Trane Gas Heat Sections for Performance Climate Changer Air Handlers, Installation, Operation And Maintenance Manual

Page 1: ...mproperly 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 Gas Heat Sections for Performance Climate Changer Air Handlers Sizes 6 120 for Indoor and Outdoor Units CLCH SVX08A EN Installation Operation ...

Page 2: ... 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 recycling of certain refrigerants and the equipment that is used in these service procedures In addition some states...

Page 3: ...ure to electrical mechanical and chemical hazards Before installing servicing this unit technicians MUST put on all Personal Protective Equipment PPE recommended for the work being undertaken ALWAYS refer to appropriate MSDS and OSHA guidelines for proper PPE When working with or around hazardous chemicals ALWAYS refer to appropriate MSDS and OSHA guidelines for information on allowable personal e...

Page 4: ...orage 11 Outdoor Air Handler Gas Heat Sections 11 Indoor Air Handler Gas Heat Sections 11 Installation 12 Contractors Responsibilities 12 Installing Contractor 12 Electrical and or Controls Contractor 13 Service Clearance Recommendations 14 Installations at High Altitude 15 Rigging Lifting 15 Assembly 15 Duct Connections 15 Combustion Air Duct 15 Duct Transitions 16 Airflow Direction 16 Rain Hood ...

Page 5: ...50 2400 MBh Output 22 Low Voltage Wiring 22 Operation 26 Initial Startup 26 Pre Startup 26 Startup 27 Final Check Out 30 Normal Startup 30 Normal Shutdown 31 Seasonal Startup Shutdown 31 Recommendations for Seasonal Shutdown 31 Recommendations for Seasonal Startup 31 Routine Maintenance 32 Heating Mode Maintenance 32 Service Personnel Maintenance 32 Troubleshooting 33 ...

Page 6: ...ion and startup difficulties 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 Note The unit serial number and order number is required when ordering parts or requesting service for a Trane air ...

Page 7: ...___________________ Altitude Above Sea Level___________________________________________________________________ Calorific Value_____________________________________________________________________________ Burner Specifications Maximum Firing MBh______________________________________________________________________ Minimum Firing MBh__________________________________________________________________...

Page 8: ...tions must be separated by a blank access section and discharge temperatures must be controlled so as not to exceed the 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...

Page 9: ...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 2...

Page 10: ...eer 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 C If horizontal runs over 20 feet or other static increasing transitions are necessary a flue booster fan will be required NOTICE Equipment Damage Do NOT use type B flue stacks with this product as the...

Page 11: ... 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 Note Trane warranty does not cover equipment damage due to negligence during storage Indoor Air Handle...

Page 12: ...s Rig and or move the 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 vestibule For outdoor sections install the flue stack The flue ...

Page 13: ...at section must be field provided All power and control wiring for any section downstream of the gas heat must be field provided WARNING 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 mixture...

Page 14: ...97 C UV Lights 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 52 56 58 58 D external starter or VFD 61 61 61 61 61 61 61 61 64 64 64 64 64 64 64 64 64 64 64 D internal starter or VFD 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 E fan 48 48 48 48 51 54 58 61 60 66 66 66 70 77 77 93 93 101 101 F gas heat Ext Vestibule N A N A 89 90 108 100 100 105 115 115 118 136 140 156 156 170 179 180 N ...

Page 15: ...dividual section It is not shipped with the air handler Hardware for fastening the gas heat section to the air handler 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 Conn...

Page 16: ...ransitions 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 i...

Page 17: ...on air opening ship loose and must be installed at the job site The assembly consists of the hood butyl tape and number 10 screws Install butyl tape between the hood and the side panel or door panel see Figure 8 Locate the bottom edge of the hood 2 3 8 inches below the bottom edge of the inlet air opening and center the hood left to right over the inlet air opening see Figure 9 Install the hood to...

Page 18: ...rom bird nests and beehives The rain hood or screen must be field provided Note It is very difficult to remove flue from inside the unit once the unit is assembled Indoor Gas Heat Section For indoor gas heat sections a field engineered flue stack is required Install according to local codes See connection sizes in Table 6 Figure 10 Outdoor air handler flue stack Figure 11 Outdoor air handler flue ...

Page 19: ...ely Pipe unions should be a ground joint type to prevent leakage 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 line to prevent moisture from being drawn into the gas train of the unit Provide a drip leg in the field installed piping installing it near the unit Proper Gas Pressure NOTI...

Page 20: ...th 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 dis...

Page 21: ...enetrations 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 All Gas Heaters All field wiring must be in accordance with the National Electric Code and state and local requirements All wiring incl...

Page 22: ...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 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 Table 8 Power supply requirements 3 1 and 10 1 Burner Turn...

Page 23: ...CLCH SVX08A EN 23 Wiring Figure 13 200 1000 MBh 3 1 or 10 1 turndown wiring diagram ...

Page 24: ...24 CLCH SVX08A EN Wiring Figure 14 1250 2000 MBh 3 1 or 10 1 turndown wiring diagram ...

Page 25: ...CLCH SVX08A EN 25 Wiring Figure 15 1250 2400 MBh 20 1 turndown wiring diagram ...

Page 26: ...t sections have been run tested 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...

Page 27: ... 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 air handling unit fan The field installed supply fan interlock and primary airflow switch contacts AI1 should close 2 The high temperature limit switch contacts HL1 the modulating gas valve actuator and its end switch con...

Page 28: ...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 27 The pilot flame can be viewed through the small sight glass on the burner Cycle the pilot on and off several times to ensure it...

Page 29: ...sequence is complete the ignition transformer will energize providing ignition spark and the main automatic gas 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 At initial start up air may be trapped in the gas lines so more than one attem...

Page 30: ...ductive harm Improper installation adjustment alteration service or use of this product could cause flammable mixtures To avoid hazardous gases and flammable vapors follow proper installation and set up of this product and all warnings 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...

Page 31: ... The following recommended procedures for seasonal shutdown and startup are important to maintaining your equipment in proper working order Recommendations for Seasonal Shutdown When heating system is to be shut down for extended period of time Disconnect the main power to the heating module section Open the manual disconnect switch in the control panel Close all manual valves in the gas line Reco...

Page 32: ...ndensate from heat exchanger Weekly This task only needs to be done if the unit runs for extended hours at low fire Clean air inlet louver Monthly 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 Check combustion air inlets...

Page 33: ...hen 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 warnings provided could result in death or serious injury WARNING Hazardous Gases and Flammable Vapors Exposure to hazardous gases from fuel substances have bee...

Page 34: ...ry 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 Induced draft exhauster fan if so equipped airflow switch contacts may be open Check airflow switch sensor tubes for clogging or obstruction Remov...

Page 35: ...CLCH SVX08A EN 35 Notes ...

Page 36: ...nvironments 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 2011 Trane All rights reserved CLCH SVX08A EN 02 Feb 2011 Supersedes NEW ...