Trane TR250 Service & Installation Manual Download Page 30 | Manualshive

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Figure 19: Wiring connection diagram.

1303103801 rev H

W
iring Connection Diagram / Schéma de Connexion de Câblage

Forced Draft Gas Heaters / Chaudière Gas à

Air pulsé

Flue Gas

T

e

mperature

Limit Switch

Commutateur limiteur de

température des gaz de

combustion

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Summary of Contents for TR250

Page 1: ...l the fire department Installation and service must be per formed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage injury or death Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance T...

Page 2: ...itch 35 Two speed pump 35 Temperature adjustment 36 Temperature lock out 37 Fahrenheit v Celsius 37 Heating mode 37 Retry Failure of light 38 Recycle Loss of flame 38 Keypad inputs 38 Automatic reset time 39 Periodic inspection 39 Winterization 39 Draining the heat exchanger 40 Spring start up 40 Section IV Technician Service 41 General 41 Maintenance 41 Heat exchanger inspection and cleaning 41 C...

Page 3: ... pools and may also be used with spas Do NOT use with storable pools A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its origi nal integrity Though this product is designed for outdoor use it is st...

Page 4: ... through an unprotected suction outlet sump or suction outlet cover which is damaged broken cracked missing or unsecured can result in evisceration disembowelment Mechanical Entrapment There is potential for jewelry swimsuit hair decorations finger toe or knuck le to be caught in an opening of a suction outlet or suction outlet cover resulting in mechanical entrap ment WARNING To reduce the risk o...

Page 5: ...ing pool and spa water circulation system all system and pump controls must be in off position and filter manual air relief valve must be in open position Before starting system pump all system valves must be set in a position to allow system water to return back to the pool Do not change filter control valve position while system pump is running Before starting system pump fully open filter manua...

Page 6: ...h the advice of a physician Always stir pool spa water before entering the pool spa to mix in any hot surface layer of water that might exceed healthful temperature limits and cause injury Do not tamper with controls because scalding can result if safety controls are not in proper working order 7 Persons with a medical history of heart disease circulatory problems diabetes or blood pressure prob l...

Page 7: ... damage or failure The heat exchanger in your Trane pool heater is made from the highest quality of copper and nickel Cu pronickel materials The premium materials and the exacting processes used in the manufacture of the heat exchanger is state of the art in pool heater design and manufacture Yet it remains vital that the heat exchang er be protected from damaging or corrosive chemicals insufficie...

Page 8: ...n the bypass so that corrosive and potentially damaging water will not flow through the heater and there fore the heat exchanger Close the bypass valve once the water is properly balanced Failure to close the bypass valve when attempting to operate the heater will result in extensive damage to the heat exchanger Ensure water flow through the heater is restored before operating the heater A bypass ...

Page 9: ... vary depending on the model Parts necessary to convert the heater for outdoor installation at altitudes up to 7 700 ft minimum are included with the heater Conversion is accomplished by replacement of the blower air inlet plate and for indoor ap plications installation of a special vent pressure switch The blower air inlet plates are clearly marked with the compatible heater model s vent configur...

Page 10: ...r your altitude 9 Re install heater front door 10 If connected turn pump main gas valve and heater power back on 11 Activate heater and check for proper function Table 1 lists the maximum altitudes each model is designed for with a no modifications b the included conversion plate installed and c the accessory conversion kit FDXLHAK1930 installed sold separately TABLE 1 Heater Model Fuel Maximum In...

Page 11: ...ct a heater s combustion air and venting areas 3 Do not install this appliance under an overhang less than 3 feet from the top of the appliance The area under the overhang must be open on 3 sides 4 Do not install the heater where water spray from ground sprinkler can contact the heater The water could splash on the controls causing electrical damage Figure 2 Shipping Screws Inside Front Access Pan...

Page 12: ...ure The vent opening shall have a minimum free area of 1 square inch per 4 000 btu hr input rating of all gas appliances in the enclosure See Table 5 9 If the heater is to be installed in front of an exterior wall with with vinyl siding increase the clearance from the back of the unit shown in Table 2 to 12 inches 10 For minimum exhaust vent clearances for all building openings including but not l...

Page 13: ... the front access panel 1 screw 4 Remove the rear access panel 4 screws 5 Position the heater on the pad so that all tap cons can bite into the pad Observe local codes regarding pad construction some jurisdictions specify a minimum thickness for concrete pads 6 Slip the tie down brackets into the slots in the front of the heater base pan from under side of the heater so that they are positioned as...

Page 14: ...Pressure Horizontal or Vertical Venting Applications TR250 50 ft max with 1 elbow 40 ft max with 2 elbows or 30 ft max with 3 elbows horizontal or vertical Single or Double Wall Stainless Steel Sealed Vent Pipe Horizontal or Vertical Termina tion Immediately Outside Wall of House Building UHXPOSHZ14002 TR400 CLEARANCES The heater must be installed such that the installation and service clearances ...

Page 15: ...all have a minimum free area of 1 square inch per 4 000 btu hr of total input rating of all equipment in the enclosure See Table 5 When installing a heater below ground in a pit combustion and ventilation air openings must be provided as shown in Figure 5 2 When communicating with the outdoors through hori zontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 btu hr o...

Page 16: ...ugh an approved roof jack or roof thimble A listed vent cap must be used Gas vents that are spaced less than 8 ft horizontally from a vertical wall or similar obstruction shall terminate not less than 2 ft above any portion of a building within 10 ft Gas vents that are spaced 8 ft or more horizontally from a vertical wall or similar obstruction shall terminate above the roof a distance H based on ...

Page 17: ...orizontal or vertical See Table 9 for vent terminals which are approved OBTAINING VENT PIPE AND TERMINALS A variety of double wall vent components including terminals elbows and straight lengths which will satisfy the needs of most applications of your Trane pool heater are available The parts are listed in the ser vice parts section in the back of this manual Also the instruction sheet included w...

Page 18: ...nch Included in UHX kit NAT LP Single Wall Heatfab Saf T Vent EZ Seal P N 980x Heatfab P N 5890CI Heatfab P N 5800CI Double Wall Heatfab Saf T Vent CI Plus P N CCA08Lx Heatfab P N CCE08WP Heatfab P N CCA08RC TR400 UHXPOSHZ14002 2 000 ft 6 inch Heatfab P N 1501646501 or DuraVent P N 810003725 NAT LP Single Wall Heatfab Saf T Vent EZ Seal P N 960x or DuraVent FasNSeal P N FSVLx06 Heatfab P N 9614TER...

Page 19: ...eater cabinet from the hole in the right hand metal side panel in the heater and re route them out through the left hand metal side panel in the heater 4 Remove countersunk screws on the heater top and remove louvered exhaust panel on heater top see Figure 8 5 Remove the heater top flue cover by removing 3 screws on each side of the heater see Figure 8 6 Remove screws and remove rain shield assemb...

Page 20: ...vered Exhaust Panel Rain Shield Assembly Heat Exchanger Assembly Temperature Limit Switches Drain Plug or Valve Pressure Switch Port Upper Plastic Heater Side Panel Ignition Control Circuit Board Upper Plastic Heater Side Panel Front Access Panel ...

Page 21: ... of 0 5 psig or less at a pressure drop of 0 50 in wc Table 11 Propane Gas Pipe Sizing Low Pressure Single Stage Regulation Distance from Tank Regulator Outlet to Heater Gas Valve Inlet Model TR250LP TR400LP Btu hr Input 250 000 400 000 Line Material Iron Pipe Tubing Iron Pipe Tubing 0 to 50 ft 1 1 1 8 1 50 to 100 ft 1 1 1 8 1 1 4 100 to 200 ft 1 1 4 1 1 4 200 to 300 ft 1 1 4 1 1 2 Based upon an i...

Page 22: ...r Input 250 000 400 000 Line Material Iron Pipe Tubing Iron Pipe Tubing First Stage 0 to 50 ft 1 2 1 2 1 2 1 2 50 to 100 ft 1 2 1 2 1 2 5 8 100 to 150 ft 1 2 1 2 1 2 5 8 Second Stage 0 to 10 ft 1 2 3 4 3 4 7 8 Based upon an inlet gas pressure of 10 psig at a pressure drop of 1 psi Based upon an inlet gas pressure of 11 in wc at a pressure drop of 0 50 in wc ...

Page 23: ...3 4 or 1 NPT If more than one appliance is installed on the gas line consult the local gas company for the proper gas line size Questions on the installation of the proper gas line size can be directed to 908 282 4897 NATURAL GAS The gas meter must have the capacity to supply enough gas to the pool heater and any other gas appli ances if they are on the same pipeline Example 225 meter 225 000 BTUH...

Page 24: ... by solvent welding PVC glue The fittings will accept either a 2 pipe or a 2 1 2 pipe fitting and seal to the heater header with rubber gaskets On plastic headers the fittings are secured in place with plastic union nuts and on bronze headers ASME models the fittings are secured in place with bolts Assemble these parts to the heater prior to plumbing Tighten union nuts or bolts securely before glu...

Page 25: ...ied for the heater 3 Once the valve is set note the position and remove the valve handle to prevent further adjustment ATTENTION Improperly adjusted manual bypass valves will result in damage to the heater if the flow rates are not maintained as specified in Table 14 under all operating conditions The heat exchang er will fail and this damage will not be covered under warranty Table 14 Allowable W...

Page 26: ... 13 Typical plumbing to pool Figure 14 Multiple heater system Figure 16 Automatic chlorinator Figure 15 Heater installation above pool spa AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS If used a chlorinator must be installed downstream from the heater in the pool return line and at a lower elevation than the heater as shown in Figure 16 Install a separate positive seal corrosion resistant check valv...

Page 27: ... wiring MUST be in conformance with applicable local and national codes and regulations Before working on heater turn off power supply GENERAL INFORMATION Wiring connections must be made as shown in the wiring diagram found inside the heater cabinet and as shown in Figure 19 The heater must include a definite means of grounding and bonding There is a ground lug inside the control box and a bonding...

Page 28: ...e fuse board All wiring connections to the heater must be made in accordance with the latest edition of the National Electrical Code ANSI NFPA 70 unless local code requirements specify otherwise In Canada follow CSA C22 1 Canadian Electrical Code Part 1 The heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with National Electrical Code ...

Page 29: ...d When the remote switch is set to Pool Low the POOL LED will be illuminated and the water temperature will be displayed When the remote switch is set to Spa High the SPA LED will be illuminated and the water temperature will be displayed The heater will use its internal thermostat to regulate the water temperature to the set point of the mode selected Figure 18 Junction Box connections L 120V or ...

Page 30: ...ion diagram 1303103801 rev H Wiring Connection Diagram Schéma de Connexion de Câblage Forced Draft Gas Heaters Chaudière Gas à Air pulsé Flue Gas Temperature Limit Switch Commutateur limiteur de température des gaz de combustion ...

Page 31: ...31 Figure 20 Lighting Oper ating Instructions label ...

Page 32: ...eak tested before placing the appliance in operation The heater and its individual shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pressure in excess of psig 3 45 kPa The heater must be isolated from the gas sup ply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at te...

Page 33: ...ing serviced 1 Obtain the necessary equipment a Manometer to read pressure in inches of water column b 1 8 pipe nipple 1 8 thread x 1 long c 3 16 hex wrench d Flat screwdriver 2 Remove the 1 8 plug from the gas valve 3 Install the 1 8 pipe nipple into the gas valve 4 Attach the manometer to the pipe nipple 5 Turn on the water system and start the heater following the lighting operating instruction...

Page 34: ...pipe nipple with the valve in the ON position The valve must be in the OFF position when the nipple is removed Removal of the nipple with the gas valve ON could cause an explosion resulting in severe injury and or death 9 Remove the 1 8 pipe nipple and replace the 1 8 pipe plug If proper pressure cannot be achieved by adjusting the gas valve regulator the installer must contact the gas supplier an...

Page 35: ...eater to operate with less than the minimum rated water flow rate For Installations with Heater Below Water Level 1 Be sure the filter is clean before making the adjustment 2 Turn ON the filter pump and ensure all air is out of the water lines and ensure water flow rate is at least the rated minimum see Table 14 3 Turn ON the heater and adjust the thermostat to create a call for heat 4 Turn the ad...

Page 36: ...temperature setting is being displayed adjusted When the numeric display is not flashing the actual water temperature is being displayed The temperature settings for both SPA and POOL modes are initially set at the factory to 65 F The minimum allowed settings for SPA and POOL modes are both 65 F The maximum allowed settings for SPA and POOL modes are adjustable up to 104 F using the temperature lo...

Page 37: ... can be displayed in Fahrenheit or Celsius TO change the display use the MODE button to place the heater in STANDBY Then press and hold the UP and MODE buttons until the display shows the F C selection Press the DOWN button to toggle between selections To accept the selection press the MODE button If the user does not act the selection will be automatically accepted after 60 seconds HEATING MODE T...

Page 38: ...lve and the blower 2 The control monitors for open contacts at the blower vacuum switch 3 The control performs a gas valve relay check 4 A normal ignition sequence resumes with Item 2 in Heating Mode above 5 If the tenth ignition trial fails the control enters a safety lockout or hard lockout after the post purge period of the tenth failed trial 6 The error code IF is displayed and the SERVICE ind...

Page 39: ...r will not be responsible for heaters that soot up due to improp er gas level in the tank resulting in inadequate gas volume 6 If another appliance is added to the gas line at a later date consult the local gas company to be sure the gas line will have the capacity to supply both units at full input rating at the same time 7 Do not use the heater if any part has been under water Contact a qualifie...

Page 40: ...ly OFF at the main shut off valve outside the heater cabinet 5 Be sure the circulating pump is OFF 6 Remove the plastic drain plug see Figure 24 7 Allow all water to drain from the heater 8 Re install the plastic drain plug SPRING START UP 1 Inspect and clean the heater being sure the heater is free of leaves and debris prior to startup 2 Be sure inlet and outlet piping are properly attached to th...

Page 41: ...e patterns 4 Main burner orifices 5 Operating controls EXTERNAL HEAT EXCHANGER INSPECTION AND CLEANING Remove the louvered exhaust cover panel see Figure 8 and inspect the external surfaces of the heat exchanger for soot accumulation If soot has accumulated it must be removed by following the recommended procedure 1 Turn pump main gas valve and heater power OFF 2 If the heat exchanger must be remo...

Page 42: ...ellow or lazy flame may be an indi cation of a fuel rich mixture due to restricted air supply Spider nests in the burner and or gas orifices may also cause yellow tips BURNER REMOVAL AND REPLACEMENT Refer to Figure 8 Figure 21 and Figure 22 as needed 1 Turn pump gas supply and heater power OFF 2 Turn gas valve knob OFF 3 Remove the front access panel 4 Disconnect the union joint in the gas supply ...

Page 43: ...y It is attached to the air box using 4 screws 6 Unscrew the gas valve from the gas manifold pipe 7 Reassemble the gas manifold assembly using the new gas valve Only use liquid pipe thread seal ant on the male threads of the gas manifold pipe Do not place pipe dope on the first two threads of any joint 8 Reverse the above procedure to re install the gas manifold IGNITER Refer to Figure 8 and Figur...

Page 44: ... over tighten as a leak may result ATTENTION Do not enlarge orifice holes GAS CONVERSION The factory installed gas train where appropriate may be changed from natural gas to propane or from propane to natural gas using the appropriate conversion kits available from the factory Gas conversions are to be performed only by a qualified service agency Detailed instructions are included with each kit EL...

Page 45: ...on the blower vacuum switch indicating to the ignition control board that it is safe to continue the ignition sequence A silicone tube connects the blower vacuum switch with the blower as shown in Figure 21 To remove the blower vacuum switch 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel It is secured with 4 screws 3 Remove the wires from the pressure switch 4 Pull the...

Page 46: ...l and remove the limit and gasket 5 Place the new limit and gasket in place and reverse the above steps to complete the procedure THERMISTOR The thermistor monitors the return water temperature See Figure 24 To replace the thermistor 1 Turn pump gas supply and heater power OFF 2 Drain the heat exchanger of all water 3 Remove the front access panel It is secured with 4 screws 4 Unplug the thermisto...

Page 47: ... box 5 Replace the transformer Reassembly is the reversal of steps above BLOWER The blower provides the air that mixes with the gas at the main burners for the combustion process The blower oper ates during the pre purge time approximately 30 seconds at the beginning of each ignition cycle during the entire time the gas valve is open and the burners are firing and for 30 sec onds after the valve g...

Page 48: ... see Figure 24 5 Slide out the bypass cartridge from the end of the header see Figure 24 6 Check the function of the bypass valve to ensure the valve flaps rotate smoothly on the shaft and the spring fully closes the valve 7 Apply silicone o ring grease Jack s 327 Multilube p n SP032712 or equivalent on o ring seals on the bypass cartridge before inserting into the header 8 Insert bypass cartridge...

Page 49: ...e heater is connected to the line side of the circuit it will be powered at all times In this situation when the pump shuts down the heater will display a fault code of LO If there is a call for heat and the pump then restarts there will be a 2 minute delay for the heater to fire After the pump has been running for at least 2 minutes there is no delay for heater operation Wiring the heater to the ...

Page 50: ...1 for board locations Fuses are available as common hardware items or may be purchased from the manufacturer in a service parts kit The fuse specifications are F1 fuse low voltage 3A blade style fast acting automotive fuse type 257 FC1 FC2 transformer primary and FC4 transformer secondary 3A slo blo fuse 5 x 20 mm ...

Page 51: ...ose after the blower starts the control will stop the ignition trial go into lockout The blower will continue to run Automatic reset is immediate after the switch closes AO Blower vacuum switch open when expected closed error If the blower prover switch opens unexpectedly during operation the control will shut down and attempt to re light If the switch does not close after the blower starts the co...

Page 52: ... or pressed for more than 30 s the error code will be displayed but the control will continue to function The error code will be cleared when the condition is corrected IF Ignition failure error If the control exceeds the maximum number of ignition retries or recycles the heater will shut down and go into lockout Automatic reset is 60 minutes CE Communication error If communication between the ign...

Page 53: ...nect plug from P4 connector from Fuse Board Mesure for 24VAC between pins 1 2 of plug of Transformer and 120VAC between pins 4 6 If 24VAC or 120VAC is not present replace Transformer Otherwise proceed to step 7 7 Fuse Board is defective Replace Fuse Board Low voltage circuit fault 1 Check for Low Voltage Output from Fuse Board Diconnect plug from P5 connector from Fuse Board Measure for 24VAC acro...

Page 54: ...Gas Valve If OK proceed to step 3 3 Check for faulty Control Module wiring Inspect Control Module wiring Ensure insulation on wiring is not worn If OK proceed to step 4 4 Control Module is defective Replace Control Module Open FC4 Fuse 1 Check for faulty Igniter wiring Inspect Igniter wiring Ensure insulation on wiring is not worn If OK proceed to step 2 2 Check for faulty Blower wiring Inspect Bl...

Page 55: ...ure Display Interface Plug is securely attached to Control Module If OK proceed to step 2 3 Control Module and or Display Interface Assembly are defective Replace Control Module and or Display Interface Assembly IO Igniter Failure 1 Check for faulty wiring or connection Inspect Igniter wiring Ensure Igniter Plug is securely attached to Control Module If OK proceed to step 2 2 Igniter is defective ...

Page 56: ...e that low pump pressure does not exist Clean filter or clear blockages Check position of valves in plumbing system If OK proceed to step 6 6 Check for correct water pressure switch setting Adjust water pressure switch setting as shown on page 35 of Installation Manual only if heater is above or below water level If LO does not clear proceed to step 7 7 Water pressure switch is defective Replace w...

Page 57: ...actors Rectify all issues with water flow through the heater and water chemistry and then replace the heat exchanger and exhaust gas temperature limit Continuing to run the heater after this limit has tripped will cause damage to the entire unit and will not be covered by the warranty IF Ignition Failure 1 Ensure gas supply shutoff valves are open Ensure that main gas shutoff installed adjacent to...

Page 58: ...ce across Blower windings Winding resistance across lead should be in the following range Red to White 4 to 5 ohms If measured values vary substantially from these values Blower is defective Replace If OK proceed to step 5 5 Check for defective blower relay Disconnect Blower plug from Control Module Place heater in Pool or Spa Mode Lower set point temperature to generate call for heat During pre p...

Page 59: ...he jurisdic tion where the product is installed There are no warranties which extend beyond the description on the face hereof We shall not in any event be held liable for any special indirect or consequential damages EXPENSE OF DELIVERY AND INSTALLATION Each pool heater or replacement part to be furnished under this warranty shall be furnished at our nearest distribution center We shall not pay n...

Page 60: ...ou specific legal rights which may vary from state to state LIMITATION ON LIABILITY All intended representations have been expressly set forth in this document This warranty may not be extended by oral or any other additional representations written sales information drawings or other mal function is strictly limited to repair or replacement of the defective heater or part as provided herein and t...

Page 61: ...61 15 16 17 18 19 20 24 25 27 29 30 32 33 34 35 36 37 38 39 42 31 28 14 13 12 11 10 10 9 8 7 6 5 4 3 2 1 21 22 23 26 SERVICE PARTS ...

Page 62: ...0 HEAT BARRIER PANEL 400K BTU HEATER 15 FDXLBBN1250 BLOWER INLET BAFFLE 250K BTU HEATER FDXLBBN1400 BLOWER INLET BAFFLE 400K BTU HEATER 16 FDXLIAC1930 IGNITER ACCESS COVER 17 FDXLGSV0001 GAS VALVE NATURAL FDXLGSV0002 GAS VALVE PROPANE 18 FDXLBON1930 BURNER ORIFICE KIT NATURAL FDXLBOP1930 BURNER ORIFICE KIT PROPANE 19 FDXLMAN1250 GAS MANIFOLD 250K BTU HEATER FDXLMAN1400 GAS MANIFOLD 400K BTU HEATER...

Page 63: ...GASKET FLUE COLLECTOR SIDE GASKET RAIN GUARD SIDE GASKET RAIN GUARD BOTTOM SIDE GASKET FLUE COLLECTOR TOP ALL MODELS GASKET RAIN GUARD FRONT REAR ALL MODELS GASKET RAIN GUARD BOTTOM FRONT REAR ALL MODELS FDXLGSK1933 INSULATION RETURN SIDE TUBE SHEET FDXLBRN1930 BURNER QTY 8 FDXLFOR1930 HEADER O RING KIT FDXLEGL1930 EXHAUST GAS TEMPERATURE LIMIT ONE USE FDXLWHA1930 WIRING HARNESS KIT COMPLETE FDXLV...

Page 64: ...IPE 24 LONG UHXHD6PIPE36 HEATFAB STAINLESS VENT KIT 6 VENT PIPE 36 LONG UHXHD8STERM HEATFAB STAINLESS VENT KIT 8 HORIZONTAL STRAIGHT TERMINAL UHXHD8ELBOW HEATFAB STAINLESS VENT KIT 8 90 DEGREE ELBOW UHXHD8PIPE18 HEATFAB STAINLESS VENT KIT 8 VENT PIPE 18 LONG UHXHD8PIPE24 HEATFAB STAINLESS VENT KIT 8 VENT PIPE 24 LONG UHXHD8PIPE36 HEATFAB STAINLESS VENT KIT 8 VENT PIPE 36 LONG FDXLCNK0001 GAS CONVE...

Page 65: ...00 Btu hr GAS PRESSURE Fuel Natural Gas Propane Gas Manifold 1 8 2 0 w c 6 8 7 0 w c Inlet Minimum 4 5 w c 9 0 w c Inlet Maximum 10 5 w c 13 0 w c ORIFICE SIZES Models Natural Gas Propane Gas TR250 25 43 TR400 25 43 WATER FLOW REQUIREMENTS Model Minimum Maximum TR250 25 125 TR400 30 125 2015 Hayward Industries Inc Printed in U S A ...

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