: .50 in. w.g.
G
Rooftop - downflow configuration.
H
Accessories
Economizer
Supplementary Electric Heat
I
Heating Capacity 88 MBh
460 volt/3 phase Electric Supplemental
Heat - at 6000 cfm
Size the equipment usingTable PD-3.
As a starting point, a rough determination
of the size of the unit must be made.This
selection will then be confirmed after
examining the performance at the given
conditions. Divide the total cooling load
by nominal BTUH per ton (12 MBh per
ton); then round up to the nearest unit
size.
172 MBh/12 MBh = 14.33 (approx. 15
tons.)
Step 3
Table PD-3 shows that a WCD180B4 has
a gross cooling capacity of 183.0 MBh
and 129.0 MBh sensible capacity at 95
degree ambient and 6000 cfm with 80
DB/67 WB air entering the evaporator.
To Find Capacity at Intermediate
Conditions
When the design conditions are between
two numbers that are in the capacity
table, interpolation is required to
approximate the capacity.
Note: Extrapolation outside of the table
conditions is not recommended.
Step 4
Verify that there will be enough capacity
by determining net capacity. In order to
select the correct unit which meets the
building’s requirements, the fan motor
heat must be deducted from the gross
cooling capacity.The amount of heat that
the fan motor generates is dependent on
the effort by the motor cfm and static
pressure.To determine the total unit static
pressure, add the following:
External Static: 0.50 in.
Standard Filter 1 in: 0.11 in. (from table
PD-13)
Economizer Return Air: 0.04 in. (from
table PD-13)
Electric Heater Size 18 kW: .06 in.
Total Static Pressure: .71 in.
Note:The Evaporator Fan Performance
Table PD-7 has already accounted for the
pressure drop for standard filters and wet
coils.
Therefore, the actual Total Static
Pressure is .71 - .11 = .60.
With 6000 cfm and .60 inches,Table PD-7
shows 2.66 Bhp.
The note below Table PD-7 gives a
formula to calculate Fan Motor Heat:
3.15 x bhp = MBh
3.15 x 2.66 = 8.38 MBh
Now subtracting the fan motor heat from
the gross cooling capacity of the unit:
NetTotal Cooling Capacity =
183-8.38=170.62
Net Sensible Cooling Capacity=
129-8.38=120.62
Step 5
If the performance will not meet the
required load of the building, try a
selection at the next higher size unit.
Heating Capacity
Step 1
Calculate the building heating load using
theTrane calculation form or other
standard accepted method.
Step 2
Size the equipment usingTable PD-16 to
match the heating loads at design
conditions.
A
Total Heating Load: 88 MBh
B
Outdoor Ambient (Winter) 17 DB
C
Indoor ReturnTemperature: 70 DB
D
Airflow: 6000 Cfm
Use the integrated portion of Table
PD-16 for the WCD180B4 to determine
capacity at winter design conditions.The
mechanical heating portion of the heat
pump will provide 45 MBh.
Step 3
Because 45 MBh is less than the
building’s required heating capacity at
winter design conditions, a
supplementary heater must be selected.
88 MBh - 45 MBh = 43 MBh
FromTable PD-20, at 480 volts, the 18 kW
Heater will be adequate to do the job.
18 kW 61 MBh
FromTable ED-3 select heater
AYDHTRK418A (18 kW 460/60/3).