Trane Performance Climate Changer CSAA Series, CSA006, CSA004, CSA010, CSA012 Installation, Operation And Maintenance Manual
...
Installation, Operation,
and Maintenance
Gas Heat — Inshot Style
Performance Climate Changer™ CSAA Air Handlers
Sizes 4 to 30 for Indoor and Outdoor Units
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. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
October 2018
SAFETY WARNING
CLCH-SVX014B-EN
Introduction
Read this manual thoroughly before operating or servici ng
this unit.
Warnings, Cautions, and Notices
Safety advisories appear throughout this manual as
required. Your personal safety and the proper operation of
this machine depend upon the strict observance of these
precautions.
The three types of advisories are defined as follows:
WARNING
CAUTIONs
NOTICE
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 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
and HCFCs such as saturated or unsaturated HFCs and
HCFCs.
Important 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 according to local rules. For
the USA, 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
must also be adhered to for responsible management of
refrigerants. Know the applicable laws and follow them.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous
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
accidents.
WARNI NG
Proper Field Wiring and Grounding
Required!
Failure to follow code could result in death or serious
injury. 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.
WARNI NG
Personal Protective Equipment (PPE)
Required!
Failure to wear proper PPE for the job being undertaken
could result in death or serious injury. Technicians, in
order to protect themselves from potential electrical,
mechanical, and chemical hazards, MUST follow
precautions in this manual and on the tags, stickers,
and labels, as well as the instructions below:
• Before installing/servicing this unit, technicians
MUST put on all PPE required for the work being
undertaken (Examples; cut resistant gloves/sleeves,
butyl gloves, safety glasses, hard hat/bump cap, fall
protection, electrical PPE and arc flash clothing).
ALWAYS refer to appropriate Material Safety Data
Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA
guidelines for proper PPE.
• When working with or around hazardous chemicals,
ALWAYS refer to the appropriate MSDS/SDS and
OSHA/GHS (Global Harmonized System of
Classification and Labelling of Chemicals) guidelines
for information on allowable personal exposure
levels, proper respiratory protection and handling
instructions.
• If there is a risk of energized electrical contact, arc, or
flash, technicians MUST put on all PPE in accordance
with OSHA, NFPA 70E, or other country-specific
requirements for arc flash protection, PRIOR to
servicing the unit. NEVER PERFORM ANY
SWITCHING, DISCONNECTING, OR VOLTAGE
TESTING WITHOUT PROPER ELECTRICAL PPE AND
ARC FLASH CLOTHING. ENSURE ELECTRICAL
METERS AND EQUIPMENT ARE PROPERLY RATED
FOR INTENDED VOLTAGE.
© 2018 Ingersoll Rand CLCH-SVX014B-EN
WARNING
Follow EHS Policies!
Failure to follow instructions below could result in
death or serious injury.
• All Ingersoll Rand personnel must follow Ingersoll
Rand Environmental, Health and Safety (EHS)
policies when performing work such as hot work,
electrical, fall protection, lockout/tagout, refrigerant
handling, etc. All policies can be found on the BOS
site. Where local regulations are more stringent than
these policies, those regulations supersede these
policies.
• Non-Ingersoll Rand personnel should always follow
local regulations.
Copyright
This document and the information in it are the property of
Trane, and may not be used or reproduced in whole or in
part without written permission. Trane reserves the right
to revise this publication at any time, and to make changes
to its content without obligation to notify any person of
such revision or change.
Introduction
Trademarks
All trademarks referenced in this document are the
trademarks of their respective owners.
Revision History
• Updated start-up procedure.
• Updated normal sequence of operation.
• Added new chapter Troubleshooting Guide.
CLCH-SVX014B-EN 3
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . 5
Overview of Manual . . . . . . . . . . . . . . . . . . . 5
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Information . . . . . . . . . . . . . . . . . . . . 6
Burner Specifications . . . . . . . . . . . . . . . . . 6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Receiving and Handling . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging/Shipping . . . . . . . . . . . . . . . . . . 8
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Receiving Checklist . . . . . . . . . . . . . . . . . . 8
Jobsite Storage . . . . . . . . . . . . . . . . . . . . . . . 9
Outdoor Storage . . . . . . . . . . . . . . . . . . . . . 9
Dimensions and Weights . . . . . . . . . . . . . . . . 10
Service Clearances . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contractors’ Responsibilities . . . . . . . . . . . 12
Installing Contractor . . . . . . . . . . . . . . . . . 12
Electrical and/or Controls Contractor . . . 12
Lifting and Rigging . . . . . . . . . . . . . . . . . . . 13
Placement and Assembly . . . . . . . . . . . . . . 13
Flue Stack for Outdoor Air Handlers . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High Altitude Installations . . . . . . . . . . . . 13
Installing Outdoor Flue Stacks . . . . . . . . 13
Installing Indoor Flue Stacks . . . . . . . . . . 14
Installing Rain Hood/Combustion Air Inlet 14
Installing Flue Stack for Hurricane Applica-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Duct Connections . . . . . . . . . . . . . . . . . . . . . 14
Combustion Air Duct . . . . . . . . . . . . . . . . 14
Duct Transitions . . . . . . . . . . . . . . . . . . . . 15
Airflow Direction . . . . . . . . . . . . . . . . . . . 15
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Wiring Checklist . . . . . . . . . . . . . . . . . . . . . . .17
High-Voltage Wiring . . . . . . . . . . . . . . . . . . .17
Wiring Entrance Locations . . . . . . . . . . . .17
Low-Voltage Wiring . . . . . . . . . . . . . . . . . . . .18
Start-Up — Indirect Gas-Fired Heating . . . . .19
Gas Heat Application Rules — Inshot . . . .19
Start-up Procedure . . . . . . . . . . . . . . . . . . . .19
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . 22
Normal Sequence of Operation . . . . . . . . .22
Normal Shutdown . . . . . . . . . . . . . . . . . . . . .23
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .24
Routine Maintenance . . . . . . . . . . . . . . . . . . . .27
Troubleshooting Guide . . . . . . . . . . . . . . . . . .28
VB1285 Sequence of Operations . . . . . . . . .29
VB1287 Sequence of Operations . . . . . . . . .31
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Proper Gas Pressure . . . . . . . . . . . . . . . . 16
Heat Exchanger Condensate Piping . . . . . 16
4 CLCH-SVX014B-EN
General Information
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.
Nameplate
Each air handler section includes a nameplate/label 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 1. Example - performance air handler section nameplate
Note: The unit serial number and order number is
required when ordering parts or requesting service
for a Trane air handler.
CLCH-SVX014B-EN 5
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
Model Number____________________________________________________________________________
Serial Number_____________________________________________________________________________
Air Handler Sales Order Number____________________________________________________________
Air Handler Serial Number_________________________________________________________________
Startup Date_______________________________________________________________________________
Altitude Above Sea Level___________________________________________________________________
Calorific Value_____________________________________________________________________________
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.
Note: This information is required when ordering repair
parts.
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________________________________________________________
6 CLCH-SVX014B-EN
Table 1. Motor and electrical specifications
Specifications Gas Heater Input Power Inducer Motor
Volts 115 115
Hertz 60 60 60
Phase 11
HP n/a n/a
FLA/Amps n/a 6
(a) Powered by a “line to 115 volt” transformer for all gas heaters except 115/60/1 rated units.
Description
The gas heat section consists of an inshot tubular heat
exchanger gas train components, and a control panel for
electrical connections. It is an integral part of the entire airhandling 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. Downstream sections
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.
(a)
General Information
Control Power(a)
CLCH-SVX014B-EN 7
Pre-Installation
Receiving and Handling
Inspection
Upon delivery, thoroughly inspect all components for any
shipping damage that may have occurred, and confirm
that the shipment is complete. See “Receiving Checklist”
for detailed instructions.
Note: Delivery cannot be refused. All units are shipped
F.O.B. factory. Trane is not responsible for shipping
damage.
Packaging/Shipping
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.
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.
Protective Covering
The large openings of the gas heat section are covered
with shipping protection parts. The parts are 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.
Flue Stack
A stainless-steel flue stack is provided with outdoor air
handlers. It ships inside the gas heat section or in one of
the other sections of the air handler, and must be mounted
on the flue opening on the side of the unit.
NOTICE
Equipment Damage!
Failure to follow this instruction could result in
equipment damage. Do not use type B flue stacks with
this product as they are not suitable for the flue gas
temperatures.
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 and is shipped
attached. Rain hoods for units with hurricane certifications
are 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.
Handling
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 4 to 30 will be shipped with a shipping
skid designed for forklift transport. If shipped on a skid, do
not remove the gas heat section from the skid at this time.
Receiving Checklist
Complete the following checklist immediately after
receiving shipment to detect possible shipping damage.
Check to ensure that the shipment is complete. Small
components may ship inside the unit or ship
separately. Check the parts list to ensure all materials
are present. If any component is missing, contact your
local Trane sales office.
Check all units, components, connections, and piping.
Check all doors, latches and hinges. Inspect interior of
each unit or section. Check for rattles, bent corners, or
other visible indications of shipping damage.
If a unit is damaged, make specific notations
concerning the damage on the freight bill. Do not
refuse delivery.
Notify the carrier’s terminal of the damage
immediately by phone and mail. Request an
immediate joint inspection of the damage by the
carrier and consignee.
Notify your Trane sales representative of the damage
and arrange for repair. Do not attempt to repair the unit
without consulting the Trane representative.
Inspect the unit for concealed damage as soon as
possible after delivery. Report concealed damage to
the freight line. It is the receiver’s responsibility to
provide reasonable evidence that concealed damage
did not occur after delivery. Take photos of damaged
material if possible.
Note: Concealed damage must be reported within 15
days of receipt.
8 CLCH-SVX014B-EN
Pre-Installation
Jobsite Storage
Indoor air handlers and field-installed accessories must be
protected from the elements. A controlled indoor
environment is recommended for proper storage.
Note: All factory shipping protection should be removed,
This wrapping is for transit protection only.
The unit controller and all other electrical/electronic
components should be stored in conditions of -20°F to
120°F and 5 to 95 percent relative humidity, noncondensing. Electrical components are not moisturetolerant.
Gas heat sections for outdoor units require no special
protection for storage prior to installation.
Outdoor Storage
NOTICE
Corrosion!
Plastic tarps can cause condensation to form in and on
the equipment, which could result in corrosion damage
or wet storage stains. Use only canvas tarps to cover air
handlers and components.
Outdoor storage is not recommended for units that will be
installed indoors. However, when outdoor storage is
necessary, several things must be done to prevent
damage:
Note: Keep the equipment on the original wooden blocks/
skid for protection and ease of handling.
• Select a well-drained area, preferably a concrete pad or
blacktop surface.
• Place the unit on a dry surface or raised off the ground
to assure adequate air circulation beneath the unit and
to assure no portion of the unit will contact standing
water at any time.
• Cover the unit securely with a canvas tarp.
• Do not stack units.
• Do not pile other material on the unit.
Trane warranty does not cover equipment damage due to
negligence during storage.
CLCH-SVX014B-EN 9
Dimensions and Weights
Filter mixing box
Coil
Fan
Gas heat
Access
door
UV
lights
VFD
F
E
D
C
B
A
Service Clearances
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 exchanger. Refer to the
following figure for service clearance recommendations
for the air handler.
Note: At a minimum, the clearance dimensions listed in
table below are recommended on one side of the
unit for regular service and maintenance. Refer to
Figure 2. Service clearance for indoor units
as-built submittal for locations of items such as
filter access doors, coil, piping connections, motor
locations, hoods, pipe cabinets, etc. Sufficient
clearance must be provided on all sides of unit for
removal of access panels, plug panels, or sectionto-section attachment brackets. Clearance for
starters, VFDs, or other high-voltage devices must
be provided per NEC requirements. For specific
dimensional and weight information, refer to the
unit submittals. The dimensions and weights in this
manual are approximate. Trane has a policy of
continuous product and product data
improvement and reserves the right to change
design and specifications without notice.
Table 2. Service clearance dimensions (in)
Component Description 4 6 8 10121417212530
F Gas Heat n/a5663747984849292106
10 CLCH-SVX014B-EN
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