InstallationOperationMaintenance

CLCH QuantumClimate ChangerAir Handling Units

CLCH-SVX05A-GB

CLCH-SVX05A-GB

GeneralInformation

©American Standard Inc. 2002

ForewordThese installation, operation, andmaintenance instructions are given as aguide to good practice in the installation,commissioning into service, operation,and periodic maintenance by the user, ofCLCH Air Handling Units. They do notcontain the full service proceduresnecessary for the continued successfuloperation of this equipment. The servicesof a qualified service technician should beemployed through the medium of amaintenance contract with a reputableservice company.

WarrantyTrane’s standard warranty covers theequipment. It does not cover damage dueto misuse, lack of maintenance, or failureto comply with the manufacturer'sinstructions or recommendations.

Receiving/HandlingOn arrival, inspect the unit before signingthe delivery note. Specify any damage onthe delivery note, and send a registeredletter of protest to the last carrier of thegoods within 72 hours of delivery. Notifythe local Trane sales office at the sametime. The unit should be totally inspectedwithin 15 days of delivery. If anyconcealed damage is discovered, stopunpacking the shipment. Take photos ofthe damaged material if possible. Notifythe carrier immediately by phone andregistered mail. Notify the local Tranesales office. Concealed damage must bereported within 15 days of delivery.

About This ManualWarnings appear at appropriate places inthis instruction manual. Your personalsafety and the correct operation of thismachine require that you follow thewarnings carefully. The manufacturerassumes no liability for installations orservicing undertaken by unqualifiedpersonnel.

About The UnitThe information contained in this manualapplies to units designated CLCH

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Contents

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1. Introduction2. Delivery Check On Arrival/Off-Loading

and Movement To The Site3. Foundations and Erection4. Assembly and Installation5. Commissioning Procedure6. Maintenance7. Troubleshooting

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CLCH-SVX05A-GB

CLCH-SVX05A-GB4

1. Introduction

Please pay particular attention to theinstructions on the unit in accordance withthe identification label, assemblydrawings, and special warnings or advicelabels.

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2. Delivery Check OnArrival/Off-Loading andMovement To The Site

2.1 Delivery CheckCheck the delivery contents on arrival ofCLCH units in respect of completeness,and note any damage which may haveoccurred. In the event of any damagebeing noted, a claim must be made byreturn. Only by compliance with thisprocedure is it possible to submit aninsurance claim. Any damage must benoted on the delivery documentation,dated and signed in the presence of thedelivery driver, and signalled byregistered letter to the last forwarder.

Claims in respect of obvious transportdamage or incompleteness of deliverycannot be accepted in retrospect. Inthe event of any complaints, pleasenotify the relevant Trane officeimmediately, and in writing within 72hours.2.1.1. IdentificationAll Trane CLCH units are identified by thesales number and manufacturer's worksorder number given on the unit ID label.Be sure to refer to the information givenon the unit identification label whenordering replacement parts or requestingservice. The nameplate (see Figure 1) ismounted on the fan-section access side,and a manufacturer's plate (see Figure 2)is fixed inside the fan section.

Figure 2 – Manufacturers Plate

2.2 Off LoadingA specific lifting method for offloading theunits is recommended as follows (seeFigure 3):1) 52 mm-diameter lifting holes, or

certified lifting lugs, are provided on theunit base frame.

2) ALL LIFTING POINTS in one axis ofthe unit must be used when offloadingand moving the unit.

3) Slings and spreader bars are to beprovided by the rigger and attached toALL LIFTING POINTS.

4) The minimum rated lifting capacity(vertical) of each sling and spreaderbar should be no less than the shippingweight.

5) The unit must be lifted with care,avoiding shock load by lifting the unitslowly and evenly.

2.3 Moving To Position OnSite

Trane units are supplied in sectionsmodules, flat packed, or as a completeunit, in accordance with the relevantassembly drawings. Any necessary useof force during unloading or movement ofthe units must only be applied via the unitbase frame or shipping pallet.

NEVER LIFT THE UNITS BY COILCONNECTIONS OR BY ANY OTHERPROTRUSIONS.THE ROOF IS NOT DESIGNED TO BEWALKED ON, BUT IF THIS ISUNAVOIDABLE, ENSURE A MOREEVEN WEIGHT DISTRIBUTION BYTHE USE OF BOARDS.FAILURE TO DO SO MAY RESULT INSEVERE PERSONAL INJURY ORDEATH.

WARNING

Figure 3

Figure 1 – Nameplate

ENSURE SLINGS DO NOT FOUL ONUNIT PROTRUSIONS.THE CENTRE OF GRAVITY WILLVARY PER UNIT…POSITION THESLINGS AND SPREADER BARSCAREFULLY TO COMPENSATE FORTHIS.FAILURE TO DO SO MAY RESULT INSEVERE PERSONAL INJURY ORDEATH.

WARNING

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2. Delivery Check OnArrival/Off-Loading andMovement To The Site

2.4 Forklift TrucksThe forks must only be applied under theunit base frame and not against the unitbase frame. The lift point should be asnear as possible to the centre of gravity(see Figures 4 and 4a). In the case oflarger units the use of several forklifttrucks may be required.2.4.1. Roller MovementUnits fitted with base frames may bemoved on roller trolleys or tubular rollers(see Figure 5).

Figure 4

Figure 4A

Figure 5

CLCH-SVX05A-GB

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3. Foundations andErection

3.1 FoundationWhen selecting and preparing the unitsite, follow these guidelines:1. Ensure that the site can support the

total weight of the unit. Unit weightfigures only provide total gross weightsand do not include the additionalweight for water in any coils.

2. Confirm that the foundation of themounting platform is large enough toinclude the unit dimensions plusservice plus service access.

3. The floor or foundation must be levelfor correct coil drainage andcondensate flow.

4. Provide adequate lighting formaintenance personnel to performmaintenance duties.

5. When the unit is positioned on site,there must be sufficient space aroundthe unit to ensure that correct operationand effective maintenance can becarried out. Figure 6 givesrecommended space allowances.

• On the designated access side of theunit, working areas must be equal to thewidth of the unit, dimension “P.”

•Allowance for coil connections,dimension “C” must be dimension “P” +200 mm.

•A clear unobstructed area before andafter an air intake or discharge isrequired to ensure correct airmovement. The width of the area mustbe >= the width of the unit, and thedepth (dimension "L") must be >= 0.5 xthe overall unit height.

Complete reinforced concretefoundations are suitable or stripfoundations may also be used (seeFigure 7).In the case of strip foundations, concreteor steel supports are permissible, butsupport is required under breakpoints andevery 2 m along the unit base.

Figure 7 – Air Handling Unit Steels Foundation

Figure 6

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CLCH-SVX05A-GB

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3. Foundations andErection

Figure 8 – Air Handling Unit Plinth Foundation

FAILURE TO PROVIDE A LEVELPLINTH OR SUPPORT WILL RESULTIN DOORS JAMMING AND AIR LEAKSFROM THE CASING.

3.2 ErectionTo minimize noise transmission,insulation material such as cork slabbing(TICO pads) may be placed between theunit base and the foundation (see Figure8).

IMPORTANT

CLCH-SVX05A-GB

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4. Assembly andInstallation

4.1 Break Point and GeneralUnit AssemblyInstructions

Ensure that all the air-handling unitsections are positioned in the correctorder. Each section will display a unit drawingwith its position OUTLINED. 1.Each of the unit sections should be

placed on a level foundation and within200 mm of its adjoining section.

2.Remove any supports and bracingwhich are supplied with the unit fortransport. All such supports will beclearly marked:

“FOR TRANSPORT ONLY – REMOVE BEFORE ASSEMBLY”

3.Remove 4 M6 fixing bolts (A) from theprotruding portion of the 4 frameworkjoining bars (see Figure 9), then loosenthe remaining 4 bolts that are locatedon the fixed side of the break pointjoining bars.Pull together the sections of the unit,ensuring that the joiner bar in each ofthe 4 corners is fitted into its adjoiningsection and the plastic “T” sectionsealing strip locates over the adjoiningpanel.The 52-mm diameter holes provided inthe unit base frame should be used tomanoeuvre the sections together. Greased skid plates will greatly assistthe whole assembly operation.

4. Secure the break point joint externallyby replacing the 4 M6 bolts andwashers, which were previouslyremoved in step (3). Retighten the 8bolts located on both sides of the breakpoint joint.

Where applicable, complete theassembly of the unit as follows:

4.1.3. Fan sectionsBolt the outlet of the fan to the flexibleconnection using the M8 bolts provided.4.1.4. Damper sectionsPop-rivet through the damper spigot andthe adjoining plastic “J” section into theadjacent fixed panel using 5-mm-diameter rivets.

4.1.5. Coil sections (with drip pans)Fix through the top of the drip pan into thebox section using the self-drilling screws,which are provided. Then seal along alljoints with a waterproof “silicone” basedsealant. We recommend “Siloflex.”4.1.6. Weatherproof roofsSlide on the “Doby” cleats, which areprovided, and then fix in position at theends with the cleat clips on the roof returnedge using 5mm diameter rivets.

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CLCH-SVX05A-GB

Figure 9Figure Notes:1. Part 12.Part 23. Break Point4. Bolts “A”5. Fixed bolts6. 52 mm diameter holes7. 8 x M6 bolts (2 per join)

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4. Assembly andInstallation

4.2 Stacked Units (Top andBottom)

Lower the top unit into position on top ofthe bottom unit, taking care not todamage the sealing gaskets.Fit the self-tapping screws to the fixingbrackets, which are already positioned onthe top edge of the bottom unit,drilling intothe top unit section (10A) or base frame(10B) depending on product, in order tosecure the top unit to the bottom unit (seeFigure 10).Fix into position any internal joining stripsand/or brackets that are provided, andthen seal up any common sections in thetop and bottom units.4.2.1. Stacked units (Side by Side)Manoeuvre the two units into their correctpositions, taking care not to damage anysealing gaskets.Fix through the fixing brackets which arelocated at both ends of the units in orderto secure the units together. Also fix intoposition any base frame, unit end, androof joining brackets that are provided.Fix into position any internal joining stripsand/or brackets that are provided, andthen seal up any common sections inboth of the units.If you require further assistance or haveany questions please contact your localTrane sales office.

4.3 Assembly of FlatpackedUnits

The unit is fully assembled in the factoryon a flat and level surface. Prior todisassembly for flat packing (see Figure11) all items are markedalphanumerically. All items marked “A”are joined at the fixing indicated at thispoint. These markings are on labels oninternal surfaces so they are not evidentupon completion. DO NOT remove labelsuntil assembly is complete.We would recommend opening one unitat a time to avoid confusion.

Figure 10 A/BFigure Notes:1. Self tapping screws2. Bottomframework of TOP unit3. Fixing bracket4. Top framework of BOTTOM unit

Figure 11

CLCH-SVX05A-GB

Figure 10A Figure 10B

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4. Assembly andInstallation

4.4 Condensate Drain FromDrain Pan

Correctly-sized traps must be fittedimmediately after the drip pan outlet (seeFigures 12, 13 and 14).An “air break,” by means of a tun dish,must be fitted immediately after the trap.

Figure 12 – Typical Air Conditioning Plant DrainFigure 12 Notes:1. Cooling coil, humidifier, or chilled battery.2. Vented drainage stack3. Fall4. Air break5. Swept connection6. Trap with water seal (with filling cap)7. Open tun dish or floor gully/channel8. Trap with water seal

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CLCH-SVX05A-GB

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4. Assembly andInstallation

Figure 13 – Negative Pressure Trap (Draw Through)

Figure 14 – Positive Pressure Trap (Blow Through)

Figure Notes:1. 25 mm for each 250 Pa of maximum

negative static pressure + 25 mm2. 0.5 x dimension 13. Dimensions 1 + 2 + pipe diameter +

insulation

Figure Notes:1. Minimum of 12 mm2. 12 mm + maximum total static pressure

Figure 15 – Drip Pans

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4.5 Drip PansA UPVC elbow and 1-1/2" [38 mm]diameter (internal dimension) dischargepipe is supplied as standard (3.2 mm wallthickness).A copper elbow and 35 mm diameterdischarge pipe is available as an option(1.2 mm wall thickness).Drip pans (see Figure 15) are notdesigned to be walked on.

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4. Assembly andInstallation

4.6 Pipework LayoutA correct pipework installation is essentialfor trouble-free coil operation. Figure 16gives an example for piping water coils.(The diagram does not limit the type ofcontrol system used.)All pipework must be supportedindependently from the coils.All connections must be made in such away that the expansion and contraction ofpipes do not impose forces on the coilheaders. Failure to do so may result incoil damage.

Figure 16 – Fluid Pipework

Figure Notes:1. Gate Valve2. Automatic or Manual Drain and Vent3. Automatic Three-Way Valve4. Main Supply Water5. Main Return Water

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4. Assembly andInstallation

4.7 Water CoilsThe air venting of the system should notbe carried out through the coil. Air ventingshould be allowed for in the pipework andany coil vent should be for the solepurposes of venting the coil itself. Whenincoming air temperature may be colderthan 0°C, do not modulate the water flowas this may cause freezing and damageto the coil.4.7.1. Steam CoilsOverhead condensate-return systemsshould not be used; allow for vacuumbreakers as close as possible to the coil.Include a float or thermodynamic trap onall steam coils (following trapmanufacturer recommendations).CORRECT TRAPPING IS VERY

IMPORTANT. FAILURE TO PROPERLYREMOVE CONDENSATE WILLRESULT IN WATER HAMMER ANDPOSSIBLE COIL FAILURE.4.7.2. Refrigerant CoilsRefrigerant pipework installation requiresspecialist design and trained refrigerationengineers for correct installation. If you have any queries, please contactyour local Trane sales office.

4.8 Electrical ConnectionsThe electrical work must be carried out inaccordance with all international, national,and local regulations.Electrical connections passing throughthe casing to the fan motor should becarried out in a flexible conduit.Cables passing through the casing mustbe made with a gland or grommet. All wiring to other accessories must becarried out in the same manner.PLEASE REFER TO THE UNITMOUNTED CONTROLS IOM.Motor connection details are contained inthe cover of the motor terminal box.If you have any queries, please contactyour local Trane sales office.4.8.1. Duct ConnectionsTo reduce noise transmission, the fittingof an intermediate flexible connection ofat least 140 mm width, between theducting and the unit flange, isrecommended. This should beunstressed when initially positioned.Compliance with the Codes of Practice induct assembly and acoustic layout areessential, to ensure the best possibleperformance of the unit whilst avoidingexcessive pressure loss in the ductsystem and minimizing airstream noise.

4.8.2. Motor ConnectionSafety measures need to be taken on siteagainst overload, short circuit, high or lowvoltage, and excessively high ambienttemperatures.Special care must be taken in theconnection of motors, especially if two-speed motors are supplied with the unit.The connection must be carried out inaccordance with the nameplate and thewiring diagrams as shown on the insideof the motor terminal box.Following the connection of the motor, atest run must be carried out in order tocheck motor performance and rotationaldirection.Please see the section on commissioningprocedures for additional information.

IMPORTANT

CLCH-SVX05A-GB

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5. CommissioningProcedure

5.1 PreparationsInitially the complete CLCH unit and allcomponents should be thoroughlycleaned and all dust and other depositscompletely removed. The unit must bemaintained in a clean condition.Prior to despatch, each unit is thoroughlychecked. Nevertheless, as part of thecommissioning procedure, it is imperativeto recheck certain items as listed below.Some of the settings on the unit mayhave changed during transport andduring the installation process.Make sure that the dampers move freelyand that all transport packing has beenremoved.

Table 1 – Torque SettingsBush Size 1008 1108 1210 1610 2012 2517 3020 3525 4030 4535 5040Screw Tightening Torque (Nm) 5.6 5.6 20 20 30 50 90 115 170 190 270Screw Details Quantity 2 2 2 2 2 2 2 3 3 3 3

Size (BSW) 1/4" 1/4" 3/8" 3/8" 1/16" 1/2" 5/8" 1/2" 5/8" 3/4" 7/8"Hexagon Socket Size (mm) 3 3 5 5 5 6 8 10 12 14 14

Large End Diameter (mm) 35.0 38.0 47.5 57.0 70.0 85.5 108.0 127.0 146.0 162.0 177.5Approximate Mass (kg) 0.1 0.1 0.2 0.3 0.7 1.5 2.7 3.8 5.6 7.5 11.1

Fenner is a registered trademark of J H Fenner & Co Ltd.Taper Lock and P B (Precision Built) are registered trademarks of F P T Group.Reproduced with permission of F P T Group.

5.2 Fan/MotorCheck that the fan revolves freely byturning the impeller manually. Check the tension of the fan belt and thealignment of the pulleys (see the sectionon maintenance for additionalinformation). Check that the grub screws in the taperlocks are tightened to the torque settingsin Table 1.Check the motor connections and makesure that the correct voltage supply isbeing used.Where a standby motor has beensupplied, only connect one motor to thepower source.Please refer to the individual supplier'sinstallation, operation, and maintenancemanual for additional information.

5.3 Anti-Vibration MountBrackets

For transport, the fan/motor base anti-vibration mounts are fitted with retainingbrackets. These must be removed beforethe unit is started (see Figure 17).

Figure 17 – Anti-Vibration Transport Bracket Removal

CLCH-SVX05A-GB

5.7 Steam Operating FillingOpen the system air vent and drain valvegradually on the condensate drain.Open the steam valve a small amountuntil steam penetrates through thecondensate drain valve and air vent.Close the condensate drain valve and airvent, and open the steam valve fully.Vent regularly during operations.If the installation is occasionally onstandby, condensate must not be

allowed to remain in the pipes onaccount of freezing and corrosion risk.To prevent overheating coils, the fanstop must be delayed by 3 to 5minutes after the steam valve hasbeen closed.

5.8 Electric HeatersElectric heaters are fitted with thermalcutouts. These must be connected to thecontrol panel on site, to preventoverheating of the unit. The fan is fittedwith an overrun for a period of 3 to 5minutes.

5.9 FiltersCheck that the filters are correctly fitted,with the working side of the filter exposedto the contaminated air stream. Refer tothe data sheets with regard to theclean/dirty pressure drop readings.Ensure that any pressure testing devicesare fitted correctly and that they arezeroed to the right values (clean/dirtypressure drops).Over time, the liquid in the pressure-testing device will fade.

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5. CommissioningProcedure

5.4 Unit ConnectionsAll electrical, water, and ductworkconnections of the unit must becompleted by a qualified person.

To avoid damaging the coilconnections it is essential to grip thehexagonal pipe connection whilstapplying counter pressure to tightenthe joint (see Figure 18).

Figure 18Completely stress-free connections areessential. The pipework of the coilsshould be arranged to facilitate easyremoval of the coil for any requiredmaintenance purposes.

5.5 CoilsCheck that the coil connections andvalves are not leaking. If there are leaks,rectify the problem.

Cooling medium refrigerant Freon.When direct condensers or air-cooledcondensers are fitted, the systemmust be filled with refrigerant.In this case a refrigerant engineermust carry out the installation andpipework.

5.6 OperatingIn general, heating and cooling coilsshould be filled with water containingadditives to protect against freezing andcorrosion:Open the air vents.Open the water supply valve a little sothat the heater battery fills slowly. Thisavoids thermal stress.As soon as the battery heater is full, closethe air vent.Open the water valve fully and switch onthe fan.Finally, the entire pipe system must becompletely vented.All traps connected to the AHU drip traysmust be primed prior to operating the unit.

CAUTION

IMPORTANT IMPORTANT

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5. CommissioningProcedure

5.10 Humidifiers and WaterQuality

The humidifier water supply quality is veryimportant to ensure correct operation.

The use of incorrectly treated oruntreated water in this equipment mayresult in scaling, erosion, corrosion,algae, or slime. The services of a qualified watertreatment specialist should beengaged to determine what treatment,if any, is required. The Trane warrantyspecifically excludes liability forcorrosion or deterioration. Traneassumes no responsibility forequipment damage or failure thatresults from the use of treated water,or saline, or brackish water.Please refer to the individual supplier'sinstallation, operation, and maintenancemanual for additional information.

5.11 Gas BurnersThe gas burner supplier will commissionthis equipment when installed on site.Please refer to the individual supplier'sinstallation, operation, and maintenancemanual for additional information.

5.12 HEPA FiltersThe HEPA filter section is supplied withcomplete front withdrawal framework.HEPA filters are supplied in originalpackaging with the unit.A specialist sealing company must beemployed to seal up the filter framework,fit and seal the HEPA filters, and completea DOP test or equivalent.

5.13 InvertersThe inverter needs to be set up and run inaccordance with the supplier's IOM.Please refer to the individual supplier'sinstallation, operation, and maintenancemanual for additional information.

5.14 ControlsSee controls IOM and wiring diagrams.Please refer to the individual supplier'sinstallation, operation, and maintenancemanual for additional information.

5.15 Test RunFollowing the completion of allpreparatory work, the unit is started up fora test run.

To conduct a test run that involves themeasurement of motor and fanperformance, the unit must beconnected to the complete installation.

All access doors must all be closed toavoid pressure loss in the installation,which may result in motor damage. Before staring the fan, open ALLdampers. The fan must not be startedif the dampers are closed. Whenstarting the fan, open the dampers.The fan should not work againstclosed dampers.After switching on, check that thedirection of the rotation is correct. Inaddition, the running power consumptionshould be checked on all phases andcompared with the power data on thenameplate. If the running power is toohigh, there is probably a faulty connectionand the unit must be switched offimmediately. Check the fan and motorbearings for undue noise. Measure the airvolume and external pressure. The following situations may arise:

1. The air volume is lower, as the systempressure is much higher thandesigned.

2. The air volume is higher, as the systempressure is much lower than designed.

Increasing the fan speed should onlybe carried out after careful study of themeasured point on the appropriate fancurve.In extreme cases exchanging the motor,fan and drive may be necessary.The adjustment of variable belt-drivepulleys is carried out with the system atrest, ensuring that the system is notrestarted unexpectedly. Remove thepulley safety screws and turn through halfof the pulley circumference to carry thisout. Then retighten the screws andreadjust the pulley belt tension.Following any change in the pulley ratio,the motor power consumption must berechecked.The nominal output rating quoted on thenameplate must not be exceeded.In all cases of airflow not conforming tothe specifications, please contact yoursales office.

CAUTION

IMPORTANT

IMPORTANT

IMPORTANT

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6. Maintenance

The maintenance interval periods arestated, guidelines only. Any largedeviations in the pattern of usage maynecessitate further maintenanceattention.

During maintenance operations theunit must be completely isolated andprecautions taken to prevent anypremature restart.

6.1 FanIf the fan/motor assembly is going to bestored for over two weeks before use, thefan should be rotated by hand at weeklyintervals to avoid bearing damage.If storage will be over one month it isrecommended that the belts beslackened as well. Check for soiling, damage, corrosion, andany tendency to bind. Clean asnecessary.Check that the flexible connections aresecurely fixed.Check the function of all antivibrationmounts.Check for any obstructions or blockagesof all the air intakes and discharges.Check the traps for leaks or blockagesand prime as necessary.

6.2 Bearing TestCheck that the fan bearing is tightenedand is not unduly noisy, by sounding itusing a metal bar as a conductor.Where a belt guard has been supplied,check that it is fitted correctly.If there is any irregular noise or knocking,renew both bearings. Fan bearings aregreased for life, but larger units withstandard bearings require annuallubrication. These have grease lineextensions. In the case of extremerunning conditions, lubricate inaccordance with the followingrecommendations:Recommended lubricants;ALVANIAGREASE 3 (SHELL)MOBILUX 3 (MOBIL)BEACON 3 (ESSO)SKF 28 (BALL BEARING

GREASE)

Do not overlubricate bearings. Excessive pressure caused byoverlubrication can displace bearinggrease seals or cause grease tooverheat the bearing, resulting inpremature bearing failure.

6.3 MotorCheck the state of cleanliness of themotor and clean it if necessary. Check thenoise level of the motor bearing bylistening to it with a metal conductor. Ifthere is any irregularity or undue noise,the bearing should be changed or themotor replaced.

6.4 Belt DriveBelts that are split or have frayed edgesor any other signs of damage must bereplaced. Rubber shred on the fansection floor is a sign of abnormal wear.

6.5 Belt Drive TensioningTensioning of the drive belt is achieved bymoving the motor in relation to the fan(see Figure 19).The motor is moved on slide rails.

Figure 19

Figure Notes:1. Slide rails2. Lock nut3. Tensioning screw4. Tensioning pad

Loosening the motor retaining bolt andthen turning the tensioning screw carriesout the adjustment. It is important tomaintain the precise alignment of thepulleys. This should be checked with a straightedge following each adjustment.Following completion of the adjustment,retighten the motor retaining bolts. The belt tension should be checked byusing a proprietary instrument such asthe Browning belt-tension checker.The belt drive must be retensionedafter the first 10 hours of operation.The high performance of FennerPrecision Built belts requires correcttension; we recommend using the FennerBelt Tension Indicator.

IMPORTANT

IMPORTANT

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6. Maintenance

Method of Belt Tensioning usingFenner Belt Tension Indicator.1. Calculate the deflection distance in

mm, on a basis of 16 mm per meter, ofcentre distance (see Figure 20). Centre distance (m) x 16 = deflection(mm).

2. Set the lower marker ring at thedeflection distance required in mm onthe lower scale.

3. Set the upper marker ring against thebottom edge of the top tube.

4. Place the belt tension indicator on thetop of the belt at the centre of the span.Apply a force at right angles to the belt,deflecting it to the point where thelower marker ring is level with the top ofthe adjacent belt.*

5. Read off the force value indicated bythe top edge of the upper marker ring.

6. Compare this force to the kgf valueshown in Table 2.

*NOTE: For a single belt drive, a straight edgeshould be placed across the two pulleysto act as a datum for measuring theamount of deflection.

Fenner is a registered trademark of J H Fenner & Co Ltd.Taper Lock and P B (Precision Built) are registered trademarks of F P T Group.

Table 2 – Tensioning Forces (Force required to deflect belt 16 mm per metre of span)Belt Section SPZ SPA SPB SPC Z A B CSmall Pull Diameter (mm) 56 100 80 140 112 236 224 375 56 80 125 200

to to to to to to to to to to to to95 130 132 200 224 315 355 560 100 140 200 400

Newton (N) 13 20 25 35 45 65 85 115 5 10 20 40to to to to to to to to to to to to20 25 35 45 65 85 115 150 7.5 15 30 60

Kilogram-Force (kgf) 1-3 2-0 2-5 3-6 4-6 6-6 8-7 11-7 0-5 1-0 2-0 4-1to to to to to to to to to to to to

2-0 2-5 3-6 4-6 6-6 8-7 11-7 15-3 0-8 1-5 3-1 6-1

Deflection in mm Deflection Force in kg

Reproduced with permission of F P T Group.

If the measurement force falls within thevalues given, the drive should besatisfactory. A measured force below thelower value indicates undertensioning.A new drive should be tensioned to ahigher value to allow for the normal dropin tension during the running-in period.After the drive has been running for 30minutes, the tension should be checkedand readjusted to the higher value, ifnecessary.

Figure 20

Fenner is a registered trademark of J HFenner & Co Ltd.Taper Lock and P B (Precision Built) areregistered trademarks of F P T Group.Reproduced with permission of F P TGroup.Figure 20 Notes:1. 1/2 Centres2. Force3. 16 mm deflection / 1 m of centre distance4. Centre Distance

Damage to the motor and fan bearingscan result from the belt beingovertensioned.In the event of the belt adjustmentbeing too slack, undue wear andslippage may result.

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6. Maintenance

6.6 Belt ReplacementWhere a belt guard has been supplied,please remove the belt guard beforestarting work.To change the belt (or belts), first movethe motor towards the fan by a sufficientamount to enable the old belts to betaken off the pulleys and the new belts tobe put on.If the belt drive has more than one belt,replace all belts at the same time (seeFigure 21). In such cases, use matchedbelts, such as sets in which all belts areexactly the same lengths.Tension the belts as per Section 6.5.

Figure 21

Fenner is a registered trademark of J HFenner & Co Ltd.Taper Lock and P B (Precision Built) areregistered trademarks of F P T Group.Reproduced with permission of F P TGroup.

TO INSTALL1. Remove the protective coating from

the bore and outside of bush, and boreof hub. After ensuring that the matingtapered surfaces are completely cleanand free from oil or dirt, insert bush inhub so that holes line up.

2. Sparingly oil thread and point of grubscrews, or thread and under head ofcap screws. Place screws loosely inholes threaded in hub.

3. Clean shaft and fit hub to shaft as oneunit and locate in position desired,remembering that bush will nip theshaft first and then hub will be slightlydrawn onto the bush.

4. Using a hexagon wrench, tightenscrews gradually and alternately to thetorques shown in Table 3.

5. Hammer against large end of bush,using a block of sleeve to preventdamage. (This will ensure that the bushis seated squarely in the bore.) Screwswill now turn a little more. Repeat thisalternate hammering and screwtightening once or twice to achievemaximum grip on the shaft.

6. If a key is to be fitted, place it in theshaft keyway before fitting the bush. Itis essential that it is a parallel key andside fitting only, and has TOPCLEARANCE.

7. After the drive has been running underload for a short time, stop and checktightness of the screws.

8. Fill empty holes with grease to excludedirt.

TO REMOVE1. Slacken all screws by several turns.

Remove one or two according to thenumber of jacking off holes. Insertscrews in jacking off holes after oilingthread and point of grub screws orthread and under head of cap screws.

2. Tighten screws alternatively until bushis loosened in hub and assembly isfree on shaft.

3. Remove assembly from shaft.

Table 3 – Torque SettingsBush Size 1008 1108 1210 1610 2012 2517 3020 3525 4030 4535 5040Screw Tightening Torque (Nm) 5.6 5.6 20 20 30 50 90 115 170 190 270Screw Details Quantity 2 2 2 2 2 2 2 3 3 3 3

Size (BSW) 1/4" 1/4" 3/8" 3/8" 1/16" 1/2" 5/8" 1/2" 5/8" 3/4" 7/8"Hexagon Socket Size (mm) 3 3 5 5 5 6 8 10 12 14 14

Large End Diameter (mm) 35.0 38.0 47.5 57.0 70.0 85.5 108.0 127.0 146.0 162.0 177.5Approximate Mass (kg) 0.1 0.1 0.2 0.3 0.7 1.5 2.7 3.8 5.6 7.5 11.1

Fenner is a registered trademark of J H Fenner & Co Ltd.Taper Lock and P B (Precision Built) are registered trademarks of F P T Group.Reproduced with permission of F P T Group.

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6. Maintenance

6.7 Filter SectionsDuring system start-up, filters are likely tobecome rapidly blocked.Filter sections may be supplied with amanometer, which gives a visualindication of filter conditions and pressuredrop.Throw-away panel filters and bag filtersmust be replaced each time or when thepressure drop reaches the indicated dirtycondition. Permanent synthetic or metallicfilters must be cleaned periodically.

Filters must be installed following thedirection of the airflow arrow.Bag filter pockets should be verticalwhen installed.

6.8 Coil SectionsIn the event of coils being out ofcommission for some time, it is advisableto completely drain down the coil. Oneach occasion when refilling isundertaken, check that the coil iseffectively vented.Periodic cleaning of the coils is required.Dirty coils have increased airsidepressure drops and reduced heattransfer, thus unbalancing the cooling orheating system.6.8.1. CleaningIn the event that fin edges have beenbent, they can be straightened with theaid of a coil comb.The cleaning is carried out with the unitintact using a powerful vacuum cleaneron the dust-contaminated side. If the unitis very dirty it will need to be removed andwet cleaned.If required, soft cleaning brushes may beused ensuring that the heat exchangerfins are not damaged.6.8.2. Frost protectionCheck that frost protection is workingbefore the commencement of each winterperiod. Ensure that the frost sensor iscorrectly installed and fitted and isworking within the correct temperaturerange.

6.8.3. Drop eliminatorCheck the cleanliness of the dropletseparator section and the bladesannually. If the blades are dirty, removeand clean them. Contamination can resultin damage through water droplets in thesystem and to a reduction in the system'sperformance. Ensure that the blades arecorrectly repositioned and that they arenot distorted.6.8.4. Steam heater coilsIn the case of steam heater batteries,arrange for automatic steam shutoff whenthe unit is at rest, and check the functionof the fan overrun in this context.6.8.5. Direct expansion coilsNever use hot water or steam to cleanthese coils. During normal operation, thefin block must not ice up. If this occurs,check the refrigeration system.

6.9 Electric HeatersCheck the heater for any dirtaccumulation. If required, clean theheating elements with a soft brush. Checksafety controls and fan overrun controls.

6.10 Steam HumidifierMaintain in accordance with themanufacturer directions. The followingdetails are general purpose instructions:Check the steam distributor and ensurethere are no undesirable deposits.Check that the steam feeds do not leak.Check that the condensate drain isfunctioning.6.10.1. Evaporative HumidifierAny evaporative modules that arestrongly encrusted with calcium depositsshould be replaced. Trane cannot beresponsible for the proper cleaning ofevaporative humidifiers.In order to avoid excess clogging of theevaporative humidifiers, it is advisable tointerlock the spray pipe operation with thefan operation.

6.11 DampersCheck for dirt deposits, damage, or signsof corrosion. Clean with high-pressure airor with a steam jet.

6.12 Sound AttenuatorsSilencer modules are basicallymaintenance free. Within the frameworkof wider maintenance programmes,check for any dust deposits and vacuumas necessary.

6.13 Weather Louvres/ Hoods

Check for any obstructions or blockagesin all of the air intakes and discharges.

6.14 Plate Heat ExchangersPlate type heat exchangers arealuminum; their service life is virtuallyunlimited. Maintenance is limited tocleaning operations. Clean thecondensate drain, check the trap, and topup as necessary.Any accumulation of fibres or dust at theexchanger point-of-entry may beremoved with a brush or vacuum.Any oil or greasy deposits must beremoved. If a bypass is fitted, maintain asyou would for dampers.

6.15 Heat WheelThe drive unit should be maintained inline with the manufacturerrecommendations. The construction ofthe matrix is such that it is virtuallycompletely self-cleaning. The rotor maybe cleaned with pressurized air, water, orsteam jet and domestic detergents asnecessary.

IMPORTANT

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6.16 Maintenance Plan for Air Handling UnitsThe following table (see Table 4) gives recommended maintenance intervals for the CLCH unit. Intervals are based upon normalrunning conditions, in a moderate climate, and assuming 24-hour running.Units operating outside these guidelines may require shorter or longer maintenance intervals.

Table 4 – Recommended Maintenance IntervalsComponent Check the Following Weekly Monthly 3-6 Monthly Annually

(see section) (see section) (see section) (see section)Fan / Motor Fan In General Yes (6.1)

For Corrosion Yes (6.1)Flexible Connection Yes (6.1)Anti-Vibration Mounts Yes (6.1)Inlet Guide Vane Controller YesDrainage Yes (6.1)Fan Bearing Yes (6.2)Motors In General Yes (6.3)Motor Bearing Yes (6.3) Belt Drive In General Yes (6.5)

Filters Panel Or Bag Filters Yes (6.7)Roll Filters YesAbsolute Filters Yes

Coils Fin Block Yes (6.8.1.)Frost Protection Yes (6.8.2.)Drainage YesDrop Eliminator Yes (6.8.3.)Steam Coils Yes (6.8.4.)

Humidifiers Scaling Yes (6.10) Condensate Drain Yes (6.10)

Dampers Dampers Yes (6.11)Attenuators Scilencers Yes (6.12) Inlet / Outlet Hoods And Louvers Yes (6.13)Energy Recovery Components Plate Heat Exchangers Yes (6.14)

Thermal Wheel Yes (6.15)Controls Control Box And Wiring Yes

6. Maintenance

CLCH-SVX05A-GB

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Symptom Probable Cause Recommended ActionBearing is excessively hot Overtensioned belts. Retension belts.

No lubricant (plummer block type). Apply grease.Overlubrication. Clean surface of grease and purge.Misaligned bearing. Correct alignment and check that shaft is level.

Motor stalls Short circuit, phase to earth. Check line phases and terminal block connection.Overloaded motor. Reduce system load, fan driven speed or increase motor

capacity.Motor overheats Overloaded motor. Reduce load or replace with larger motor.

Motor fan damaged. Replace motor fan/clean.Excessive vibration Poor pulley alignment. Check pulley alignment.

Transport brackets not removed. Remove items used for transport only.Overtensioned belts. Retension belts.Fan/unit vibration isolator collapsed. Replace vibration isolator.

Excessive motor noise Motor mounting bolts loose. Tighten motor mounting bolts.Worn motor bearings. Replace bearings and seals.

Excessive fan noise Fan rubbing on inlet cone or guard. Remove item and repair.Worn fan bearings. Replace bearings and seals.Loose impeller. Retighten hub.

Premature belt wear Incorrect tension or alignment. Re-tension and align.Dirt or grease on belts. Clean belts and pulleys; check for grease leaks.Belts rubbing. Remove obstruction.Odd belts being fitted. Replace with full set.

Filters collapsing Blocked with dirt. Change at advised dirty condition.Air velocity too high. Check unit running conditions.

Filters wrong size. Replace with filter sizes as suppliedfrom Trane.

Damper seizing Blade bent. Repair or replace blade.Spindle or mechanism loose. Tighten lever fixings.Actuator loose. Refit actuator correctly.

Low coil capacity Incorrect airflow. Check fan operating conditions.Incorrect water flow. Check water pumps, valves, and lines for obstructions.Incorrect water temperature. Provide correct water temperature.Coil tubes are blocked. Clean and unblock tubes.Expansion valve not operating DX. Check sensing-bulb location and valve operation.Poor refrigerant distribution DX. Check for blockage in distributor and tubes.

Leaking coil Header/exposed pipe damage. Repair damaged part.Cracks in joints due to strain of Check support and alignment of pipework and rectify.pipework on headers.Swelling of joints due to frost. Check frost protection method and correct, improve.(Water-hammer Steam Coils) Trapping of steam supply.

Drain pan overflow Incorrect hydraulic trapping. Resize/fit trap and check air break arrangement.Blockage in trap. Clean trap and refit.

7. Troubleshooting

CLCH-SVX05A-GB

Trane An American Standard Companywww.trane.com

For more information contactyour local sales office ore-mail us at comfort@trane.com

Literature Order Number

File Number

Supersedes

Stocking LocationSince The Trane Company has a policy of continuous product and product data improvement, it reserves the right to change design and specifications without notice.

Only qualified technicians should perform the installation and servicing of equipment referred to in this publication.

Société Trane – Société Anonyme au capital de 61 005 000 Euros – Siège Social: 1 rue des Amériques – 88190Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188Numéro d’identification taxe intracommunautaire: FR 83 3060501888

CLCH-SVX05A-GB

SV-RF-CLCH-SVX05A-GB-1102

New

Colchester UK