Trane CLCP User manual

1010-2359-01E
CLCP-SVX01A-E4
Installation, Operation and Maintenance
CLCP
Air Handler
April 2020
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.
Supersedes CLCP-SVX01A-E4
CLCP-SVX01A-E4 April 2020
Aug 2018

World enviromental scientists have
concluded, based on the best currently
available evidence, that ozone in our
upper atmosphere is being reduced
due to the release of CFC fully
halogenated compounds.
The Trane Company urges that all
HVAC servicers working on Trane
equipment, or any manufacturer's
products, make very effort to eliminate,
if possible, or vigorously reduce the
emission of CFC, HCFC and HFC
refrigerants to the atmosphere
resulting from installation, operation,
routine maintenance, or major service
on this equipment. Always act in a
responsible manner to conserve
refrigerants for continued use even
when acceptable alternatives are
available.
Refrigerant used in any type of air-
conditioning or refrigerating equip-
ment should be recovered for reuse,
recovered and / or recycled for reuse,
reprocessed (reclaimed), or properly
destroyed, whenever it is removed from
equipment. Never release to the
atmosphere!
The equipment covered by this manual
is designed for safe and reliable
operation when installed and operated
within its design specifcation limits. To
avoid personal injury or damage to
equipment or property while installing
or operating this equipment, it is
essential that qualified, experienced
personnel perform these functions
using good judgement and safe
pratices. See the following cautionary
statement.
Notice Safety Considerations
Notice that WARNING and CAUTION
appear at appropriate intervals
throughout this manual.
Warning and Cautions
WARNING
WARNING indicates a potentially
hazardous situation that could result
in personal injury or death.
WARNING
CAUTIONs are designed to alert you
to conditions that could result in minor
personal injury or equipment damage.

1
1
3
4
6
8
18
20
27
40
Contents
General Information
Foreword
Warranty
Unit Description
Model Nomenclature
Receiving
Nameplate
Delivery Check
Resolving Shipping Damage
Storage Consideration
Outdoor Storage
Rigging and Handling
Rigging and Handling
Off Loading
Moving to Position On Site
Forlift Trucks
Roller Movement
Installation
Foundation
Erection
Assembly and Installation
External Connection
Frame to Frame Connection, CLCP
Panel to Frame Connection, CLCP
Paneling, CLCP
Vertical Unit / Final Filter / Damper Joining Method
Piping
Start-Up
Start-Up Procedures
Maintenance
Periodic Maintenance Checklist
Maintenance Plan
Trouble Analysis
General
Pulley and Belt
Appendix A-Unit Weight, CLCP
Appendix B-Fans and Arrangement
Appendix C-Filter ad Qty
Appendix D-Typical Wiring Diagram
Safety Recommendations, Maintenance Contract and Training
Pre - Start Up Checklist
General Information
●Foreword
These installations, operation and
maintenance instructions are given as
a guide to good practice in the
installation, commission into service,
operation and periodic maintenance
TM
by the user, of TRANE Quantum Air
Handler. They do not contain full
service procedures necessary for the
continued successful operation of this
equipment; the services of a qualified
technician should be employed
through the medium of a maintenance
contract with a reputable service
company.
●Warranty
Trane's standard warranty covers the
equipment. It does not cover damage
due to misuse, lack of maintenance, or
failure to comply with the manufacturer's
instructions or recommendations.
●Unit Description
TRANE QuantumTM Air Handler are
Central Station Air Handlers designed
for a variety of controlled air application.
The basic unit consists of a fan,
heating and/or cooling coils, filters and
air dampers. See product catalogue for
list of available modules and options.
The TRANE QuantumTM Air Handler are
designed for cooling load conditions
of 1000-65000 nominal CFM. Fans are
double width, double inlet, centrifugal
types with forward curved, backward
curved, and airfoil blade designs.
To insure fan motor assembly stability
the unit ships with shipping brackets
Located between the fan support frame.
These spacers must be removed prior to fan
operation, to assure proper vibration isolation.
Units ship as complete units, sections or
subassemblies. Each section is provided with
a nameplate (label) which includes type of
section, unit serial number, customer tag
number and unit model number.

CLCP Model Nomenclature
3
2
EG:CLCP 020
Receiving
DIGIT Description
1,2,3
4
5,6,7
CLC=Climate Changer
P=Development sequence
Casing Sizes:003/004/006/008/010/012/014/016/020/025/030/035/040/045
060/065/070/080/085/090/095
●Nameplate
TM
All of TRANE Quantum Air Handler
are identified by a multiple-character
model number. lts use enables owner/
operator, installing contractors, and
service technicians to define the
operation, components and options for
a particular unit. Be sure to refer to the
information printed on the unit
nameplate (figure1) when ordering
replacement or requesting service.
●Delivery Check
All unit sections are securely fasten to
skids for shipping and handling
purpose.
Upon receipt of the unit(s), inspect for
damage that may have occurred during
shipment and any items, which were
ordered but did not arrive with the unit.
Complete the following checks:
1. Visually inspect the exterior unit
casing and all accessories for any
dents, punctures or shipping and
handling damage.
2. Cut all banding (if applicable) loose
from skid, but do not remove the
skids.
3. Check all access doors to confirm
that they are secured with latches.
4. Manually rotate the fan wheel to
ensure free movement of the shaft
and bearings.
Inspect the fan housing for any
foreign objects.
5. Inspect the coil(s) for fin damage.
●Storage Considerations
When storing a TRANE QuantumTM
Air
Handler, for a period of time before
installation, it must be protected. The
warranty will not cover damages to
the unit do to negligence during
storage. Indoor storage is ideal and
requires only a few special pre-
cautions.
To protect the unit from damage due to
the elements and prevent it from
possibly becoming a contaminant
source for indoor air quality (IAQ)
problems, the unit should be stored
indoors.When outdoor storage is
necessary, several things must be
done to prevent damage.
●Outdoor Storage
1. Select a well-drained area,
preferably a concrete pad or
blacktop surface.
2. Place the unit(s) on a dry surface or
raised off the ground to assure
adequate air circulation beneath unit
and to assure that no portion of the
unit contacts standing water at any
time.
3. Allow proper clearance around the
unit to perform periodic inspection
and maintenance of the equipment
while in storage.
4. Keep the equipment in the original
shipping container for protection
and ease of handling.
5. Cover the unit securely with a
CANVAS tarp.
6. Ensure that the canvas tarp is
secure.
7. Do not stack units.
8. Do not pile other material on the
units.
9. Loosen belt tension on drive belts.
Figure 1
QUANTUM CLIMATE CHANGER AIR HANDLER
STANDARD:GB/T 14294-2008
PRODUCTION DATE
T.S.P.
ORDER NO.MODEL NO.
kg
kW
kW
kW
COOLING CAPACITY1
COOLING CAPACITY2
kW
kW
HEATING CAPACITY1
HEATING CAPACITY2
POWER
WEIGHT
VOLTAGE
IOM ATTACHMENT
VFREQUENCY Hz
mm
SIZE(LxWxH) IOM ATTACHMENT
TRANE AIR CONDITIONING SYSTEMS (CHINA) CO.,LTD.
Pa Pa
E.S.P. AIR VOLUME
3
m/h
SERIAL NO.
CLCP006H PAU-LG2-1
2012.05.04 30220020506112
554 410 2771.41
51.25
1.1 380 50
●Resolving Shipping damage
If damage is found or items are missing:
1. Report all claims of shipping
damage to the delivering carrier
(transporter) immediately, and
schedule an inspection.
2. Make specific notations concerning
the damage on the freight bill.
3. Keep damaged material in the same
location as received. It is the
receiver's responsibility to provide
reasonable evidence that damage
was not incurred after delivery.
4. Photograph damage if possible.
5. Do not move or discard damaged
freight packaging materials.
6. Notify the Trane sales representative
of the damage and arrange for
repair. Do not attempt and arrange
for repair. Do not attempt to repair
the unit without consulting the sales
representative. TRANE IS NOT
RESPONSIBLE FOR SHIPPING
DAMAGE.

5
4
Rigging and Handling
Figure 3
Figure 4
Figure 5
Rigging and Handling
Rigging and Handling
Confirm that factory installed (if any)
attachment brackets are in place and
screws tight, before rigging. The unit
will ship either assembled or as
sections. Before preparing the unit for
lifting, estimate the approximate center
of gravity for lifting safety. Because of
placement of internal components, the
unit weight may be unevenly
distributed, with more weight in the coil
and fan area. Approximate unit weights
are given in Appendix A & B.
Always apply good rigging procedures
when lifting a unit. Before hoisting the
unit into position, be sure that a proper
method of rigging is used, with straps
or slings and spreader bars for
protection and safety during lifting.
Always test-lift the unit to determine
exact unit balance and stability before
hoisting it to the installation location.
WARNING
NEVER ASSEMBLE OR BOLT
SECTIONS OR SUBASSEMBLIES
TOGETHER BEFORE RIGGING.
ALWAYS RIG SECTIONS OR
SUBASSEMBLIES AS RECEIVED
FROM THE FACTORY.
WARNING
DO NOT LIFT THE UNIT WITHOUT
TEST-LIFT FOR BALANCE AND
RIGGING. DO NOT LIFT THE UNIT
ABOVE PERSONNEL. FAILURE TO
OBSERVE THESE WARNINGS
MAY
RESULT IN PERSONAL INJURY,
DEATH OR EQUIPMENT DAMAGE.
(See Appendix A & B for components
weight).
Off Loading
A specific lifting method for offloading
the units is recommended as follows
(See Figure 2):
1. 75mm-diameter lifting holes,or
certified lifting lugs, are provided on
the unit base frame.
2. ALL LIFTING POINTS in one axis of
the unit must be used when
offloading and moving the unit.
3. Slings and speader bars are to be
provided by the rigger and attached
to ALL LIFTING POINTS.
4. The minimum rated lifting capacity
(vertical) of each sling and spreader
bar should be no less than the
shipping weight.
5. The unit must be lifted with care,
avoiding shock load by lifting the unit
slowly and evenly.
WARNING
ENSURE SLINGS DO NOT FOUL ON
UNIT PROTRUSIONS.
THE CENTRE OF GRAVITY WILL
VARY PER UNIT... POSITION THE
SLING AND SPREADER BARS
CAREFULLY TO COMPENSATE FOR
THIS.
Moving To Position On Site
TRANE QuantumTM Air Handler are
supplied in sections modules, flat
packed, or as a complete unit, in
accordance with the relevant assembly
drawings. Any necessary use of force
during unloading or movement of the
units must only be applied via the unit
base frame or shipping pallet.
WARNING
NEVER LIFT THE UNITS BY COIL
CONNECTIONS OR BY ANY OTHER
PROTRUSIONS.
THE ROOF IS NOT DESIGNED TO
BE WALKED ON, BUT IF THIS IS
UNAVOIDABLE, ENSURE A MORE
EVEN WEIGHT DISTRIBUTION BY
THE USE OF BOARDS.
FAILURE TO DO SO MAY RESULT
IN
SEVERE PERSONAL INJURY OR
DEATH.
Forklift Trucks
The forks must only be applied under
the unit base frame and not against
the unit base frame. The lift point
should be as near as possible to the
centre of gravity (see Figures 3 and 4).
In the case of larger units the use of
several forklift trucks may be required.
Roller Movement
Units fitted with base frames may be
moved on roller trolley or tubular rollers
(see Figure 5).
Figure 2

7
6
Installation Installation
Foundation
When selecting and preparing the unit
site, follow these guidelines:
1.Ensure that the site can support the
total weight of the unit. Unit weight
figures only provide total gross
weights and do not include the
Additional weight for water in any
coils.
2.Confirm that the foundation of the
mounting platform is large enough to
Include the unit dimensions plus
service plus service access.
3.The floor or foundation must be level
for correct coil drainage and
condensate flow.
4.Provide adequate lighting for
maintenance personnel to perform
maintenance duties.
5.When the unit is positioned on site,
there must be sufficient space
around the unit to ensure that correct
operation and effective main-
tenance can be carried out. Figure 6
gives recommended space
allowances.
●On the designated access side of
the unit, working areas must have
minimum 1 mtr, space (P).
●Allowance for coil connections,
dimension“C” must be dimension
200mm + unit width.
●A clear unobstructed area before
and after an air intake or discharge
is required to ensure correct air
movement. The width of the area
must be >= the width of the unit, and
the depth (dimension “L”)must be
>= 0.5 x the overall unit height.
Complete reinforced concrete
foundations are suitable or strip
foundations may also be used (see
Figure 7).
In the case of strip foundations,
concrete or steel supports are
premissible, but support is required
under breakpoints and every 2 m along
the unit base.
Figure 7 - Air Handling Unit Steels Foundation
Figure 6
P = 1 MTR min
IMPORTANT
FAILURE TO PROVIDE A LEVEL
PLINTH OR SUPPORT WILL
RESULT IN DOORS JAMMING
AND AIR LEAKS FROM THE
CASING.
Erection
To minimize noise transmission,
insulation material such as cork
slabbing (TICO pads) or rubber pad
May be placed between the unit base
and the foundation (see Figure 8).
Figure 8 - Air Handling Unit Plinth Foundation
L
P
C
2m BREAKPOINT 2m

9
8
Assembly & Installation
CLCP Break Point - Frame to Frame
BREAK POINT JOINING METHOD
MODULE TO MODULE BREAK
POINT EXTERNAL JOINING
(TO BE DONE AT JOB SITE)
ENSURE GASKET IS IN-PLACE
&GOOD CONDITION AT FRAME.
DETAIL EXTERNAL CONNECTION
TOP JOINT BRACKET
GASKET,
PE FOAM TAPE
A
A
DETAIL‘A’
AIR
FLOW
GASKET
HEX.HD.BOLT,M10 X35
FLAT WASHER M10
BREAKPOINT CONNECTOR
FLAT WASHER,M10
SPRING WASHER,M10
HEX NUT M10
WOOD TO
PROTECT
THE FRAME
SURFACE
USE A LONG CLAMP, TO BRING
THE TWO SECTION CLOSER.
INSTALL THE TOP , INTERNAL
JOINING PLATES BEFORE REMOVE
THE CLAMP
TOP, EXTERNAL
CONNECTION
BOTTOM,EXTERNAL
CONNECTION
DETAIL
VIEW
UNIT BASE
3
INTERNAL JOINT (SIDE & TOP & BOTTOM)
Plote
Internal sealed sheet metal
Screw
Internal sealed sponge
Silica gel Sponge (joint seal)
STEAL TH (AL,FRAME)
ARR3
Assembly & Installation CLCP
(External connection)

Assembly & Installation
CLCP Paneling
11
10
Assembly & Installation CLCP
INSERTING WEDGE METHODOLOGY
ACCESSORIES
1″×2″×10″WOOD
V-GROOVE HELPS
TO EASE WEDGING
GRROOVE
SPACER
(STICK-ON RUBBER)
2mm
REQUIRED TO
INSERTING WEDGE
2″DIA NYLON-FACE HAMMER
ACCESSORIES
ACCESSORIES TO DISMANTLE & ASSEMBLE CLCP
2″DIA NYLON-FACE
HAMMER
1″×2″×10″
WOOD
PNEUMATIC
BLINDRIVET
TOOL
M8 & M10×200mm
INSERT-BIT
HOLDERS
(MAGNTIC TYPE)
SLIDING-HEAD BAR
CLAMPS(8″OPEING)
AIR/ELECTRIC
DRILL
SCRAPER
(HARD BLADE
PREFERRED)
2 NOS.8″
BLADE LENGTH
SCREWDRIVER
2″DIA NYLON-FACE
HAMMER
AIR/ELECTRIC
DRILL
SCRAPER
(HARD BLADE
PREFERRED)
2 NOS.8″
BLADE LENGTH
SCREWDRIVER
PERSONAL PROTECTION EQUIPMENTS
SAFETY
FEET PROTECTION
ALERT
SAFETY
HAND PROTECTION
ALERT
SAFETY
EYE PROTECTION
ALERT
REMOVING WEDGE METHODOLOGY
ACCESSORIES
REMOVING WEDGE METHODOLOGY
SEQUENCE TO REMOVE WEDGES
12
3
4
AFTER WEDGE NO.3
REMOVED GO INSIDE BOX
TO PUSH OFF THE PANEL.
PULL WEDGE-OFF
190mm
LIMITED SPACEFOR TOOLS
TO REMOVE WEDGE
VERTICAL UNIT JOINING METHOD
HEX.HD.BOLT.
M10X35
BREAK POINT
COMMECTOR
HEX.NUT M10
GASKET
SILICON
FINAL FILTER JOINING METHOD
FINAL FIL TER SECTION
FINAL FIL TER
UNIT BASE
HEX.HD.BOLT.M12X35
SILICON
RIVET
GASKET
ANGLE

Assembly & Installation CLCP
13
12
Assembly & Installation
DAMPER INSTALLATION
SILICON
SELF DRILLING SCREW
Piping - Condensate Drain
Pan Connections
On cooling section(s) the drain pan
should always be connected directly
to a trap to ensure proper drainage
of condensate.
CAUTION
Failure to provide adequate
condensate piping may result in
water damage to the equipment or
building.
IMPORTANT
The applicable "rule of thumb" for
amount of condensate may as high
as 6 lbs/hr/ton for units serving areas
with high latent heat.
Male-threaded, 1-1/2" BSPT conden-
sate drain connection is provided on
one side of the coil section. The main
drain lines and trap must be the same
size as the drain connection.
Pitch the connection line horizontal or
downward toward an open drain and
install a plugged tee to facilitate
cleaning. Condensate lines should not
be connected to a closed drain. This is
to avoid the possibility of drawing
sewer gasses into the unit.
Drain traps must be primed. lf they
are not, the trap is essentially non-
existent and the drain pan will likely
overflow.
Units With More Than One
Drain Pan
With the Trane QuantumTM Air
Handler,
each module can be ordered with or
without a drain pan. When more than
one module has a drain pan, you must
trap each module individually.
Connecting all drains to a common line
with only one trap will result in
condensate retention, and possible
water damage to the air handler or
adjoining space.
If a module has a drain pan for
cleaning
purposes only, it does not need a trap;
however a cap or shut off valve should
be installed on the drain connection.
Only modules handling condensate,
such as a cooling coil module or
eliminator module, require a trap.
Figure 9 through Figure 10 are
examples of typical installations.
Figure 9
Drain Pan Trapping for module under Negative Pressure
Figure 10
Drain Pan Trapping for module under Positive Pressure
H = (1″of each 1″of
maximum negative
pressure) + 1″
J = 1/2 H
L = H + J + Pipe diameter +
Insulation
L
Normal Operation
H
J
K = min. 1/2″
H = 1/2″ plusmaximum
total static pressure
H
K

15
14
Assembly & Installation Assembly & Installation
Steam Coil Piping
Type A, AA Steam Coils
These are for central system, industrial
and process application with one row,
opposite-end connections. Maximum
standard operating limits:
Copper tubes: 100 psig and 400oF
Type AA coils feeds alternate tubes.
Refer to Figure 13 for typical steam coil
piping.
CAUTION
Condensate must flow freely from
coil at all times to prevent physical
coil damage from water hammer,
unequal thermal stresses, freeze-up
and/or corrosion.
Complete the following recom-
mendations to prevent coil damage.
1. lnstall a 1/2 inch, 15 degree swing
check vacuum breaker in the
unused condensate return tapping
as close as possible to the coil.
2. Vent the vacuum breaker line to the
atmosphere or connect it to the
return main at the discharge side of
the steam trap.
Note: Vacuum breaker relief is
mandatory when the coil is controlled
by a modulating steam supply or a two-
Position (ON-OFF) automatic steam
supply valve.
3. Run the return pipe at the full size of
the steam trap connection except for
the short nipple screwed directly
into the coil condensate connection.
Do not bush or reduce the coil return
tapping size.
4. Proper steam trap selection and
installation is necessary for
satisfactory coil performance and
service life. For installation, use the
Following steps:
Select trap based on maximum
possible condensate rate.
Locate the steam trap discharge at
least 12 inches below the
condensate return tapping, this
provides sufficient hydrostatic
head pressure to overcome trap
losses and assure complete
condensate removal.
Float and thermostatic traps are
recommended because of gravity
drain and continuos discharge
operation.
Use float and thermostatic traps
are recommended because of
gravity drain and continuos
discharge operation.
Use float and thermostatic traps
with atmospheric pressure gravity
condensate return, with automatic
control or where the possibility of
low-pressure supply steam exists.
Use bucket traps ONLY when the
supply steams in unmodulated
and 25 psig or higher.
Always install strainers as close
as possible to the inlet side of the
trap. Do not modulate Type A, AA
coils. Use two position (ON-OFF)
steam supply controls.
●
●
●
●
●
●
●
CAUTION
Caution: Always open the steam
supply control valve slowly to
prevent possible coil damage.
6. Do not modulate systems with
overhead or pressurized returns
unless the condensate is drained
by gravity to a receiver (vented to
the atmosphere) and returned to
the main by a condensate pump.
7. At start-up on units with fresh air
dampers, slowly turn the steam on
full at least 10 minutes before
opening the fresh air.
8. Pitch all supply and return steam
piping down minimum of 1-inch
per 10 feet in the direction of flow.
9. Do not drain the steam mains or
take-off through the coils. Drain the
mains ahead of the coils through
a steam trap to the return line.
10. Overhead return require 1 psig of
pressure at the steam trap
discharge for each 2 - feet
elevation to assure continuous
condensate removal.
5. Use a V-port modulating valve to
obtain gradual modulating action.
Figure 13
Typical Piping for Steam Coil
AV - Automatic or manual air vent MV - Magnetic valve
GV - Gate valve FT - Float and thermostatic steam trap
VB - Vacuum breaker ST - Strainer 21
OV - Automatic two-position control valve
3
LEVEL
AIR FLOW
STEAM
SUPPLY
MAIN
COWDENSATE
RETURN MAIN
1，2
OV.4 ST
GV.B
9
VB
12″MIM
11
GV ST
FT.3
1，2
9
Chilled Water
Piping - Coil Connection
General Coil Piping Recommendation
Refer to Figure 11 for typical cooling /
heating and steam coil piping.
Proper installation, piping and trapping
is necessary to assure satisfactory coil
operation and to prevent operational
damage. Water inlet and outlet
connections protrude through the coil
section side panel. Follow standard
piping practices when piping to the
coil. Note the following:
1. Support all piping independently of
the coils.
2. Provide swing joints or flexible
fittings in all connections that are
adjacent heating coils in order to
absorb thermal expansion and
contraction strains.
3. When attaching piping to the coil
header, make the connection only
tight enough to prevent leaks, the
maximum recommended torque is
200ft-lbs.
4. Teflon tape or teflon piping
compound should not be used
because of its high lubricity, teflon
makes it easier to tighten the pipe
to the header joint past the point
where an effective seal is created,
thus damage to the coil could result.
5. "White Zinc" compound / pipe
sealer on all threaded connection is
Recommended, instead.
Figure 11
Typical Piping for Water Coil
NOTE: DRAIN AND VENT CON-
NECTIONS ARE PROVIDED AS
STANDARD ON COIL HEADERS.
IF EXTENDED DRAINS AND VENTS
ARE REQUIRED, THEY MUST BE
FIELD PROVIDED.
IMPORTANT
To avoid damaging the coil
connections it is essential to grip
the pipe connection whilst
applying counter pressure to
tighten the joint (see Figure 12).
Use “Back-up wrench”when
attaching piping to coils, on
threaded connections. Figure 12
Completely stress-free
connections are essential. The
pipework of the coils should be
arranged to facilitate easy
removal of the coil for any
required maintenance purposes.
3
LEVEL
AIR FLOW
DRAIN
1，2
1，2
AV
AV
GV
GV
MV-2
45′ELL
WATER SUPPLY
MAIN
AV-Automatic or manual air vent
GV-Magnetic vaive
MV-Gate valve
WATER RETURN
MAIN

17
16
Assembly & Installation Assembly & Installation
Refrigerant Coil Piping
TYPE FD COILS HAVE BEEN
DEHYDRATED AND CHARGED WITH
A HOLDING CHARGE OF DRY
NITROGEN. 10-20 PSIG TO
PREVENT LEAKS AND SYSTEM
CONTAMINATION, DO NOT BREAK
THE SEALS UNTIL THE COIL IS
INSTALLED.
1. Follow accepted refrigeration piping
practices and safety precautions for
typical refrigerant coil piping and
components.Specific recommen-
dations are provided with the
condensing units, including
instructions for pressure-testing,
evacuation, and system charging.
General recommendations for
component selection and line
sizing follow.
2. Leak-test the entire refrigeration
system after all piping is complete.
3. Charge the unit according to
approximate weight requirements,
operating pressures and super-
heat / subcoling measurements.
4. Adjust the thermal expansion valve
Setting if necessary.
General Refrigerant Piping
Recommendations
IMPORTANT: REFER TO THE NOTE
ON THE INSIDE FRONT COVER OF
THIS MANUAL REGARDING
HANDLING OF REFRIGERANTS.
Liquid Line Components
Trane recommends the use of a
properly sized liquid line filter-drier
installed upstream from the expansion
valve and as close to the
evaporatorcoil as possible. Base filter-
drier selection on a minimum
pressure drop of 2 psi at the design
condition.
1. Install moisture indicator/sight
glass between the expansion valve
and filter-drier. The moisture
indicator/ sight glass must be sized
to match the size of the liquid line
at the thermal expansin valve.
2. Size liquid line shutoff valve with an
access port using the selected
liquid line OD, and install it close to
the condenser.
3. Minimize use of other valves, tube
bends and reducers since these
items tend to increase pressure
drop and to reduce subcooling at
the expansion valve.
4. The Thermal Expansion Valve (TEV)
must be selected for proper size
and capacity. The size of the TEV
should cover the full range of
loadings. Check that the valve will
successfully operate at the lightest
load condition. Select expansion
valves with external equalizer
connections, and those designed
to operate against a back pressure
of 20 pounds per square inch
higher than actual evaporator
pressure.
5. Install the TEV directly in the coil
liquid connection (distributor)
provided.
The liquid distributor must be in a
true vertical position.
Suction Line Components
Install suction line pressure tap on the
leaving side of the evaporator coil near
the TEV sensing bulb location.
Accurate superheat measurement and
thermal expansion valve adjustment
demands that suction pressure be
measured near the evaporator coil.
Liquid Line Sizing
All compressors have a Refrigerant
Charge Limit (RCL) that must not be
exceeded. Since the RCL and
pressure drop are in direct conflict with
each other, Trane recommends that the
liquid line be sized as small as
possible, while maintaining a low
enough pressure drop to ensure
5℉(3℃) of subcooling at the expansion
valve.
Suction Line Sizing
Suction line tubes must be sized to
maintain refrigerant vapor velocities
that are high enough to ensure oil
entertainment under all operating
conditions.
It is not necessary to pitch horizontal
suction lines toward the compressor
when refrigerant coils is used with
Trane condensing units that are
designed with a gas trap in the suction
line just prior to the compressor.
To avoid equipment malfuntion,
use care when brazing or solder-
ing so that distributor tubing is not
restricted or blocked. To braze
Thermostatic Expansion Valves
(TXV) avoid direct flame (figure 15)
to the valve body and avoid
excessive heat on diaphragm. As
an extra precaution. a wet cloth may
be around the body and element
during brazing operation.
CAUTION
Figure 15
Solder Technique
Note: Flame should heat away from TXV element
Figure 14
Typical Piping for Refrigerant Coil
NOTE : THE EXPANSION VALVE SHOULD BE INSTALLED
DIRECTLY ON THE DISTRBULTOR.
SUCTION LINE
TO COMPRESSOR
SOLENOID
LIQUID VALVE
SIGHT
GLASS
EXPANSION VALVE
CAPILLARY TUBES
STRAINER
LIQUID LINE
FROM RECEIVER
EXPANSION
VALVE
EXPANSION VALVE
THERMAL BULBS
EXPANSION VALVE
EQUALIZER LINES
OK
Min.5%Ag
Max.700℃
（1300℉）
OD
OD
OD
OD
1/2-5/8in
12-16mm
﹛
3/4-7/8in
18-22mm
﹛
3
1-1 / in
8
25-35mm
﹛
TDE
OK

19
18
Start - Up Start - Up
Perform the following steps prior to
starting the unit.
1. Inspect electrical connections. They
should be clean and secure.
Compare actual wiring with specific
diagrams provided on the unit.
2. Check piping and valves for leaks.
Open or close the valves to check
for proper operation. Drain lines
should be open.
CAUTION
The use of untreated or improperly
treated water in unit coils may
cause scaling, erosion, corrosion,
algae, smile or other equipment
damage. Consult a qualified water
treatment specialist to determine if
water treatment is required. The
Trane Company assumes no
respon-sibility for equipment
damage caused by untreated or
improperly treated water.
3. If equipped with a refrigerant coil,
charge and leak-test the unit and
get it ready for operation according
to instructions provided with the
condenser equipment.
4. Check that all air filters are in place
and positioned properly. Under
Periodic Maintenance, see section
titled “Air Filters.”
5. Close and secure all unit access
doors. Check that the latch set
screws are tight.
6. Remove all foreign material from the
drain pan and check drain opening
and condensate line for obstruc-
tions.
7. Prime the DRAIN TRAP.
Start-up Procedures
After completing all start-up checks
and procedures, the unit may be
started. The following checks and
adjustments should be made during
initial start-up:
WARNING
Disconnect electrical power prior
to access into a fan or ductwork.
Even when locked out electrically,
fans may cause injury or damage
if the impeller is subject to “wind-
milling.”The impeller should be
secured to physically restrict
rotational move-ment. Failure to
secure impeller can cause severe
personal injury r death. Disconnect
electrical power source when
connecting or disconnecting
electrical wires for test procedures.
Do not open service access doors
while the unit is operating. Failure
to exercise caution or while
inspecting. unit operation may
result in injury or death from
electrical shock, air movement or
rotating parts.
If the unit was stored for an extended
period of time, the following items
should be checked before starting the
unit.
1. Inspect motor bearings for moisture
and rust. Replace bearings if
necessary and repack with new
grease.
2. Check motor winding. An
acceptable winding resistance
reading is from 6 meg-ohms to
infinity. If reading is less than 5
Meg-ohms, winding should be
dried out in an oven or by ablower.
3. Inspect the entire motor for rust and
corrosion.
4. Lubricate the motor as instructed in
the section titled “Periodic
Maintenance,”or as indicated by
the maintenance tag on the motor.
5. Bump-start unit and observe the fan
wheel for proper rotation, as
indicated by rotation arrow located
on fan housing.
6. Measure the motor voltage and
ampeage on all phases to ensure
proper operation. The readings
Should fall within the range given
on the motor nameplate.
Maximum allowable voltage imbalance
is two percent. Voltage imbalance is
defined as 100 times the sum of the
deviation of the three voltage from the
average, divided by twice the average
voltage. For example, if the three
measured voltages are 221, 230 and
227, the average would be 226 volts.
The percent of voltage imbalance is
then calculated:
100 x {[226-221] + [230-226] + [227-226]}
2 x 226
= 2.2% (Unacceptable)
In this example, 2.2 percent imbalance
is not acceptable and the power
company should be notified to correct
it.
7. Check unit vibration if the fan speed
is changed more than 5% from the
original designed rpm, or if parts
such as shafts, fan wheels, bear-
ings, or other drive components are
replaced. Do not exceed max. fan
rpm.
8. Pay particular attention to any
vibration, noise or overheating of the
motor and fan bearings.
(Bearings may run warm during
break in.)
Determine Fan RPM
Fan rpm can be determined by using a
strobe-type tachometer, or revolution
counter.
Sheave Alignment
Align the fan and motor sheaves by
using a straightedge. The straightedge
must be long enough to span the
distance between the outside edges of
the sheaves. For more details refer to
maintenance section.
Excessive Vibration
EXCESSIVE VIBRATION MUST BE
CORRECTED TO PREVENT BEAR-
ING AND SHAFT DAMAGE. SEE THE
SECTION TITLED “TROUBLE-
SHOOTING”FOR DETAILS ON THE
COMMON CAUSES FOR VIBRATION.

21
20
Maintenance Maintenance
Periodic Maintenance Checklist
The following checklist describes the
suggested maintenance schedule to
maintain proper operation of the unit.
Detailed procedures for owner-
operator maintenance checks are
given after this checklist.
WARNING
Disconnect electrical power and
allow rotating parts to stop before
servicing the unit. Exercise caution
if unit must be on for test or
maintenance procedures. Failure to
do so may result in injury or death
from electrical shock or moving
parts.
WARNING
Disconnect electrical power prior to
access into fan or ductwork. Even
when locked out electrically, fans
may cause injury or damage if the
impeller is subject to "windmilling".
The impeller should be secured to
physically restrict rotational
movement can cause severe
personal injury or death.
After 48 Hours Operation
■Belts have acquired their
permanent stretch. Readjust but do
not overtighten.
Weekly
■Observe unit weekly for any
change
in running condition and any unusual
noise.
Every Month or weekly
■Check air filters. Clean or replace if
clogged or dirty. Change bag filters
when pressure drop is 1-inch W.G.
Every Three to Six Months
■Check greasing on fan and motor.
■Align fan and motor sheaves (pulley).
Tighten sheaves setscrews to the
proper torque.
■Check and adjust fan belt tension.
■Tighten electrical connection.
■lnspect coils for dirt build-up or coil
freeze up
Every Year
■lnspect the unit casing for corrosion.
lf damage is found, clean and repaint
the surface with a rust-resistant primer
and vinyl chlorinated lacquer.
■Clean the fan wheels and fan shaft.
Remove rust with emery cloth and
apply a coat of LPS#3 or an equivalent.
■lnspect the condensate drain pan
and drain line, remove sludge or
foreign materials that might obstruct
proper drainage. Remove obstacles.
■Check damper linkages, set-screws
and blade adjustment for proper
damper operation.
■lnspect the control and power box
wiring for secure connections and
insulation.
■Rotate the fan wheel and check for
obstruction in the fan housing. The
wheel should not rub on the fan
housing. Adjust the center if necessary
and tighten wheel setscrews to the
proper torque.
■Check condition of gasketing and
insulation around unit, door and
damper.
■Examine flex connections for cracks
or leaks. Repair or replace damage
material.
IMPORTANT
Small & Medium size fans are
furnished shielded bearings. The
bearings are lubricated for life
and maintenance free. If re-
lubrication is necessary, on larger
fans it is recommended to use a
lithium base grease suitable for all
temperatures within the
operational limits.
Maintenance Plan
The following table (see Table 1) gives recommended maintenance intervals for the CLCP unit. Intervals are base
upon normal running conditions, in a moderate climate, and assuming 24 hour running.
Units operating outside these guideline may require shorter or longer maintenance intervals.
Table 1 - Recommended Maintenance Intervals
Component
Fan / Motor
Filter
Coils
Humidifiers
Dampers
Attenuators
Inlet / Outlet
Energy Recovery Componetnts
Controls
Check the following
Fan In General
For Corrosion
Flexible Connection
Anti-Vibration Mounts
Drainage
Fan Bearing
Motors In General
Motor Bearing
Belt Drive In General
Panel Or Bag Filters
Roll Filters
Fin Block / Fin Bundle
Frost Protection
Drainage
Drop Eliminator
Steam Coils
Scaling
Condensate Drain
Dampers
Scilencers
Hoods And Louvers
Plate Heat Exchangers
Themal Wheel
Control Box And Wiring
Weekly
Yes Yes Yes
Monthly
Yes Yes Yes Yes Yes
Yes Yes Yes Yes
3 - 6 Monthly
Yes Yes Yes Yes Yes
Yes
Yes Yes
Annual
Yes Yes Yes Yes Yes

23
22
Maintenance Maintenance
The maintenance interval periods are
stated, guidelines only. Any large
deviations in the pattern of usage may
necessitate further maintenance
attention.
IMPORTANT
During maintenance operation
the unit must be compelety
isolated and precautions teken
to prevent any premature restart.
1. Fan
If the fan / motor assembly is going to
be stored for two weeks before use,
the fan should be rotated by hand at
weekly intervals to avoid bearing
damage.
If storage will be over one month it is
recommended that the belts be
slackened as well.
Check for soiling, damage, corrosion,
and any tendency to bind. Clean as
necessary.
Check that the flexible connection are
securely fixed.
Check the function of all antivibration
mounts.
Check for any obstructions or
blockages of the air intakes and
discharges.
Check the traps for leaks or blockages
and prime as necessary.
2. Bearing Test
Check that the fan bearing is tightened
and is not unduly noisy, by sounding it
using 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
bearing are greased for life, but larger
units with standard bearings require
annual lubrication. These have grease
nipple. In the case of extreme running
conditions, lubricate in accordance
with the following recommendations:
Recommended lubricants;
ALVANIA
GREASE 3 (SHELL)
MOBILUX 3 (MOBIL)
BEACON 3 (ESSO)
SKF 28 (BALL BEARINGGREASE)
IMPORTANT
Do not overlubricate bearings.
Excessive pressure caused by
overlubrication can displace bearing
grease seals or cause grease to
overheat the bearing, resulting in
premature bearing failure.
3. Fan Motors
lnspect periodically for excessive
vibration or temperature. Operating
conditions will vary the frequency of
inspection and lubrication. Contact the
motor manufacturer or Trane for
lubrication instruction. Most smaller
frame motors comes without grease
nipple where the bearings are
permanently sealed.
The motors with double shielded
bearings are lubricated for life and
cannot be relubricated.
W.E motors up to 132 frame and TECO
and Brook Hansen motors up to 180
frame comes with sealed for life
bearings,while motors above this range,
have open bearings with“flush
through”re-greasing facilities.
WARNING
DISCONNECT POWER SOURCE
FOR MOTOR LUBRICATION.
FAILURE TO DO SO MAY RESULT
IN INJURY OR DEATH FROM
ELECTRIAL SHOCK OR MOVING
PARTS.
To re-lubricate the motor, complete the
following:
1. Turn the motor off. Make sure it
cannot accidentally restart.
2. Remove the relief plug and clean out
any hardened grease.
3. Add fresh grease through the fitting
with low pressure grease gun.
4. Run the motor for few minutes to
expel any excess grease through
the relief vent.
5. Stop the motor and replace the relief
plug.
Table2
Motor Greasing lntervals
Rated
output kW Poles
Relubrication Period
Standard
condition Severe condition
0-30
37-75
90-110
4upwards
4upwards
4upwards
7years
210days
90days
3years
70days
30days
Standard condition: 8 hour operation
per day with rated or light loading in a
clean and low vibration environment.
Severe condition: 24 hour operation
per day with rated/light loading or in a
dirty/ dusty environment or where the
motor is subject to vibration/light
shock loading.
Grease Type:
TECO/Brook Hansen motor - Use
Esso Unirex Lithium N3 grease. W.E
motor - Use Shell Alvania R3.
5. Drain Pans
Inspecting Cleaning
The condensate drain pan and drain
line must be checked to assure that
the condensate drains as designed.
This inspection should occur a
minimum of every six months or more
often as dictated by operating
experience.
For units with sloped drain pans: If
evidence of standing water or
condensate overflow exists. steps
should be taken to identify and remedy
the cause immediately. Refer to the
troubleshooting section of this manual
for possible causes and solutions. If
microbial growth in the drain pan is
observed, it should be cleaned and
removed immediately. Drain pans
should be cleaned using the following
procedure:
5. Thoroughly clean the contaminated
area(s) with a mild bleach and water
solution or an EPA-approved sanitizer
specifically designed for HVAC use,
Carefully follow the sanitizer
manufacturer's instructions regarding
the use of the product.
6. Immediately rinse the drain pan
thoroughly with fresh water to prevent
potential corrosion from the cleaning
solution of the drain pan and drain line
components.
7. Allow the unit to dry thoroughly
before putting the system back into
service. 8. Determine and correct the
cause of the microbial contamination.
9. Be careful that the contaminated
material does nit contact other areas of
the unit or building. Properly dispose of
all contaminated materials and
cleaning solution.
6.Coil Cleaning
Steam, hot water and chilled water
coils should be kept clean to maintain
maximum performance. lf fins become
dirty, clean with steam and detergent,
hot water spray and detergent, or one
of the commercially available chemical
coil cleaners. Rinse coils throughly
after cleaning.
1. Disconnect all electrical power to the
unit.
2. Don the appropriate personal
protective equipment (PPE).
3. Remove all standing water.
4. Use a scraper or other tools to
remove any solid matter. Remove solid
matter with a vacuum device that
utilizes high efficiency particulate
arrestance (HEPA) filters with a
minimum efficiency of 99.97% at 0.3
micron particle size.
In the event of coils being out of com-
mission for some time, it is advisable to
completely drain down the coil. On
each occasion when refilling is
undertaken, check that the coil is
effectively vented.
Periodic cleaning of the coils is
required.
Dirty coils have increased airside
pressure drops and reduced heat
transfer, thus unbalancing the cooling
or heating system.
Cleaning
In the event that fin edges have been
bent, they can be straightened with the
aid of a coil comb.
The cleaning is carried out with the unit
intact using a powerful vacuum cleaner
on the dust-contamainated side. If the
unit is very dirty it will need to be
removed and wet cleaned.
If required, soft cleaning brushes may
be used ensuring that the heat
exchanger fin are not damaged.
Frost protection
Check that frost protection is working
before the commencement of each
winter period. Ensure that the frost
sensor is correctly installed and fitted
and is working within the correct
temperature range.
Drop eliminator
Check the cleanliness of the droplet
separator section and the blades
annually. If the blades are dirty, remove
and clean them. Contamination can
result in damage through water
droplets in the system's performance.
Ensure that the blades are correctly
repositioned and that they are not
distorted.
WARNING
Follow all directions provided with
chemical cleaners to avoid
personal injury and/or coil damage.
Commercially available chemical
cleaners may contain caustic or
hazardous agents.
4.Air Filters
Suggest the panel filter allowable
maximum resistance is about 130 Pa,
the bag filter allowable maximum
resistance is about 260 Pa, the highly
efficient filter allowable maximum
resistance is about 500 Pa. When the
resistance is close to the allowable
maximum, the filter need to be clean or
replaced, and according to the actual
usage of the unit, when the filter need
cleaning for many times, please
choose aluminum mesh filter, in
addition, the chemical fiber filter after
when cleaning must be soaked in
water for gentle scrub and fully dry,
when the filter efficiency is lower than
the original efficiency 85%, the filter
must be replaced in accordance with
size,type and filtration efficiency.

25
24
Maintenance Maintenance
Direct expansion coils
Never use hot water or steam to clean
these coils. During normal opeartion,
the fin block must not ice up. If this
occurs, check the refrigeration system.
Refrigerant coils should be kept clean
to maintain maximum performance. If
fins become dirty, clean with cold water
and detergent or one of the
commercially available chemicals coil
cleaners. Rinse coils thoroughly after
cleaning.
WARNING
Never use steam or hot water to
clean a refrigerant coil. Dangerous
pressures may be built up by
improper application of heat
resulting in equipment damage oe
personal injury.
7. Coil Winterization
Provisions must be made to drain those
coils that are not in use when subjected
to freezing temperature.
CAUTION
Failure to properly drain and vent
coils when not in use during freezing
temperatures may result in coil
freeze-up damage. Drain and vent
hardware provided by installing
contractor.
To drain these coils, blow out the coils
with compressed air, fill and drain the
tubes with full-strength ethylene glycol
several times, and then drain the coil
as completely as possible.
8. Pulley and Belt
Proper installation techniques will
assure that you get full service life and
minimum down time from your belt
drives.
1. Turn machine OFF and lock out
power source.
2. Remove belt guard, loosen motor
mounts and shorten center distance
between pulleys. Remove old belts.
3. lnspect. Repair or replace drives
components.
Clean oil, grease and debris from
pulleys, remove rust with wire
brush.
lnspect and replace damage
pulleys. Get your moneys worth
from a new set of belts by checking
and replacing worn or damaged
Pulleys. ln the long run,
replacement pulley cost will more than
be recovered in increased belt life,
reduced downtime, and lower
maintenance expenses.
Check following:
a) Worn groove sidewalls, "Dishing"
should not exceed 1/32"(0.8mm) for
individual belts. With a banded belt,
dishing should not exceed
1/64"(0.4mm). When a banded belt
rides too low in worn pulley
grooves the tie band can be cut
bythe flanges between the grooves.
b) Shiny pulley groove bottoms. This
is a sure sign that the belt has
Bottomed out. The resulting
slippage shortens belt life.
c) Wobbling and/or damaged pulleys.
Generally caused by improper
pulley or bushing installation,
wobbling and/or damaged pulleys
can unbalance a drive, wear out
belt rapidly, and damage bearings
and bend shafts.
Check and repair worn bearings and
bent shafts.
4. Select replacement belts.
Replace all belts on a drive with a new
matched set.
a) Do not mix old and new belts on a
drive. A new belt will ride higher in
the pulley groove and operate at a
higher tension than an old belt.
Running them together will
damaged the new belt as it cannot
carry its share of the load.
b) Do not mix belt from different make,
because dimensions and
constructions will vary running such
"Mis-Matched" belts will not give full
service life.
c) Replace with correct type and cross
section belt. Matched SPA section
belt with SPA section pulleys. Do not
put a SPA belt section on a SPB
section pulley. Also dimensionally
similar belts can have very different
horsepower rating.
5.lnstall new belts
Loosen the drive take up and place
the new belts on the pulley. Press
the belts with your hand to position
the slack of each belt on the same
side of the drive. lf the slack is on
different sides. start up loads can
break belt tensile cords.
Do not pry or force belts onto the
pulleys. This can break the load
Carrying tensile cords of the belt
and the belts will break or turn
Overs hortly after installation.
Take Up sleck until belts fit snugly.
6. Check pulley alignment.
Place a straight edge across
pulleys faces to correct alignment.
Check parallel position of shafts
And correct alignment or grooves.
Note: Mount pulleys as close to
Bearing as possible.
Note: Store belts in a cool, dry place
out of direct sunlight.
Types of sheave and shaft misalignment
Horizonal Angular
Vertical Angular
Parrallel
Align with straightedge along sheave faces
Figure 16
Sheave Alignment
Fan Belt Tension
Note: Fan belt tension should be
checked at least twice during the first
day of operation, since there is a rapid
decrease in tension until belts are run
in.
Proper belt tensioning is required to
ensure maximum bearing and drive
component life and is based on fan
brake horsepower requirement.
Belt Tension Measurement
Check the belt tension as follows:
Measure the span length mm of the
drive. With a belt tensioner at the
center of the span. apply a force K
(perpendicular to the span) large
enough to deflect the belt 15mm per 1
meter of span. Refer to figure 17.
DEFLECTION = SPAN mm X 15/1000mm
The deflection force for the belt should
be within the minimum and maximum
force shown in the Table 3. When the
tension drops to the minimum
value,readjust to the maximum value.
To measure belt tension, use a belt
tensioner as shownin Figure 18.
Determine actual deflection by
depressing one belt with th belt
tensioner and measuring the
deflection relative to the other belts or
to belt line. Adjust the belt tension to
the correct force (Newton) and tighten
all setscrews to the proper torques.
Figure 17
Belt Tension Measurement
Dishing
Driver
Equal distance,top and
bottom, from belt center
line to straight edae.
Driver
A
B
C
D
Deflection=SPANmm×15/1000mm
Bell Span

27
26
Maintenance Trouble Analysis
General
Use the tables in this section to assist in identifying the cause or causes of a malfunction in Air Handler operation. The column
header RECOMMENDED ACTION will suggest repair procedures.
Note: These tables are intended as a diagnostic aid only. For detailed repair procedures, contact your local Trane Service
Company.
Loosen bearing setscrews and realign
Grease bearing(s) (Plummer block)
Retension belts
Apply grease
Clean surface of grease and purge
Correct alignment and check that shaft is level
Check across AC line. Correct voltage if
possible
Check line phases and terminal block
connection. Reduce system load, fan
driven speed or increase motor capacity
Remove fan cover, clean fan and replace
cover
Reduce load or replace with larger motor
Replace motor fan / clean
Check pulley alignment
Remove items used for transport only
Retension belts
Replace vibration isolator
Align drive
Tighten motor mounting bolts
Replace bearings and seals
Remove interference in motor fan housing
Remove item and repair
Replace bearings and seals
Retighten hub
Re-tension and align
Clean belts and pulleys; check for grease
leaks
Remove obstruction
Replace with full set
Change at advised dirty condition
Check unit running conditions
Replace with filter
sizes as supplied from Trane
Poor alignment
Inadequate lubrication
Overtensioned belts
No lubricant (plummer block type)
Overlubrication
Misaligned bearing
Low line voltage
Short circuit, phase to earth (open Phase)
Overloaded motor
Motor fan is clogged with dirt preventing
proper ventilation
Overloaded motor
Motor fan damaged
Poor pulley alignment
Transport brackets not removed
Overtensioned belts
Fan / unit vibration isolator collapsed
Misalign drive
Motor mounting bolts loose
Worn motor bearings
Fan rubbing on fan cover
Fan rubbing on inlet cone or guard
Worm fan bearings
Loose impeller
Incorrect tension or alignment
Dirt or grease on belts
Belts rubbing
Odd belts being fitted
Blocked with dirt
Air velocity too high
Filter wrong size
Bearing noise
Bearing is excessively hot
Motor stalls
Motor overheats
Excessive vibration
Excessive vibrator
Excessive motor noise
Excessive fan noise
Premature belt wear
Filter collapsing
Symptom Probable Cause Recommended Action
SPAN，mm
DEFLECTION
K
Figure 18 Belt Tension Measurement
Table 3. Deflection Force,K
Cross Section Force
DEFLECTION FORCE,K
SPZ SPA SPB SPC
min. Max. min. Max. min. Max. min. Max.
63-80,mm kgF 1.2 1.9 1.5 2.3 - - - -
N12 19 14 23
81-112,mm kgF 1.6 2.4 1.9 3.0 2.5 3.7 - -
N16 24 19 29 24 36
113-160,mm kgF 1.9 2.9 2.7 4.1 3.4 5.1 4.5 6.9
N19 28 26 40 33 50 45 68
161-224,mm kgF 1.9 3.0 3.1 4.7 4.4 6.5 5.9 8.9
N19 29 30 46 43 64 58 87
225-355,mm kgF - - 3.3 4.9 5.2 7.9 8.1 12.1
N32 48 51 77 79 119
356-630,mm kgF - - - - 5.6 8.4 10.5 15.7
N55 82 103 154
N=Newton
kgF=kilogram Force=9.80665 N
Small O-Ring
Large O-Ring
Force Scale
Span Scale

29
28
Trouble Analysis Trouble Analysis
Repair or replace blade
Tighting lever fixings
Refit actuator correctly
Prevent bypass with block-off
Clean and unblock tubes
Check water pumps, valves and lines for
obstructions
Provide proper water temperature
Prevent bypassing with block-off
Clean and unblock tubes
Check fan-operating conditions
Check sensing bulb location and TXV operation
Check for blockage in distributor and tube
Repair damaged part
Check support and alignment of pipework and
rectify
Check frost protection method and correct, improve
Trapping of steaam supply
Resize / fit trap and check air break arrangement
Clean trap and refit
Clean drain line
Level unit
Design trap per unit installation instructions
Reduce fan speed
Design trap per unit installation instructions
Repair leaks
Insulate surfaces
Replace filters
Reduce filters bypass
See “Standing water” symptom
See “Wet interior insulation” section
Adjust tension
Replace belt or belt set. Check sheave alignment
Replace sheaves
Replace sheaves
Realign drive with MVP sheave set at mean pitch
diameter
Check for leaky bearings. Clean belts and sheaves
Adjust tension
Remove obstruction or realign drive for clearance
Check belt tension and overhung load
Replace sheave with larger one
Blade bent
Spindle or mechanism loose
Actuator loose
Air is by passing coil
Coil tubes are blocked
Incorrect airflow (CFM)
Incorrect water flow rate (GPM)
Incorrect water temperature
Air is by passing coil
Coil tubes are blocked
Incorrect airflow
Expansion valve not operating
Poor refrigerant distribution
Header / exposed pipe damage
Cracks in joints due to strain of pipework
on headers
Swelling of joints due to frost
(Water-hammer Steam Coils)
Incorrect hydraulic trapping
Blockage in trap
Plugged Drain Line
Unit not level
Improper trap design
Coil face velcity too high
Improper trap design
Drain pan leaks / overflows
Condensation on surfaces
Missing filters
Filter bypass
Standing water in drain pan
Moisture problems
Motor is poorly positioned
Worn or damaged belt
Worn Sheaves
Worn Sheaves
Misalign belt
Grease or oil on belts
Belt slipping
Belts rubbing
Excessive overhung load due to
overtensioned drive
Excessive overhung load due to a small
Damper seizing
Low coil capacity (Chilled Water)
Low coil capacity (Refrigerant)
Leaking Coil
Drain pan overflow
Standing water in drain pan
Wet interior insulation
Excess dirt in unit
Microbial growth (mold) inside
air handler
Loose fan belt
Short belt life
Rapid motor bearing wear
Symptom Probable Cause Recommended Action
√ Indicates Most Common Causes
@ Indicates Other Possible Causes
Pulley and Belt
Rapid side wall wear @ @ √ √ @ @ @ @ @ @ @ @
Worn cove on back √@ @
Belt turns over or
jump off pulley @ @ @ √@
Belt soft,swollen √@
Belt slips,squeals
(Spin Burn)√ √ √ √ @ @ @ @
Belt cover split @ @
Underside cracked @ @ @ @ √ √ @
Tie-band damakaged @ @ √ √ @√
Repeated breakage @ @ @ @ √
Belts ride too high @ @
Belts bottoming √ √ @√
Repeated take up
necessary @ @ @ @
Belt vebrate
excessively or
appear mismatched
@ @ @ @ @ @ √@ @
Bearing are hot @ @ @ @ @ √@ @
Shafts whip orbend @ @ @ @ @ √
Cracked bushings @ @ √
Pulley wobble @ @ @ √
Couscs SYMPTOMS
Belt pries on or misplaced slack Belts rubbing guard
Pulleys misalign
Won or damaged pulleys
Pulleys too far from pulleys Poor bearing or shaft conditions
Insufficient tension
Excessive tension
Improper pulley installation
Belt worn(Normal service life)
Wrong belt cross section or type
Mismatched or mixed belts Machince induced impulse or type
Improper or prolonged storage
Excessive heat Excessive oil or grease
Abrasive environment
Foreign objects in grooves
Excessive moisture
Overloaded drive-undebelting
Drive seriously overbelted Pulley too small
Insufficient wrap on small pulley
Backside ldler
Use of belt dressing

Appendix A
HDT - Unit Weight (CLCP)
31
30
Appendix A
HDT - Unit Weight (CLCP)
Note:
1. Coil weight is the operating weight
50mm Casing
25mm Casing
Model
Size
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement
1 2 4
Front-Top.
Front-Bottom.
Top-Front &
Top-Back
003
004
006
008
010
012
014
016
020
025
030
035
68
82
111
128
140
178
196
238
282
364
406
466
68
82
111
128
140
190
209
251
297
379
407
483
52
67
82
97
109
131
150
165
187
217
268
302
55
71
87
103
117
141
162
178
203
237
292
330
69
91
116
134
152
183
212
234
268
315
384
436
040
045
050
060
065
070
080
085
090
095
567
592
740
765
930
930
1067
1099
1137
1168
585
611
782
809
923
954
1092
1125
1164
1196
335
376
409
465
539
577
620
676
716
754
368
413
451
515
594
637
685
747
791
835
487
549
601
694
790
852
912
994
1056
1116
83
112
140
170
192
234
273
300
348
410
500
571
112
153
193
236
269
332
390
429
502
596
729
838
101
136
171
208
235
288
337
371
431
510
622
712
123
171
217
263
304
377
444
488
573
684
840
965
Coil Row
6 8 10 12
644
726
798
926
1051
1134
1219
1328
1414
1497
949
1074
1181
1379
1560
1689
1817
1984
2111
2239
803
907
999
1163
1317
1424
1530
1668
1775
1882
1093
1238
1369
1603
1808
1958
2107
2300
2447
2595
51
62
81
96
105
135
149
179
212
277
51
62
81
96
105
144
159
188
222
288
50
62
75
90
102
123
141
156
177
206
52
65
80
96
110
133
153
169
193
227
66
83
102
124
141
171
199
221
254
299
003
004
006
008
010
012
014
016
020
025
Model
Size
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement
1 2 4
Front-Top.
Front-Bottom.
Top-Front &
Top-Back
319
354
319
360
256
289
281
318
367
418
80
104
130
159
181
222
260
287
333
394
483
553
97
126
159
194
221
272
319
353
411
489
599
688
108
142
181
222
255
316
372
412
482
575
707
814
119
160
204
249
290
361
426
471
554
663
817
940
030
035
Coil Row
6 8 10 12
439
458
582
452
472
613
321
361
394
355
399
436
468
528
579
624
705
776
777
880
970
922
1046
1151
1067
1210
1339
040
045
050
HDT Unit Weight (kg) - Fan and Coil Sections (without motor weight)
50mm Casing
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
Filter Section Weight(kg)
31 36
29 39
34 48
39 56
43 59
49 68
55 80
52 85
58 96
66 112
77 123
Model
Size Front-Top &
Front-
Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
50
62
75
90
102
123
141
156
177
206
256
289
321
361
394
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
003 51 51 52 66 80 97 108 119 19 42
004 62 62 65 83 104 126 142 160 23 48
006 81 81 80 102 130 159 181 204 31 58
008 96 96 96 124 159 194 222 249 37 70
010 105 105 110 141 181 221 255 290 33 72
012 135 144 133 171 222 272 316 361 39 88
014 149 159 153 199 260 319 372 426 46 97
016 179 188 169 221 287 353 412 471 42 103
020 212 222 193 254 333 411 482 554 48 112
025 277 288 227 299 394 489 575 663 51 131
030 319 319 281 367 483 599 707 817 53 146
035 354 360 318 418 553 688 814 940 65 172 85 140
040 439 452 355 468 624 777 922 1067 72 183 94 153
045 458 472 399 528 705 880 1046 1210 80 209 102 171
050 582 613 436 579 776 970 1151 1339 73 206 118 195
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
36 41
38 48
44 58
50
67
54 71
62 81
70 94
67 100
74 112
83 129
96
142
106 161
116 175
125 194
142
219
157
249
169 269
180 288
187 315
198 328
209 349
220 362
Filter Section Weight(kg)
Model
Size Front-Top &
Front-
Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
003 68 68 52 55 69 83 101 112 123 21 47
004 82 82 67 71 91 112 136 153 171 25 57
006 111 111 82 87 116 140 171 193 217 32 67
008 128 128 97 103 134 170 208 236 263 38 81
010 140 140 109 117 152 192 235 269 304 35 84
012 178 190 131 141 183 234 288 332 377 41 102
014 196 209 150 162 212 273 337 390 444 48 111
016 238 251 165 178 234 300 371 429 488 44 117
020 282
297
187 203 268 348 431 502 573 50 128
025 364 379 217 237 315 410 510 596 684 54 149
030 406 407 268 292 384 500 622 729 840 56 165
035 466 483 302 330 436 571 712 838 965 68 193
040 567 585 335 368 487 644 803 949 1093 75 205
045 592 611 376 413 549 726 907 1074 1238 82 232
050 740 782 409 451 601 798 999 1181 1369 75 230
060 765 809 465 515 694 926 1163 1379 1603 82 251
065 930 923 539 594 790 1051 1317 1560 1808 88
279
070 930 954 577 637 852 1134 1424 1689 1958 95 290
080 1067 1092 620 685 912 1219 1530 1817 2107 101 319
085 1099 1125 676 747 994 1328 1668 1984 2300 108 330
090 1137 1164 716 791 1056 1414 1775 2111 2447 114 359
095 1168 1196 754 835 1116 1497 1882 2239 2595 119 365
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
25mm Casing
Note:
1. Coil weight is the operating weight.
2. Filter weight include filter media.
Fan + Coil + Filter Sections (without motor weight)

Appendix A
HDT - Unit Weight (CLCP)
33
32
Appendix A
VDT - Unit Weight (CLCP)
Model
Size Front-Top &
Front-
Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
Mixing Box/
Rear or Top
Inlet Section
Weight
50
62
75
90
102
123
141
156
177
206
256
289
321
361
394
Fan Section Weight(kg) Coil Section Weight(kg) Filter Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
003 51 51 52 66 80 97 108 119 0 42 31 26 35
004 62 62 65 83 104 126 143 160 0 48 31 31 42
006 81 81 80 102 130 159 181 205 0 58 34 39 51
008 96 96 96 124 159 194 222 249 0 70 39 46 60
010 105 105 110 141 181 221 255 290 0 72 43 49 58
012 135 144 133 171 222 273 316 361 0 88 49 57 68
014 149 159 153 199 260 320 372 426 0 97 55 68 71
016 179 188 169 221 287 353 412 471 0103 55 74 89
020 212 222 193 254 333 411 482 554 0112 58 83 95
025 277 288 227 299 394 483 575 663 0131 66 98 98
030 319 319 281 367 483 600 707 817 0 146 77 108 114
035 354 360 318 418 553 688 814 940 0 172 85 125 127
040 439 452 355 468 624 777 922 1067 0 183 94 137 140
045 458 472 399 528 705 880 1046 1210 0 209 102 154 181
050 582 613 436 579 776 970 1151 1339 0 209 118 177 181
Model
Size Front-Top &
Front-
Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
Mixing Box/
Rear or Top
Inlet Section
Weight
003 51 51 50 52 66 80 97 108 119 0 47 36 29 38
004 62 62 62 65 83 104 126 143 160 0 57 38 34 45
006 81 81 75 80 102 130 159 181 205 0 68 44 43 54
008 96 96 90 96 124 159 194 222 249 0 81 50 50 64
010 105 105 102 110 141 181 221 255 290 0 84 55 54 66
012 135 144 123 133 171 222 273 316 361 0 101 62 63 76
014 149 159 141 153 199 260 320 372 426 0 111 70 74 81
016 179 188 156 169 221 287 353 412 471 0117 71 80 104
020 212 222 177 193 254 333 411 482 554 0 128 74 90 111
025 277 288 206 227 299 394 483 575 663 0 149 83 105 115
030 319 319 256 281 367 483 600 707 817 0 165 96 116 134
035 354 360 289 318 418 553 688 814 940 0 193 106 134 148
040 439 452 321 355 468 624 777 922 1067 0 205 115 146 161
045 458 472 361 399 528 705 880 1046 1210 0 232 142 163 211
050 582 613 394 436 579 776 970 1151 1339 0230 157 187 215
060 765 809 465 515 694 926 1163 1379 1603 0 251 157 214 241
065 900 923 539 594 790 1051 1317 1560 1808 0 279 169 233 279
070 930 954 577 637 852 1134 1424 1689 1958 0 290 180 251 324
080 1068 1092 619 685 912 1219 1530 1817 2107 0 319 187 276 332
085 1099 1120 676 747 994 1328 1668 1984 2300 0330 198 287 379
090 1137 1164 715 791 1056 1414 1775 2111 2447 0359 209 307 388
095 1168 1196 754 834 1116 1497 1882 2239 2595 0 365 220 317 397
Fan Section Weight(kg) Coil Section Weight(kg) Filter Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
25mm Casing
Note:
1. Coil weight is the operating weight
2. Filter weight includes filter media
Fan+Coil+Filter and Mixing Sections(without motor weight)
50mm Casing
100
132
162
204
226
281
324
372
414
518
616
695
123
167
209
262
295
370
431
490
557
692
833
948
113
150
186
233
261
326
378
432
486
606
725
822
134
184
232
288
330
414
484
550
629
780
942
1074
Model
Size
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
Front-Top.
Front-Bottom.
Back-Top &Back-
Bottom
Top-Front &
Top-Back
003
004
006
008
010
012
014
016
020
025
030
035
107
121
175
205
228
254
272
355
471
582
609
773
107
121
175
205
228
267
286
370
486
599
627
792
76
94
112
139
151
187
211
246
264
336
396
438
78
98
117
146
159
197
223
260
281
357
420
468
87
111
135
168
186
230
263
306
335
423
500
560
88
99
146
169
189
211
224
296
400
491
520
657
88
99
146
167
189
220
235
307
412
504
534
671
70
79
94
115
127
156
177
203
221
274
328
366
72
82
99
121
135
166
189
217
238
295
353
395
81
96
116
144
162
199
228
262
292
361
432
487
95
116
144
179
201
249
290
328
371
456
548
622
107
134
168
209
237
295
344
389
443
544
657
749
118
151
190
237
270
338
396
447
514
630
765
875
129
168
213
264
305
383
450
507
586
717
875
1001
003
004
006
008
010
012
014
016
020
025
030
035
Model
Size
Fan Section Weight(kg) Coil Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
Front-Top.
Front-Bottom.
Back-Top &Back-
Bottom
Top-Front &
Top-Back
Fan and Coil Sections(without motor weight)
50mm Casing
25mm Casing
Note:
1. Coil weight is the operating weight.

Appendix A
VDT - Unit Weight (CLCP)
35
34
Appendix B-
Fans and Arrangement
Fan+Coil+Filter and Mixing Sections(without motor weight)
50mm Casing
003 107 107 76 78 87 100 113 123 134 0 47 36 29
004 121 121 94 98 111 132 150 167 184 0 57 38 34
006 175 175 112 117 135 162 186 209 232 0 68 44 43
008 205 205 139 146 168 204 233 262 288 0 81 50 50
101 228 228 151 159 186 226 261 295 330 0 84 55 54
012 254 267 187 197 230 281 326 370 414 0 101 62 63
014 272 286 211 223 263 324 378 431 484 0 111 70 74
016 355 370 246 260 306 372 432 490 550 0 117 71 80
020 471 486 264 281 335 414 486 557 629 0 128 74 90
025 582 599 336 357 423 518 606 692 780 0 149 83 105
030 609 627 396 420 500 616 725 833 942 0 165 96 116
035 773 792 438 468 560 695 822 948 1074 0 193 106 134
Model
Size Front-Top,
Front-Bottom,
Back Top &
Back-Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
Fan Section Weight(kg) Coil Section Weight(kg) Filter Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
25mm Casing
003 0
004 0
006 0
008 0
101 0
012 0
014 0
016 0
020 0
025 0
030 0
035 0
88 88 70 72 81 95 107 118 129 42 31 26
99 99 79 82 96 116 134 151 168 48 31 31
146 146 94 99 116 144 168 190 213 58 34 39
169 167 115 121 144 179 209 237 264 70 39 46
189 189 127 135 162 201 237 270 305 72 43 49
211 220 158 166 199 249 295 338 383 88 49 57
224 235 177 189 228 290 344 396 450 97 55 68
296 307 203 217 262 328 389 447 507 103 55 74
400 412 221 238 292 371 443 514 586 112 58 83
491 504 274 295 361 456 544 630 717 131 66 98
520 534 328 353 432 548 657 765 875 146 77 108
657 671 366 395 487 622 749 875 1001 172 85 125
Model
Size Front-Top,
Front-Bottom,
Back Top &
Back-Bottom
Top-Front
& Top-
Back
2"Flat
Filter
2"Hi-
Capacity
Filter
2"Flat
Filter+
15"Bag
Filter
2"Flat Filter
+
4"Cartnidger
Filter
Fan Section Weight(kg) Coil Section Weight(kg) Filter Section Weight(kg)
Fan Arrngement Coil Row
1 2 46 8 10 12
Note:
1. Coil weight is the operatight
2. Filter weight includes filter media
1
FRONT-TOP
COIL
AIR
FLOW
2
3
4
COIL
AIR
FLOW
COIL
AIR
FLOW
COIL
AIR
FLOW
FRONT-BOTTOM
TOP-FRONT
TOP-BACK
003 KAT9/7 229
BC 180
004 KAT10/8
180
KAT9/7
006 FC 250 250
BC 250
008 FC 280 280
BC 280
010 FC 315 315
BC 315
012 FC 400
BC 400
014 FC 400 400
BC 400
016 FC 450
500
FC 500
020 BC 500
560
FC 560
025 BC 560
560
FC 560
030 BC 560
630
FC 630
035 BC 630
710
FC 710
040 BC 710
710
FC 710
045 BC 710
800
FC 800
050 BC 800
800
FC 800
060 BC 800
900
FC 900
065 BC 900
900
FC 900
070 BC 900
1000
FC 1000
080 BC 1000
1000
FC 1000
085 BC 1000
1000
FC 1000
090 BC 1000
1000
FC 1000
095 BC 1000
250
225
450
BC 450
400
Model Size Fan size Fan size
Diameter (mm)
Fan Size and Diameter Fan Discharge Arrangements
8
FRONT-BOTTOM
9
BACK-TOP
10
BACK-BOTOM
7
FRONT-TOP
6TOP-FRONT
5
TOP-BACK
COIL
COIL
COIL
COIL COIL COIL
AIR
FLOW
AIR
FLOW
AIR
FLOW
AIR
FLOW
AIR
FLOW
AIR
FLOW