Trane Intellipak 2 Service Manual

							Installation
RT-SVX24K-EN71
Table 16. Sizing natural gas pipe mains and branches
Gas Supply
Pipe Run  (ft) Gas Input (Cubic Feet/Hour)*
1¼ Pipe 1½
Pipe  2
Pipe 2½
Pipe  3
Pipe4
Pipe
10 1050 1600 3050 4800 8500 17500
20 730 1100 2100 3300 5900 12000
30 590 890 1650 2700 4700 9700
40 500 760 1450 2300 4100 8300
50 440 670 1270 2000 3600 7400
60 400 610 1150 1850 3250 6800
70 370 560 1050 1700 3000 6200
80 350 530 990 1600 2800 5800
90 320 490 930 1500 2600 5400
100 305 460 870 1400 2500 5100
125 275 410 780 1250 2200 4500
150 250 380 710 1130 2000 4100
175 225 350 650 1050 1850 3800
200 210 320 610 980 1700 3500
Notes:  1. *Table is based on a specific gravity of 0.60. Use  Table 17, p.  71 for 
the specific gravity of the local gas supply.
 2. If more than one unit is served by the same main gas supply, 
consider the total gas input (cubic feet/hr.) and the total length when 
determining the appropriate gas pipe size.
 3. Obtain the Specific Gravity and BTU/Cu.Ft. from the gas company.
 4. The following example demonstrates the considerations necessary 
when determining the actual pipe size: 
Example: A 40 pipe run is needed to connect a unit with a 850 MBH 
furnace to a natural gas supply having a rating of 1,000 BTU/Cu.Ft. 
and a specific gravity of 0.60
Cu.Ft/Hour =
 Furnace MBH Input 
Gas BTU/Cu.Ft. X Multiplier  Table 17, p.  71
Cu.Ft/Hour = 850 
Table  16, p.  71 indicates that a 2 pipe is required.
Table 17. Specific gravity multipliers
Specific 
Gravity Multiplier
0.50 1.10
0.55 1.04
0.60 1.00
0.65 0.96
Table 18. Gas heating capacity altitude correction factors
Altitude (Ft.)
Sea Level  To 2000 2001 to 
2500 2501 to 
3500 3501 to 
4500 4501 to 
5500 5501 to 
6500 6501 to 
7500
Capacity 
Multiplier
1.00 .92 .88 .84 .80 .76 .72
Note: Correction factors are per AGA Std. 221.30 - 1964, Part VI, 6.12. Local codes may supersede.
Figure 46. Two-stage natural gas train for 850, 1100 Mbh heaters 
						

							Installation
72RT-SVX24K-EN
Flue Assembly Installation
1. Locate the collapsed flue assembly in the
compartment above the gas heat controls by removing
the panel screws. The assembly is secured by screws
up through the roof of the gas controls compartment
roof.
2. Separate the pieces of the collapsed assembly.
3. Then assemble the stack as shown in Figure48.
4. Insert the tube on the flue assembly into the hole located
 in the vertical support for the heat section.
5. Butt both tube sections together and center the pipe clamp
 over joint.
6. Using the pre-punch hole in the flue assembly, extension,
 and the vertical support, install the
appropriate number of mounting brackets (Refer to the
installation instructions that ship with the flue
assembly.)
Figure 47. Modulating (850-2500 Mbh heaters) and two-stage (1800-2500 Mbh heaters) natural gas train
Ignition control board
Ignition transformer
Safety valveSingle stage 
regulating valve 
Combustion blower Combustion blower
pressure switch
Butterfly gas
control valve
Actuator
Gas heat inlet sizes Standard Gas Heat  Input (MBh)  Gas Heat Inlet 
Sizes (in.)
850 1 
1100 1 1/4
1800 1 1/2
2500 1 1/2
Figure 48. Flue assembly 
						

							Installation
RT-SVX24K-EN73
Figure 49. Gas heat piping penetration locations
K
17
8
11 5
8
W
D
2.5M & 1.8M  (W=16 1/8in,  D=14 11/16in)
1.1M, 0.8M    (W=9 15/16in,  D=9 12/16in)
H
C
2119
20 7
16
B
Horizontal gas pipe inlet
Pipe type: Black pipe, sch 40
Condensate drain outlet
Pipe type: cpvc
Hole at the base
Ø3
Unit end plane
Edge of mist eliminatorTop View
Side View 
						

							Installation
74RT-SVX24K-EN
General Coil Piping and Connection
Recommendations
Proper installation, piping, and trapping is necessary to
ensure satisfactory coil operation and to prevent
operational damage:
 Support all piping independently of the coils.
 Provide swing joints or flexible fittings on all
connections
 that are adjacent to heating coils to
absorb thermal expansion and contraction strains.
 Install factory supplied control valves (valves ship separately).
Note: The
 contractor is responsible for supplying the
installation hardware.  When attaching the piping to the coil header, make the
connection
 only tight enough to prevent leaks.
Maximum recommended torque is 200 foot-pounds.
 Use pipe sealer on all thread connections.
Table 19. Gas heat piping penetration measurements
Tons
Energy 
Recovery  Wheel 
(ERW) Pieces Heat 
(MBH) Gas Flue
Condensate Drain 
Outlet Gas Connection, 
Horizontal  Gas Connection, 
Base
Horizontal Distance
Mist Elim 
to Flue C/L Unit End 
to Hole C/L Unit End 
to Hole C/L
KCHB
90-118 No ERW 1 & 2 Pc 1800 160  1/16254 14/16 266  4/16274 11/16
90-118 No ERW 1 & 2 Pc 1100 159 15/16 263 15/16265  5/16274 11/16
90-118 No ERW 1 & 2 Pc 850 159 15/16263 15/16 265  5/16274 11/16
120-162 No ERW 1 & 2 Pc 2500 214 11/16 321      337  7/16 339  7/16
120-162 No ERW 1 & 2 Pc 1800 214 13/16 319 11/16331      339  7/16
120-162 No ERW 1 & 2 Pc 1100 214 11/16 327 14/16330  1/16339  7/16
90-118 ERW 1 & 2 Pc 1800 164 11/16 351  5/16362 10/16 371  1/16
90-118 ERW 1 & 2 Pc 1100 164  8/16360  6/16361 12/16 371  1/16
90-118 ERW 1 & 2 Pc 850 164  8/16360  6/16361 12/16 371  1/16
120-162 ERW 1 & 2 Pc 2500 219 13/16 417  7/16433 14/16 435 14/16
120-162 ERW 1 & 2 Pc 1800 220      416  2/16 427  7/16435 14/16
120-162 ERW 1 & 2 Pc 1100 219 13/16 424  5/16426  8/16435 14/16
90-118 No ERW 3 Pc 1800 179  6/16274  3/16285  8/16293 15/16
90-118 No ERW 3 Pc 1100 179  3/16283  3/16284  9/16293 15/16
90-118 No ERW 3 Pc 850 179  3/16283  3/16284  9/16293 15/16
120-162 No ERW 3 Pc 2500 240  2/16346  8/16362 15/16 364 15/16
120-162 No ERW 3 Pc 1800 240  5/16345  3/16356  8/16364 15/16
120-162 No ERW 3 Pc 1100 240  2/16353  6/16355  9/16364 15/16
90-118 ERW 3 Pc 1800 183 15/16 376 13/16388  2/16390  6/16
90-118 ERW 3 Pc 1100 183 13/16 385 13/16387  3/16390  6/16
90-118 ERW 3 Pc 850 183 13/16385 13/16 387  3/16390  6/16
120-162 ERW 3 Pc 2500 245  5/16442 15/16 459  6/16461  6/16
120-162 ERW 3 Pc 1800 245  8/16441  9/16452 15/16 461  6/16
120-162 ERW 3 Pc 1100 245  5/16449 12/16 452      461  6/16
CAUTION
Connection Leaks!
Use a backup wrench when attaching piping to coils
with copper headers to prevent damage to the coil
header. Do not use brass connectors because they
distort easily and could cause connection leaks.
CAUTION
Over Tightening!
Do not use teflon-based products for any field
connections because their high lubricity could allow
connections to be over-tightened, resulting in damage
to the coil header. 
						

							Installation
RT-SVX24K-EN75
 After completing the piping connections, seal around
pipe from inner panel to outer panel.
Hot Water Heat Units
Hot water heating coils are factory installed inside the
heater section of the unit. Once the unit is set into place,
the hot water piping and the factory provided three way
modulating valve must be installed. The valve can be
installed inside the heat section or near the unit. If the
valve is installed in a remote location, use field supplied
wiring to extend the control wires from the heater section
to the valve.Two access holes are provided in the unit base
as illustrated in Figure 50, p. 76.
Following the guidelines listed below will enhance both
the installation and operation of the “wet heat” system.
Figure 51, p. 77 illustrates the recommended piping
configuration for the hot water coil. Table 20 on page 76
lists the coil connection sizes.
Note: The valve actuators are not waterproof. Failure to
protect the valve from moisture may result in the
loss of heating control.
1. Support all field-installed piping independently from the heating coil.
2. Use swing joints or flexible connectors adjacent to the heating
 coil. (These devices will absorb the strains of
expansion and contraction).
3. All return lines and fittings must be equal to the diameter
 of the “outlet” connection on the hot water
coil.
4. Install a “Gate” type valve in the supply branch line as close
 as possible to the hot water main and upstream
of any other device or takeoff.
5. Install a “Gate” type valve in the return branch line as close
 as possible to the return main and down stream
of any other device.
6. Install a strainer in the hot water supply branch as shown
 inFigure 51, p.77.
7. Install the 3-way valve in an upright position, piped for valve
 seating against the flow. Ensure that the valve
location lends itself to serviceability.
8. The Type “W” hot water coil is self-venting only when the
 tube water velocity exceeds 1.5 feet per second
(fps). If the tube velocity is less than 1.5 feet per second,
either: a. install an automatic air vent at the top of the return
header
 , using the tapped pipe connection
or,
b. vent the coil from the top of the return header down to the return piping. At the vent connection, size the
return piping to provide sufficient water velocity.
9. Install a “Globe” type valve in the Bypass line as shown inFigure 51 on page 77.
Steam Heat Units
Steam heating coils are factory installed inside the heater
section of the unit. The coils are pitched, within the units,
to provide the proper condensate flow from the coil. To
maintain the designed degree of pitch for the coil, the unit
must be level.
Once the unit is set into place, the steam piping and the
factory provided two way modulating valve must be
installed. The valve can be installed inside the heater
section or near the unit. If the valve is installed in a remote
location, use field supplied wiring to extend the control
wires from the heater section to the valve. Two access
holes are provided in the unit base as illustrated in
Figure 50, p. 76 .
Following the guidelines listed below will enhance both
the installation and operation of the “wet heat” system.
Figure 52, p. 77 illustrates the recommended piping
configurations for the steam coil. Table 20, p. 76lists the
coil connection sizes.
Note: The valve actuators are not waterproof. Failure to
protect the valve from moisture may result in the
loss of heating control.
1. Support all field-installed piping independently from the heating coil.
2. Use swing joints or flexible connectors adjacent to the heating
 coil. (These devices will absorb the strains of
expansion and contraction.)
3. Install the 2-way valve in an upright position. Ensure that
 the valves location lends itself to serviceability.
4. Pitch the supply and return steam piping downward 1 per
 10 of run in the direction of flow.
5. All return lines and fittings must be equal to the diameter
 of the “outlet” connection on the steam
coil(s). If the steam trap connection is smaller that the
coil “outlet” diameter, reduce the pipe size between
the strainer and the steam trap connections only.
6. Install a 1/2 15 degree swing-check vacuum breaker at the
 top of the return coil header using the tapped pipe
connection. Position the vacuum breaker as close to
the coil as possible.
Note: Vacuum breakers should have extended lines from
the vent ports to the atmosphere or connect each
vent line to the return pipe on the discharge side of
the steam traps.
CAUTION
Leakage!
Properly seal all penetrations in unit casing. Failure to
seal penetrations from inner panel to outer panel could
result in unconditioned air entering the module, and
water infiltrating the insulation, resulting in equipment
damage. 
						

							Installation
76RT-SVX24K-EN
7. Install a “Gate” type valve in the supply branch line as
close as possible to the steam main and upstream of
any other device.
8. Install a “Gate” type valve in the return branch line as close
 as possible to the condensate return main and
downstream of any other device.
9. Install a strainer as close as possible to the inlet of the control
 valve and steam trap(s).
10. Steam trap selection should be based on the maximum
 possible condensate flow and the
recommended load factors.
11. Install a Float-and-Thermostatic (FT) type trap to maintain
 proper flow.They provide gravity drains and
continuous discharge operation. FT type traps are
required if the system includes either;
a. an atmospheric pressure/gravity condensate return;
or

,
b. a potentially low pressure steam supply.
12. Position the outlet or discharge port of the steam trap at
 least 12 below the outlet connection on the coil(s).
This will provide adequate hydrostatic head pressure to overcome the trap losses and assure complete
condensate removal.
The two steam coils are stacked together and must be piped
 in a parallel arrangement.The steps listed below
should be used in addition to the previous steps.
Figure 52, p. 77 illustrates the recommended piping
configuration for the steam coils.
13. Install a strainer in each return line before the steam trap.
14. Trap each steam coil separately as described in steps 1
 0 and 11 to prevent condensate backup in one or both
coils.
15. In order to prevent condensate backup in the piping header
 supplying both coil sections, a drain must be
installed utilizing a strainer and a steam trap as
illustrated in Figure52, p.77. Figure 50. Hot water and steam heat connection location
T
 able 20. Hot water and steam coil connection sizes
Hot Water Coil Steam Coil
Unit  Size Supply Return Drain/
Vent Supply Return Vent
90-162  To n 2 ½ 2 ½ ½ 3.0 1 ¼ 1 ¼
Notes:
 1. Type W coils, with center offset headers, are used in Hot Water units; 
Type NS coils are used in Steam units.
 2. Hot water and Steam units have multiple headers.
 3. All sizes are in inches.
 4. All connection threads are internal.
Table 21. Hot water and steam heat connection
dimensions
Tons ABY Diameter
90-118 276  9/16 290  5/16 18       5      
120-162 341  5/16 355  1/16 18       5      
A
B
Y
Supply Air Opening Return Air Opening
Unit bottom view
InletOutletRecommended 
						

							Installation
RT-SVX24K-EN77
Figure 51. Hot water coil piping
Figure 52. Steam coil piping 
						

							Installation
78RT-SVX24K-EN
Disconnect Switch w/External Handle
Units come equipped with a factory mounted disconnect
switch with an externally mounted handle.This allows the
operator to disconnect power from the unit without having
to open the control panel door. The handle locations and
its three positions are shown below;
“ON” - Indicates that the disconnect switch is closed,allowing the main power supply to be applied at the
unit.
“OFF” - Indicates that the disconnect switch is open, interrupting the main power supply to the unit
controls.
“RESET” - Turning the handle to this position resets the circuit breaker (if so equipped).
The handle can be locked in the “OFF” position. While holding the handle in the “OFF” position, push the spring
loaded thumb key, attached to the handle, into the base
slot. Place the lock shackle between the handle and the
thumb key. This will prevent it from springing out of
position.
An overall layout of the field required power wiring is illustrated beginning with Figure 54, p. 79. To ensure that
the unit supply power wiring is properly sized and
installed, follow these guidelines. Note:
All field installed wiring must conform to NEC
guidelines as well as State and Local codes.
Verify that the power supply available is compatible with the unit nameplate rating for all components. The
available power supply must be within 10% of the rated
voltage stamped on the nameplate. Use only copper
conductors to connect the
3-phase power supply to the unit.
Electric Heat Units
Electric Heat Units require one power entry as illustrated
in Figure 54, p. 79. Use the information provided in
Table 24, p. 82 and the “Power Wire Sizing & Protection
Device Equations”, to determine the appropriate wire size
and Maximum Over current Protection for the heaters/
unit.
Note: Each power supply must be protected from short
circuit and ground fault conditions.To comply with
NEC, protection devices must be sized according to
the “Maximum Over current Protection” (MOP) or
“Recommended Dual Element” (RDE) fuse size data on the unit nameplate.
Provide grounding for the supply power circuit in the
electric heat control box.
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. Verify with an appropriate
voltmeter that all capacitors have discharged. Failure to
disconnect power and discharge capacitors before
servicing could result in death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
Figure 53. Disconnect switch external handle
WARNING
Live Electrical Components!
During installation, testing, servicing and
troubleshooting of this product, it may be necessary to
work with live electrical components. Have a qualified
licensed electrician or other individual who has been
properly trained in handling live electrical components
perform these tasks. Failure to follow all electrical
safety precautions when exposed to live electrical
components could result in death or serious injury.
CAUTION
Use Copper Conductors Only!
Unit terminals are not designed to accept other types
of conductors. Failure to use copper conductors may
result in equipment damage. 
						

							Installation
RT-SVX24K-EN79
Main Unit Power Wiring
Figure 56, p. 80lists the field connection wire ranges for
both the main power terminal block and the optional main
power disconnect switch. The electrical tables beginning
with Table 22, p. 81 list the component electrical data.The
electrical service must be protected from over current and
short circuit conditions in accordance with NEC
requirements. Protection devices must be sized according
to the electrical data on the nameplate. Refer to the “Power
Wire Sizing and Protection Device Equations”, for determining;
the appropriate electrical service wire size based on
“Minimum Circuit Ampacity” (MCA), 
the “Maximum Over current Protection” (MOP)
device,
 the “Recommended Dual Element fuse size” (RDE).
1. Location for the electrical service entrance is illustrated inFigure 54, p. 79. Complete the unit power wiring
connections onto either the main terminal block, or the
factory mounted non-fused disconnect switch, inside
the unit control panel. Refer to the customer
connection diagram that shipped with the unit for
specific termination points.
2. Provide proper grounding for the unit in accordance with local and national codes
Figure 54. Typical field power wiring
Field Supplied SurviceOver Current Protection
Pitch Pocket
Pitch Pocket
3-Wire Power 
Supply+Ground
Front View Control Box
1TB1 or
1S1
Electric Heat Control Panel Gas Heat Control Panel
Steam or Hot Water Control Panel
Heat Control Box Condenser
Section 
						

							Installation
80RT-SVX24K-EN
Figure 55. Typical field power wiring
Figure 56.Customer connection wire range
Note:Non-fused disconnect switch size is
calculated by selecting the size
greater than or equal to 1.15 X (sum of
unit loads). See unit literature for unit
load values. (See following page for
circuit breaker sizing)