Trane Horizon OAB Series Installation, Operation And Maintenance Manual
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Trane Horizon OAB Series Installation, Operation And Maintenance Manual

Trane Horizon OAB Series Installation, Operation And Maintenance Manual

Outdoor air unit, direct gas-fired
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Installation, Operation,
and Maintenance
Horizon™ Outdoor Air Unit
Direct Gas-Fired
Model: OAB, OAG
Important:
Proper execution of the tasks outlined in this Installation, Operation, and Maintenance manual
KCC
require and assume the technician has been certified as a start up technician for the Horizon Outdoor
International Inc.
Air unit. This includes working knowledge of the Tracer TU program.
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
L'installation et l'entretien de cet équipement doivent être assurés exclusivement par du personnel qualifié.
L'installation, la mise en service et l'entretien d'équipements de chauffage, de ventilation et de climatisation
(CVC) présentent un danger et requièrent des connaissances et une formation spécifiques. Une installation,
un réglage ou une modification inappropriés d'un équipement par une personne non qualifiée peut provoquer
des blessures graves, voire la mort. Lors de toute intervention sur l'équipement, respectez les consignes de
sécurité figurant dans la documentation, ainsi que sur les pictogrammes, autocollants et étiquettes apposés
sur l'équipement.
November 2019
SAFETY WARNING
AVERTISSEMENT DE SÉCURITÉ
OAU-SVX005C-EN

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Summary of Contents for Trane Horizon OAB Series

  • Page 1 Installation, Operation, and Maintenance Horizon™ Outdoor Air Unit Direct Gas-Fired Model: OAB, OAG Important: Proper execution of the tasks outlined in this Installation, Operation, and Maintenance manual require and assume the technician has been certified as a start up technician for the Horizon Outdoor International Inc.

  • Page 2: Important Responsible Refrigerant Practices

    Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.
  • Page 3 Introduction WARNING AVERTISSEMENT Personal Protective Equipment (PPE) Équipements de protection individuelle Required! (EPI) obligatoires! Failure to wear proper PPE for the job being undertaken En cas d’équipement de protection individuelle could result in death or serious injury. Technicians, in inadapté au travail entrepris, les techniciens s’exposent order to protect themselves from potential electrical, à...
  • Page 4 Introduction WARNING AVERTISSEMENT Follow EHS Policies! Fluide frigorigène sous haute pression! Failure to follow instructions below could result in Tout manquement aux instructions indiquées ci- death or serious injury. dessous peut provoquer une explosion pouvant causer des blessures graves voire mortelles ou des dommages •...
  • Page 5 3. Extinguish any open flame. 4. Immediately call your gas supplier. This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right AVERTISSEMENT...

  • Page 6: Table Of Contents

    Table of Contents Model Number Descriptions Filter Installation .....19 ....8 Horizon Outdoor Air Unit Field Installed Power Wiring .
  • Page 7 Table of Contents Dampers ......40 Air Filters ......40 Belt Tensions and Adjustments .

  • Page 8: Model Number Descriptions

    Model Number Descriptions Horizon Outdoor Air Unit Digit 1, 2 — Unit Type Digit 13 — Compressor Digit 17 — Indoor Fan Wheel OA = Outdoor Air No Compressors Scroll Compressors Digit 3 — Cabinet Size Digital Scroll (1 Circuit Only) 450 X 2 500 cfm–3,000 cfm Digital Scroll (1...
  • Page 9 Digit 25, 26 — Unit Controls Digit 28 — Powered Exhaust Fan (Primary Heat Source) Wheel 00 = Non-DDC—Electromechanical AA = Trane—Discharge Air Control No Powered Exhaust ELEC w/LON Read-Write w/Display No Heat No Heat AB = Trane—Space Control w/LON...
  • Page 10 Model Number Descriptions Digit 34 — Filtration Options Digit 37 — Air Flow Monitoring No Filters No Airflow Monitoring MERV-8,30% Airflow Monitoring—IFM MERV-13, 80% Piezo Ring MERV-14, 95% Airflow Monitoring—PE MERV-8 30%, MERV-13 80% Piezo Ring MERV-8 30%, MERV-14 95% Airflow Monitoring—Outdoor Air MERV-8, 30% with UVC with Display and IFM...

  • Page 11: General Information

    General Information Overview of Manual and RTRM receive information from sensors and customer binary contacts to satisfy the applicable request Note: One copy of this document ships inside the control for ventilation, cooling, dehumidification and heating. panel of each unit and is customer property. It must Indoor Fan Failure Input be retained by the unit’s maintenance personnel.

  • Page 12: Space Temperature / Rh Sensor (Optional)

    General Information Space Temperature / RH Sensor (Optional) Unit Inspection Field installed, wall mounted temperature sensor (BAYSENS036A) and humidity to control space cooling, WARNING heating and dew point. Fiberglass Wool! High Temperature Sensor Product may contain fiberglass wool. Disturbing the The Discharge Air Temperature Sensor (DTC) supplies a insulation in this product during installation, maintenance or repair will expose you to airborne...

  • Page 13: First Aid Measures

    General Information • Wash clothes separately from other clothing: rinse washer thoroughly. • Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respiration in these situations. First Aid Measures Eye Contact Flush eyes with water to remove dust.

  • Page 14: Unit Clearances, Curb Dimensions, And Dimensional Data

    Unit Clearances, Curb Dimensions, and Dimensional Data Curb Dimensions WARNING Figure 2. Unit curb data for direct-fired OAB tons (in.) Combustible Materials! Failure to maintain proper clearance between the unit 25.500 heat exchanger, vent surfaces and combustible 48.500 3.750 materials could cause a fire which could result in death or serious injury or property damage.

  • Page 15: Direct-Fired Oag Units

    Unit Clearances, Curb Dimensions, and Dimensional Data Direct-Fired OAG Units Dimensional Data Unit Clearances Figure 6. Unit dimensional data for direct-fired OAG (in.) Figure 4. Typical installation clearances for direct-fired OAG unit (in.) 121.371 5.5852 66.096 GAS INLET 3.078 33.751 ELECTRIC DISCONNECT 74.000...

  • Page 16: Unit Weight And Rigging

    Unit Weight and Rigging Unit Weight WARNING Table 1. Typical unit weight Heavy Objects! Operating Weight (lb) Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing Model Number operator/technician which could result in death or OABD036* 1655 1839...

  • Page 17: Rigging

    Unit Weight and Rigging Rigging 3. Test-lift the unit to ensure it is properly rigged and balanced, make any necessary rigging adjustments. Figure 7. Rigging 4. Lift the unit and position it into place. Remove fork pockets prior to setting on the curb. 6-point lift 5.

  • Page 18: Installation

    Installation duct work must be installed and connected to top of roof curb before the unit is set on curb. WARNING If a Curb Accessory Kit is not used: Hazardous Service Procedures! 1. Be sure to use flexible duct connections at the unit. Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or 2.

  • Page 19: Main Electrical Power Requirements

    Installation  Set the unit onto the curb; check for level. Figure 9. Condensate trap installation  Ensure unit-to-curb seal is tight and without buckles D" NPT FEMALE CONNECTOR or cracks.  Install and connect proper condensate drain line to the evaporator condensate pan drain connection (see Figure 9, p.

  • Page 20: Field Installed Power Wiring

    Installation Field Installed Power Wiring Figure 11. OAG utility connections (in.) WARNING Proper Field Wiring and Grounding 121.371 Required! Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards.

  • Page 21: Main Unit Power

    Installation Main Unit Power The electrical service must be protected from over current and short circuit conditions in accordance with NEC requirements. Protection devices must be sized according WARNING to the electrical data on the nameplate. Hazardous Voltage! 1. Location of the electrical service entrance is illustrated Figure 11.

  • Page 22: Electrical Phasing (Three-Phase Motors)

    Installation Electrical Phasing (Three-Phase Motors) AVERTISSEMENT Composants électriques sous tension! WARNING Le non-respect de toutes les consignes de sécurité lors Live Electrical Components! de la manipulation de composants électriques sous Failure to follow all electrical safety precautions when tension peut entraîner des blessures graves, voire exposed to live electrical components could result in mortelles.

  • Page 23: Compressor Crankcase Heaters

    Installation Compressor Crankcase Heaters Main Unit Display and ReliaTel Controls When first powered “On”, the controls perform self- diagnostic initialization to check that all internal controls WARNING are functional. The Status LED located on the Main Unit Live Electrical Components! Display and the Liteport LED located on the RTRM module is turned “On”...

  • Page 24: Controls Using 24 Vac

    Installation Note: Resistance in excess of 3 ohms per conductor may cause component failure due to AVERTISSEMENT insufficient AC voltage supply. Risque d’électrocution! 3. Be sure to check all loads and conductors for grounds, Le non-respect de cette consigne peut entraîner des shorts, and mis-wiring.

  • Page 25: Dc Conductors

    Installation DC Conductors Table 4. Zone sensor module wiring Distance from Unit to Control Recommended Wire Size 000–150 feet 22 gauge 0–45.7 m 0.33 mm 151–240 feet 20 gauge 46–73.1 m 0.50 mm 241–385 feet 18 gauge 73.5–117.3 m 0.75 mm 386–610 feet 16 gauge 117.7–185.9 m...

  • Page 26: System Configuration And Pre-Start

    System Configuration and Pre-Start The following procedure must be completed prior to remote operator display screens. For performing the procedure in the Start-up chapter. This additional control system information, refer section describes procedures to navigate the various to Integration Guide: Tracer™ UC600 displays on the Unit Display and configure the Outdoor Air Programmable Controller for Packaged Unit Main Unit Display system setpoints and operating...
  • Page 27 System Configuration and Pre-Start Table 5. Menu descriptions Screen Menu Point List Min/Inactive Default Max/Active Point? Active Alarms List of all active alarms Alarms All Alarms List of all previous alarms Custom Graphics *NOT USED* Program Control Discharge Air Control Space Control Space Control Heat Cool Mode Active Heat...
  • Page 28 System Configuration and Pre-Start Table 5. Menu descriptions (continued) Screen Menu Point List Min/Inactive Default Max/Active Point? DAT High Temp Cutout 100°F 125°F 150°F DAT Low Temp Cutout 35°F 35°F 50°F DAT Temp Cutout Time 10 min. 10 min. 25 min. Discharge Air Cooling Setpoint 55°F 55°F...

  • Page 29: Startup

    Startup Direct Heating Startup AVERTISSEMENT Procédures d’entretien dangereuses! WARNING Le non-respect de toutes les précautions contenues Hazardous Service Procedures! dans ce manuel ainsi que sur les étiquettes et les autocollants peut entraîner des blessures graves voire Failure to follow all precautions in this manual and on mortelles.

  • Page 30: Direct Gas-Fired Heating Start-Up Procedure

    Startup 2. Use only hand force to operate the gas control lever to Table 6. Acceptable measured pressures the “ON” position. NEVER use tools. If lever does not operate by hand, replace gas valve prior to staring the OAT (°F) Burner Pressure Drop (in.
  • Page 31 Startup After confirming gas flow to unit , verify and record gas • Starting Sequence pressure at PG1. Note: In the event Outdoor Air Conditions or Unit 3. Heating Starting Sequence for Gas Input Rating Controls are such that the unit will not ...

  • Page 32: Initiate

    Startup Figure 14. > 400 MBh Gas train AVERTISSEMENT Risque d’explosion! Des composants au gaz défectueux peuvent exploser ou entraîner des fuites de gaz inflammable pouvant provoquer un incendie résultant en des blessures graves, voire mortelles, ou des dommages matériels. Pour éviter d’endommager l’unité...

  • Page 33: Standby

    Startup frequency fluctuations of ±10 percent during any part of 3 seconds, depending on the flame failure response the operating sequence. The initiate sequence lasts for time (FFRT) of the amplifier. 10 seconds unless the voltage or frequency tolerances are •...

  • Page 34: Settings And Adjustments

    Startup Notes: Figure 15. Sequence status LEDs • 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 then be replaced. Figure 17.
  • Page 35 Startup If ignition is not achieved within 10 seconds, the control • Low Fire Test Following Normal Burner Starting valve shuts off the gas and locks out. If the trial for ignition Sequence has been accomplished without ignition, the control shuts –...

  • Page 36: Maintenance

    Maintenance Make sure all personnel are standing clear of the unit • Inspect the evaporator and condenser coils for dirt, before proceeding. The system components will start bent fins, etc. If the coils appear dirty, clean them when the power is applied. according to the instructions described in “Condenser Coil Cleaning,”...
  • Page 37 Maintenance At least once each year, or more often if the unit is located in a “dirty” environment, clean the condenser coils using AVERTISSEMENT the instructions outlined below. Be sure to follow these Produits chimiques dangereux! instructions as closely as possible to avoid damaging the coils.

  • Page 38: Direct-Fired Unit Maintenance Schedule

    Maintenance d. spray the solution perpendicular (at 90°) to the coil face. AVERTISSEMENT 6. Spray the leaving-airflow side of the coil first; then Procédures d’entretien dangereuses! spray the opposite side of the coil. Allow the cleaning Le non-respect de toutes les précautions contenues solution to stand on the coil for five minutes.

  • Page 39: Lubrication Requirements

    Maintenance b. Check set-screws and bolts on the fan, bearings, a. Complete the monthly and quarterly maintenance and burner assembly. schedule. b. Inspect all fan wheels and housings. Clean if NOTICE: necessary. Belt Over-Tension! c. Check that all fan wheels and sheaves are securely set on the shaft.

  • Page 40: Pillow Block Bearings

    Maintenance Lubrication of motors should be done while the motor is Table 9. Frequency of lubrication warm and at a standstill. Remove and clean all grease plugs and insert a grease fitting in the upper hole in the Speed Temp. motor casing at each end (viewed as if motor were sitting (rpm) (°F)

  • Page 41: Belt Tensions And Adjustments

    Maintenance Belt Tensions and Adjustments Gaskets Belt tension is adjusted during the initial run-in and test Gaskets are used on doors, inspection covers, some filter periods at the factory. However, belts are run as slack as racks and some outdoor air dampers. Inspect gaskets possible to prevent excessive damage to the bearings, yet periodically and repair or replace as required.
  • Page 42 Maintenance caused by thermal stresses occurring during combustion. The presence of these hairline cracks AVERTISSEMENT in no significant way affects the combustion Risque d’électrocution! efficiency or performance of the heater. Should a large opening develop, the specific mixing plate or Le non-respect de cette consigne peut entraîner des blessures graves, voire mortelles.

  • Page 43: Inspection And Maintenance Of Gas Ports

    Maintenance Inspection and Maintenance of Gas Ports _____________________________________________________ _____________________________________________________ Conduct initial inspection within the first month after commissioning. Visually check the gas ports of the new _____________________________________________________ burner assemblies for any piping scale or debris. Use pin — connection(s) vise with drill bit to remove. _____________________________________________________ Figure 18.
  • Page 44 Maintenance Table 11. Sample maintenance log Refrigerant Circuit #1 Refrigerant Circuit #2 Current Suct. Disch. Liquid Suct. Disch. Liquid Ambient Compr. Press. Press Press Super- Sub-cool Compr. Press. Press Press Super- Sub-cool Psig/kPa Psig/kPa heat F/C Date Temp F/C Oil Level Psig/kPa Psig/kPa Psig/kPa...

  • Page 45: Performance Data

    Performance Data Table 12. OABD General Data—Cooling 3–5 Tons High Efficiency 3 Tons 4 Tons 5 Tons OABD036A OABD048A OABD060A Cooling Performance Gross Cooling Capacity, Btu (kW) 41,462 (12.15) 55,709 (16.33) 66,870 (19.60) Nominal cfm (m 500–2000 (850–3398) 500–2000 (850–3398) 500–2000 (850–3398) Compressor Number...
  • Page 46 Performance Data Table 13. OABD General Data—Cooling 6–9 Tons High Efficiency 6 Tons 7 Tons 8 Tons 9 Tons OABD072A OABD084A OABD096A OABD108A Cooling Performance Gross Cooling Capacity, Btu (kW) 78,600 (23.04) 88,768 (26.02) 99,099 (29.04) 108,214 (31.71) Nominal cfm (m 625–3000 (1061–5097) 625–3000 (1061–5097) 625–3000 (1061–5097) 625–3000 (1061–5097) Compressor Number...
  • Page 47 Performance Data Table 14. OAGD General Data—Cooling 10–17 Tons High Efficiency 10 Tons 12 Tons 15 Tons 17 Tons OAGD120A OAGD144A OAGD180A OAGD210A Cooling Performance Gross Cooling Capacity, Btu (kW) 150,692 (44.16) 165,990 (48.65) 206,544 (60.53) 230,212 (67.47) Nominal cfm (m 1250–2500 (2124–4248) 1500–3000 (2549–5097) 1875–3750 (3186–6371) 2125–4250 (3610–7221) Compressor Number...
  • Page 48 Performance Data Table 15. OAGD General Data—Cooling 20–30 Tons High Efficiency 20 Tons 22 Tons 25 Tons 30 Tons OAGD240A OAGD264A OAGD300A OAGD360A Cooling Performance Gross Cooling Capacity, Btu (kW) 286,302 (83.91) 319,026 (93.50) 368,012 (107.85) 395,596 (115.94) 2500–5000 2750–5500 3125–6250 3750–7500 Nominal cfm (m...

  • Page 49: Superheat And Refrigeration Circuit Data

    Performance Data Superheat and Refrigeration Figure 20. Refrigeration diagram: Single compressor Circuit Data with reheat Figure 19. Refrigeration diagram: Single compressor without reheat OAU-SVX005C-EN...
  • Page 50 Performance Data Figure 21. Refrigeration diagram: dual compressor Figure 22. Refrigeration diagram: dual compressor with without reheat reheat OAU-SVX005C-EN...

  • Page 51: Alarms And Troubleshooting

    Alarms and Troubleshooting Microprocessor Control • System status • Cooling status The Main Unit Display and RTRM have the ability to provide the service personnel with some unit diagnostics If a System failure is indicated, proceed to Step 4. If no and system status information.
  • Page 52 Alarms and Troubleshooting Table 16. TOAU UC600 alarms (continued) Table 16. TOAU UC600 alarms Point Diagnostic Possible Cause Point Diagnostic Possible Cause Applies to 5:1 and 10:1 Gas Heaters Only VFD not operating Trips after heat command “ON” and no GV Outdoor and/or Return Air Dampers not status offer 1 minute Operating Properly...

  • Page 53: Rtrm Failure Modes

    Alarms and Troubleshooting Table 17. TOAU UC600 troubleshooting (continued) Cool Failure Trouble Possible Cause Measure the voltage between terminals J6-8 and J6-6. High fire gas manifold pressure too high Cool Operating = approximately 32 Vdc Supply fan speed too low Cool Off = less than 1 Vdc, approximately 0.75 Vdc Dirty or clogged filters Unit Trips Heater...

  • Page 54: Direct-Fired Oab And Oag Unit Flame Relays £ 400 Mbh

    Alarms and Troubleshooting Direct-Fired OAB and OAG Unit Flame Relays  400 MBh AVERTISSEMENT Procédures d’entretien dangereuses! WARNING Le non-respect de toutes les précautions contenues dans ce manuel ainsi que sur les étiquettes et les Hazardous Service Procedures! autocollants peut entraîner des blessures graves voire mortelles.

  • Page 55: Direct-Fired Oag Unit Flame Relays

    Alarms and Troubleshooting Flame Current Measurement AVERTISSEMENT Flame current of the device can be measured using a standard micro-ammeter by simply inserting the meter Procédures d’entretien dangereuses! probes into the holes labeled FLAME CURRENT. Le non-respect de toutes les précautions contenues •...
  • Page 56 Alarms and Troubleshooting Table 20. Troubleshooting guide for flame relays during problem of safety shutdown (lockout) (continued) Occurs In Occurs If Prepurge Period • Airflow lockout feature is enabled and the airflow switch opens • Ignition/pilot valve terminal is not energized •...
  • Page 57 Alarms and Troubleshooting PFEP Post Purge Initiate Standby Start Time Purge Standby 4-10 Sec. 15 Sec. Power Power Power Power Power Power Power Power LED Display Pilot Pilot Pilot Pilot Pilot Flame Flame Flame Flame Flame Main Main Main Main Main Alarm Alarm...
  • Page 58 Alarms and Troubleshooting PFEP Post Purge Initiate Standby Start Time Purge MFEP Standby 4-10 Sec. 15-Sec Power Power Power Power Power Power Power Power Power LED Display Pilot Pilot Pilot Pilot Pilot Pilot Flame Flame Flame Flame Flame Flame Main Main Main Main...

  • Page 59: Appendix

    Appendix OAU Filter Guide Table 21. OAB units Thickness MERV Height Width 2 in. Mist Eliminators 2 in. 8, 13 Table 22. OAG units Thickness MERV Height Width 2 in. Mist Eliminators 2 in. 8, 13 Note: 2 in. mist eliminators and 2 in. MERV 8 filters are standard; MERV 13 filter is optional.
  • Page 60 Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results.

This manual is also suitable for:

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