Installation, Operation and Maintenance Gas Heat Sections for Performance Climate Changer™ Air Handlers Sizes 6-120 for Indoor and Outdoor Units SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning 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.
Warnings, Cautions and Notices Warnings, Cautions and Notices. Note that warnings, 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.
Table of Contents Warnings, Cautions and Notices . . . . . . . . . . 2 Heat Exchanger Condensate Piping . . . . .14 Model Number Description . . . . . . . . . . . . . . . 4 Overview of Manual . . . . . . . . . . . . . . . . . . . 4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 High-Voltage Wiring . . . . . . . . . . . . . . . . . . .15 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiring Entrance Locations . . . . . . . . . . . .
Model Number Description Overview of Manual Use this manual to install, startup, operate, and maintain the Performance Climate Changer™ air handler gas heat section. Carefully review the procedures discussed in this manual to minimize installation and startup difficulties.
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 retain these settings in case the unit should ever need adjustment after service repairs.
General Information 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. An access door is 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.
General Information Table 2.
Pre-Installation Arrival at Jobsite 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.
Installation Trane warranty does not cover equipment damage due to negligence during storage. Keep access doors closed to prevent damage to gas train components. Indoor Units 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. For a gas heat section designed for indoor use, Trane recommends indoor storage.
Installation • 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 (MBh) 200-560 700-1000 Connection Size (NPT) • 1 in. 1 1/4 in. 12501750 20002400 1 1/2 in. 2 in.
Installation Installations at High Altitude WARNING 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. Adjustment of gas train linkages is not normally required.
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 section Rain Hood - Combustion Air Inlet Rain hoods are only required on an outdoor unit with an internal vestibule. Depending on unit size, the combustion air opening will be in the access door or in the side panel.
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 10. Figure 11.
Piping Piping WARNING 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, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs.
Wiring Figure 12. Heat exchanger condensate piping Tee with cap L=H+J+diameter where: H = 5 inches J = 2.5 inches Normal operation H L J Wiring 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.
Wiring Ampacity (MCA) and Maximum Overcurrent Protection (MOP) requirements for proper electrical installation. • Input voltage 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˚F or higher. Radiant heat from the heat exchanger will damage wire insulation that is unsuitable for high temperatures. Table 8.
Wiring Figure 13.
Wiring Figure 14.
Wiring Figure 15.
Operation Pre-Startup 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 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 warnings as provided in this manual.
Operation Figure 17. Control panel for the FDM burner on 12502400 (20:1 turndown) units 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 Turndown, 200-2000 MBh) Move the manual disconnect switch in the heater vestibule to the ON position.
Operation yellow, indicating a need for adjustments by a qualified technician. Note that smaller sized heaters have the sight glass on the side opposite the piping connection side. 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). 4. Check the flame-signal strength from the ultra-violet sensor.
Operation : 7. NOTICE: Over Firing Burners! If fuel and air adjustment linkages were adjusted in the start-up process, insure that the burner is not allowed to over fire. The gas pressure on the manifold must not exceed the gas pressure stated on the Powerflame burner name plate. Over firing operation could result in equipment and property damage.
Routine Maintenance : 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 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 warnings as provided in this manual.
Troubleshooting : WARNING Hazardous Service Procedures! WARNING Hazardous Gases and Flammable Vapors! The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures.
Troubleshooting Table 12. Troubleshooting gas heat sections Flame sensor not sensing pilot flame • 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.
Notes Notes CLCH-SVX08A-EN 27
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