The TU-502 Gas Fired Heating Control Board training unit is a comprehensive set of electrical controls designed for furnaces equipped with air conditioning units. Its purpose is to demonstrate fundamental principles and offer hands-on electrical service training. By using this compact HVAC/R trainer, technicians can engage in interactive learning experiences centered around heating systems.
Joey Henderson, an experienced HVAC instructor with 34+ years in the field, walks through possible lesson ideas that instructors can use to teach their students more about heating systems. Watch the video here!
Here are 10 lessons to be used with iConnect Training’s Gas Fired Heating Control Board trainer:
#1: Simulate 3 types of gas valves
To facilitate hands-on learning, the equipment is equipped with pilot assemblies that allow students to hook up a propane bottle. The unit comes with a tank holder and regulator, enabling the use of either a propane or map tank. Students can connect these tanks to each pilot and light them to gain experience with the process. This practical exercise provides students with a deeper understanding of the system’s functionality and enables them to develop important skills in propane system operation and maintenance.
#2: Demonstrate maintaining a lit pilot
Show students how to hold down the pilot button for 30 seconds. This will light the pilot and ensure it remains lit. On the backside of the trainer, there’s a fan that pressurizes the cabinet. When the pilot is proved and the student turns the gas valve to the “on” position, it will set a call for heat at the thermostat. This will actually open up the gas valve allowing students to feel the air pressure coming out and know the system is actually operating.
#3: Fan/Limit control and heater simulation of turning on the system
This unit has a 24-volt thermostat, line voltage thermostat and fan limit control. There’s even a heater behind it so that it will activate and turn on the system. Let students simulate turning it on.
#4: Show a trip-out on high limit with overheating
If the heater is left running for too long, it will overheat and trip the high limit switch, providing students with a practical demonstration of the system’s safety features.
Additionally, the equipment includes a transformer, fan relay and AC relay, as well as indicator lights that show when these components are energized. By observing these components in action, students can gain a better understanding of how the system functions and learn to diagnose potential issues.
#5: Troubleshoot with failed thermocouples
This live working trainer is designed to simulate both magnetic and millivolt gas valves, complete with live pilot flames for hands-on troubleshooting. To further enhance the learning experience, students can change out the thermocouples with failed ones and work on diagnosing the issues. With this approach, they can develop a deep understanding of the system’s functionality and gain practical experience in addressing common problems.
#6: Check voltage on gas valves
As the voltage travels through, it is important to check the readings along the way. The training unit operates at 115 volts and then transfers to 24 volts via the transformer. Be sure to have students monitor the voltage levels carefully to ensure proper functioning of the equipment.
#7: ID and trace each circuit for heating and cooling, and then use banana jacks and patch cords to complete each circuit and verify
To complete each circuit, students will use banana jacks. They should begin by identifying the circuits for heating and cooling. A helpful diagram is available to assist them in this task. The next step is to locate the cooling circuit, trace it out and confirm its identity. As part of the exercise, students can even try jumping R to Y to activate the circuit and ensure it works as intended.
#8: Wire the unit for heating or cooling and verify it works. Set the thermostat to a call for cool/heat and troubleshoot.
The equipment features a built-in fan in the back that runs continuously and gas valves with adjustable pressure. To begin troubleshooting, students can examine the cooling side of the thermostat and proceed to wire it in. Banana jumpers can be used to connect the thermostat for heating or cooling, after which students can turn the system on to test if it works as intended.
#9: Reset the fan limit switch and run it till the unit overheats
Engage students in troubleshooting scenarios where they reset the fan limit switch for varying temperature settings. If it overheats, they can see the bi-metallic moving inside and tripping out on high temperatures.
#10: Replicate various relay problems
There are all kinds of tricks to show relay problems. Instructors can take off the connector, put a little tape on there and then slide it back on. Instructors can also create fake connectors and mimic a failed contactor or relay a loose connection.
Remember! At the end of the day, your only limitation is your imagination!