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Trane CCEB Installation Operation & Maintenance

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Installation
Operation
Maintenance
CCEB Air Handling Units
July 2016
AH-SVX01E-GB
Original instructions

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  • Page 1 Installation Operation Maintenance CCEB Air Handling Units July 2016 AH-SVX01E-GB Original instructions...
  • Page 2 In addition to the instructions in this guide, subject-specific standards, as well as local, na- tional and international regulations must be observed...

  • Page 3: Table Of Contents

    Contents Introduction ................................. 6 Model code ................................6 Intended use / foreseeable misuse ........................7 1.2.1 Intended use ..............................7 1.2.2 Foreseeable misuse ............................7 Modular design ..............................7 Documentation ..............................8 Safety instructions ..............................9 CE-conformity / installation instructions for safe operation ................... 9 2.1.1 CE-conformity declaration according to Machinery Directive 2006/42/EC ............9 2.1.2...
  • Page 4 AHUs equipped from TRANE with control ETAMATIC................66 7.5.2 AHUs which are not equipped from TRANE with control (which have to be equipped with controls on responsibility of the client) ............................66 Differential pressure restriction for plate heat exchangers .................. 68 Lighting ................................
  • Page 5 11.3.2 Assembly connection ..........................104 11.3.3 Fan section ............................... 105 11.3.4 Air filters ..............................105 11.3.5 Heat exchangers / steam humidifiers ......................105 11.3.6 Field devices ............................. 105 11.3.7 Declaration of conformity .......................... 106 Disassembly and disposal ............................. 106 12.1.1 Disassembly ..............................

  • Page 6: Introduction

    – 15/6 AHU type (standard) AHU execution Unit size supply air Unit size exhaust air Legend used for AHU type CCEB 2000 / CCEB T-TWO / Housing types CCEB INOVA ETA XXX key ETA: including control ETA XXX COOL including refrigeration circuit...

  • Page 7: Intended Use / Foreseeable Misuse

    Operation at other conditions must be agreed in writing. If products and components of other manufacturers are used, these must be recommended or ap- proved by TRANE. On-site changes are in full safety responsibility of the operator. 1.2.2 Foreseeable misuse...

  • Page 8: Documentation

    In addition to the contents of this manual, the instruction manuals of the component manufacturers must be followed. In the corresponding chapters is pointed on the manuals. In case of contradiction between manual CCEB 2000 and components manufacturer for safety instructions, the most re- strictive interpretation is valid.

  • Page 9: Safety Instructions

    2.1.1 CE-conformity declaration according to Machinery Directive 2006/42/EC An AHU (or any part thereof) supplied by TRANE is by definition of Machinery Directive 2006/42/EC an incomplete machine, because it is limited in function and is only a part of the build- ing system.

  • Page 10: Indications For Minimizing Specific Hazards

    See chapter 7.2 (AC motors). Frequency controller for Plug fans Also if not supplied by TRANE a frequency converter must be installed to reach the calculated op- erating point. For details see chapter 7.4 (Variable, frequency-controlled drives (VFD, frequen- cy converters)).
  • Page 11 Lighting For work on AHU (maintenance and inspection work) is to provide adequate lighting. Firefighting in case of fire In general, the local fire protection regulations must be observed. If the AHU is part of the smoke extraction concept, then the specifications of this concept have to be observed.

  • Page 12: Refrigeration Circuit

    nobody is in the AHU. all protective devices are working, (optional safety devices such as door guard and belt guard mounted again) and doors equipped with door locks are locked and the keys are removed – re- fer to chapter 5.2 (Doors). Storage of potential energy in gases and fluids All heat exchangers can be operating up to a maximum pressure of 15 bar.

  • Page 13: Atex Units

    Risk of burns on hot surfaces On the compressor casing, pipelines and circuit components and on the oil sump heater surface temperatures of far higher than 100 ° C may occur, which may cause serious injuries. Wear the required personal protective equipment (protective gog- gles, gloves, ...) Prevention of risks due to contact with refrigerant Physical contact with refrigerant must be strictly avoided as it can cause severe...

  • Page 14: Staff Selection And Qualification

    For maintenance and repair work, the power supply of the unit must be inter- rupted. Use only suitable tools according to EN 1127-1:2011 to prevent sparking. Perform work only with conductive footwear (according to BGR 132) in order to avoid electrostatic charging. To avoid static charging, cleaning work may only be performed with a wet cloth.
  • Page 15 If damages are found, immediately a damage report must be created and sent to TRANE. Only then the transport company can make the claim against the insured (Note damage on the ship- ping documents with date and signature in the presence of the carrier). Complaints about ap- parent damaged or missing parts of the delivery cannot be subsequently recognized.
  • Page 16 Figure 2: Delivery in parts (delivery sections) Delivery sections allow the supply of major equipment in small and more easily insertable parts. Sections have a base frame, on which on each corner a (supplied) crane lug can be attached. Size and weight of the sections are indicated on the AHU drawing, see Figure 7.

  • Page 17: Unloading / Transportation To Installation Location

    Forklift, lift truck transport In accordance with the TRANE drawing the AHU will be delivered as one or more delivery sec- tion(s). The AHU parts are delivered on a pallet and can be unloaded and moved by forklift or lift...

  • Page 18: Overlifting Of Ahu Sections With Crane Lugs

    Figure 4: Transport correct Figure 5: Transport incorrect Center of gravity must be centrally located between the forks (see Figure 6). For large parts use several lift trucks. Figure 6: Center of gravity centrally between the forks For the overlifting directly from the truck applies the following chapter 3.3 (Overlifting of AHU sections with crane lugs) for AHU sections or chapter 3.4 (Overlifting of monoblocs) for monoblocs.

  • Page 19: Control Of Weight Limits Of Delivery Sections

    The Lifting of monoblocs by crane lugs is permitted only in exceptional circum- stances and requires the written approval by TRANE. 3.3.1 Control of weight limits of delivery sections Depending on the base frame height (see Figure 15), delivery sections may be lift- ed with lifting lugs up to the following weight, refer to Table 1.

  • Page 20: Necessary Actions Before Lifting Delivery Sections With Crane Lugs

    3.3.2 Necessary actions before lifting delivery sections with crane lugs Opening accessories such as dampers, flexible connections, hoods, etc. must be removed before lifting, see the following examples. This equipment must be lifted separately on a pallet and then be reinstalled. Example 1: Figure 8: Delivery section with mounted damper Figure 9: Delivery section with dismounted damper...
  • Page 21 Figure 10: Delivery section with mounted crane lugs Example 2: Figure 11: Delivery section with mounted flexible connection Figure 12: Delivery section with dismounted flexible connection...

  • Page 22: Mounting Of Crane Lugs

    Figure 13: Delivery section with mounted crane lugs 3.3.3 Mounting of crane lugs Crane lugs are supplied in two versions and will be attached on the front side of the respective delivery section in accordance with the necessary preparations. Execution of the lifting lugs: 1.

  • Page 23: Lifting Of Delivery Sections With Crane Lugs

    Base frame height Figure 15: Base frame height Base frame height H [mm] Screw type M8x20 M8x20 M12x30 M12x30 Table 2: Anzugsdrehmoment für Schrauben 3.3.4 Lifting of delivery sections with crane lugs The load carrying equipment must not run over the operating side of the AHU, but it must run over the opening or the front side of the AHU (Figure 16).

  • Page 24: Overlifting Of Monoblocs

    Figure 16: Load carrying equipment guided Figure 17: Uniform force effect over front side 3.4 Overlifting of monoblocs If several sections or even the entire AHU is combined into one delivery unit, then this is called a monobloc. Chapter 3.3 (Overlifting of AHU sections with crane lugs) is only valid for the delivery form “Monobloc”.

  • Page 25: Lifting Of Monoblocs

    Figure 18: A monobloc, which consists of the two sections L1 and L2 3.4.2 Lifting of monoblocs Monoblocs are generally delivered with a perforated counter-frame – hole diameter 50 mm – for inserting suitable tubes/rods, where the unit is lifted, see Figure 19 and Figure 20. The tubes/rods are not included in the delivery scope, but have to be provided by the company, which is responsible for the lifting operation.
  • Page 26 3.5 (Further necessary actions for the overlifting of both, delivery sec- tions on crane lugs as well as monoblocs) have to be performed. The Lifting of monoblocs by crane lugs is permitted only in exceptional circum- stances and requires the written approval by TRANE.

  • Page 27: Further Necessary Actions For The Overlifting Of Both, Delivery Sections On Crane Lugs As Well As Monoblocs

    Further necessary actions for the overlifting of both, delivery sections on crane lugs as well as monoblocs The AHU sections or monoblocs must be lifted with appropriate equipment e.g. belt with hook. The recommended minimum load capacity per load carrying equipment is 50% of the total weight of the delivery section or monobloc.

  • Page 28: Storage

    3.6 Storage The delivery sections generally are packed in nylon. This package is suitable to protect the AHU during loading and unloading from bad weather, but not for outdoor storage. The insertion into a dry area after unloading is therefore essential for the preservation of the unit. Standstill maintenance Prolonged standstill times can cause damage on motors, fans or pumps.

  • Page 29: Foundation

    4.1 Foundation Recommended are solid foundations of reinforced concrete, as shown in Figure 24 left, or strip foundations, as shown in Figure 24 right. For strip foundations, concrete or steel beams shall be used, see Figure 24 bottom-right. Steel beams constructions must have an appropriate stiffness in relation to the unit size.

  • Page 30: Erection

    In this context, it is recom- mended to conclude an insurance against damage caused by water and other liquids. TRANE is not liable for damages that may arise due to leakage of the AHU, of fittings, of pipes or hoses or due to condensation.

  • Page 31: General Indications For The Erection

    4.2.3 General indications for the erection The AHU sections must be precisely aligned and the front sides shall be exactly parallel to the oth- er. If necessary, some minor corrections can be made by placing steel plates under the section. After the prepositioning the AHU-sections can be pulled together with belts which act on the base frame, as shown on Figure 25 and Figure 26.
  • Page 32 Figure 28: Suspension of ceiling units AHU which are not designed to stack, may not be stacked (one on the other).Air washer will need either one-both sides higher foundations or on one-both sides feet, which are supplied if ordered, refer to Figure 29. Figure 29: Air washer with both sides feet Treatment of GfK air washer and plastic parts Thermoplastics are compared with steel impact and shock sensitive.

  • Page 33: Special Guidelines For Flat Units - Ceiling Units

    4.2.4 Special guidelines for flat units – ceiling units Usage For the suspension under a ceiling. Assembly of the individual components of the flat units The individual components are screwed together by use of comfort compound – see Figure 30. The assembly should still be done on the ground, since the comfort compounds on the top side of the flat unit may no longer be accessible after positioning on the ceiling.
  • Page 34 Figure 31: Suspension with transverse profiles Figure 32: Suspension with longitudinal and transverse profiles...

  • Page 35: Assembly

    Assembly 5.1 Assembly of casing 5.1.1 Actions before the assembly of casing If several AHU sections have to be connected, then the procedure after the pre-positioning of the sections is as follows: Remove crane lugs If lifting lugs are mounted, remove them. To set the unit in the exact assembling position, it can be moved by a rod (leverage).Use the rod only on the base frame profile.
  • Page 36 Figure 34: Removal of the external panel Applying the sealing strip The supplied self-adhesive sealing strip (Figure 35) has to applied on the inner edge of the section flange, refer to Figure 36. Figure 36: Applying the sealing strip Figure 35: Sealing strip For roof units as well as at device separations directly before or after a wet area (e.g.

  • Page 37: Standard Connections And Connection Components

    5.1.2 Standard connections and connection components Base frame connection Figure 39: Hexagon bolt with locknut M8x20 / Figure 40: Screw connection of base frames M10x30 / M12x40 Connection via panels, connection angles and connection frame Depending on the cross section of the AHU, cases A, B and C (as described below) can be differ- entiated.

  • Page 38: Detailed Solutions And Connection Components

    Figure 45: Hexagon bolt with nut M6x6 Figure 46: Connection frame Additionally the following rule applies: 1) Internal mounted connection angles and frames are accessible and the sections are properly aligned - The following connection is sufficient: in case B, connection only via connection angles in case C, connection only via connection frames 2) Internal mounted connection angles and frames are not accessible and/or the sections are not properly aligned:...

  • Page 39: Assembly Of Delivery Sections

    Figure 50: Self-tapping screw ø6,3 x 22 Figure 51: Application of self-tapping screws Connection of internal panels with the front side of the casing Figure 52: Self-tapping screw TORX Figure 53: Joint on the AHU draw- Figure 54: Joint at the AHU 25 ø4,8 x 16 Connection of roof plates Screw spacing: minimum 305 mm...
  • Page 40 Figure 58: Screwing delivery sections together Is only one side accessible (panels and connection frame) the tapping screws ø8 x 11 shall be used, otherwise bolts and nuts (all supplied separately): Screws M8 x 20 for connection angles and base frame Screws M6 x 16 for connection frame and panels For the tightness at least every second hole (bolt spacing 305mm) shall be used.

  • Page 41: Special Features For Roof Units And Device Separations At Wet Areas

    Figure 60: Removing the protective film Start at the bottom to mount the external panels (Figure 61). Figure 61: Pushing in the external panel For roof units also the supplied slide bar must be mounted on the roof flange. 5.1.5 Special features for roof units and device separations at wet areas For roof units as well as at device separations directly before or after a wet area (e.g.
  • Page 42 Note: To prevent leaks, these actions shall also be performed when extreme operating conditions are expected or wet cleaning is planned! Figure 62: Sealing surfaces Figure 63: Sealing the frontal joints Only careful sealing secures the long tightness of the unit. For roof units, also the roof flange is to seal, refer to Figure 64.

  • Page 43: Cable Gland

    5.1.6 Cable gland For the connection of engines, pumps, electric heaters, sensors, etc., TRANE loosely supplies ma- terial for cable glands (Figure 71), which must be installed properly. The following procedure is recommended: 1. Drilling through unit casing (at right angles to the surface).
  • Page 44 Size External drilling diameter Internal drilling diameter (of the cable gland) (for screwing) (for sleeve) M 16 M 20 M 25 M 32 M 40 M 50 M 63 Table 3: Drilling diameters for cable glands Figure 68: Step drill 3.

  • Page 45: Doors

    Figure 72: Transport lock 5.2 Doors Hinged doors The EU-hinge doors have the following design features: Space-saving design Operated by a handle lever. For open door, the handle is in horizontal position; refer to Figure 73. For closed door, the handle is in vertical position; see Figure 74. Figure 73: Door ‚open’...
  • Page 46 Figure 75: Door ‚closed’ and Figure 76: Delivery of the keys ‚locked’ Abovementioned doors with lock are an effective safety device according to EN ISO 12499: there is no case where entering during fan operation is required, refer also to chapter 2.2 (Indications for minimizing specific hazards).

  • Page 47: Dampers

    5.3 Dampers The close position of the dampers is indicated as shown in Figure 82. Figure 82: Closed position It is not permitted to drill in the damper, otherwise it may cause damage to the gear wheels and the function of the damper is no longer ensured. The dampers must not be strained.
  • Page 48 Figure 83: Pulling out the filters Figure 84: Pull-out tool...

  • Page 49: Prefilters And / Or Bag Filters In Filter Frame

    5.4.2 Prefilters and / or bag filters in filter frame Filters are supplied loose and have to be fixed by clips as follows: 1. Take the filter clips, which are included in the supply and are attached in brackets on the filter frame (Figure 85).

  • Page 50: Hepa Filters

    If a sealing is not included in the manufacturer delivery, a suitable sealing is delivered (loose) by TRANE. This sealing is then to fix on the filter cell, or alternatively on the filter frame. The assembly of the filter is done through the filter fixer supplied loose, as shown in Figure 92 up to Figure 95.

  • Page 51: Dampers With External Gear Wheels

    (if not chosen as an option and supplied by TRANE). External gear wheels have to be covered on site Figure 96: Damper with external gear wheels 5.6 Hygienic AHU’s...

  • Page 52: Heat Exchanger Connection

    6.1 Heat exchanger connection 6.1.1 General notes Before connecting the heat exchanger, the piping system must be rinsed thoroughly. To prevent damage of the heat exchanger connection, it is necessary to hold against with a pipe wrench during the screwing (Figure 97). Figure 97: Holding against with a pipe wrench An absolutely stress-free connection has to be ensured and the transmission of vibrations and longitudinal expansion between the device and the piping system...

  • Page 53: Steam Heat Exchanger

    Figure 98: Heat exchanger connection The heat exchanger operates according to the cross-counter-flow principle. Only preheat can be supplied for parallel flow operation on request. 1. All standard heating and cooling heat exchangers - counter flow 2. Steam heat exchangers: steam inlet top, condensate bottom - counter flow 3.

  • Page 54: Plate Heat Exchangers For Refrigeration Circuits

    Supply and installation of thermostat thermostat trigger temperature: 70°C thermostat probe position: approx. 100 mm downstream of airflow through steam heat exchanger / approx. 100mm below of top panel integration of thermostat in AHU control system in a way that immediately after triggering steam supply to heat exchanger is interrupted function: interruption of steam supply at overtemperature for example because of missing airflow...

  • Page 55: Connection Of Indirect Adiabatic Cooling

    ETA-PAC-AHU’s are equipped with an indirect adiabatic cooling device. Carry out connection to piping system as shown in Figure 104. Figure 104: Indirect adiabatic cooling 6.3 Condensate drain Each drain must be equipped with a siphon. Siphons are available as accessories from TRANE. 6.3.1 Standard siphons...
  • Page 56 A space-saving design of the necessary siphon height we can do on request. Contact your sales representative for detailed information. The following conditions are essential for correct operation: At each drain a siphon must be connected. Several drains may not be connected to one siphon. The water from the siphon must run in a funnel.

  • Page 57: Ball Siphons

    6.3.2 Ball siphons If ball siphons with the below shown design are included in the delivery from TRANE, then the fol- lowing items should be observed during installation: Depending on the suction side or pressure side mounting position, the siphon body has to be in- stalled so that the direction of the arrow (see Figure 107) corresponds to the flow direction.

  • Page 58: Duct Connection

    The black plug must be removed for the pressure side installation (see Figure 110). Figure 109: Pressure side execution Figure 110: Pressure side installation: remove the black closing plug 6.4 Duct connection The air conditioning work must be executed tension and torsion free. To prevent structure-borne sound transmission is an intermediary flexible connector recom- mended with at least 140 mm width.

  • Page 59: Insulation Of Fresh Air Damper

    The AHU must be connected to an external protective conductor system. The AHU shall be either: connected at the base frames or alternatively, at the potential compensation, that is mounted on the flexible connection by TRANE. Furthermore, each electrical component must be connected to the protective conductor sys- tem.
  • Page 60 Single-speed motors Single-speed motors are suitable for direct and star-delta starting. If the wiring to the unit outside was done by TRANE, standard wiring is for direct start. Wiring for star-delta start is possible on request. All single-speed motors are suitable for frequency converters. The frequency range of the motor is shown in Figure 111.
  • Page 61 If the motor is operated at the frequency converter, a short circuit protection by a circuit breaker is adequately. In addition to 1) or 2) full motor protection with PTC (thermistor) As standard a PTC thermistor (specified in the technical data sheet as PTC) is used for: Motors for belt-driven fans capacity >= 11 kW As an option for smaller capacities available For all plug fan motors...
  • Page 62 Block diagram for connection: refer to Figure 113. Figure 113: Wiring diagram for thermal contacts ETA - AHU Are as standard equipped with circuit protection switch and frequency converters. When the motor is equipped with a PTC, it is connected to the temperature monitoring of the fre- quency converter.
  • Page 63 Figure 115, for fan with housing refer to Figure 116. Before connecting the motor check the rotating field of mains connection with a suitable device. Afterwards, connect the phases accordingly to motor terminal or repair switch (if supplied and wired by TRANE).

  • Page 64: Repair Switch (Emergency Stop Switch)

    Figure 115: Rotation marking of Figure 116: Rotation marking of plug fans housing fans Fastening torque for electrical connections on the control panel refer to Table 4: Thread M4 M5 M6 Ø min. 0,8 1,8 2,7 max. 1,2 2,5 Table 4: Torques for the motor terminal board Before connecting to the local power network, must be controlled, that the local power supply coincides with the motor requirements from the nameplate.

  • Page 65: Variable, Frequency-Controlled Drives (Vfd, Frequency Converters)

    CCEB-AHU without TRANE-control Specified repair switch must be provided on responsibility of the client Is to carry out independent from TRANE supply of repair switch for fan motor. Fan motor repair switch cuts just the motor off. Furthermore on responsibility of the client must be ensured that all items 1 to 10 of the above...

  • Page 66: Electric Heaters

    Subsequent damages up to fire spread to the building are possible. In order to avoid the above mentioned risks TRANE provides as a standard electric heaters with 2 independent safety thermostats.
  • Page 67 Control-side limitation of the air temperature after the electric heater The control of the electric heater has always to take place so, that the air temperature after the electric heater never exceeds the permitted air temperature in the unit (40°C, if not differently spec- ified in the technical data).

  • Page 68: Differential Pressure Restriction For Plate Heat Exchangers

    In case of dehumidification wheel downstream of electric heater ensure that control rotates the wheel while electric heater is on (additional enabling contact). If control is not supplied by TRANE, this feature has to be ensured on responsibility of client.
  • Page 69 The switches are to connect as below described. If no differential pressure switches are included in the delivery of TRANE (shown in the technical data sheet), then another appropriate on site measure device must protect the plate heat exchang-...

  • Page 70: Lighting

    7.7 Lighting Depending on the number of delivered (optional) lamps, the assignment of the switches and junc- tion boxes can be found below: 1 Lamp 1 switch > 1 <= 4 Lamp 1 switch 1 junction box > 4 <= 8 Lamp 1 switch 2 junction box >...

  • Page 71: Variable Frequency Controlled Drives - Parameters

    + -5% is permitted. 8.1.1 Variable frequency controlled drives - parameters The frequency converter must be configured, if not done by TRANE (please refer to technical data sheet): parameterization using the following Table 6 respectively the provided manufacturer's op- erating instructions and data from TRANE technical data sheet.
  • Page 72 Parameters for Danfoss frequency converter FC102 Description Value Note 0-... Display 0-01 Language [1] German [0] English, [5] Italian 0-02 Switching between Hz/rpm [1] Hz Display in Hz or rpm 0-20 Display line 1.1 [1601] Setpoing [unit] 0-21 Display line 1.2 [1610] Power [kW] 0-22 Display line 1.3...

  • Page 73: Airflow Measurement By Differential Pressure Measurement At The Fan Nozzle

    The air density at the measuring point is to set up manually, depending on altitude, temperature and humidity. In most cases, 1.2 kg/m³ is a suitable value. Note: If in the TRANE delivery the device for airflow measurement is included, this must be config- ured on site in responsibility of the client before commissioning.

  • Page 75: Heat Exchanger

    Processing the pressure signal in other devices Devices from other manufacturers may require a conversion of the K-value. Therefore always ask for the formula, which the device is using. 8.1.3 Heat exchanger...

  • Page 76: Electric Heater

    The heat exchangers, fittings and valves shall be tested for tightness. Attention! Refrigerant If direct expansion heat exchangers or air cooled heat exchangers are installed, the system must be filled with refrigerant after the complete assembly. In this case, a refrigeration engineer must execute the installation and piping.

  • Page 77: Humidifier / Air Washer

    8.1.6 Humidifier / Air washer Drain pan must be cleaned thoroughly. Pollution from construction dust can later cause failure of the pump. In this case, there is no warranty. Check pumps strainer, washer nozzles and tubes for proper fit. Check pump strainer and clean it if necessary. Fill pan and U-trap with fresh water and adjust float valve so that valve closes with a water level 2-3 cm below the overflow.

  • Page 78: Refrigeration Circuit

    8.2.2 Manually starting the compressor via TRANE control system The compressor can be started via the display of the TRANE control system as: 1. Start page  All Settings  Password handling  Enter the password Note: Manually starting the compressor can only be performed at service level (Password level 4;...

  • Page 79: Refrigerant

    8.2.3 Refrigerant Refrigerants used by TRANE are halogenated hydrocarbons, preferably R407C and R134a. These are also known as safety refrigerants (safety group A1 according to EN378 part 1) in contrast to flammable refrigerants such as Propane or toxic refrigerants such as Ammonia.
  • Page 80 In addition, the actual power consumption of all phases’ shall be measured and compared with the nameplate. If the actual power consumption is too high, there is maybe a faulty connection. The system must be shut down immediately. Measure the volume flow and the pressure difference. Often the measured airflow does not match with the design data of the device.
  • Page 81 Belt type Pulley type Min. working di- H max. Max. working di- ameter [mm] [mm] ameter [mm] RST 84 RST 95 RST 100 RST 108 RST 108 RST 120 RST 129 RST 139 RST 146 RST 156 RST 164 RST 177 RST 187 RST 156 RST 164...

  • Page 82: Maintenance

    Most commercially available frequency con- verters have a feature to address these problems. If the air flow is incorrect, then please contact in doubt the competent TRANE office. Maintenance TRANE units are built mostly maintenance free and easy to maintain. The maintenance in- tervals are indicative for normal operating conditions.
  • Page 83 Check vibration isolators for proper mounting / damage (visual inspection). Check the protection grid (Fan in and/or outlet) if available for correct installation / dam- aged (visual inspection). Check the drain (if available) for function. Test the wheel by rotating it by hand for abnormal noises. Rotate the wheel by hand and check for strange bearing noise.

  • Page 84: Motor

    Plug fan The fan is directly flanged to the motor due to the absence of the belt drive it is a service friendly component. To reach the operating point, a frequency converter is required. Deposits on the wheel can cause damage (risk of fatigue fracture) - impeller can burst - Danger! Visually inspect: Check the wheel for any particular weld cracking.
  • Page 85 Reasons for increased belt wear or defect Belt contact the groove bottom / unequal set of belt / tension is too high or too low – Fig- ure 130 Figure 130: Unfavourable operating conditions (1) Slippage / pulley too small / overloading / damaged disc / eccentricity, wobble – Figure Figure 131: Unfavourable operating conditions (2) Disc worn / grooved not uniform / dust, dirt / moisture, humidity –...

  • Page 86: Re-Tensioning Of Belts

    9.2.4 Re-tensioning of belts Moving the motor away from the fan does the tensioning of the belt. Depending on the size of the motor is this: On a rocker swivel On rails slidably mounted. Loosening the lock nut and then turning the adjustment screws make the adjustment. It is important to maintain the alignment of the discs accordingly –...
  • Page 87 Figure 135: Adjustment of pulleys via threaded rods In case of various pulley widths, the gap must be equal on both sides. The belt drive is to re-tension the first time after about 10 hours. Belt tension The correct tension of the belt is obtained if you have the same data as calculated (separate- ly for each drive).

  • Page 88: Replacing Of Belts

    Following two methods for determining the tensioning are described: Force-way measurement The information Test force FE Indentation depth TE Statistical belt tension (belt tension), FS The belts are to be tensioned so that the deflection TE is when the belt is loaded with the test load in point FE (such as with a spring balance).

  • Page 89: Panel Filters

    If units are equipped with TRANE control, then a corresponding warning message is dis- played on the HMI (see Figure 138) when the differential pressure limitation is reached. Figure 138: Warning message filter If such a warning message is displayed, then appropriate actions have to be taken immedi- ately (e.g.

  • Page 90: Bag Filters

    9.3.2 Bag filters Contamination level of the filter can be controlled by the differential pressure drop (check every 14 days to 1 month). Reaching the pressure difference indicated in the technical data sheet cleaning or replacement is required. Bag filters of class G3, G4 are repeatedly reclaimable. Clean the bags from the dust airside with a vacuum cleaner.

  • Page 91: Auto Roll Filters

    9.3.4 Auto roll filters Detailed maintenance instructions are in the auto roll filter section! These filters work automatically and can be monitored by the controlling device. A warn- ing indicates the filter strip is finished. The filter roll must be replaced. Every six months the oil level is to check.

  • Page 92: Refrigerant

    Droplet eliminator Check droplet eliminator about once a year for contamination. Remove fins and clean if nec- essary. Contamination can cause damage by water drops and reduce the performance of the device. Please make sure that the fins are installed properly and are not bent. Pollutants can cause poor performance of the AHU as well as damage due to drop flight.

  • Page 93: Air Washers

    9.5.2 Air washers In general: Check water supply for properly function and check the water level, adjust if necessary. Fill tank and siphon with clean water and adjust the float valve so that the valve closes at a water level of 2-3 cm below the overflow. Depending on water pollution, hardness and processing the air washer are to rid of de- posits and impurities: Severe calcification of components such as nozzles and droplet eliminators indicate an insufficiently effective water treatment.

  • Page 94: Spray Tube Humidifiers

    Clean drain pan and drain. 9.6 Dampers TRANE dampers of type J are nearly maintenance free. Check for dirt, damage and corro- sion, clean if necessary with compressed air or steam jet. Check the function and correct rotation. Spray the wheels with silicone spray if necessary.

  • Page 95: Heat Wheels

    o Removed fibers and dust at the exchanger inlet with a brush. o Clean oils and fats with hot water, household cleaners or degreasing steam. Check for proper operation of differential pressure switch – for function refer to chapter 7.6 (Differential pressure restriction for plate heat exchangers). If there is a bypass damper, please refer to chapter 9.6 (Dampers).

  • Page 96: Refrigeration Circuit

    9.10.1 Leakage checks have to be performed according to EU-regulations indicated in Records for refrigeration circuit application in air-conditioning units supplied by TRANE. Execution by certified re- frigeration technician at intervals that depend on the refrigerant filling quantity. have to be documented in Records for refrigeration circuit application in air-conditioning...

  • Page 97: Maintenance

    (Manually starting the compressor via TRANE control system). Follow maintenance and inspection requirements of compressor manufacturer. These instructions are supplied from TRANE or can be ordered from TRANE. Filter drier: Each refrigeration circuit is equipped with a filter drier. If refrigeration circuit has to be re- paired filter drier must be replaced.

  • Page 98: Inspection

    With an electronic expansion valve the corresponding values must be followed by control unit. Instructions from valve manufacturer are supplied by TRANE. High pressure safety switch: The high pressure switch stops the compressor when the allowed equipment pressure is exceeded. A functional check must be carried out during commissioning and must be per- formed at each maintenance work.

  • Page 99: Hygienic Units

    Clean or rinse out condensate outlet from time to time. 9.11 Hygienic units The maintenance plan for TRANE AHU’s you will find in the general part of instruction manu- al. TRANE recommends maintenance in dependence on: VDMA 24186 part 1 and VDI6022 part 1.
  • Page 100 Ch = Check, C = Clean, M = Maintenance Component Action Section month- ¼ year ½ year year Reference chapter Fan / motor Corrosion check 9.2.1 Fan Flexible connection Vibration isolators Protection grid Water drain Ch / Cl / M Fan bearings Fan bearings with lubricat- according to Table 8 (Lubrication intervals...

  • Page 101: Information On Airborne Noise Emitted By The Air Conditioning Units - On Request

    10 Information on airborne noise emitted by the air conditioning units - on re- quest Sound data can be printed on request on the technical data sheet, sample see Figure 143. The sound power is specified as A-weighted sound power level: Line 1: Sound power over the casing Line 2: Sound power inlet Line 3: Sound power outlet...
  • Page 102 Selection for type of Avoidance sources Degree of Use in Unit category explosive atmosphere of ignition security zone Gas / gas-mixture or Even steam / gas-mixture or very high in rare malfunctions Gas / gas-mixture or Even with the usu- steam / gas-mixture or high al malfunctions...

  • Page 103: Information Regarding The Unit, Protective Systems And Components

    11.2 Information regarding the unit, protective systems and components Example of designation T3 (in- side/outside) Group Category( 2 inside / 3 outside) G for gas, D for dust Ignition protection type (abbr.) Temperature class Evidence of compliance with EC - Directive 2014/34/EC The manufacturer declares conformity to ATEX, in addition to equipment in category 2, the technical documentation in accordance with EC Directive 94/9/EC of TÜV South Germany deposited.

  • Page 104: Information For Commissioning, Maintenance And Repair

    The device-specific explosion protection, outside this category must provide themselves with frequent disturbances or equipment faults, which normally have to be considered, the re- quired level of security. Air leakage rate: The air leakage rate of the air conditioner is determined at a vacuum of 400 Pa. The device corresponds to the tightness class L1 to EN 1886.

  • Page 105: Fan Section

    11.3.6 Field devices On site assembled field devices must comply the ATEX class specified by TRANE. The electrical components (switches, lights, sensors, motors, etc.) must be approved for operation in explosive atmospheres and must be equipped with an appropriate marking.

  • Page 106: Declaration Of Conformity

    11.3.7 Declaration of conformity The declaration of conformity to ATEX applies only to the original delivery AHU and with proper repair and maintenance. When changes on the AHU are made, which are not agreed in writing, the declaration of conformity loses its validity. 12 Disassembly and disposal 12.1.1 Disassembly At disassembly, the safety instructions of chapter 2 (Safety instructions) must be consid-...

  • Page 107: Disposal

    170411 Casing insulation Mineral wool 170604 Air filter Plastic, metal 150106 Droplet separator slats Insulation profile CCEB Inova Plastic 150102 Sealing tape Piping EC – motor Guidelines for the disassembly and instructions for the disposal can be found on the homepage of the manufacturer. Detailed information Electronic components of the manufacturer can be found on the component.
  • Page 108 Figure index Figure 1: Do not climb on the unit ............................15 Figure 2: Delivery in parts (delivery sections) ........................16 Figure 3: Delivery as monobloc ............................17 Figure 4: Transport correct ..............................18 Figure 5: Transport incorrect ............................. 18 Figure 6: Center of gravity centrally between the forks ......................
  • Page 109 Figure 63: Sealing the frontal joints ........................... 42 Figure 64: Sealing the roof flange ............................42 Figure 65: Applying the sealing agent on the frontal joints ....................43 Figure 66: Unit separation accessible via door ........................43 Figure 67: Sealing the section connection (joint) with the sealing agent ................43 Figure 68: Step drill ................................
  • Page 110 Figure 129: Fan bearing with grease nipple (example Comefri NTHZ) ................83 Figure 130: Unfavourable operating conditions (1) ......................85 Figure 131: Unfavourable operating conditions (2) ......................85 Figure 132: Unfavourable operating conditions (3) ......................85 Figure 133: Unfavourable operating conditions (4) ......................85 Figure 134: Adjustment of pulleys .............................
  • Page 111 HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. © 2016 Trane All rights reserved...

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