Trane Gas Heat Sections Installation and Maintenance Manual
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. Improper ly installed, adjusted or alt ered 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
CLCH-SVX08A-EN
Warnings, Cautions and Notices
Warnings, Cautions and Notices.
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 situ ations 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:
appropriate sections throughout this literature. Read
these carefully:
WARNING
CAUTION
NOTICE:
Warnings, Cautions and Notices appear at
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous
s
situation which, if not avoided, could
result in minor or moderate injury. It
could also be used to alert against
unsafe practices.
Indicates a situation that could result in
equipment or property-damage only
Note that warnings,
Important
Environmental Concerns!
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 oz one 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. T rane advocates the responsible handling of
all refrigerants-including industry replacements for CFCs
such as HCFCs and HFCs.
must also be adhered to for responsible management of
refrigerants. Know the applicable laws and follow them.
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 r equirements f or
field wiring installat ion and grounding as described in
NEC and your local/state electrical codes. Failure to
follow code could result in death or serious injury.
WARNING
Personal Protective Equipment (PPE)
Required!
Installing/servicing this unit coul d result in exposure to
electrical, mechanical and chemical hazards.
• Before installing/servi cing this unit, technicians
MUST put on all P ersonal Protectiv e Equipment (PPE)
recommended for the work being undertaken.
AL WAYS r efer to appropr iate MSDS sheets and OSHA
guidelines for proper PPE.
• When work ing with or ar ound hazar dous c hemicals,
ALWAYS refer to the appropriate MSDS sheets and
OSHA guidelines for information on allowable
personal exposure levels, proper respiratory
protection and handling recommendations.
• If there is a risk of arc or flash, tec hnicians MUST put
on all Personal Protective Equipment (PPE) in
accordance with NFPA 70E or other country-specific
requirements for arc flash protection, PRIOR to
servicing the unit.
Failur e to f ollow r ecommendation s could resul t in death
or serious injury.
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 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 CLCH-SVX08A-EN
Table of Contents
Warnings, Cautions and Notices
Model Number Description
Overview of Manual
Nameplate
General Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 5
Product Information
Burner Specifications . . . . . . . . . . . . . . . . . 5
Description
Pre-Installation
Arrival at Jobsite
Flue Stack for Indoor Air Handler . . . . . . . 8
Protective Covering . . . . . . . . . . . . . . . . . . 8
Hardware Kits . . . . . . . . . . . . . . . . . . . . . . . 8
Rain Hood . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instruction Manuals . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . 8
Receiving Inspection
Storage
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Outdoor Units . . . . . . . . . . . . . . . . . . . . . . . 8
Indoor Units . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contractors’ Responsibilities
Installing Contractor . . . . . . . . . . . . . . . . . . 9
Electrical and/or Controls Contractor . . . 10
. . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . 9
Service Clearance Recommendations
Installations at High Altitude
Rigging/Lifting
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 11
Duct Connections
Combustion Air Duct . . . . . . . . . . . . . . . . 11
Duct Transitions . . . . . . . . . . . . . . . . . . . . 11
Airflow Direction . . . . . . . . . . . . . . . . . . . 11
Rain Hood - Combustion Air Inlet . . . . . . 12
Flue Stack Installation
Outdoor Gas Heat Section . . . . . . . . . . . . 13
Indoor Gas Heat Section . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . 11
. . . . . . . . . . 2
. . . 10
Heat Exchanger Condensate Piping . . . . .14
Wiring
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
High-Voltage Wiring
Wiring Entrance Locations . . . . . . . . . . . .15
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Low-Voltage Wiring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Initial Startup
Pre-Startup . . . . . . . . . . . . . . . . . . . . . . . . .20
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pre-Purge and Pilot Ignition . . . . . . . . . . .21
Main Burner Ignition . . . . . . . . . . . . . . . . .21
Pre-Purge and Main Flame Ignition . . . . .22
. . . . . . . . . . . . . . . . . . . . . . . . .20
Final Check Out
Normal Shutdown
. . . . . . . . . . . . . . . . . . .15
. . . . . . . . . . . . . . . . . . . .16
. . . . . . . . . . . . . . . . . . . . . . .22
. . . . . . . . . . . . . . . . . . . . .23
Seasonal Startup/Shutdown
Seasonal Shutdown . . . . . . . . . . . . . . . . . .23
Seasonal Startup . . . . . . . . . . . . . . . . . . . .23
Routine Maintenance
. . . . . . . . . . . . . . . . . . . .24
Heating Mode Maintenance
Service Personnel Maintenance
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . .25
. . . . . . . . . . . .23
. . . . . . . . . . . . .24
. . . . . . . . .24
Piping
CLCH-SVX07C-EN 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gas Piping
Proper Gas Pressure . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Model Number Description
Overview of 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, t he build-section position for installation, and the
unit model number.
Figure 1. Performance 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.
4 CLCH-SVX08A-EN
General Information
Product Info rmation
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
retain these settings in case the unit should ever need
adjustment after service repairs.
Note: This information is required when ordering repair
parts.
settings for whic h the g as heat unit is capable. R ecord and
Model Number____________________________________________________________________________
Serial Number_____________________________________________________________________________
Air Handler Sales Order Number____________________________________________________________
Air Handler Serial Number_________________________________________________________________
Startup Date_______________________________________________________________________________
Altitude Above Sea Level___________________________________________________________________
Calorific Value_____________________________________________________________________________
Burner Specifications
Maximum Firing MBh______________________________________________________________________
Minimum Firing MBh______________________________________________________________________
Type of Gas________________________________________________________________________________
Maximum Inlet Gas Pressure_______________________________________________________________
Minimum Inlet Gas Pressure___________________________________________________________ _____
Temperature Rise (ºF)_______________________________________________________________________
Manifold Pressure at Maximum MBh________________________________________________________
Table 1. Motor and Electrical Specifications
Specifications Gas Heater Input Power Burner Motor
Volts 115 115
Hertz 60 60 60 60
Phase 1 1
HP n/a n/a
FLA/Amps n/a 6
MCA n/a n/a n/a
MOP n/a n/a n/a
Note:1Powered by a "line to 115 volt" transformer for all gas heaters except 115/60/1 rated units.
1
Control Power
1
Exhaust Motor
CLCH-SVX08A-EN 5
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 serv ice 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 blank access section and discharge
temperatures must be controlled so as not to exceed the
Figure 2. Gas heat section with external vestibule Figure 3. Gas heat section with internal 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.
6 CLCH-SVX08A-EN
Table 2. Vestibule locations
General Information
Unit Size
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 1250 Int
10 200 Ext 35 1000 Ext 66 1500 Int
10 360 Ext 35 1 250 Ext 66 1750 Int
12 200 Int 35 1500 Ext 66 2000 Ext
12 360 Ext 35 1 750 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 1 000 Ext 80 1500 Int
17 560 Ext 40 1250 Ext 80 1750 Int
17 700 Ext 40 1 500 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
(MBH)
Gas Output
Vestibule
Type Unit Size
Gas Output
(MBH)
57 2000 Ext
Vestibule
Type Unit Size
Gas Output
(MBH)
Vestibule
Type
CLCH-SVX08A-EN 7
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. Indo or sections size 3-30 will
also be shipped with a shipping skid designed 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 th e side of the unit. The
flue stack mus t 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 fieldinstalled flue stack. Local codes and practices vary
throughout the country . The engineer shoul d 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 staticincreasing transitions are necessary , a flue booster fan will
be required.
Hardware Kits
Hardware kids ship inside the air handler fan section in a
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 sepa r ate woo d
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 he at section, inspect it for 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 damage.
• Open the access door and check for internal, hidden
damage. Concealed damage must be reported within
15 days of receipt.
• Locate the hardware kit.
• Locate the flue stack if it is an outdoor unit.
• If shipped on a skid, do not remove the gas heat section
from the skid at this time.
NOTICE:
Equipment Damage!
Do not use type B flue stacks with this product as they
are not suitable for the flue gas temperatur es. Failur e to
follow this recommendation could result in equipment
damage.
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 it is ready to install to
prevent debris from entering the section.
8 CLCH-SVX08A-EN
Storage
Outdoor Units
A gas heat section designed for outdoor use requires no
special protection during storage. Select a solid, welldrained 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 un it. 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.
Installation
T rane war ranty does not cover equipment damage due to
negligence during storage.
Indoor Units
For a 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
:
WARNING
Improper Unit Lift!
Do not lift unit from top! Lift unit from 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 proper ly lift unit could result in unit
dropping and possibly crushing operator/technician
which could result in death or serious injury and
possible equipment or pr operty-only damage.
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.
T rane war ranty does not cover equipment damage due to
negligence during storage.
WARNING
Combustible Materials!
Maintain proper clearance between the unit heat
exchanger, vent surfaces and combustible materials.
Refer to unit nameplate and installation instr uctions 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
WARNING
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 arrang ements could cause
equipment or property damage. Failure to follow
instructions above or properly lift unit could result in
unit dropping and possib ly crushing operator/
technician which could r esul t in death or serious injury .
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 t his
product and all warnings as provided in this manual.
Failur e t o f ollo w all instr u ctions could result in death or
serious injury.
Installing Contractor
• Unpack the gas heat section and remove the skid.
• Remove protective coverings.
• 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
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 inlet s 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.
• Assemble the gas heat section to the air-handling
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.
CLCH-SVX08A-EN 9
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