Trane Performance Air Handlers Installation and Maintenance Manual
Contents
1. POWERFLAME WIRING NA i Ha WIRING NA ALARM H 120 VAC l 1 PILOT DUTY 19 Hazardous Gases and Flammable Vapors Exposure to hazardous gases from fuel substances have been shown to cause cancer birth defects or other reproductive ham Improper installation adjustment alteration service or use of this product could cause flammable mixtures or lead to excessive carbon monoxide To avoid hazardous gases and flammable vapors follow proper installation and set up of this product and all wamings as provided in this manual Failure to follow all instructions could result in death or serious injury 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 Hazard of Explosion Installations at altitudes of 3 000 feet above sea level or higher may require adjustment of the air fuel linkage for proper combustion Linkage and air fuel adjustment should only be done by an experienced qualified gas heat technician Failure to follow these recommendations could result in death or serious injury or equipment or property only damage Gas heat sections have been run teste2. NUMBER PART NAME SETTINGS er AUX GAS VALVE GIT1 GAS IGNITION TRANSFORMER NA HIGH PRESSURE GAS SWITCH 14 _HFR1 HONEYWELL FLAME RELAY MAIN cas valve TA PILOT VALVE SENSOR NA MODULATING MOTOR WITH 07230 INTERFACE im 2 10 0 yol 18 CONTROLLER 2 10 0 4 20 as FIRE START INTERLOCK BLUE 1FD PURGE INTERLOCK w scan O SCANNER MODULATING MOTOR est 1 5 CONTROL TRANSFORMER MJC TERMINAL BLOCK Eee a 120 VAC Ie WIRING RM7845A CLCH SVX08A EN 17 208 230 460 575 VOLT i 3 PHASE POWER FIELD ro 5 7 INSTALLED BY OTHERS 1 kossn 4 i SEE NAMEPLATE FOR ELECTRICAL REQUIREMENTS POWER JUNCTION BOX MANUAL DISCONNECT SWITCH EXHAUST FAN EXHAUST FAN THERMAL OVERLOAD CONTACTOR RELAY EXHAUST FAN ees PRIMARY FUSES __ FOR TRANSFORMER bus TRANS1 eas n VAC 3 2 ee 5 6 HEAT START SWITCH INTERLOCK WITH CONTROLS BY TRANE AIR HANDLER OR OTHERS SUPPLY FAN 120 VAC 1 mA 2 CAFS1 EXFS1 is oe 5 0 Al 2 8 1 115 2 13 215 09 14 PV1 OP
3. 22 Instruction Manuals 8 Normal Shutdown 23 Receiving Inspection 8 Seasonal Startup Shutdown 23 Storage 8 Seasonal Shutdown 23 5 8 Seasonal Startup 23 Indoor Units 9 Routine Maintenance 24 Installation 9 Heating Mode Maintenance 24 Contractors Responsibilities 9 Service Personnel Maintenance 24 Installing 9 Troubleshooting 25 Electrical and or Controls Contractor 10 Service Clearance Recommendations 10 Installations at High Altitude 11 Rigging Lifting 11 Assembly 11 Duct Connections 11 Combustion Air Duct 11 Duct Transitions 11 Airflow Direction 11 Rain Hood Combustion Air Inlet 12 Flue Stack Installation 13 Outdoor Gas Heat Section 13 Indoor Gas Heat Section 13 PIPING 55 14 Gas Piping 14 Proper Gas Pressure 14 CLCH SVX07C EN 3 TRANE Model Number Description Overview of
4. Protective Covering The large openings of the gas heat section are protected by an Oriented Strand Board OSB panel covering The OSB panel is held in place by sheet metal screws Leave the covering attached to the section until itis ready to install to prevent debris from entering the section Hardware Kits Hardware kids ship inside the air handler fan section ina plastic bag or cardboard box This kit contains gasketing and screws For outdoor units roof joint connection strips and wall panel seam caps are included These are used when fastening the gas heat section to the air handler Keep the hardware with the gas heat section until it is ready to install Rain Hood A rain hood is provided for outdoor units with internal vestibules The rain hood is shipped on a separate wood skid A kit containing mounting hardware ships inside the gas heat section and must be removed before assembly to the air handler Instruction Manuals Individual instruction manuals for all of the gas train components such as flame control relay valves pressure switches and actuators ship inside the piping vestibule Retain these manual for future repair or troubleshooting Receiving Inspection Upon receipt of the gas heat section inspectitfor damage that may have occurred during shipment Report damage immediately to the freight company Trane is not responsible for shipping damage Inspect the access door latches and hinges for
5. TRANE Installation Operation and Maintenance Gas Heat Sections for Performance Climate Changer Air Handlers Sizes 6 120 for Indoor and Outdoor Units ASAFETY WARNING Only qualified personne should install and service the equipment The installation starting up and servicing of heating ventilating and airconditioning equipment can be hazardous and requires specific knowledge and training Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and on the tags stickers and labels that are attached to the equipment November 2012 5 S TRANE Wamings Cautions and Notices Wamings Cautions and Notices Notethatwarnings cautions and notices appear at appropriate intervals throughout this manual Warnings are provide to alert installing contractors to potential hazards that could result in death or personal injury Cautions are designed to alert personnel to hazardous situations that could result in personal injury while notices indicate a situation that could result in equipment or property damage only accidents Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions Read this manual thoroughly before operating or servicing this unit ATTENTION Warnings Cautions and Notic
6. 14 GIT1 MODULATING MOTOR WITH 07230 INTERFACE 2 10VDC TEMP CONTROLLER 4 20 2 10VDC 2 OOO 6 1 EARTH GROUND CONNECTION GREEN SCREW IN SUBBASE RM7845A 18 NOTES 4 ALL FIELD WIRING SHOULD HAVE INSULATION RATED FOR 600 VOLTS lt 2 WIRING FOR PROOF OF CLOSURE OPTION SEE INSET A WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING FAILURE TO DISCONNECT POWER BEFORE SERVICING CAN CAUSE SEVERE PERSONAL INJURY OR DEATH CAUTION USE COPPER CONDUCTORS ONLY UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT TRANSFORMER FUSE REPLACEMENT SCHEDULE NUMBER PART NAME SETTINGS 1 AIRFLOW INTERLOCK NA AGVI AUX GAS VALVE NA CAFS1 COMBUSTION AIR FLOW SWITCH NA 1 COMBUSTION MOTOR NA 5 OVERLOAD NA EF1 EXHAUST STARTER NA EXFS1 EXHAUST AIR FLOW SWITCH NA cm GAS IGNITION TRANSFORMER NA HUA HIGH LIMIT INTERLOCK NA HPGS1 HIGH PRESSURE GAS SWITCH 14 1 HONEYWELL FLAME RELAY NA LPGS1 LOW PRESSUFRE GAS SWITCH 7 1 MAIN GAS VALVE NA PILOT VALVE TRANS1 1 5 CONTROL TRANSFORMER NA 1FD NA 15 LOW FIRE START INTERLOCK NA 215 PURGE INTERLOCK NA 1MM MODULATING M
7. Figure 13 200 1000 MBh 3 1 or 10 1 tumdown wiring diagram 12 1 PHASE POWER FIELD 2 LINSTALLED BY OTHERS a Mia 4 STANDARD 120 VOLT POWER CONNECTION i i SEE NAMEPLATE FOR ELECTRICAL REQUIREMENTS SEE NAMEPLATE FOR LI N ELECTRICAL REQUIREMENTS POWER JUNCTION BOX 1120 VOLT 1 PHASE POWER MANUAL DISCONNECT SWITCH MANUAL DISCONNECT SWITCH PRIMARY FUSES TRANS1 115 OPTIONAL LINE VOLTAGE CONNECTION NOTES 1 ALL FIELD WIRING SHOULD HAVE INSULATION RATED FOR 600 VOLTS lt Z WIRING FOR PROOF OF CLOSURE OPTION SEE INSET A 1 HUI 4 HPGSI iposi o 5 HEAT START SWITCH INTERLOCK WITH CONTROLS BY TRANE AIR HANDLER OTHERS SUPPLY FAN 120 VAC 1 A WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING FAILURE TO DISCONNECT POWER BEFORE SERVICING CAN CAUSE SEVERE PERSONAL INJURY OR DEATH CAUTION USE COPPER CONDUCTORS ONLY UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT TRANSFORMER FUSE REPLACEMENT SCHEDULE RATINGS 2 FUSE IDENTIFIER FUSE amp VOLTAGE RATING F1 F2 mme DELAY CLASS 600 V 208
8. 24 CLCH SVX08A EN S TRANE Troubleshooting A WARNING Hazardous Service Procedures Hazardous Gases and Flammable Vapors The maintenance and troubleshooting procedures Exposure to hazardous gases from fuel substances have recommended in this manual could result in exposure been shown to cause cancer birth defects or other to electrical mechanical or other potential safety reproductive Improper installation adjustment hazards Always refer to the safety wamings provided alteration service or use of this product could cause throughout this manual conceming these procedures flammable mixtures or lead to excessive carbon Unless specified otherwise disconnect all electrical monoxide To avoid hazardous gases and flammable power including remote disconnect and discharge all vapors follow proper installation and set up of this energy storing devices such as capacitors before product and all wamings as provided in this manual servicing Follow proper lockout tagout procedures to Failure to follow all instructions could result in death or ensure the power can not be inadvertently energized serious injury 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 Failure to follow all of the recommended safety wamings provided could result in death or seri
9. Butyl tape Hood 12 CLCH SVX08A EN TRANE Installation Flue Stack Installation Outdoor Gas Heat Section The flue stack for outdoor gas heat sections ships inside the gas heat section see Figure 10 Attach the flue stack to the flue collar and secure it with screws as indicated in Figure 11 See Table 6 for flue connection sizes Figure 1 Outdoor air handler flue stack installation Figure 10 Outdoor air handler flue stack Indoor Gas Heat Section A rain hood or screen is recommended on the flue to For indoor gas heat sections a field engineered flue stack prevent possible blockage from bird nests and beehives is required Install according to local codes See The rain hood or screen must be field provided connection sizes in Table 6 Itis very difficult to remove flue from inside the unit once the unit is assembled Table 6 Flue connection sizes for gas heat sections Gas Output MBh Flue Size inches 200 360 560 8x8 300 360 9x9 700 860 1000 12 x 12 1750 10 x 10 2000 2400 14x14 CLCH SVX08A EN 13 AWARNING Hazard of Explosion and Deadly Gases Never solder braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate After refrigerant removal u
10. Electrical and or Controls Contractor Provide powerto the gas heat section See Wiring on page 15 for power requirements e Provide a binary start stop signal e Provide an analog Oto 10 Vdc modulating signal A Oto 10 Vdc interface module is installed as standard equipment A 4 to 20 mA interface module is available and may have been installed on the unit for the control signal in lieu of the 0 to 10 Vdc signal e Provide an interlockin the start stop signal circuit with the air handler supply fan This interlock must insure the start stop signal is interrupted to the gas heat system if the supply fan is shutoff The gas heatsystem must not operate without the supply fan providing airflow All wiring must comply with applicable local and National Electric Code NEC specifications Table 5 Service clearances inches e For units provide temperature sensors for entering and leaving air in gas heat section All power and control wiring for the gas heat section must be field provided All power and control wiring for any section downstream of the gas heat must be field provided Service Clearance Recommendations A minimum clearance of the section width plus 12 inches on the access door side of the gas heat section is recommended for routine maintenance This clearance provides enough room to replace the heat exchanger in the event of failure The section side panels must be removed to access the heat
11. combustible gases before ignition 3 1 and 10 1 turndown 200 2000 Mbh The pilot light ignites and the pilot light on the flame relay module should illuminate The pilot flame can be viewed through the small sight glass on the burner The pilot flame will burn for 10 seconds then the flame light on the flame relay module should illuminate 3 1 and 10 1 turndown 200 2000 Mbh The main burner ignites the modulating gas valve actuator starts to open and the main light on the flame relay module should illuminate Note that it could take as long as 30 seconds for the actuator to fully open 5 20 1 turndown 1250 thru 2400 Mbh The main burner lights and the main burner light on the flame relay should illuminate The modulating gas valve actuator starts to open and the main lighton the flame relay module should illuminate Note that it could take as long as 30 seconds for the actuator to fully open w gt 6 gas valve actuator slowly modulates open closed in response to the heat load required in the building CLCH SVX08A EN 7 Complete the start up checklist and send a copy as directed to Trane to validate the warranty Normal Shutdown When thesystem no longer requires heat the temperature control system opens the heat start contacts The pilot valve 3 1 10 1 turndown burners modulating gas valve 20 1 turndown burners automatic gas valve regulator redundant automatic gas valve and combustion blo
12. 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 2012 Trane All rights reserved must also be adhered to for responsible management of refrigerants Know the applicable laws and follow them A WARNING Proper Field Wiring and Grounding Required 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 electrical codes Failure to follow code could result in death or serious injury AWARNING Personal Protective Equipment PPE Required Installing servicing this unit could result in exposure to electrical mechanical and chemical hazards Before installing servicing this unit technicians MUST put onall Personal Protective Equipment PPE recommended for the work being undertaken ALWAYS refer to appropriate MSDS sheets and OSHA guidelines for proper PPE When working with or around hazardous chemicals ALWAYS refer to the appropriate MSDS sheets and OSHA guidelines for information on allowable personal exposure levels proper respiratory protection and handling recommendations e if there is a risk of arc or flash technicians MUST put on all Personal Protec
13. 250 Int 10 200 Ext 35 1000 Ext 66 1500 Int 10 360 Ext 35 1250 Ext 66 1750 Int 12 200 Int 35 1500 Ext 66 2000 Ext 12 360 Ext 35 1750 Ext 66 2400 Ext 14 200 Int 40 560 Int 80 860 Int 14 360 Ext 40 700 Int 80 1000 Int 17 200 Int 40 860 Int 80 1250 Int 17 360 Ext 40 1000 Ext 80 1500 Int 17 560 Ext 40 1250 Ext 80 1750 Int 17 700 Ext 40 1500 Ext 80 2000 Ext 21 200 Int 40 1750 Ext 80 2400 Ext 21 360 Ext 50 560 Int 100 1000 Int 21 560 Ext 50 700 Int 100 1250 Int 21 700 Ext 50 860 Int 100 1500 Int 21 860 Ext 50 1000 Int 100 1750 Int 21 1000 Ext 50 1250 Ext 100 2000 Int 25 360 Ext 50 1500 Ext 100 2400 Ext 25 560 Ext 50 1750 Ext 120 1000 Int 25 700 Ext 50 2000 Ext 120 1250 Int 25 860 Ext 57 560 Int 120 1500 Int 25 1000 Ext 57 700 Int 120 1750 Int 30 360 Int 57 860 Int 120 2000 Int 30 560 Int 57 1000 Int 120 2400 Int 30 700 Int 57 1250 Ext 30 860 Int 57 1500 Ext 30 1000 Ext 57 1750 Ext 57 2000 Ext CLCH SVX08A EN 7 TRANE Pre Installation Anival at J obsite Gas heat sections arrive at the jobsite with an integral base frame for the purpose of mounting units to a housekeeping pad or roof curb The base frame variables in height from the standard 2 5 inches to 8 inches The gas heat section is designed with the necessary number of lift points for safe installation The lift points are designed to accept standard rigging devices and are removable after installation Indoor sections size 3 30 will also be shipped with a shipping skid de
14. 5 15 Note The MCA and MOP for the 2000 MBh with optional 3 hp exhaust motor will be the same as 2400 MBh Gas Heaters with 200 1000 MBh Output Single phase 120 208 230 460 or 575 volt power is required to operate the heater controls or power the transformer TRANS1 if provided Single phase power for 208 230 460 and 575 voltage is provided for the gas heat off two legs of the three phase supply to the air handling unit A transformer in the piping vestibule is provided to step down the voltage required for gas heat Gas Heaters with 1250 2400 MBh Output Three phase 208 230 460 or 575 volt power is required to operate the exhaust fan and power the transformer TRANS1 16 Low Voltage Wiring Equipment Damage The gas heat system will not operate without a supply fan providing airflow Operating the gas heat system without a supply fan could result in damage to equipment or property The gas heat control system requires a binary signal for on off control Provide an interlock in the start stop signal circuit with the air handler supply fan This interlock must insure the start stop signal is interrupted to the gas heat system if the supply fan is shut off The gas heat system must not operate without the supply fan providing airflow The control system also requires a 0 to 10 Vdc analog signal for modulation where 10 Vdc is a signal for full heat A 4to 20 mA interface module is available CLCH SVX08A EN
15. 5 percent or higher Oxygen 8 1012 percent d Carbon dioxide 8 2 to 9 4 percent CLCH SVX08A EN NOTICE Over Firing Bumers If fuel and air adjustment linkages were adjusted in the start up process insure that the bumer is not allowed to over fire The gas pressure on the manifold must not exceed the gas pressure stated on the Powerflame bumer name plate Over firing operation could result in equipment and property damage Hazardous Gases and Flammable Vapors Exposure to hazardous gases from fuel substances have been shown to cause cancer birth defects or other reproductive harm Improper installation adjustment alteration service or use of this product could cause flammable mixtures or lead to excessive carbon monoxide To avoid hazardous gases and flammable vapors follow proper installation and set up of this product and all wamings as provided in this manual Failure to follow all instructions could result in death or serious injury The gas heat module section goes through the following routine every time itis started The air handler fan must be running and the Power light on the flame relay module should be illuminated L Acontact closure command the signal to start comes from a thermostat or building automation system N The combustion air blower starts and runs for approximately 90 seconds This 90 second run is a pre purge cycle to clear the heat exchanger of
16. 7 Remove any debris from combustion air inlets and or hoods Note that some combustion air inlets are located on the floor panel of the piping vestibule Insure the openings are not blocked 8 For units with burners size 1250 and larger ensure exhaust fan rotation is correct Figure 16 Control panel for the J R bumer on 200 1000 mbh 3 1 amp 10 1 tumdown units CLCH SVX08A EN Figure 17 Control panel for the FDM bumer 1250 2400 20 1 tumdown units Startup A WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been propery trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury 1 Start the ai handling unit fan The field installed supply fan interlock and primary airflow switch contacts 11 should close 2 The high temperature limit switch contacts HL1 the modulating gas valve actuator and its end switch contacts AES should be closed 3 The building control system should call for heat closing a contact between terminals four and five 4 Open the manual gas valve outside the unit next to the gas pressure regulator and bleed air from the piping 5 Me
17. ED Installation Airflow from the supply fan should enter on the drum or primary side of the heat exchanger Figure 6 and exit on the tube or secondary side Figure 7 Figure 6 Entering airside drum or primary of gas heat Figure 7 Leaving air side tube or secondary of gas heat section section Rain Hood Combustion Air Inlet Install butyl tape between the hood and the side panel 20 or door panel see Figure 8 Rain hoods are only required on an outdoor unit with an internal vestibule Depending on unit size the combustion e Locate the bottom edge ofthe hood 2 3 8 inches below air opening will be in the access door or in the side panel the bottom edge of the inlet air opening and center the A unit with an external vestibule has the combustion air hood left to right over the inlet air opening see opening in the floor of the vestibule and does not require Figure 9 a rain hood unless excessive snowdrifts are expected Install the hood to the unit with number 10 screws Rain hoods for the combustion air opening ship loose and must be installed at the job site The assembly consists of Figure 9 Center inlet air opening the hood butyl tape and number 10 screws Figure 8 Installation of rain hood for combustion air Access door opening Hinge side 4 Rain hood 4 Airflow Combustion air opening 2 3 8in _ Center hood left to right over opening
18. Manual Use this manual to install startup operate and maintain the Performance Climate Changer air handler gas heat Nameplate Each air handler section includes a nameplate label see Figure 1 which identifies the type of section customer tagging information the unit serial number the unit order number the build section position for installation and the unit model number Figure L Perfomance air handler section nameplate section Carefully review the procedures discussed in this manual to minimize installation and startup difficulties Note The unit serial number and order number is required when ordering parts or requesting service for a Trane air handler Order No A5K703A B M A Serial No K01K12345 Unit Model No 5 006 0 00 Tag ID AHU 1 Build Section 2 of 2 GAS HEATSECTION NATURAL GAS MIN INPUT MBH HR 375 125 OUTPUT MBH HR 300 100 GAS INLET 55 W C 14 rf MANIFOLD PRESS IN W C 041 TEMPERATURE RISE 91 30 EXT STATIC PRESS IN W C 25 INPUT V HZ PH 115 60 3 114 BURNER V HZ PH 120 60 1 FLA 43 HP CONT CKT V HZ PH 120 60 1 A 6 0 CLEARANCES TO COMPBUSTIBLE MATERIAL FLUE 6 inches CABINET 0 inches DUCT 2 inches for 3 feet 0 inches thereafter Manufactured under one or more of the following patent numbers Trane www trane com Performance Climate Changer Air Handler Airflow GAS FIRED C US 150 LISTED GAS HEATING SECTI
19. ON OF A CENTRAL STATION 5396782 5674125 6237354 6973795 7017356 7150314 7178355 7340906 7389646 7526903 7685834 AIR HANDLER 541R Made in USA CLCH SVX08A EN General Information Product Information Model and serial numbers for the gas heat section are designated on the nameplate located on the piping side access door inside the section Record the information below for a permanent record of the equipment installed on your job site The nameplate also contains the range of settings for which the gas heat unit is capable Record and Model Number Serial Number Air Handler Sales Order Number Air Handler Serial Number Startup Date Altitude Above Sea Level Calorific Value Bumer Specifications Maximum Firing MBh Minimum Firing MBh Type of Gas Maximum Inlet Gas Pressure Minimum Inlet Gas Pressure Temperature Rise F Manifold Pressure at Maximum MBh Table 1 Motor and Electrical Specifications Specifications Gas Heater I nput Power Burner Motor retain these settings in case the unit should ever need adjustment after service repairs Note This information is required when ordering repair parts Control Power Exhaust Motor Volts 115 Hertz 60 60 60 Phase 1 HP n a n a FLA Amps n a 6 MCA n a n a MOP n a n a Note Powered by a line to 115 volt transformer for all gas heaters except 115 60 1 rated units CLCH SVX08A EN General In
20. OTOR NA o MJC TERMINAL BLOCK NA FIELD WIRING NA POWERFLAME WIRING NA WIRING NA PART SETTINGS CLCH SVX08A EN Figure 15 1250 2400 MBh 20 1 tumdown wiring diagram 13 1 208 230 460 575 VOLT 3 PHASE POWER FIELD co INSTALLED BY OTHERS 1 4 i SEE NAMEPLATE FOR ELECTRICAL REQUIREMENTS POWER JUNCTION BOX MANUAL DISCONNECT SWITCH EXHAUST FAN EXHAUST FAN RELAY THERMAL OVERLOAD NOTES ALL FIELD WIRING SHOULD HAVE INSULATION TERMINAL 1 2 PRIMARY FUSES EXHAUST FOR TRANSFORMER 5 51 115 il WHT E 2 1MC CM1 1 on HPGS1 LPGS1 AO HEAT START SWITCH iar Soa 10 CONTROLS BY TRANE HCTRL RM7845A o po 4 CLCH SVX08A EN RM7895A RATED FOR 600 VOLTS WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING INTERLOCK WITH ler JO DOE ERE EESTE OR OTHERS SUPPLY FAN OR DEATH 120 VAC 1 mA i CAFS1 HL Alt CAUTION me AH USE CO
21. PPER CONDUCTORS ONLY UNIT TERMINALS ARE NOT DESIGNED EXFS1 TO ACCEPT OTHER TYPES OF 2 02 CONDUCTORS 2 FAILURE DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT 1 0O 2 TRANSFORMER FUSE REPLACEMENT SCHEDULE VA F1 F2 CLASS PART 15 LOW FIRE START INTERLOCK NA 25 PURGE_INTERLOCK NA 1MC BURNER MOTOR CONTACTOR NA ve 1MM MODULATING MOTOR NA Alt AIRFLOW INTERLOCK NA AUX GAS NA FLAME ROD CAFS1 COMBUSTION AIR FLOW SWITCH NA SENATE CONDUTOR i 1 BURNER MOTOR NA EXHAUST OVERLOAD NA A Se EXHAUST STARTER NA 115 EXFS1 EXHAUST AIR FLOW SWITCH NA E SS TRANSFORMER HCTRL HONEYWELL RM7845A CONTROLLER NA MOD MOTOR 215 i HPGS1 HIGH PRESSURE GAS SWITCH 14 59 HIGH INTERLOCK 180 F PURGE INTERLOCK Bate a LPGS1 LOW PRESSURE GAS SWITCH 7 IN MOD MOTOR MARI ADJUSTABLE TIMER 4 SEC MGV1 GAS VALVE NA 2 10 VOC TRANS1 1 5 OR 2 0 KVA CONTROL TRANSFORMER BELIMO 4 o MJC TERMINAL BLOCK NA POWERFLAME REMOTE NA Renae ee MOTOR i gt POWERFLAME BURNER TB NA A POWERFLAME GAS TRAIN JUNCTION FIELD WIRING NA
22. air needed for combustion The additional static pressure of the inlet air duct may change the fuel air ratio slightly necessitating system adjustment Separated combustion can be a desirable option but will require more field installation time and material The burner fans are not sized to handle any static in the combustion air stream A booster fan will likely be required to overcome combustion air duct static Combustion air cannot be ducted directly to the combustion air fan The airflow through the vestibule is needed to keep the temperatures in the vestibule down Duct Transitions When the gas heat section is the last section of the air handler and duct transitions should be smooth and uniform from all sides Follow recommendations for duct transitions from SMACNA Fasten the ductwork directly to the ductwork opening When using lined ductwork the insulation should not obstruct the discharge opening Airflow Direction The airflow direction through the gas heater is important because it prevents localized hot spots on the heat exchanger Airflow direction labels denoting correct airflow direction through the gas heat section are provided on the burner side of the heating section See Figure 5 Figure 5 Airflow direction label Performance Climate Changer Air Handler Cotes he Aan rene Me Une ett ia Airflow isi GAS MEATSECTION GAS FIR
23. and Maximum Overcurrent Protection MOP requirements for proper electrical installation Inputvoltage must be within 10 percent of specified value Ground the supply power in the junction box to the ground lead provided Do not route any wires through the heat exchanger section unless the insulation is rated for 600 or higher Radiant heat from the heat exchanger will damage wire insulation that is unsuitable for high temperatures Table 8 Power supply requirements See Table 8 for power supply requirements Note Factory wiring routed through the heated part of the cabinet has insulation rated for 600 3 1 and 10 1 Burner Turndown Units Gas Output MBh 200 1000 1250 2000 20003 Voltage Ph 115 575 1 208 575 3 208 230 460 575 3 Minimum Circuit Ampacity MCA less than 15 less than 151 19 71 17 9 9 0 7 2 Maximum Overcurrent Protection MOP 15 152 25 25 15 15 Note 1 except the 2000 MBh output 208 volt phase unit This unit will have a marked MCA of 16 1 2All except the 2000 MBh output 208 and 230 volt 3 phase units These units have a marked MOP of 20 32000 MBh with optional 3 hp exhaust motor required for long horizontal flue vents 20 1 Burner Turndown Units Gas Output MBh 1250 1750 2000 2400 Voltage Ph 208 575 3 208 230 460 575 3 208 230 460 575 3 Minimum Circuit Ampacity MCA less than 15 17 3 16 0 8 0 6 4 20 9 19 0 9 5 7 6 Maximum Overcurrent Protection MOP 15 20 20 15 15 25 25 1
24. asure the gas pressure at the manual gas valve The inlet gas pressure should not exceed 14 inches wg Adjust the gas pressure if necessary 6 Open the first manual gas valve in the burner vestibule 7 Open the manual gas valve in the pilot gas line and bleed the air from the line CLCH SVX08A EN 8 Remove any debris from combustion air inlets and or hoods Note that some combustion air inlets are located on the floor panel of the piping vestibule Insure the openings are not blocked Pre Purge and Pilot Ignition 3 1 10 1 Tumdown 200 2000 MBh Move the manual disconnect switch in the heater vestibule to the ON position The system should energize and the combustion blower motor should start indicating that all of the safety limit contacts are closed HLI1 high temperature limit All airflow interlock e HPGS1 high pressure gas switch e LPGS1 low pressure gas switch The combustion airflow switch CAFS1 should close starting the purge timer the green power light should illuminate on the flame relay panel the combustion air dampers should open and the prepurge cycle should begin The combustion air blower should run for approximately 90 seconds to evacuate the heat exchanger of any combustible gases before the ignition sequence This prepurge cycle is initiated before every startup With the prepurge cycle complete the ignition transformer and pilot solenoid should be energized allowing gas to flow to the
25. by a qualified technician Note that smaller sized heaters have the sight glass on the side opposite the piping connection side 5 Check the flame signal strength from the flame rod A Oto 15 Vdc 1 megohm volt minimum meter is required 6 Insert the positive probe of the voltmeter into the positive flame signal test point on the flame relay cover 7 Connect the negative probe to the negative test point on the flame relay cover Flame signal strength should be a steady dc voltage between 125 and 5 0 volts 8 Allow the burner to ramp up to full fire Final Check Out 1 Check the gas pressure at the burner manifold It should be the same pressure that is indicated on the Manifold Pressure at Max Input nameplate at full fire Refer to the Power Flame burner nameplate for this value 2 Adjust the gas pressure at the automatic gas valve regulator by removing the dust cap on the main gas valve regulator and turning the adjusting screw Turn the adjusting screw clockwise to increase the gas pressure turn the adjusting screw counter clockwise to decrease the gas pressure If the pressure cannot be maintained at full fire at the setting shown on the nameplate and the regulator is adjusted fully open contact your local gas utility 3 Using a gas analyzer check the emissions in the exhaust gas Acceptable values are a Carbon monoxide CO 400 ppm or less corrected to 12 percent carbon dioxide b Efficiency 7
26. d in the factory to assure proper operation and ease of startup The actuator linkages controlling the air fuel mixture are preset for optimum efficiency and performance Thoroughly review all service literature before startup and servicing The sequence of operation and all details of the flame safeguard control system can be found in the burner equipment literature The technical bulletins cover the individual components of the heating system This literature ships inside the piping vestibule of the gas heat section Initial Startup Note The procedures discussed in this section should be done by qualified technicians who are experienced with gas heating equipment 20 Pre Startup 1 Close all manual gas valves 2 Movethe manual disconnect switch in the vestibule to the OFF position 3 Check the air shutter and modulating gas valve linkages for tightness 4 Attach a manometer to the bleed porton the side of the first manual gas valve in the burner vestibule at the inlet end of the gas train upstream of the automatic gas valve regulator This manometer checks incoming gas pressure and should measure 7 to 14 inches wc Exception 1250 through 2000 Mbh with 10 1 turndown require 9 to 14 inches wc 5 Attach another manometer to the burner manifold to check the burner manifold pressure while the unit is firing 6 Attach a third manometer to the pilot gas line to check the pilot gas pressure while the unit is firing
27. damage Open the access door and check for internal hidden damage Concealed damage must be reported within 15 days of receipt e Locate the hardware kit e Locate the flue stack if it is an outdoor unit e Ifshipped onaskid do not remove the gas heat section from the skid at this time Storage Outdoor Units A gas heat section designed for outdoor use requires no special protection during storage Select a solid well drained area Concrete or black top surfaces are recommended If concrete or black top is not available set the section on wood timbers to prevent dirt mud snow etc from getting into the unit Keep access doors closed to prevent damage to gas train components If needed cover with a canvas tarp Covering the unit with clear or black plastic sheets is not recommended because this material traps condensed moisture which can cause equipment damage resulting from rust and corrosion CLCH SVX08A EN Trane warranty does not cover equipment damage due to negligence during storage Indoor Units For gas heat section designed for indoor use Trane recommends indoor storage If outdoor storage is necessary select a solid well drained area Concrete or black top surfaces are recommended If concrete or black top is not available set the unit on wood timbers to prevent dirt mud snow etc from getting into the module Installation AWARNING Improper Unit Lift Do not lift unit from top Lift unit fro
28. dler can be found in the fan section Final assembly of the air handler should be done at the unit installation site Refer to the Performance Climate Changer air handler Installation Operation and Maintenance manual CLCH SVX07B EN for further instructions on equipment assembly Duct Connections All duct connections to the gas heat section should be installed in accordance with the standards of the National Fire Protection Association NFPA and the Sheet M etal and Air Conditioning Contractors National Association Inc 6 Combustion Air Duct e Outdoor units with internal vestibules havea rain hood that requires field mounting CLCH SVX08A EN TRANE Installation Outdoor units with external vestibules do not have rain hood Combustion air enters through openings in the bottom of the vestibule All indoor units ship with a screened opening on the combustion air inlet If combustion air is to be ducted to the gas heat vestibule the unit s capacity must be derated to account for the resistance in the air duct For every 0 14 inches wg of duct resistance unit capacity MBh output will reduce by five percent If combustion air is ducted to the vestibule it is strongly recommended that an experienced gas heat technician checkthe system and emission levels the exhaust flue at start up Carbon dioxide should be between 8 2 and 9 4 percent This corresponds to the allowable range of excess
29. does not form in the heat exchanger during normal heating operation However if the unit operates for extended periods of time at very low fire or if the air handler serves as a cooling unit also condensate can form in the heat exchanger and should be removed All units are equipped with a condensate drain and drain valve The condensate drain is on the same side as the gas train located inside the piping vestibule Since the drain line is equipped with a shut off valve a condensate p trap is not required but may be installed for convenience to avoid periodic manual draining If a p trap and drain is to be connected to the condensate drain line consult local plumbing codes for disposal of the condensate may be a slightly acidic solution Use Figure 12 as a guideline for p trap construction The use of a tee fitting atthe connection to the condensate outlet is recommended This allows for priming and cleaning the trap If a tee fitting is used be sure to furnish a plug or cap for the clean out opening Be sure to replace the plug after priming or cleaning the trap CLCH SVX08A EN Figure 12 Heat exchanger condensate piping L H J diameter where H 5 inches J 2 5 inches Wiring A WARNING Proper Field Wiring and Grounding Required 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 foll
30. e 23 TRANE Routine Maintenance A WARNING serious injury Hazardous Gases and Flammable Vapors Exposure to hazardous gases from fuel substances have been shown to cause cancer birth defects or other reproductive ham Improper installation adjustment alteration service or use of this product could cause flammable mixtures or lead to excessive carbon monoxide To avoid hazardous gases and flammable vapors follow proper installation and set up of this product and all wamings as provided in this manual Failure to follow all instructions could result in death or Heating Mode Maintenance Table 10 Routine maintenance in heating mode Task Frequency Remarks Unit startup Weekly Listen to and visually inspect the unit during normal startup Unit shutdown Weekly Listen to and visually inspect the unit during normal shutdown Check fuel valves pilot and main Weekly Open limit switches and listen to and visually inspect Check combustion safety controls Flame failure Weekly Close manual fuel supply for the pilot and the main fuel valves check safety shutdown timing and record Flame signal strength Weekly e to check flame signal strength outlined in Main Burner Ignition page 21 Drain condensate from heat exchanger Weekly This task only needs to be done if the unit runs for extended hours at Tow fire Clean air inlet louver Mo
31. e e For outdoor sections install the flue stack The flue must be removed from the airstream before assembly Install the flue stack on the gas heat section before assembling the gas heat section to the air handler Clear debris from combustion air inlets located on the side or bottom of the gas heat section Remove any debris obstructing combustion air inlets In areas where snow drifts are higher than the bottom of the vestibule a hood or louver may have to be installed for combustion air e Assemble the gas heat section to the airhandling system Refer to the Performance Climate Changer air handler Installation Operation and Maintenance manual CLCH SVX07B EN for specific assembly instructions This manual ships inside the supply fan section of the air handler TRANE Installation e Penetrate the unit casing and connect the supply gas line to the gas train Gas supply line connection sizes are shown in Table 3 Table 3 Gas supply line connection sizes Gas Output 1250 2000 MBh 200 560 700 1000 1750 2400 Connection Size 1 in 11 4 in 11 2 in 2 in Forindoor gas heat sections install a field engineered flue stack according to local codes See Table 4 for flue connection sizes Table 4 Flue connection sizes for gas heat sections Gas Output MBh Flue Size inches 200 360 560 8x8 300 360 9x9 700 860 1000 12 x 12 1750 10 x 10 2000 2400 14x 14
32. es appear at appropriate sections throughout this literature Read these carefully Indicates a potentially hazardous WARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous CAUTION situation which if not avoided could result in minor or moderate injury It could also be used to alert against unsafe practices oT Indicates a situation that could resultin N ICE equipment or property damage only Important Environmental Concems 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 including industry replacements for CFCs such as HCFCs and HFCs 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 The Federal Clean Air Act Section 608 sets forth the requirements for handling reclaiming recovering and
33. exchanger Refer to Figure 4 for service clearance recommendations for the air handler Figure 4 Service Clearance Filter mixing box 21 25 30 35 40 50 57 66 80 100 120 Component 3 4 6 8 10 12 14 17 A filter 48 48 48 48 48 48 48 48 coil 48 59 59 66 77 82 87 87 UV Lights 48 48 48 48 48 48 48 48 61 61 61 61 6 61 61 6l 48 48 48 48 48 48 48 48 48 48 48 48 51 54 58 61 89 90 108 100 100 105 F gas heat WJA N A 56 63 74 79 84 84 Int Vestibule 48 48 48 48 48 48 48 52 56 58 58 95 95 109 128 141 141 156 156 170 197 48 48 48 48 48 48 48 52 56 58 58 64 64 64 64 64 64 64 64 64 64 64 48 48 48 48 48 48 48 48 48 48 48 60 66 66 66 70 77 77 93 9 101 101 115 115 118 136 140 156 156 170 179 180 N A 92 92 106 112 125 138 138 153 153 167 194 Note At minimum the above clearance dimensions recommended side of the unit for regular service maintenance Refer to as built submittal for locations of items such as filter access doors coil piping connections motor locations etc Sufficient clearance must be provided on all sides of unit for removal of access panels plug panels or section to section attachment brackets Clearance for starters VFDs or other high voltage devices must be provided per NEC requirements 10 CLCH SVX08A EN Installations at High Altitude Hazard of Explosion Installations at alti
34. formation Description The gas heat section consists of a drum and tube heat exchanger burner gas train components and a control panel for electrical connections It is an integral part of the entire air handling system Anaccess dooris provided for service and maintenance of the burner and gas train components The gas heat section must be in a blow thru position downstream from the supply fan Downstream sections must be separated by a blankaccess section and discharge temperatures must be controlled so as not to exceed the Figure 2 Gas heat section with extemal vestibule temperature limits of components in the downstream sections Depending on the heater size an external vestibule that extends the width of the gas heat section may be used to house the burner and gas train components see Figure 2 The external vestibule if required ships attached to the gas heat section Some heaters have gas train components in an internal vestibule see Figure 3 Refer to Table 2 for vestibule locations Figure 3 Gas heat section with intemal vestibule CLCH SVX08A EN 2 TRANE General Infomation Table 2 Vestibule locations Gas Output Vestibule Gas Output Vestibule Gas Output Vestibule Unit Size MBH Type Unit Size MBH Type Unit Size MBH Type 6 200 Ext 35 360 Int 66 700 Int 6 300 Ext 35 560 Int 66 860 Int 8 200 Ext 35 700 Int 66 1000 Int 8 300 Ext 35 860 Int 66 1
35. he sight glass on the side opposite the piping connection side 4 Check the flame signal strength from the ultra violet sensor Oto 15 Vdc 10K ohm minimum voltmeter is required 5 Insert the positive probe of the voltmeter into the positive flame signal test point on the flame relay cover 6 Connect the negative probe to the negative test point on the flame relay cover Table 9 shows the desired signal strengths 7 Allow the burner to ramp up to full fire Table 9 Signal strengths Signal Strength Ultra Violet Sensor Good 5 0 11 0 Marginal 1 7 5 0 Vdc Inadequate 0 0 1 7 Vdc Pre Purge and Main Flame Ignition 20 1 Tumdown 1250 2400 MBh With the manual gas cocks closed move the manual disconnect switch in the heater vestibule to the ON position The system should energize and the combustion blower motor should start indicating that all of the safety limit contacts are closed HLI1 high temperature limit All airflow interlock HPGS1 high pressure gas switch LPGS1 low pressure gas switch The combustion airflow switch CAFS1 should close starting the purge timer the green power light should illuminate on the flame relay panel and the prepurge cycle should begin The combustion air blower should run for approximately 90 seconds to evacuate the heat exchanger of any combustible gases before the ignition sequence This prepurge cycle is initiated before every startu
36. his product and all wamings as provided in this manual Failure to follow all instructions could result in death or serious injury CLCH SVX08A EN TRANE Installation Keep access doors closed to prevent damage to gas train components Cover the unit with a canvas tarp Covering the unit with clear or black plastic sheets is not recommended because this material traps condensed moisture which can cause equipment damage resulting from rust and corrosion Trane warranty does not cover equipment damage due to negligence during storage AWARNING Combustible Materials Maintain proper clearance between the unit heat exchanger vent surfaces and combustible materials Refer to unit nameplate and installation instructions for proper clearances Improper clearances could result in combustible materials catching on fire Failure to maintain proper clearances could result in death or serious injury or property damage Contractors Responsibilities Installing Contractor Unpack the gas heat section and remove the skid e Remove protective coverings e Rigand or movethe section to the air handler location The contractor must provide slings spreader bars clevis hooks pins etc for rigging For outdoor gas heat sections a level roof curb or structural steel support system is required If the gas heat section is provided with an external piping vestibule no support is required for the vestibul
37. m lifting lugs only located at bottom of unit Test lift unit approximately 24 inches to verify proper center of gravity lift point To avoid dropping of unit reposition lifting point if unit is not level Failure to properly lift unit could result in unit dropping and possibly crushing operator technician which could result in death or serious injury and possible equipment or property only damage AWARNING Heavy Objects Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted Each of the cables chains or slings hooks and shackles used to lift the unit must be capable of supporting the entire weight of the unit Lifting cables chains or slings may not be of the same length Adjust as necessary for even unit lift Other lifting arrangements could cause equipment or property damage Failure to follow instructions above or properly lift unit could result in unit dropping and possibly crushing operator technician which could result in death or serious injury Hazardous Gases and Flammable Vapors Exposure to hazardous gases from fuel substances have been shown to cause cancer birth defects or other reproductive harm Improper installation adjustment alteration service or use of this product could cause flammable mixtures or lead to excessive carbon monoxide To avoid hazardous gases and flammable vapors follow proper installation and set up of t
38. nthly Use brush and vacuum cleaner Clean combustion air blower and motor Monthly Use brush and vacuum cleaner Clean exhaust flue Monthly Use brush and vacuum cleaner Clean combustion air dampers Monthly Use brush and vacuum cleaner combustion ab Monthly Use brush or vacuum cleaner obstruction Remove debris Use soap bubble solution equivalent leak tester Check gas piping for leaks Yearly WARNING Do not use open flame to perform a leak test as personal injury or death could occur Service Personnel Maintenance Table 1L Routine maintenance for trained service personnel Task Frequency Remarks Inspect burner components Semiannually Refer to burner and component manufacturer s manuals Visually inspect safety switches Semiannually Inspect airflow sensor lines for obstructions Inspect terminal connections for tightness Inspect switches for fused contacts Check that settings haven t changed or been tampered with Check flue emissions Annually Use a combustion analyzer Check fuel valves main Annually Perform valve leak test per valve manufacturer s instructions Check safety controls e High limit Airflow Low gas pressure High gas pressure Exhaust fan switch where applicable Annually Refer to control manufacturer s instructions Inspect gas pilot assembly Annually Remove and clean if applicable
39. o piping vestibule for obstructions blocking entrance of contacts may be open combustion air Remove obstructions or debris CLCH SVX08A EN 25 Troubleshooting Table 12 Troubleshooting gas heat sections Flame sensor not sensing pilot flame Unit will not run locks out on flame failure Alarm LED illuminated on flame relay panel The manual gas valve may be closed open it 3 1 and 10 1 turndown burners UV flame sensor may be dirty check the lens for dirt soot and so on and clean the lens if necessary Check the ignition cable and wiring for loose frayed connections or broken wiring Repair as necessary Pilot solenoid valve may not be opening Check for voltage at the pilot solenoid valve Check for sufficient gas pressure in the pilot line and adjust the pilot pressure regulator 20 1 Turndown Burners Check flame rod for cleanliness adequate grounding and that it is properly located in the flame Also ensure that temperature at flame rod insulator is no greater than 500 F 260 Perform Ignition Interference Test per component manufacturers manual Low flame signal voltage Check flame signal voltage per procedure in Start Up section 3 1 and 10 1 turndown burners UV flame sensor may be dirty check lens for dirt soot and so on and clean the lens if necessary The flame sensor may be defective replace it 20 1 turndown burners Check flame rod for cleanliness ade
40. on flame failure Press the Reset button to reset the flame relay and attempt to restart the gas heat heat in building Alarm LED illuminated on flame module section If the unit continues to trip out see the troubleshooting symptom relay panel below The combustion air motor may be overloaded Press the Reset button on back side of the combustion air blower motor Thermostat not calling for heat The combustion air blower motor may be defective Replace the motor The modulating gas valve end switch contacts may be open indicating that the gas Combustion airflow switch valve is not fully closed Look for jammed linkages and repair as necessary contacts may be open Replace the modulating gas valve and actuator Check airflow switch sensor tubes for clogging or obstruction Remove debris to clear tubes Check exhaust flue for obstructions Clear obstructions Check inlet air damper for obstructions Clear obstructions Check airflow switch sensor tubes for clogging or obstruction Remove debris to clear tubes Induced draft exhauster fan if so equipped airflow switch contacts Check exhaust flue for obstructions Clear obstructions may be open Check if air balancing damper is closed Open damper Check 3 phase wiring to unit for correct phasing Motor may be running backwards Unit only runs when service access door on piping vestibule is open Combustion airflow switch Check combustion air inlet int
41. ous injury Table 12 Troubleshooting gas heat sections Symptom Probable Cause Recommended Action Loss of power fuse blown or Check the fuse breaker panel and reset or replace the device circuit breaker tripped Check the fuses if provided in gas heat control panel and replace as needed Open the gas valve There may be more than one manual gas valve in the piping system Manual gas valve closed 9 sure to check all valves e Repair or replace the thermostat if defective Set thermostat to heating mode Verify that one of the following safety switches has tripped e High Limit This switch trips due to a high temperature condition in the gas heat section Allow the air handler fan to run and cool heat exchanger The switch must be manually reset when the heat exchanger cools Airflow Interlock This switch trips when there is no or very low airflow over the heat Safety switch tripped exchanger Repair the air handler fan if necessary Also check to see if the unit is running with a variable frequency drive The minimum speed may be set too low High Pressure Gas This switch trips if there is excessive gas pressure in the gas piping Adjust the gas pressure regulator or contact the local gas utility Low Pressure Gas This switch trips when there is very low gas pressure in the gas piping Adjust the gas pressure regulator or contact the local gas utility Unit not running Unit locked out
42. ow requirements for field wiring installation and grounding as described in NEC and your local state electrical codes Failure to follow code could result in death or serious injury VIN NNT Ne 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 CLCH SVX08A EN Tee with cap Normal operation Use Copper Conductors Only Unit terminals are not designed to accept other types of conductors Failure to use copper conductors could result in equipment damage High Voltage Wiring Wiring Entrance Locations Indoor air handlers can accept conduit penetrations on any side of the piping vestibule For outdoor air handlers the recommended conduit entrance into the gas heat section is through the floor of the piping vestibule Terminate conduits on the power junction box or gas heater control panel as appropriate Wiring e All field wiring must bein accordance with the National Electric Code and state and local requirements All wiring including low voltage wiring must be copper conductors only with the insulation rated for 600 volts e Refer to the nameplate located on the gas heater section for the proper Input Voltage Minimum Circuit 15 Ampacity MCA
43. p Atthe end of the purge cycle the ignition transformer and automatic gas valves will energize With the manual gas cocks closed the burner should go into a safety lockout condition The flame safeguard will have to be reset manually Turn the manual disconnect switch in the control panel to the OFF position Note Prior to opening the manual gas cock make certain the modulating gas linkage is set to operate in all positions without binding 1 Turn the manual disconnect switch in the control panel to the ON position After the prepurge sequence is complete the ignition transformer will energize providing ignition spark and the main automatic gas 22 valves will open With the ignition spark energized and the automatic gas valve open slowly open the manual gas shut off cocks Flame should be established Make sure the modulating gas valve is adequately open 2 Atinitial start up air may be trapped in the gas lines so more than attemptto light off may be required Do not allow unburned gas to accumulate in the combustion chamber 3 Once flame is established run the mod motor to position the modulating gas valve wide open 4 The amber Main Flame light should illuminate on the flame relay panel after the ultra violet flame sensor has detected the main flame The flame can be observed through the larger sight glass under the burner Normal flame color is blue abnormal color is yellow indicating a need for adjustments
44. pilot burner The pilot should light immediately The pilot flame gas pressure should be 2 5 to 3 inches wg If the pilot does not light within 10 seconds the flame relay should shut down the system and the red Flame Failure light should illuminate on the flame relay panel If the pilot does not light press the Reset button to clear the fault and repeat the procedure outlined in Startup on page 21 The pilot flame can be viewed through the small sight glass on the burner Cycle the pilot on and off several times to ensure its reliability Turn the manual disconnect switch in the control panel to the Off position Main Bumer Ignition 3 1 10 1 Tumdown 200 2000 1 With the manual disconnect switch in the Off position open the second manual gas valve located downstream of the automatic gas valve regulator in the piping vestibule Note that this valve is just upstream of the modulating gas valve 2 Turn the manual disconnect switch to the On position After the pre purge and pilot cycle the main gas valve will energize and the main burner will light 3 The amber Main Flame light should illuminate on the flame relay panel after the ultra violet flame sensor has detected the main flame The flame can be observed through the larger sight glass under the burner Normal flame color is blue abnormal color is 21 yellow indicating aneed for adjustments by a qualified technician Note that smaller sized heaters have t
45. quate grounding and that it is properly located in the flame Also ensure that temperature at flame rod insulator is no greater than 500 F 260 C CO is above 400 ppm Gas pressure not adjust properly Adjust gas pressure See Proper Gas Pressure on page 14 26 CLCH SVX08A EN Notes CLCH SVX08A EN 27 TRANE Trane optimizes the performance of homes and buildings around the world A business of Ingersoll Rand the leader in creating and sustaining safe comfortable and energy efficient environments Trane offers a broad portfolio of advanced controls and HVAC systems comprehensive building services and parts For more information visit www Trane com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice 2012 Trane All rights reserved CLCH SVX08A EN 10 Nov 2012 We are committed to using environmentally ece that Ingersoll Rand upersedes CLCH SVX08A EN 02 Feb 2012 conscious print practices that reduce waste
46. se dry nitrogen to bring system back to atmospheric pressure before opening system for repairs Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion Excessive heat from soldering brazing or welding with refrigerant vapors present can form highly toxic gases and extremely conosive acids Failure to follow all proper safe refrigerant handling practices could result in death or serious injury Gas Piping Note Installation must conform with the American National Standard 2223 1 NFPA 54 the National Fuel Gas Code latest edition inthe absence of local codes Gas piping should always be done accordance with local codes e Tighten all joints securely e Pipeunions should bea ground joint typeto prevent leakage e Provide adequate support for field installed piping to avoid placing stress on the gas train and controls Run takeoff lines from the side or top of the main gas lineto prevent moisture from being drawn into the gas train of the unit e Provideadrip leg inthe field installed piping installing it near the unit Proper Gas Pressure NOTICE Excessive Gas Pressure The gas pressure at the inlet to the gas train must not exceed 14 in wc A properly sized gas regulator that provides a maximum of 14 in wc of gas pressure must be supplied in the gas inlet line to unit Failure to maintain proper gas pressure co
47. signed for forklift transport Outdoor gas heat sections ship with wooden blocks fastened under the base channel The blocks elevate the section for shipping protection and ease of handling Leave the wooden blocks attached until the section is placed in its final position to avoid bending the base channel during rigging and handling Flue Stack for Outdoor Air Handler A stainless steel flue stack is provided with outdoor air handlers It ships inside the gas heat section and must be mounted on the flue opening on the side of the unit The flue stack must be installed on the gas heat section before assembling the gas heat section to the air handler It is very difficult to remove the flue from inside the unit once the unit is assembled Flue Stack for Indoor Air Handler Indoor air handlers require a field engineered and field installed flue stack Local codes and practices vary throughout the country The engineer should size the flue based on MBh output horizontal and vertical run lengths type of flue material NFPA 54 Fuel Gas Code and local codes The flue should be designed for 800 degrees F 430 degrees If horizontal runs over 20 feet or other static increasing transitions are necessary a flue booster fan will be required Equipment Damage Do not use type B flue stacks with this product as they are not suitable for the flue gas temperatures Failure to follow this recommendation could result in equipment damage
48. tive Equipment PPE in accordance with NFPA 70E or other country specific requirements for arc flash protection PRIOR to servicing the unit Failure to follow recommendations could result in death or serious injury CLCH SVX08A EN 2 Table of Contents Warnings Cautions and Notices 2 Heat Exchanger Condensate Piping 14 Model Number Description 4 WING So bend ane a 15 Overview of Manual 4 High Voltage Wiring 15 Nameplate 4 Wiring Entrance Locations 15 General Information 5 WIG ae eas 15 Product 5 Low Voltage 0 16 Burner Specifications 5 een as 20 Description 6 Initial Startup 20 Pre Installation 8 5 20 Arrival at obsite 8 SAMUD eae EEA 21 Flue Stack for Indoor Air Handler 8 Pre Purge and Pilot Ignition 21 Protective Covering 8 Main Burner Ignition 21 Hardware Kits 8 Pre Purge and Main Flame Ignition 22 Rain Hood 8 Final Check Out
49. tudes of 3 000 feet above sea level or higher may require adjustment of the air fuel linkage for proper combustion Linkage and air fuel adjustment should only be done by an experienced qualified gas heat technician Failure to follow these recommendations could result in death or serious injury or equipment or property only damage Adjustment of gas train linkages is not normally required However for high altitude installations adjustment to the air fuel linkages may be necessary for proper combustion Heater outputs must be derated four percent for every 1000 feet over 2000 feet above sea level When specifying gas heaters the engineer should provide the MBh and airflow required at altitude All Trane literature is based on nominal outputs at sea level It is recommended that the services of an experienced qualified gas heat technician be employed to adjustair fuel linkages for proper combustion Rigging Lifting Refer to the Performance Climate Changer air handler Installation Operation and Maintenance manual CLCH SVX07B EN for instructions on equipment rigging and lifting This manual ships inside the unit fan section Assembly Refer to the design engineer s plans and submittals for the location of the gas heat section in the air handler The gas heat section will arrive at the job site as an individual section Itis not shipped with the air handler Hardware for fastening the gas heat section to the air han
50. uld result in damage to the gas train components To assure sufficient gas pressure at the unit use appropriately sized gas pipe for unit capacity Refer to the National Fuel Gas Code for pipe sizing information 14 Selectan appropriately sized gas pressure regulator to assure the required gas supply pressure is maintained at the unit e Required gas pressure to the gas train is 7 to 14 inches wc 0 25 to 0 5 psig for units through 2400 MBh Note that a minimum of 9 inches wc 0 32 psig is required for 1250 2000 MBh heaters with 10 1 turndown capability For all size units do not exceed 14 inches wc 0 5 psig inlet gas pressure Gas pressure and volume must be maintained stable at high fire Ifthe gas pressure regulator serves more than heating unit it must be sized appropriately to ensure that the inlet gas pressure at each unit is 7 to 14 inches wc while all burners are firing Nine inches wc is required for 1250 to 2000 10 1 turndown heaters Gas pressure must not exceed 14 inches wc when all units are off Check the gas supply pressure before making the final connection to the unit If the gas pressure is too high damage to the gas valve could occur Table 7 Gas supply line connection sizes Gas Output MBh 200 560 700 1000 1250 1750 2000 2400 Connection Size 1 in 11 4 in 11 2 in 2 in Heat Exchanger Condensate Piping Condensate usually
51. wer motor immediately de energize shutting down the heating system The airhandling unit fan should run for a minimum of three to ten minutes after heater shutdown to cool the heat exchanger Seasonal Startup Shutdown Note This procedure should be performed by a qualified technician who is experienced in the servicing of gas heating equipment The following recommended procedures for seasonal shutdown and startup are important to maintaining your equipment in proper working order Seasonal Shutdown When heating system is to be shut down for extended period of time e Disconnect the main power to the heating module section Open the manual disconnect switch the control panel e Close all manual valves in the gas line Seasonal Startup When heating system is to be started for first time in the season Disconnect electrical power Ifthe heat exchanger does not have a p trap condensate drain line connect a hose to the drain valve and drain any accumulated condensate e Check all electrical terminals for tight connections Open all manual gas valves and ensure that these valves operate freely e Check the air shutter and modulating gas valve linkages for tightness e Clean dust dirt and debris from the air shutters on the combustion fan and the air inlet louver e Check the exhaust flue for debris and clean as necessary e Re connect the power and initiate the startup sequenc
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