Trane DFIA Installation Operation & Maintenance Download Page 2

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MUA-SVX01A-EN

Overview of Manual

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hazard Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Model Number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Model Numbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DFIA Model Number Descriptions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DFOA Model Number Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Horizontal Configurations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Vertical Configurations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(DFOA only)

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Vertical Configurations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(DFIA only)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Pre-Installation Check List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Weights and Clearances

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DFIA only

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DFOA Only

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Rigging/ Suspension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pre-installation Verification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

For Canadian Installations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Handling the Equipment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Locating the Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Outdoor, Curb Mounting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Roof Support

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Roof curb Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installation Procedure:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inlet Hood Support (By Others)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Location of Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Electrical Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Field Piping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Field Wiring and Remote Control Installation

. . . . . . . . . . . . . . . . . . . . . . . . . 40

Locating Temperature Controls

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pre-Start-Up Check List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Start-Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General Start-up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Unit Start: Systems with Pilot

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Honeywell™ Flame Safeguard Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Setting Main Flame

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Contents

Summary of Contents for DFIA

Page 1: ...Installation Operation Maintenance February 2007 MUA SVX01A EN DFIA DFOA Direct Fired Make Up Air Units...

Page 2: ...Suspension 25 Installation 28 Pre installation Verification 28 For Canadian Installations 28 Handling the Equipment 28 Locating the Unit 29 Outdoor Curb Mounting 29 Roof Support 29 Roof curb Installa...

Page 3: ...Adjustments 55 Suggested Belt Tension Method 55 Optional Coils and Related Items 56 Condensate Drain Pan 56 Gaskets 56 Annual Maintenance 56 Heater 57 Inspection and Maintenance of Gas Ports 58 Burne...

Page 4: ...4 MUA SVX01A EN Contents...

Page 5: ...s equipment Hazard Identification Warnings and Cautions appear at appropriate sections throughout this manual Read these carefully WARNING Indicates a potentially hazardous situation which if not avoi...

Page 6: ...stallation 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 a...

Page 7: ...is typical All products are semi custom and changes may occur Suggested Tools Instruments Microammeter Volt Ohm Meter Ammeter Tachometer Thermometer Manometer 0 10 of W C Standard Hand Tools Gas Pres...

Page 8: ...15 16 1 7 1 8 1 9 2 0 2 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 109 Unit Size 109 112 Unit Size 112 115 Unit Size 115 118 Unit Size 118 120 Un...

Page 9: ...MBH Input AN 3025 2925 MBH Input AP 3300 3150 MBH Input AQ 3575 3375 MBH Input AR 3850 3825 MBH Input AT 4125 4050 MBH Input AV 4400 4275 MBH Input AW 4675 4500 MBH Input AX 4950 4950 MBH Input AY 55...

Page 10: ...eptacle with trans DIGIT 30 PAINTED CABINET AZ Painted cabinet 0 No Selection 1 Single Speed odp 1800 rpm 2 Single Speed tefc 1800 rpm 3 Single Speed ener effic odp 4 Single Speed ener effic tefc 5 2s...

Page 11: ...tch AT Omit disconnect switch DIGIT 42 HIGH GAS PRESSURE REGULATOR CA High gas press reg 0 5 1 psi AV High gas press reg1 5 psi AW High gas press reg 5 10 psi BH High gas press reg over 10 psi DIGIT 4...

Page 12: ...2 3 4 567 8 9 1 0 1 1 1 2 13 14 15 16 17 18 19 20 21 22 23 2 4 2 6 27 30 32 33 34 35 36 37 38 39 41 42 43 44 45 46 109 Unit Size 109 112 Unit Size 112 115 Unit Size 115 118 Unit Size 118 215 Unit Size...

Page 13: ...H Input AK 2475 2475 MBH Input AL 2750 2700 MBH Input AP 3300 3150 MBH Input AQ 3575 3375 MBH Input AR 3850 3825 MBH Input AT 4125 4050 MBH Input AV 4400 4275 MBH Input AW 4675 4500 AX 4950 4950 MBH I...

Page 14: ...3 Single Speed ener effic odp 4 Single Speed ener effic tefc 5 2s1w odp 1800 900 rpm 6 2s2w odp 1800 1200 rpm 2 Horizontal Arrangement 2 Front 3 Horizontal Arrangement 3 Bottom 4 Vertical Arrangement...

Page 15: ...service receptacle DIGIT 28 PAINTED BASIC UNIT AND ACCESSORIES M Painted basic unit and accessories DIGIT 29 UV FLAME SENSOR N UV flame sensor DIGIT 30 CLOGGED FILTER INDICATOR P Clogged filter indica...

Page 16: ...unit DIGIT 38 CONTROL OPTIONS 2 7 day time clock 5 On off night setback thremostat 7 BACview remote panel DIGIT 39 DISCHARGE LOUVER M Discharge louver DIGIT 40 SEPARATOR FOR UNIT MODEL NUMBER Separat...

Page 17: ...orizontal units are available with special options cooling coils DX chilled water steam and electric coils no burner section Contact your Trane representative for availability and pricing General Info...

Page 18: ...only For all arrangements shown the gas piping and controls are on the near side Selected vertical units are available with special options steam and electric coils no burner section Figure 2 Vertical...

Page 19: ...he air entering side Selected vertical units are available with special options steam and electric coils no burner section Contact your Trane representative for availability Figure 3 DFIA only vertica...

Page 20: ...ar 15 May 15 May 20 May 25 Oct 10 May 20 May 7 5 25 15 30 15 50 20 60 DFIA Filters 2 Quantity 4 4 9 9 10 10 24 24 18 18 35 35 42 42 Size inches 20 x 20 20 x 20 20 x 16 20 x 16 20 x 25 20 x 25 20 x 16...

Page 21: ...hipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problems that may be found Pre Installation Ins...

Page 22: ...ed Make up AIr MUA SVX01A EN Pre Installation Check List If any damage is found the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with transport...

Page 23: ...port Stand Inlet Hood Inlet Damper V bank Filter Burner Section Return Air Discharge Louver A B C D 109 350 180 140 55 165 260 104 70 67 149 67 67 112 350 180 140 55 165 260 104 70 67 149 67 67 115 53...

Page 24: ...et Hood Inlet Damper V Bank Filter Burner Section Return Air Discharg e Louver A B C D 109 350 180 140 55 165 260 104 70 67 149 67 67 112 350 180 140 55 165 260 104 70 67 149 67 67 115 535 210 150 70...

Page 25: ...points Depending on sling length one or more spreaders are recommended In no case should the lift be less than 80 degrees from horizontal or more than 30 degrees from threaded shank direction 3 Set an...

Page 26: ...opposite Note 8 Unit configuration shown may not match specific configuration Lifting points shown are typical per section section order is not relevant Figure 7 Vibration Feet Assembly typical for i...

Page 27: ...figuration shown may not match specific configuration Lifting points shown are typical per section section order is not relevant Figure 9 Hanging assembly typical for Indoor Units Size A 109 118 6 120...

Page 28: ...stion would contain chlorinated halogenated or acidic vapors If located in such an environment premature failure of the unit will occur Handling the Equipment The direct gas fired unit has been design...

Page 29: ...e 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 clear...

Page 30: ...oisted to the roof as the curb can be assembled more conveniently at that location Squaring and leveling of the curb is critical Shims for leveling must be applied to the curb Application of shims to...

Page 31: ...s can be bolted to the hood The bottom of the angle iron support should be fitted with a base The base may sit on the roof and does not have to be fixed to the roof A field provided isolation pad may...

Page 32: ...post mounted Gaskets to be shipped with unit Bolting accessories shipped with curb urb drawings shown are for units which have controls on the standard side Figure 12 DFOA Roof Curb Models 109 118 Dim...

Page 33: ...3 DFOA Roof Curb Models 215 230 Table 4 DFOA Roof Curb Models 215 230 Model Dimensions feet inches A B C D E F G H J K 215 1 4 9 5 8 1 6 15 16 5 1 8 1 10 1 2 1 11 3 8 6 3 5 11 1 2 7 8 7 4 1 2 218 1 7...

Page 34: ...ipped with unit Bolting accessories shipped with curb Curb drawings shown are for units which have controls on the standard side Figure 14 DFOA Roof Curb Models 109 118 Return Air Downstream of Burner...

Page 35: ...turn air opening downstream of burner Model Dimensions feet inches A B C D E F G H J K L M W 215 1 4 9 5 8 1 6 15 16 5 1 8 1 10 1 2 1 11 3 8 6 3 5 11 1 2 7 8 7 4 1 2 5 5 3 4 1 4 1 4 1 2 1 4 218 1 7 9...

Page 36: ...ipped with unit Bolting accessories shipped with curb Curb drawings shown are for units which have controls on the standard side Figure 16 DFOA Roof Curb models 109 118 with mixing box Table 7 DFOA Ro...

Page 37: ...8 DFOA Roof Curb models 215 230 with mixing box Model Dimensions feet inches A B C D E F G H J K L M 215 1 4 9 5 8 1 6 15 16 5 1 8 1 10 1 2 1 11 3 8 6 3 5 11 1 2 7 8 7 4 1 2 1 8 1 4 7 0 218 1 7 9 5 8...

Page 38: ...or serious injury WARNING Electric Shock Controls must be protected from exposure to water Allowing water to drip on the ignition system could result in death or serious injury WARNING Live Electrical...

Page 39: ...gauge connection must be installed immediately upstream of the gas supply connection to the unit WARNING Equipment Damage Disconnect gas piping to the unit when performing a gas supply line pressure l...

Page 40: ...y those with mercury bulb contacts be mounted on a vibration free surface The side of building columns away from the heater or interior walls are usually the location best suited for mounting thermost...

Page 41: ...ventilation requirements for the facility must be addressed separately The heater inlet shall be located in accordance with applicable building code provisions for ventilation air Field constructed in...

Page 42: ...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 Inspection This inspection is very...

Page 43: ...manual gas shut off valves are closed 19 When failure or malfunction of this heater creates a hazard to other fuel burning equipment e g when the heater provides make up air to a boiler room the heat...

Page 44: ...rvicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized When necessary to work with live electrical components have a qualified licensed electrician or o...

Page 45: ...ed in this manual Failure to follow all instructions could result in death or serious injury 5 Turn FAN and HEAT OFF ON switches to ON position Blower fan will run 6 Unit will run for 10 seconds befor...

Page 46: ...t any blowout spots Main burner flame sensor must be activated if applicable Burner must hold in low fire for approximately 10 seconds before modulating up 7 Check pilot and main gas lines for leaks 8...

Page 47: ...PM __________ RPM __________ 3 Check voltage L1__________ L2__________ L3__________ 4 Check control voltage _________________ 7 Check amp draw refer to nameplate Fan Motor 1 L1__________ L2__________...

Page 48: ...x 1 25 500 VA transformer amps 4 Procedure is identical for ODP Energy Efficiency ODP TEFC and Energy Efficient TEFC motors Electrical Requirements Table 9 Motor electrical data full load Amps FLA HP...

Page 49: ...ers may occur It is the installer s responsibility to inspect and correct any problems that may be found Pre Installation Instructions When the unit is received and uncrated check the external data pl...

Page 50: ...none are provided a jumper may be added 3 The damper opens optional 4 Damper interlock closes energizing the supply fan starter and motors Fan light on optional Winter Operation 1 SUMMER OFF WINTER s...

Page 51: ...defects or other reproductive harm Improper installation adjustment alteration service or use of this product could cause flammable mixtures To avoid hazardous gases and flammable vapors follow proper...

Page 52: ...ll fan wheels and housings Clean if necessary c Check that all fan wheels and sheaves are securely set on the shaft d Inspect all bearings and alignment Adjust if necessary e Inspect all V belts Repla...

Page 53: ...ose the grease plugs Pillow Block Bearings Pillow block bearings are used on supply blower s Bearings have been prelubricated with a number 2 lithium based greased Re lubrication should be done with a...

Page 54: ...excess from the area Ensure to note that dampers over 49 inches long have intermediate bearings which require lubrication Air Filters All filter banks should be equipped with a manometer or different...

Page 55: ...ion frequently during the first 24 to 48 hours of run in operation Ideal tension is the lowest tension at which the belt will not slip under peak load conditions Over tensioning shortens belt and bear...

Page 56: ...ampers Inspect gaskets periodically and repair or replace as required Warning Gas Valve Integrity Inspect the tightness of the gas safety shut off valves annually Failure to do so could result in deat...

Page 57: ...scale or foreign material on either side of the mixing plates should be removed with a wire brush Visually check that no holes in the mixing plates are blocked If burner ports are plugged even partial...

Page 58: ...10 Inspect the support means to be sure that everything is firmly anchored in place Inspection and Maintenance of Gas Ports Conduct initial inspection within the first month after commissioning Visua...

Page 59: ...y of gas is admitted to the burner sufficient air to gas mixing takes place in the low fire slot within the burner casting Combustion takes place in this zone Since the burner casting contains the low...

Page 60: ...VX01A EN Maintenance Figure 20 Gas burner section view Flame Rod 71 0201 06 Spark Ignitor 65 0910 28 Pilot Tubing when required Gas Manifold 65 0910 28 Gas Manifold Plan View Burner Plates Removed Pin...

Page 61: ...esired manifold pressure clockwise rotation increases pressure 3 Reconnect the wires to amplifier Note If low bypass is on maximum the desired high fire outlet pressure may not be achieved MR212 Valve...

Page 62: ...Adjust the pressure regulator to obtain the desired manifold pressure 7 W C maximum 3 Reconnect the wires to amplifier MR212 Valve Low Fire Manifold Adjustments 1 Disconnect wires from amplifier term...

Page 63: ...ous to connect the selector at the heater location Connect the DC volt meter capable of reading 0 24 VDC on the modulator or modulator regulator valve terminals Figure 13 Set the temperature to the mi...

Page 64: ...nce readings are approximate Connection of MRT Controls Section 1 1 Wire the system per Wire 1 diagram 2 Connect the DC voltmeter to amplifier terminals 6 and 7 3 Turn the test potentiometer to minimu...

Page 65: ...cuit connected to terminals 6 and 7 Section 3 Observe burner flames and or burner pressure as test potentiometer is turned through full range Note From 0 5 volts heater should be at bypass or low 5 15...

Page 66: ...ed air temperatures are observed the problem is identified with the space temperature sensing and or temperature selecting components and circuits See trouble shooting section If proper delivered air...

Page 67: ...Flame signal is detected after 30 seconds c Ignition pilot valve intermittent pilot valve terminal is energized d Main valve terminal is energized e Delayed 2nd stage main valve terminal is energized...

Page 68: ...s c Interrupted pilot valve terminal is energized RM7895C D EC7895C RM7896C D d Main valve terminal is not energized e Delayed second stage main valve terminal is not energized RM7895C D EC7895C RM789...

Page 69: ...Q7800 Line Voltage Alarm Blower Motor Blower Intermittent Pilot Ignition Main Fuel Valve s Ignition Flame Detector Master Switch L1 Hot L2 See Note 1 Burner Controller Limits Lockout Interlock Includi...

Page 70: ...13 14 15 16 17 18 19 20 21 22 Q7800 Line Voltage Alarm Blower Motor Blower 10 Sec Interupt Pilot Ignition Main Fuel Valve s Ignition Flame Detector Master Switch L1 Hot L2 See Note 1 Burner Controller...

Page 71: ...that can prevent a sufficient reading of the line voltage inputs Low line voltage brownouts The initiate sequence also delays the burner motor starter from being energized and de energized from an int...

Page 72: ...flameout occurs the relay module locks out within 0 8 or 3 seconds depending on the amplifier FFRT Run The RM7895C D EC7895C RM7896C D has a delayed main valve that is energized once the run period i...

Page 73: ...are jumpered Note When the relay module is switched to the test mode it stops and holds at the next run test switch point in the operating sequence Ensure that the run test switch is in the run posit...

Page 74: ...e Note Clipping and removing a site configurable jumper enhances the level of safety Clipping and removing a jumper after 200 hours of operation causes a non resettable fault 100 The relay module must...

Page 75: ...If flame is sensed during a purge period when no flame should be present the control will remain in a purge with the gas valve off until the false flame disappears If the gas valve is found to be powe...

Page 76: ...the gas pressure to the burner 10 Once high and low pressure have been checked and adjusted replace pressure regulator adjustment cap If the desired outlet pressure regulator or flow rate cannot be ac...

Page 77: ...diagram Flame Rod Spark Ignitor Opening 71 0213 12 Pilot Tubing when required Gas Manifold 7 1 2 3 2 3 4 1 4 45 New Flame Rod 71 0213 00 Step 1 Bend Rod at 45 Angle 3 From Fitting Ensure Porcelain is...

Page 78: ...s and wiring are checked The following is a simplified list of possible problems and typical causes and remedies However it does not cover all possibilities and is intended as a guide only The AdaptAi...

Page 79: ...hnical cut sheet on flame safeguard relay a Determine the cause of lockout Push reset button on flame safeguard relay 4 If pilot does not light after prepurge has timed out 10 seconds and voltage is p...

Page 80: ...not check voltage at gas valve If voltage is found to be correct replace gas valve or actuator see Maxitrol trouble shooting guide for modulating valve Main flame rod or scanner not sensing main burne...

Page 81: ...tohelic or null switch not installed correctly a Check wiring Temperature control defective a Install correctly see manufacturers cut sheets Temperature control wired incorrectly a Check and or replac...

Page 82: ...read between 20 to 24 volts If it does not disconnect the wires from the valve and measure the output without the valve connected If it reads 20 to 24 volts refer to the valve manufacturer literature...

Page 83: ...Faulty amplifier Check all items listed in Symptom 2 3 Continuous low fire electronics ok Short circuit or open circuit in modulator coil Measure resistance across modulator terminals with connecting...

Page 84: ...ter with unit operating at full fire Pressure should be equal to the sum of outlet pressure setting plus pressure drop of the valve a Increase inlet pressure if possible Incorrect outlet pressure adju...

Page 85: ...bration procedure Improper discharge air sensor location Sensed temperature thermometer next to discharge air sensor does not represent average discharge air temperature a Move discharge air sensor to...

Page 86: ...irect fired control labeled ADJUST will adjust the discharge temperature by 10 F when rotated Rotating it clockwise will increase the temperature and counter clockwise will decrease the temperature b...

Page 87: ...ed then amplifier may be assumed at fault Install replacement amplifier 3 Continuous low fire electronics ok Open circuit in modulator coil Remove wires connected to amplifier terminals 6 7 and measur...

Page 88: ...g plus pressure drop of the valve plus 1 0 w c a Increase inlet pressure if possible or change to larger valve Consult factory about possibility of using special spring to reduce pressure drop on sele...

Page 89: ...e can be sensed Incorrect discharge air temperature calibration Follow procedures outlined in Burner Operating Principles p 59 a If proper temperatures are not observed refer to discharge air temperat...

Page 90: ...r Check to see if heater is delivering air at minimum discharge air setting a If desired temperature is not reached decrease minimum discharge air temperature setting Insufficient burner capacity Chec...

Page 91: ...ot to exceed 18 months from shipment Extended Warranty The optional extended warranty is a second through fifth year warranty The time starts at the end of the standard 1 year coverage through the fif...

Page 92: ...92 Direct Fired Make up Air MUA SVX01A EN Warranty...

Page 93: ...MUA SVX01A EN Direct Fired Make up Air 93 Warranty...

Page 94: ...act your local Trane office or e mail us at comfort trane com Literature Order Number MUA SVX01A EN Date 03 2007 Supersedes MUA IOM 1B 10 1995 Trane has a policy of continuous product and product data...

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