Trane Intellipak 2 Service Manual

							Unit Startup
RT-SVX24K-EN161
8. Tighten the set screw to the drive shaft.
9. Stretch the belt over the pulley and engage it in the
groo
 ve.
Compressor Startup
1. Ensure that the “System” selection switch at theremote panel is in the “Off” position.
2. Before closing the disconnect switch, ensure that the compressor
 discharge service valve and the liquid line
service valve for each circuit is back seated.
3. Close the disconnect switch or circuit protector switch that provides the supply power to the unit terminal
block or the unit mounted disconnect switch to allow
the crankcase heater to operate a minimum of 8 hours
before continuing.
4. Turn the 115 volt control circuit switch and the 24 volt control
 circuit switch to the “On” position.
5. Open the Human Interface access door, located in the unit
 control panel, and press the SERVICE MODE key to
display the first service screen. Refer to the latest
edition of the applications programming guide for
applications for the SERVICE TEST screens and
programming instructions.
6. Use Table37, p.11 2to program the following system
components for operation by scrolling through the
displays;
Compressors
Compressor 1A (On)
Compressor 1B (Off)
Compressor 2A(Off)
Compressor 2B (Off)
Condenser Fans
1. Attach a set of service gauges onto the suction and discharge gauge ports for each circuit. See
Figure 115, p. 165 for the various compressor
locations.
2. Once the configuration for the components is complete,
 press the NEXT key until the LCD displays
the “Start test in __Sec.” screen. Press the + key to
designate the delay before the test is to start. This
service test will begin after the TEST START key is
pressed and the delay designated in this step has
elapsed. Press the ENTER key to confirm this choice.
3. Press the TEST START key to start the test. Remember that the delay designated in step 8 must elapse before
the system will begin to operate.
4. Once each compressor or compressor pair has started, verify
 that the rotation is correct. If a scroll compressor
is rotating backwards, it will not pump and a loud
rattling sound can be observed. Check the electrical
phasing at the load side of the compressor contactor.
If the phasing is correct, before condemning the
compressor, interchange any two leads to check the
internal motor phasing. If the compressor runs
backward for an extended period (15 to 30 minutes),
the motor winding can over heat and cause the motor
winding thermostats to open. This will cause a
“compressor trip” diagnostic and stop the compressor.
5. Press the STOP key at the Human Interface Module in the
 unit control panel to stop the compressor
operation.
6. Repeat steps 5 through 11 for each compressor stage and
 the appropriate condenser fans.
Refrigerant Charging
1. Attach a set of service gauges onto the suction anddischarge gauge ports for each circuit.
See Figure 115, p. 165 for the various compressor
locations.
2. Open the Human Interface access door, located in the unit
 control panel, and press the SERVICE MODE key to
display the first service screen. Refer to the latest
edition of the applications programming guide for CV
or VAV applications for the SERVICETEST screens and
programming instructions.
NOTICE:
Compressors Failure!
Unit must be powered and crankcase heaters energized
at least 8 hours BEFORE compressors are started. This
will protect the compressors from premature failure.
CAUTION
Compressor Damage!
Do not allow liquid refrigerant to enter the suction line.
Excessive liquid accumulation in the liquid lines could
result in compressor damage.
COMPRESSOR SERVICE VALVES MUST BE FULLY
OPENED BEFORE STARTUP (SUCTION, DISCHARGE,
LIQUID LINE, AND OIL LINE).
WARNING
Rotating Components!
The following procedure involves working with rotating components. Disconnect all electric power,
including remote disconnects before servicing. Follow
proper lockout/tagout procedures to ensure the power
can not be inadvertently energized. Failure to
disconnect power before servicing could result in
rotating components cutting and slashing technician
which could result in death or serious injury. 
						

							Unit Startup
162RT-SVX24K-EN
3. UseTable37, p.11 2to program the following system
components for the number 1 refrigeration circuit by
scrolling
 through the displays;
Supply Fan (On)
VFD
 (100%, if applicable)
OCC/UNOCC Relay (Unoccupied for VAV units)
All Compressors for each circuit (On) Condenser Fans for each circuit (On)
4. Once the configuration for the components is complete,
 press the NEXT key until the LCD displays
the “Start test in __Sec.” screen. Press the + key to
designate the delay before the test is to start. This
service test will begin after the TEST START key is
pressed and the delay designated in this step has
elapsed. Press the ENTER key to confirm this choice.
5. Press the TEST START key to start the test. Remember that the delay designated in step 4 must elapse before
the system will begin to operate.
6. After all of the compressors and condenser fans for the number
 1 circuit have been operating for
approximately 30 minutes, observe the operating
pressures. Use the appropriate pressure curve
beginning with Figure84, p.136to determine the
proper operating pressures. For superheat and
subcooling
 guidelines, refer to “Thermostatic
Expansion Valves and Charging by Subcooling” at the
end of this section.
Note: Do
Not release refrigerant to the atmosphere! If
adding or removing refrigerant is required, the
service technician must comply with all Federal,
State and local laws.
7. Verify that the oil level in each compressor is correct. The
 oil level may be down to the bottom of the
sightglass but should never be above the sightglass.
8. Press the STOP key at the Human Interface Module in the
 unit control panel to stop the system operation.
9. Repeat steps 1 through 8 for the number 2 refrigeration circuit.
10. After shutting the system off, check the compressor oil appearance.
 Discoloration of the oil indicates that an
abnormal condition has occurred. If the oil is dark and
smells burnt, it has overheated because: the compressor is operating at extremely high condensing
temperatures; high superheat; a compressor
mechanical failure; or, occurrence of a motor burnout.
If the oil is black and contains metal flakes, a
mechanical failure has occurred. This symptom is
often accompanied by a high compressor amperage
draw.
If a motor burnout is suspected, use an acid test kit to
check the condition of the oil. Test results will indicate
an acid level exceeding 0.05 mg KOH/g if a burnout
occurred.
The scroll compressor uses Trane OIL00079 (one quart container) or OIL00080 (one gallon container) without
substitution. The appropriate oil charge for CSHN250
and CSHN315 scroll compressors is 14.2 pints. For
CSHN374 scroll compressor, use 15.2 pints.
Compressor Crankcase Heaters
Each scroll compressor is equipped with a 160-watt
crankcase heater.
Compressor Operational Sounds
Because of the scroll compressor design, it emits a higher
frequency tone (sound) than a reciprocating compressor.
It is designed to accommodate liquids, both oil and
refrigerant, without causing compressor damage. The
following discussion describes some of the operational
sounds that differentiate it from those typically associated
with a reciprocating compressor. These sounds do not
affect the operation or reliability of the compressor.
At Shutdown
When a Scroll compressor shuts down, the gas within thescroll expands and causes momentary reverse rotation
until the discharge check valve closes. This results in a
“flutter” type sound.
At Low Ambient Startup
When the compressor starts up under low ambient conditions, the initial flow rate of the compressor is low
due to the low condensing pressure. This causes a low
differential across the thermal expansion valve that limits
its capacity. Under these conditions, it is not unusual to
hear the compressor rattle until the suction pressure
climbs and the flow rate increases.
Note: Evaporative Condensers ordered with sump
heaters will have low ambient down to 10 deg as
standard
WARNING
Rotating Components!
The following procedure involves working with rotating components. Disconnect all electric power, including
remote disconnects before servicing. Follow proper
lockout/tagout procedures to ensure the power can not
be inadvertently energized. Failure to disconnect power
before servicing could result in rotating components
cutting and slashing technician which could result in
death or serious injury. 
						

							Unit Startup
RT-SVX24K-EN163
Evaporative Condenser Startup
Important:Water treatment by a qualified water
treatment expert is required to ensure
proper equipment life and product
performance. Dolphin Water Care™ is an
option offered by Trane that is NOT a
subsitute for regular water treatment by a
qualified water treatment professional. If a
water treatment system is not operating on
the unit, do not proceed.
Startup for evaporative and air-cooled condensers is
initially the same. In addition, the following is required for
evaporative condensers prior to startup:
 All water and drain connections must be checked and verified
 Evaporative condensers will ship with a fan support c
 hannel to reduce damage caused by vibration during
shipment. The shipping support brackets must be
removed prior to unit startup. See “To remove
shipping brackets,” p. 163and Figure 113, p.164for
removal instructions.
 Verify that inlet water pressure is 35-60 PSIG, dynamic pressure
 (measured with the valve open)
 Verify that drain valve is set to drain during power loss
 or hold during power loss per job specification
 Upon a call for cooling, the sump will fill with water. V
 erify that the sump fills to a level within the slot on the
max float bracket as shown in Figure114, p.164.
To remove shipping brackets
Important: Remove fan shipping brackets before
startup. Failure to remove brackets could
result in fan damage.
Evaporative condensers are shipped with fan shipping
brackets to reduce damage caused by vibration during
shipment. The fan shipping brackets must be removed
prior to unit startup.
To remove the shipping brackets start from the side opposite to the drain actuator:
1. Loosen the screw for the bracket that holds the inlet louvers below the door side.
2. Remove inlet louvers and set to the side.
Note: S
ervice technician may need to step on the
horizontal surface of FRP coated base.
Step with care.
3. Unscrew the bolt in the middle of the door. Keep the bolt
 in a safe place.
4. Lift one door with handle until it touches the top. S
 wivel bottom of door to remove it from the door
opening and set it to the side.
5. Slide and remove the middle mist eliminator section so
 that the shipping bracket is visible. 6. Use screw gun to unscrew the two screws that hold the
fan
 shipping bracket. The bracket should drop down
but still remain engaged with a hook on the bracket.
7. Go to the other side of the unit and follow the procedure
 for inlet louver and door removal
(see steps1-6
 ).
8. Hold the bracket with one hand and remove remaining two
 screws.
9. Remove the bracket and all the removed screws from the
 unit.
Important: Mak
 e sure there are no screws remaining in
the coil area.
10. Reinstall inlet louvers, mist eliminators and louvers.
11. Check that the direction of arrow on the inlet louver is cor
 rect 
						

							Unit Startup
164RT-SVX24K-EN
Figure 113. Fan shipping bracket removal
Mist Eliminator
Fan Shipping Bracket ScrewsFan Shipping Bracket
Access Doors
Inlet Louvers
Actuator Side
Figure 114. Float bracket setting
Fill sump so float shuts 
off when water is within these slots 
						

							Unit Startup
RT-SVX24K-EN165
Thermostatic Expansion Valves
The reliability and performance of the refrigeration system
is heavily dependent upon proper expansion valve
adjustment.Therefore, the importance of maintaining the
proper superheat cannot be over emphasized.
On air-cooled units, the expansion valves shipped
installed were factory set to control between 14-18°F at the
ARI full load rating conditions (approximately 45°/125°F saturated suction/discharge). On evaporative condenser
units, the expansion valves shipped installed were factory
set to control between 18-22°F at the ARI full load rating
conditions (approximately 45°/105°F saturated suction/
discharge). At part load, expect lower superheat. Systems
operating with lower superheat could cause serious
compressor damage due to refrigerant floodback.
Pressure curves, included in the IOM, are based on
outdoor ambient between 65° & 105°F, relative humidity
above 40 percent. Measuring the operating pressures can
be meaningless outside of these ranges.
Measuring Superheat
1. Measure the suction pressure at the suction line gauge access port located near the compressor.
2. Using a Refrigerant/Temperature chart, convert thepressure reading to a corresponding saturated vapor
temperature.
3. Measure the suction line temperature as close to the expansion
 valve bulb, as possible. Use a thermocouple
type probe for an accurate reading.
4. Subtract the saturated vapor temperature obtained in step
 2 from the actual suction line temperature
obtained in step 3. The difference between the two
temperatures is known as “superheat”.
When adjusting superheat, recheck the system subcooling before
 shutting the system “Off”.
Note: If unit includes the modulating reheat
dehumidification option, adjust superheat only in
the cooling mode of operation.
Charging by Subcooling
The outdoor ambient temperature must be between 65
and 105°F and the relative humidity of the air entering the
evaporator must be above 40 percent. When the
temperatures are outside of these ranges, measuring the
operating pressures can be meaningless. Make sure hot
gas bypass (if applicable) is not flowing when taking
performance measurements. With the unit operating at
“Full Circuit Capacity”, acceptable subcooling ranges for air-cooled units is between 14°F to 22°F.
For evaporative condenser units, acceptable subcooling
range is between 8°F to 14°F.
Measuring Subcooling
1. At the liquid line service valve, measure the liquid line pressure. Using a Refrigerant R410A pressure/
temperature chart, convert the pressure reading into
the corresponding saturated temperature.
2. Measure the actual liquid line temperature as close to the
 liquid line service valve as possible. To ensure an
accurate reading, clean the line thoroughly where the
temperature sensor will be attached. After securing the
sensor to the line, insulate the sensor and line to isolate
it from the ambient air. Use a thermocouple type probe
for an accurate reading.
Note: Glass
 thermometers do not have sufficient contact
area to give an accurate reading.
3. Determine the system subcooling by subtracting the actual
 liquid line temperature (measured in step 2)
from the saturated liquid temperature (converted in
step 1).
Standard Ambient Units
The following Table gives the minimum starting temperatures for Standard Ambient Units. Do not start the
unit in the cooling mode if the ambient temperature is
below the recommended operating temperatures.
Figure 115. Compressor locations and staging sequence
Table 46. Staging sequence
Compressor Staging  (Lead) Compressor Staging 
(Lag)
1A 1B 2A 2B 1A 1B 2A 2B
Stage 1
XX
Stage 2XXXX
Stage 3X XXXXX
Stage 4XXXXXXXX
K4 
						

							Unit Startup
166RT-SVX24K-EN
Electric, Steam and Hot Water Startup
(Constant Volume & Variable Air Volume
Systems)
1. Ensure that the “System” selection switch at the
remote panel is in the “Off” position.
2. Close the disconnect switch or circuit protector switchthat provides the supply power to the unit terminal
block or the unit mounted disconnect switch.
HIGH VOLTAGE IS PRESENT AT TERMINAL BLOCK OR
UNIT
 DISCONNECT SWITCH.
3. Turn the 115 volt control circuit switch and the 24 volt control
 circuit switch to the “On” position.
4. Open the Human Interface access door, located in the unit
 control panel, and press the SERVICE MODE key to
display the first service screen. Refer to the latest
edition of the appropriate programming manual for CV
or VAV applications for the SERVICETEST screens and
programming instructions.
5. Use Table37, p.11 2to program the following system
components for operation by scrolling through the
Human
 Interface displays;
Electric Heat
Supply Fan (On)
Variable Frequency Drive (100% Output, if applicable) RTM Occ/Unocc Output (Unoccupied)
Heat Stages1&2(On)
Steam or Hot Water Heat
Supply Fan (On)
Variable Frequency Drive (100% Output, if applicable) RTM Occ/Unocc Output (Unoccupied)
Hydronic Heat Actuator (100% Open)
Open the main steam or hot water valve supplying the
rooftop heater coils.
6. Once the configuration for the appropriate heating system
 is complete, press the NEXT key until the LCD
displays the “Start test in __Sec.” screen. Press the +
key to designate the delay before the test is to start.
This service test will begin after theTEST START key is pressed and the delay designated in this step has
elapsed. Press the ENTER key to confirm this choice.
7. Press the TEST START key to start the test. Remember that the delay designated in step 6 must elapse before
the fan will begin to operate.
8. Once the system has started, verify that the electric heat
 or the hydronic heat system is operating properly
by using appropriate service technics; i.e. amperage
readings, delta tees, etc.
9. Press the STOP key at the Human Interface Module in the
 unit control panel to stop the system operation.
Gas Furnace Startup
(Constant Volume and Variable Air Volume
Systems)
It is important to establish and maintain the appropriate
air/fuel mixture to assure that the gas furnace operates
safely and efficiently.
Since the proper manifold gas pressure for a particular
installation will vary due to the specific BTU content of the
local gas supply, adjust the burner based on carbon
dioxide and oxygen levels.
The volume of air supplied by the combustion blower determines the amount of oxygen available for
combustion, while the manifold gas pressure establishes
fuel input. By measuring the percentage of carbon dioxide
produced as a by-product of combustion, the operator can
estimate the amount of oxygen used and modify the air
volume or the gas pressure to obtain the proper air/fuel
ratio.
Arriving at the correct air/fuel mixture for a furnace results in rated burner output, limited production of carbon
Table 47. Minimum ambient
Minimum Starting Ambient
Unit Size Standard Ambient
with HGBP without HGBP
90-162 4055
Notes:
 1. Minimum starting ambients in degrees F and is based on unit 
operating at min. step of unloading, and unloading and 5 mph wind 
across condenser
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote
disconnects before servicing. Follow proper lockout/
tagout procedures to ensure the power can not be
inadvertently energized. Do not open the service access
doors while the unit is operating. Failure to disconnect
power before servicing could result in death or serious
injury.
WARNING
Rotating Components!
During installation, testing, servicing and
troubleshooting of this product it may be necessary to
work with live and exposed rotating components. Have
a qualified or licensed service individual who has been
properly trained in handling exposed rotating
components, perform these tasks. Failure to follow all
safety precautions could result in rotating components
cutting and slashing technician which could result in
death or serious injury. 
						

							Unit Startup
RT-SVX24K-EN167
monoxide, and a steady flame that minimizes nuisance
shutdowns.
Two Stage Gas Furnace
High-Fire Adjustment
1. UseTable 37, p. 112 to program the following system
components for operation by scrolling through the
Human Interface displays;
Gas Heat
Supply Fan (On)
Return Fan (On, if supplied)
Variable Frequency Drive (100% Output, if applicable) RTM Occ/Unocc Output (Unoccupied)
Heat Stages1&2(On)
Turn the 115 volt control circuit switch 4S24 located in the heater control panel to the “On” position.
Open the manual gas valve, located in the gas heat
section.
2. Once the configuration for the appropriate heating system is complete, press the NEXT key until the LCD
displays the “Start test in __Sec.” screen. Press the +
key to designate the delay before the test is to start.
This service test will begin after theTEST START key is pressed and the delay designated in this step has
elapsed. Press the ENTER key to confirm this choice.
3. Press the TEST START key to start the test. Remember that
 the delay designated in step 2 must elapse before
the system will begin to operate. 4. Once the system has started, check the appearance of
the
 flame through the sight glass provided on the front
of the heat exchanger. In appearance, a normal flame
has a clearly defined shape, and is primarily (75%) blue
in color with an orange tip.
5. Check the manifold gas pressure by using the manifold pressure
 port on the gas valve. Refer to Table48, p.168
for the required manifold pressure for high-fire
operation.
 If it needs adjusting, remove the cap
covering the high-fire adjustment screw on the gas
valve. Refer to Figure118, p.169for the adjustment
screw location. Turn the screw clockwise to increase
the
 gas pressure or counterclockwise to decrease the
gas pressure.
6. Use a carbon dioxide analyzer and measure the percentage
 of carbon dioxide in the flue gas. Refer to
the illustration in Figure11 7, p .169. Take several
samples to assure that an accurate reading is obtained.
R
 efer to Figure116, p.168for the proper carbon
dioxide levels. A carbon dioxide level exceeding the
listed
 range indicates incomplete combustion due to
inadequate air or excessive gas.
Combustion Air Adjustment (O2)
7. Use an oxygen analyzer and measure the percentage of oxygen in the flue gas. Take several samples to
assure an accurate reading. Compare the measured
oxygen level to the combustion curve in Figure11 6 ,
p. 168 . The oxygen content of the flue gas should be
4% to 5%. If the oxygen level is outside this range,
adjust
 the combustion air damper to increase or
decrease the amount of air entering the combustion
chamber. Refer to Figure120, p. 171for the location of
the combustion air damper.
8. Recheck the oxygen and carbon dioxide levels after eac
 h adjustment. After completing the high-fire
checkout and adjustment procedure, the low-fire
setting may require adjusting.
Low-Fire Adjustment
(850 & 1100 MBH only)
1. Use the TEST initiation procedures outlined in the previous section to operate the furnace in the low-fire
state (1st Stage).
2. Use a carbon dioxide analyzer and measure the percentage
 of carbon dioxide in the flue gas. Refer to
the illustration in Figure116, p.168, Inset A. Take
several samples to assure that an accurate reading is
obtained.
 Refer toTable48, p. 168for the proper
carbon dioxide levels. If the measured carbon dioxide
level
 is within the listed values, no adjustment is
necessary. A carbon dioxide level exceeding the listed
range indicates incomplete combustion due to
inadequate air or excessive gas.
3. Check the manifold gas pressure by using the manifold pressure
 port on the gas valve. Refer to Table48, p.168
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 and result in a fire. To avoid
hazardous gases and flammable vapors follow proper
installation and set up of this product and all warnings
as provided in this manual. Failure to follow all
instructions could result in death or serious injury.
WARNING
Hazardous Pressures!
When using dry nitrogen cylinders for pressurizing units for leak testing, always provide a pressure
regulator on the cylinder to prevent excessively high
unit pressures. Never pressurize unit above the
maximum recommended unit test pressure as specified
in applicable unit literature. Failure to properly regulate
pressure could result in a violent explosion, which
could result in death or serious injury or equipment or
property-only-damage. 
						

							Unit Startup
168RT-SVX24K-EN
for the required manifold pressure during low-fire
operation. If it needs adjusting, remove the cap
covering the low-fire adjustment screw on the gas
valve. Refer toFigure118, p.169for the adjustment
screw location. Turn the screw clockwise to increase
the
 gas pressure or counterclockwise to decrease the
gas pressure. Note:
Do
not adjust the combustion air damper while
the furnace is operating at low-fire.
4. Check the carbon dioxide levels after each adjustment.
5. Press the STOP key at the Human Interface Module in the
 unit control panel to stop the system operation.
Figure 116. Natural gas combustion curve (ratio of oxygen to carbon dioxide in percent)
0 1
2 3 4
5
6 7 8
9
10
11 12 13
14
15 16 17
18
012345 6789101112131415161718192021
Percent Oxygen
Percent Carbon Dioxide
Curve       Fuel
   A     =    1,000 BTU per c u. ft.
                 of Natural Gas.
A
Table 48. Recommended manifold pressures and CO2levels during furnace operation
2-STAGE MODULATING
MBH FIRING 
RATES % CO2
NAT GAS MANIF 
PRESS  “W.C. % CO2
PROPANE MANIF 
PRESS  “W.C. MBH FIRING 
RATE  % CO2
NAT GAS MANIF 
PRESS “W.C. % CO2
PROPANE MANIF 
PRESS “W.C.
850 100% 8.0-9.0 3.0-3.5 9.0-10.0 3.0-3.5 850 100% 8.0-9.0 3.0- 3.5 7.8-8.4 1.7-2.2
510 60%  5.0 -7.0 0.8-0.95 5.0-7.0 1.5-3.0 85 10%  5.0 -7.0 0.8- 0.9.5 2.0-3.0 .1-.2
1100 100% 8.0-9.0 3.0-3.3 9.0-10.0 3.0-3.3 1100 100% 7.0-9.0 .8-.9 8.5-9.5 .5-.75 550 50%  5.0 -7.0 0.8-0.95 5.0-7.0 0.8-0.95 55 5% 1.5-3.0 .05-1.0 1.5-2.5 .02-.04
1800 100% 7.0- 8.0 1.5- 1.8 N/A N/A 1800 100% 7.0-9.0 1.5- 1.8 N/A N/A 900 50% 5.0- 7.0 0.5- 0.7 N/A N/A 90 5% 1.5-3.0 .05-1.0 N/A N/A
2500 100% 7.5- 8.5 2.0- 2.5 N/A N/A 2500 100% 7.0-9.0 2.0- 2.5 N/A N/A
1250 50% 5.0- 7.0 0.5-  0.7 N/A N/A 125 5% 1.5-3.0 .05-1.0 N/A N/A 
						

							Unit Startup
RT-SVX24K-EN169
Full Modulating Gas Furnace
Full Modulating gas heaters are available for the 850, 1100,
1800, 2500 MBH heater sizes.
– The firing rate of the 850 MBH modulating heatercan vary from 10% to 100% of the 850 MBH.
– The firing rate of the 1100, 1800 and 2500 MBH can vary from 5% to 100% of its nameplate value.
Heat Exchanger
The heat exchanger drum, tubes and front and rearheaders are constructed from stainless steel alloys.
Unit Control
The unit is controlled by a supply air temperature sensorlocated in the supply air stream for VAV units. CV units
have two sensors, one located in the supply air stream and
the zone sensor. The temperature sensor signal is sent to
the Heat module of the IntelliPak™ II Unit Control. The
control signal from the Heat Module signal is directly
proportional 0-10 VDC. The higher the voltage signal, the
lower the call for heat. The 0-10 VDC signal controls the air damper actuator
which is mounted on the end of the air damper shaft. As
the actuator rotates clockwise, more combustion air
passes through the combustion air blower. In turn, the gas
butterfly valve opens more through a directly connected
linkage, resulting in a higher rate of firing.
1. Use Table 37, p. 112 to program the following system
components for operation by scrolling through the
Human Interface displays;
Gas Heat
Supply Fan (On)
Variable Frequency Drive (100% Output, if applicable) RTM Occ/Unocc Output (Unoccupied)
High Fire (90%)
Turn the 115 volt control circuit switch 4S24 located in the heater control panel to the “On” position.
Open the manual gas valve, located in the gas heat
section.
2. Once the configuration for the appropriate heating system is complete, press the NEXT key until the LCD
displays the “Start test in __Sec.” screen. Press the +
key to designate the delay before the test is to start.
This service test will begin after theTEST START key is pressed and the delay designated in this step has
elapsed. Press the ENTER key to confirm this choice.
3. Press the TEST START key to start the test. Remember that
 the delay designated in step 2 must elapse before
the system will begin to operate.
4. Once the system has started, check the appearance of the flame through the sight glass provided on the front
of the heat exchanger. In appearance, a normal flame
has a clearly defined shape, and is primarily (75%) blue
in color with an orange tip.
5. Check the inlet gas pressure at the modulating gas valve.
 The inlet pressure should be 6 to 8 w.c.
6. Use a carbon dioxide analyzer and measure the percentage
 of carbon dioxide in the flue gas. Refer to
the illustration in Figure11 7, p .169. Take several
samples to assure that an accurate reading is obtained.
The
 C0
2level should fall in the ranges shown in the
guide values Table48, p. 168
Figure 117. Flue gas carbon dioxide and oxygen
measurements
Figure 118. High/low pressure regulator
WARNING
Rotating Components!
During installation, testing, servicing and
troubleshooting of this product it may be necessary to
work with live and exposed rotating components. Have
a qualified or licensed service individual who has been
properly trained in handling exposed rotating
components, perform these tasks. Failure to follow all
safety precautions could result in rotating components
cutting and slashing technician which could result in
death or serious injury. 
						

							Unit Startup
170RT-SVX24K-EN
Note:The burner capacity is controlled by the movement
of the air damper. This has been preset at the
factory and normally does not need field
adjustment. The combustion quality (air/gas) is
controlled by the setup of the air damper and
butterfly valve linkage relationship.
7. Use Table37, p.11 2to program the minimum (5%)
firing rate. Allow the system to operate for
appro
 ximately 10 minutes.
8. Use a carbon dioxide analyzer and measure the percentage
 of carbon dioxide in the flue gas. If the
measured carbon dioxide level is in the ranges shown
in the Guide Values Table48, p. 168, no adjustment is
necessary. Note:
It
is normal for the low fire CO2to be lower than the
high fire.
9. If the measured carbon dioxide level is below the recommended
 values for low heat, return the burner to
90% fire rate and repeat step 6, to achieve optimum
combustion.
10. Program the burner for 100% operation and recheck the
 CO
2or O2value.
11. Check the flue gas values at several intermediate output
 levels. If corrections are necessary;
– Adjust butterfly linkage
12. Press the STOP key at the Human Interface Module in the
 unit control panel to stop the system operation.
Figure 119. Modulating gas regulator