Installation, Operation, and Maintenance Gas Unit Heater Indoor Gas-Fired Duct Furnace 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.
Warnings, Cautions and Notices WARNING Hazardous Service Procedures! 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. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Introduction WARNING Safety Alert! You MUST follow all recommendations below. Failure to do so could result in death or serious injury. For Your Safety The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. If you smell gas: 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
Table of Contents Warnings, Cautions and Notices . . . . . . . . . . 2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .42 Model Number Descriptions . . . . . . . . . . . . . . 6 Indoor Gas Heating Units . . . . . . . . . . . . . . . 6 Horizontal Blower Assembly . . . . . . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . . . 7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Safety Information . . . . . . . . . . . . .
Model Number Descriptions Indoor Gas Heating Units Note: All units are AGA approved. For CGA approved units, contact Air Handling Product Support.
General Information Description The duct furnace design is certified by ETL for use with natural and LP (propane) gases. ANSI and NFPA Standards as well as Canadian installation codes referred to in this manual are the ones that were applicable at the time that the design was certified. In addition, the duct furnace may be installed on the downstream side of a cooling unit, without need of a bypass duct.
General Information ground, the grounding means must be tested by a qualified electrician. Figure 2. Duct furnace components • Do not insert fingers or foreign objects into the furnace or its air moving device. Do not block or tamper with the heater in any manner while in operation or just after it has been turned off, as some parts may be hot enough to cause injury. • This furnace is intended for general heating applications ONLY.
Unit Dimensions and Weights Figure 4. Table 1. Unit Size 100 125 150 175 200 225 250 300 350 400 Figure 5. Power Vented Furnace—bottom service access Power Vented Duct Furnace A in. (mm) 17-7/8 (454) 20-5/8 (524) 20-5/8 (524) 23-3/8 (594) 26-1/8 (664) 28-7/8 (733) 31-5/8 (803) 37-1/8 (943) 42-5/8 (1083) 48-1/8 (1222) B in. (mm) 15-1/2 (394) 18-1/4 (464) 18-1/4 (464) 21 (533) 23-3/4 (603) 26-1/2 (673) 29-1/4 (743) 34-3/4 (883) 40-1/4 (1022) 45-3/4 (1162) C in.
Unit Dimensions and Weights Table 2. Unit Size 100 125 150 175 200 225 250 300 350 400 Performance data Input MAX MIN MBh (kW) MBh (kW) 100 50 (29.3) (14.6) 125 62.5 (36.6) (18.3) 150 75 (43.9) (22.0) 175 87.5 (51.2) (25.6) 200 100 (58.6) (29.3) 225 112.5 (65.9) (32.9) 250 125 (73.2) (36.6) 300 150 (87.8) (43.9) 350 175 (102.5) (51.2) 400 200 (117.1) (58.6) Output MBh (kW) 80 (23.4) 100 (29.3) 120 (35.1) 140 (41.0) 160 (46.9) 180 (52.7) 200 (58.6) 240 (70.3) 280 (82.0) 320 (93.7) MIN Temp.
Installation: Mechanical NOTICE: Equipment Damage! NOTICE: Maintain Minimum Thermostat Setting! Do not install duct furnaces in corrosive or flammable atmospheres! Premature failure of, or severe damage to the unit could result! Avoid locations where extreme drafts can affect burner operation. Duct furnaces must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors.
Installation: Mechanical Clearances Ductwork WARNING 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 a fire hazard. Failure to maintain proper clearances could result in death or serious injury or property damage. Maintain adequate clearances around air openings into combustion chamber: Table 3.
Installation: Mechanical Figure 8. Recommended ductwork design for elbowed arrangement resulting in a low air temperature rise, install a damper bypass around the gas duct furnace to bypass a portion of the air. Suspension WARNING Heavy Objects! Ensure that all hardware used in the suspension of each duct furnace is capable of supporting the unit weight. Failure to do so could result in unit falling off its mounting location, which could result in death or serious injury.
Installation: Mechanical is facing the unit heater, attach the top panel (P/N 251-07942-00X) to the top bracket and the two (2) side panels. Figure 9. Note: The top panel must be attached so that the side with the larger holes is facing the unit heater; this is a requirement for later steps in this installation procedure. 6.
Installation: Mechanical Note: For 90-degree nozzle assemblies, repeat Step 8 to create a second sub-assembly. 9. For 60- and 90-degree nozzle assemblies: Using the enclosed #8-18 x 1/2 screws, attach the sub-assembly created in Step 8 to the 30-degree assembly installed to the unit (in Step 1 through Step 6 of this procedure). Attach the corresponding panels (i.e., top panel to top panel, right side panel to right side panel, etc).
Installation: Piping Gas Piping company to make certain that the existing line is of adequate size to handle the combined load. WARNING Flammable Vapors! When connecting to existing gas lines be sure to valve off the gas supply ahead of connection point. To avoid explosion or possible fire, always purge all residual gas from piping before cutting into existing line or removing threaded fittings. Failure to remove all gas vapors could result in death or serious injury or equipment or property-only damage.
Installation: Piping Table 4. Gas pipe size(a) Nominal Internal 10 Iron Pipe Diameter, Size, in. in. (mm) (3.0) 1/2 Length of Pipe, ft (m) 20 (6.1) 30 40 50 60 70 80 90 100 125 150 175 200 (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 (16) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 0.
Installation: Piping Pipe directly in to combination valve (see Figure 10, p. 18). 5. A 1/8 in. N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the appliance. 6. Provide a drip leg in the gas piping near the gas duct furnace. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing.
Installation: Piping WARNING Carbon Monoxide! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! A blocked venting system could result in carbon monoxide poisoning. Symptoms of such condition include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms. Failure to follow these recommendations could result in death or serious injury.
Installation: Piping The vent terminal must be installed with a minimum clearance of four feet (1.2 m) from electric meters, gas meters, regulators and relief equipment. Seal ALL vent pipe joints and seams to prevent leakage. Use General Electric RTV-108 or Dow Corning® RTV-732 silicone sealant or 3M #425 aluminum foil tape or equivalent. Reconnect all wires according to the unit’s wiring diagram. Figure 11.
Installation: Piping Figure 12. Adaptor installation Note: USA units—The reducer must be field supplied for 100, 125, 150, and 175 MBh unit sizes. Refer to specification table and installation manual for proper usage. The following instructions apply to Canadian installations in addition to installation and operating instructions: 1. Installation must conform with local building codes, or in absence of local codes, with current CSA B149.
Installation: Piping Figure 13. Horizontal arrangement—single wall vent system to single wall termination Figure 14.
Installation: Piping Figure 15. Horizontal arrangement—single wall vent system to double wall termination Figure 16.
Installation: Piping Figure 17. Horizontal left vent position (rear view of unit heater) To Horizontal Flue Vent Termination Reducer/Increaser Where Applicable Power Venter Tee With Drip Leg & Cleanout Cap At Lowest Point Of Vent System (Typ.) D4072 Figure 18. Horizontal right vent position (rear view of unit heater) Reducer/Increaser Where Applicable To Horizontal Flue Vent Termination Power Venter Tee With Drip Leg & Cleanout Cap At Lowest Point Of Vent System (Typ.) D4073 Figure 19.
Installation: Electrical Electrical Connections WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the 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. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Installation: Electrical results. Use the recommended ranges as a guide. If further information is needed, consult your thermostat manufacturer’s instructions. Recommended Heat Anticipator Setting Ranges: 25 ft. (7.6 m) T’stat Wiring 0.85 to 0.90 A 50 ft. (15.2 m) T’stat Wiring 0.90 to 1.1 A Max. Setting on T’stat Fan Time Delay Control Leads from the time delay controls are factory wired to the junction box (when ordered as an optional component).
Start-Up Operation Power Vented Duct Furnaces with Intermittent (Spark) Pilot Ignition WARNING Check and Test Safety Devices! It is the installer’s responsibility to check all safety controls! Check and test the operational functions of all safety devices supplied with this unit, and ensure that all are operating effectively. Failure to do so could result in unsafe conditions and could result in death, serious injury or property damage. Explanation of Controls 1.
Start-Up 4. The unit should be under the control of the thermostat. Turn the thermostat to the highest point and determine that the power venter motor starts and the pilot and main burners ignite. Turn the thermostat to the lowest point and determine that the power venter motor shuts off and pilot and main burners are extinguished. 5. If pilot adjustment is required, remove the pilot adjustment seal cap and adjust the pilot screw to obtain proper flame. Clockwise rotation decreases pilot flame size.
Start-Up Burner components—intermittent pilot ignition(a) Figure 21. Burner Drawer Common Parts: 1. Main Burners 2. Burner Manifold Note: Manifold shown for duct furnaces with bottom service access. 3. Air Shutters 4. Burner Springs 5. Main Burner Orifice 6. Transformer 7. Pilot Tubing 1 Controls: 8A. Main Gas Valve (Honeywell) 8B. Main Gas Valve (White-Rodgers) 9. Honeywell Ignitor 10. Honeywell Pilot Burner 11. Honeywell Pilot Orifice 13.
Start-Up Gas Input Rate so equipped, the propane gas supply system pressure must be regulated to attain this manifold operating pressure. NOTICE: Table 8. Overfiring! Never overfire the duct furnace, as this could cause unsatisfactory operation, or shorten the life of the heater. Check the gas input rate as follows: 1. Turn off all gas appliances that utilize gas through the same gas meter as the heater. 2. Turn gas on to the unit heater.
Start-Up Figure 22. Main burner flames NORMAL (HARD FLAME) YELLOW TIPPING (MARGINAL) LIFTING (TOO MUCH AIR) YELLOW FLAME (TOO LITTLE AIR) Pilot Adjustment 1. Remove the pilot adjustment cap. 2. Adjust the pilot screw to provide a properly sized flame. 3. A proper pilot flame is a soft steady flame that envelops 3/8- to 1/2-inch (9.5 to 12.7 mm) of the flame sensor tip. 4. Replace the pilot adjustment cap.
Start-Up Gas Equipment Start-Up Customer _____________________________________________ Job Name & Number _________________________ Pre-Inspection Information with Power and Gas Off Type of Equip: Indoor Duct Furnace Serial Number: _________________________ Model Number: _____________________________ Name Plate Voltage: ____________________ Name Plate Amperage: ______________________ Type of Gas: Tank Capacity: Natural LP _______ lb Rating: _______ kg _______ Btu @ ____ °F ________ kW @ ____
Maintenance WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the 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. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Maintenance should close, extinguishing the flame on the main burners. 12. Inspect and service the blower section of the system. 13. Check and test the operational functions of all safety devices supplied with your unit.
Maintenance Figure 23. Power venter assembly (Power Vented Duct Furnaces only) For usage, see Figure 4, p. 9, Figure 5, p. 9, Figure 12, p. 21, Figure 17, p. 24, Figure 19, p. 24, and Table 1, p. 9. Ref. No. Description Ref. No.
Maintenance Installation Instructions for Field Replacement of Power Venter Motor Important: This replacement must be performed only by a qualified technician. Note: All hardware (screws, nuts, washers) that will be removed from the unit will be reused for this motor replacement. DO NOT LOSE ANY OF THESE PARTS. Figure 24. Identification of parts Ref. No. Tools and Parts Needed Wire Stripper and Crimper; Slotted Head and #2 Phillips Head Screwdriver; 3/8-in. Wrench; 1/8-in.
Maintenance How to Order Replacement Parts Please send the following information to your local Parts center; If further assistance is needed, contact the manufacturer’s customer service department. • Model number • Serial Number • Part description and Number as shown in the Replacement Parts Catalog.
Diagnostics Troubleshooting WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the 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. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Diagnostics Table 9. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action F. 1. Shut off gas supply immediately! 1. Inspect all gas piping and repair. 2. Blocked heat exchanger/venting. 2. Clean heat exchanger/flue. 3. Drafts around heater. 3. Eliminate drafts. Refer to “Installation: Mechanical,” p. 11. 4. Negative pressure in building. 4. See “Installation: Piping,” p. 16. Gas Odor. G. Delayed ignition. H. Failure to ignite. 5. Blocked draft hood. 5.
Diagnostics Table 9. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action 2. 2. Pilot adjustment screw turned too low on combination/automatic main gas valve. 3. Air in gas line. 3. Purge air from gas supply. 4. Incorrect lighting procedure. 4. Follow lighting instruction label adjacent to gas valve. 5. Dirt in pilot orifice. 5. Remove pilot orifice. Clean with compressed air or solvent. (Do not ream.) 6. Extremely high or low gas pressure. 6.
Diagnostics Table 9. Troubleshooting guide (continued) Symptoms Possible Cause(s) U. No Spark. 1. Thermostat not calling for heat. 1. Close thermostat contacts. 2. No low voltage. 2. Check for 24V across 24V terminals of S8600. 3. Spark gap closed or too wide. 3. Set gap to 0.1. 4. Broken or cracked ceramic on spark electrode. 4. Replace pilot assembly. 1. Loose S8600 connections. 1. Check all connections, term. PV feeds 24V to pilot valve. 2. Improper gas pressure. 2.
Wiring Diagrams Figure 25.
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.