CG-SVX15A-E4

InstallationOperationMaintenanceLARGE COMMERCIALAIR COOLED CHILLERCGAP 025-030-040-050-060 & CGAH 08050 Hz

TRANER

i

charge is not included in the standardmanufacturer Warranty Cover.

General InformationAbout this manualCaution appears at appropriate placesin this instruction manual.Your personal safety and the properoperation of this machine require thatyou follow them carefully. The con-structor assumes no liability for instal-lations or servicing performed by un-qualified personnel.

About the unitThese chiller units are assembled,pressure tested, dehydrated, chargedand run tested before shipment. Theinformation contained in this manualapplies to units designated CGAP025 ~ 060 & CGAH 080.

RefrigerantThe refrigerant provided by themanufacturer meets all therequirements of our units. Whenusing recycled or reprocessedrefrigerant, it is advisable to ensure itsquality is equivalent to that of a newrefrigerant. For this, it is necessary tohave a precise analysis made by aspecialized laboratory. If this conditionis not respected, the manufacturerwarranty could be cancelled.

Foreword

These installation, operation andmaintenance instructions are given asa guide to good practice in theinstallation, putting into service,operation, and maintenance by theuser, of Trane chillers. They do not con-tain full service procedures necessaryfor the continued successful operationof this equipment: The services ofa qualified technician should be em-ployed through the medium of a main-tenance contract with a reputable ser-vice company.

WarrantyWarranty is based on the general termsand conditions of the manufacturer.The warranty is void if the equipmentis repaired or modified without thewritten approval of the manufacturer, ifthe operating limits are exceeded or ifthe control system or the electricalwiring is modified. Damage due tomisuse, lack of maintenance orfailure to comply with themanufacturer's instructions orrecommendations is not covered by thewarranty obligation. If the user doesnot conform to the rules of chapter"Maintenance", it may entail cancella-tion of warranty and liabilities bythe manufacturer.

ReceptionOn arrival, inspect the unit beforesigning the delivery note. Specify anydamage on the delivery note, andsend a registered letter of protest tothe last carrier of the goods within 72hours of delivery. Notify the local TraneSales Office at the same time. Theunit should be totally inspected within7 days of delivery. If any concealeddamage is discover, send a resgiteredletter of protest to the carrier within 7days of delivery and notify the localTrane Office.Units are shipped with the refrigerentoperatring charge and should beexamined with an electronic leakdetector to determine the hermeticintegrity of the unit. The refrigerant

Contents

General InformationContentsIntroductionModel NomenclatureGeneral DataUnit InstallationGeneral start-upControl SystemDimensional Data

Wiring DiagramInstallation Check ListMaintenance

Troubleshooting

ii

(i)(ii)1

2

4

5

11

13

14

17

23

24

26

NOTICE:Warnings and Cautions appear atappropriate sections throughout thismanual. Read these carefully.

WARNING - Indicates apotentially hazardous situation which,if not avoided, could result in death orserious injury.

CAUTION - Indicates apotentially hazardous situation which,if not avoided, may result in minor ormoderate injury. It may also be usedto alert against unsafe practices.

CAUTION-Indicates a situationproperty-damage-only accidents.

1

Overview of ManualNote: One copy of this document shipsinside the control panel of each unitand is customer property. It must beretained by the unit 's maintenancepersonnel.

This booklet describes properinstallation, operation, andmaintenance procedures for air cooledchiller systems. By carefully reviewingthe information within this manual andfollowing the instruction, the risk ofimproper operation and/or componentdamage will be minimized.

It is important that periodicmaintenance be performed to helpassure trouble free operation. Amaintenance schedule is provided atthe end of this manual. Shouldequipment failure occur, contact aqualified service organization withqualified, experienced HVACtechnicians to properly diagnose andrepair this equipment.

Note: The procedures discussed inthis manual should only beperformed by qualified, experiencedHVAC technicians. Do Not releaserefrigerant to the atmosphere! Ifadding or removing refrigerant isrequired, the service technician mustcomply with all federal, state, andlocal laws.

2

DIGIT 1,2,3

DIGIT 4

DIGIT 5,6,7

DIGIT 8

DIGIT 9

DIGIT 10

DIGIT 11

DIGIT 12

DIGIT 13DIGIT 14

DIGIT 15

Chiller / Cooling Only / Air-Cooled

Development Sequence

Nominal Cooling Capacity025 = 250 MBH 040 = 400 MBH 060 = 600MBH030 = 300 MBH 050 = 500 MBH

Electrical Rating / Utilization RangeD = 380-415V / 3 Phase / 50Hz

Factory Mounted Control1 = DOL Starter with CAREL controller2 = Soft Starter with CAREL controller

Minor Design SequenceH = Introduction of Carel Controller and FUJI Starter

Factory Installed OptionsX = None1 = Corrosion Resistant Coated Fin

Refrigerant TypeA = R22B = R407C

Future UseFuture Use

Service Indicator

C G A P 0 2 5 D 1 H X A 0 0 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

C G A

P

0 2 5

D

1

H

X

A

00

A

3

DIGIT 1,2,3

DIGIT 4

DIGIT 5,6,7

DIGIT 8

DIGIT 9

DIGIT 10

DIGIT 11

DIGIT 12

DIGIT 13

DIGIT 14

DIGIT 15

Chiller / Cooling Only / Air-Cooled

Development Sequence

Nominal Cooling Capacity080 = 208kW

Electrical Rating / Utilization RangeD = 380-415V / 3 Phase / 50Hz

Minor Design Sequence

Factory Installed OptionsX = NoneJ = Condenser Protecting GrilleL = Compressor Sound AttenuatorK = J & L

Factory Mounted Control1 = DOL Starter with CAREL Controller2 = Soft Starter with CAREL Controller

Operating Ambient TemperatureR = Normal, 3-43 C

Refrigerant TypeA = R22B = R407C

Built In Water PumpN = Without [Standard]

Service Indicator

C G A H 0 8 0 D E X 1 R A N A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

C G A

H

0 8 0

D

E

X

1

R

A

N

A

!

"

4

Notes[1] Based on chilled water EWT & LWT of 54 deg. F & 44 deg F and 95 deg F, ambient air temp.[2] Per Motor @ 400V

[3] Minimum Circuit Ampacity (MCA) is 125% of the largest compressor RLA plus 100% of the other compressor RLA plus the sum of the condenser fan FLA.

Performances (1)Gross Cooling Capacity [R22] (1)Gross Cooling Capacity (R407C)Unit Capacity Steps (%)Total Compressor Power Input (1)Main Power SupplyUtilization RangeSound Power Level

CompressorNumberTypeModelSpeeds NumberMotors NumberUnit MCA Amps(3)RLA / LRA(2)Motor RPM

Condenser CoilTypeTube SizeTube TypeHeight

Length Quantity

Rows Fins Per Foot (fpf)Evaporator Data Type Water Flowrate

Nominal Flow, water PDMinimum FlowrateMaximum FlowrateWater StrainerWater Connection

FanTypeNumberDiameterDrive TypeSpeeds NumberMotors QuantityMotors kW (2)FLA (2)Motor RPM

DimensionsHeightWidthLengthWeight UncratedWeight Crated

System DataRefri erant Circuit

Minimum Outdoor Air Temperature for Mechanical CoolingStandard Ambient Operating Range

Hight Pressure [cut out-cut in]Low Pressure [cut out-cut in]

CGAP - CGAH General DataCGAP 030

77.7 / 265.273.8 / 252

100-5026.8

400/3/50

89

2Scroll

2 X 15T11

5724/1752900

Plate Fin9.52

Smooth727013

144

547.5

40.567.5

2 1/2

Propeller2

711/28Direct

12

0.6/0.751.5900

191110022264593613

1

59-109F15-43 C

(kW)/(MBH)(kW)/(MBH)

(kW)

(dB(A)

(A)(A)(rpm)

(mm)

(in)(in)

US GPMft H2OUS GPMUS GPM

BSPT

(mm)/(in)

kw/hp(A)(rpm)

(mm)(mm)(mm)(kg)(kg)

(F)(C)(psig)(psig)

CGAP 040

100.1/341.895/324.7

100-75-50-2536.2

400/3/50

89

4Scroll

2x(10T+10T)11

7516.5/130

2900

Plate Fin9.52

Smooth727022

144

708

52.587.5

2 1/2

Propeller3

711/28Direct

13

0.6/0.751.5900

191119922264990

1025

2

59-109F15-43 C

CGAP 050

127.1/433.8120.7/412

100-75-50-2550.4

400/3/50

90

4Scroll

2x(13T+13T)11

7520.5/135

2900

Plate Fin9.52

Smooth72702

2+3144

888.366110

2 1/2

Propeller4

711/28Direct

14

0.6/0.751.5900

19111992226411531188

2

59-109F15-43 C

CGAP 060

156.1/532.8148.3/506.2

100-75-50-2553.6

400/3/50

92

4Scroll

2x(15T+15T)11

10824/1752900

Plate Fin9.52

Smooth727023

144

108.58.6

81.4135.6

2 1/2

Propeller4

711/28Direct

14

0.6/0.751.5900

19111992226411771212

2

59-109F15-43 C

CGAP 025

64.5 / 220.361.3 / 209.3

100-5025.2

400/3/50

87

2Scroll2x13T

11

4920.5/135

2900

Plate Fin9.52

Smooth72701

2+3144

457.4

33.856.3

2 1/2"

Propeller2

711/28Direct

12

0.6/0.751.5900

191110022264583603

1

59-109 F15-43 C

CGAH 080

208/710197/674

100-75-50-2575.2

400/3/50

92

4Scroll

2x(20Tx2)11

14731/2152900

Plate Fin9.52

Smooth62

10823

144

14212.4

106.5177.5

2 1/2

Propeller6

760/30Direct

16

0.9/1.22.5720

20021950316020302080

2

59-109F15-43 C

400+, -10%

415 +/- 10 psig, 250 +/- 15 psig45 +/- 5 psig, 60 +/- psig

------ Brazed Plate Heat Exchanger ------

Standard, Accessory, Ship with but installed at site

Before preparing the unit for lifting, es-timate the approximate centre of grav-ity for lifting safety. Due to the place-ment of internal components, the unitweights may be unevenly distributed.Unit shipping weights are provided inthe general data.

#

5

WARNING: To prevent injuryor death and unit damage, observehandling cautions and proceduresgiven in Figure 1 when lifting theunit. Always test-lift the unit todetermine actual centre of gravity.

Figure 1 - Lifting of the unit

GeneralAll Trane products are identified by amodel number that precisely identifiesthe unit. An explanation of thealphanumeric identification codes forCGAP units is provided on theprevious page. Its use will enable theowner / operator installing contractorsand service enable the owner /operator installing contractors andservice engineers to define the opera-tion, components and options for anyspecific unit.When ordering replacement parts orrequesting service, be sure to refer tothe serial number and specific modelnumber stamped on the unitnameplate.

Unit NameplateThe unit nameplate specifies theunit' s specific model number, serialnumber, electrical characteristics, typeof refrigerant and other pertinent unitdata.

Compressor NameplateThe nameplate for the "Scroll"compressors are located on thecompressor lower housing.

Unit DescriptionAll air-cooled chillers are designed foroutdoor installation with vertical air dis-charge. Each refrigerant circuit isprovided with and operating charge ofrefrigerant and refrigerant oil, a filterdrier, sight glass/moisture indicator, Hi/Low pressure switches, and Hi/Lowpressure ports (schraeder valves) andexternally equalized thermostaticexpansion valve. All units are leaktested, dehydrated, charged and testedfor proper control operation beforeshipment.An access panel(s) provides accessto the compressor section(s), and aremovable cover allows access to thecontrol box.The brazed plate heat evaporatorsused in these units are with integraldistributor. Each evaporator is fullyinsulated.Standard capacity and safety controlsare provided. Unit operation isgoverned by chilled water temperatureleaving the evaporator.

CAUTION: These units mustbe lifted with utmost care. Avoidshock load by lifting slowly andevenly.

Special Lifting And MovingInstruction

A specific lifting method is recom-mended as follows:1.Four lifting points are built into the

unit.2.Slings and spreaded bar to be

provided by rigger and attached tothe four lifting points.

3.Minimum rated lifting capacity(vertical) of each sling and spreaderbar shall be no less than thetabulated unit shipping weight asabove.

6

#

Special Note onRefrigeration EmissionsBased on the best currentlyavailable evidence, worldenvironmental scientists haveconcluded that the cause of ozonedepletion in our upperatmosphere is due to the releaseof CFC fully halogenatedcompounds.The Trane Company urges allHVAC servicing be done in aresponsible manner to conserverefrigerants for continued use(even when acceptablealternatives are available). Alwaysmake every effort to eliminate, ifpossible, or vigorously reduce theemission of CFC, HCFC and HFCrefrigerants to the atmosphereresulting form installation,operation, routine maintenance,or major service on thisequipment

Isolating rubber padsPlace between the supporting floor andthe unit to isolate from the ground.- 6 pads for the sizes 025-030- 8 pads for the sizes 040-060/080- Trane does not recommend to install spring isolators.

ClearanceRespect recommended clearancearround the unit to allow maintenanceoperation to take place withoutobstruction and recommendedclearance around condenser.

In this case the standard operatingconditions and performance aremodified.

Operation of the unit may be affectedby an increase in air temperature onthe condenser. When the units arepositioned in a windy area, avoid allthe risks of air recycling. Refer to cer-tified drawings.

CautionUnit operation is function of the airtemperature. Any recycling of theair fed out by the fans will increasethe air intake temperature over thecondenser fins and can result inhigh pressure cut-out.

General unit characteristicsFor minimum clearance, consult thecertified submittals, which areavailable on request from your TraneAgency.

Unit nameplateThe unit nameplate gives the completemodel reference numbers. The unitpower rating is shown, and powersupplies should not deviate by morethan 5% from the rated power.Compressor motor amperage isshown in electrical data table.The customer's electrical installationmust be able to withstand this current.

Installation instructions

FoundationsNo special foundations are required,provided the supporting surface is flatand level, and can withstand the weightof the unit.

7

#

Caution: If using an acidiccommercial flushing solution,construct a temporary bypassaround the unit to prevent damageto the evaporator internalcomponents.

8 Strainer : avoid to get heatexchangers dirty. All installtion mustbe equipped with efficient strainer inorder that only clean water enters intoexchanger.The strainer used must be able tostop all particles with a diametergreater than 0.8 mm.

9 Draining: used as the draining theplate heat exchanger.

Before making any connections,make sure the labeling for enteringand leaving water corresponds tothe submittals.

Unit Water PipingGeneral Piping RecommendationsThoroughly flush all water supplypiping before making the final pipingto the unit.

Evaporator water inlet and outlet types,sizes and locations are shown in the"Dimensional data" section Figure 2on page 10 illustrates a typical waterpiping components. Isolate the waterpump from the system to avoidvibration transmission. All waterpiping are to be insulated to minimizeheat gain and prevent condensation.Use a pipe sealant or Teflon tape onall threaded connections.

Net Positive Suction HeadEvaporator water pumps should belocated in their piping systems suchthat they operate with a net positivesuction head. This is to reduce thepossibity of pump cavitation andpossibility differential aeration in thewater system which can rapidly resultin chiller internal corrosion.

Figure 2 - Typical water circuit

1 Pressure gauges: show enteringand leaving water pressure

2 Balancing valve: adjusts water flow.3 Air purge allows to remove the air

from the water circuit during fill up.4 Stop valves: isolate chillers and

water circuiting pump duringmaintenance operations.

5 Thermometers: indicate chilledwater entering and leaving tempera-tures.

6 Expansion compensators: avoidmechanical stress between chillerand piping installation.

7 Stop valve located on the outletconnection: used to measure thewater pressure inlet or outlet ofevaporator.

8

#

EVAPORATOR - Water Pressure Drop DataTable 1

2.12.32.42.62.72.83.03.13.33.43.52.62.72.93.13.23.43.63.73.94.14.33.33.53.84.04.24.44.64.95.15.35.54.24.44.75.05.35.65.86.16.46.76.95.15.55.86.26.56.87.27.57.98.28.6

127.8136.3144.8153.3161.8170.3178.9187.4195.9204.4212.9153.3163.5173.7184.0194.2204.4214.6224.9235.1245.3255.5198.7212.0225.2238.5251.7265.0278.2291.5304.7318.0331.2249.8266.5283.1299.8316.5333.1349.8366.4383.1399.7416.4308.0328.6349.1369.6390.2410.7431.3451.8472.3492.9513.4

CGAP025

CGAP030

CGAP040

CGAP050

CGAP060

lit/minm3/secModelEVAP. Water Flowrate

33.836.038.340.542.845.047.349.551.854.056.340.543.245.948.651.354.056.759.462.164.867.552.556.059.563.066.570.073.577.080.584.087.566.070.474.879.283.688.092.496.8

101.2105.6110.081.486.892.297.7

103.1108.5113.9119.4124.8130.2135.6

gpm(us) kPa4.34.95.56.16.87.48.08.69.29.8

10.64.45.05.66.26.87.58.18.79.39.9

10.74.84.46.16.77.38.08.69.39.9

10.811.75.05.66.36.97.68.38.99.6

10.311.212.25.25.96.57.27.98.69.39.9

10.911.812.8

ft H20WPD

CGAH080

Model

6.77.27.68.18.59.09.49.9

10.310.811.2

403.1430.0456.9483.8510.7537.5564.4591.3618.2645.0671.9

lit/minm3/secEVAP Water flowrate

106.5113.6120.7127.8134.9142.0149.1156.2163.3170.4177.5

gpm(us) kPa7.58.39.2

10.011.212.413.614.816.017.218.5

ft H20WPD

22.424.927.429.933.437.040.744.247.951.555.2

12.814.716.518.320.222.023.825.727.529.331.613.114.916.818.420.422.324.126.027.829.632.114.213.118.120.021.923.925.827.729.632.234.914.816.818.720.722.724.726.728.630.933.636.415.517.519.521.623.625.627.729.732.535.338.2

CG

AP/

H:

EVA

PW

ater

Pres

sure

Dro

pC

urve

10.0

100.

0

1000

.0

1010

0

Pres

sure

Dro

p (k

Pa)

Water Flow Rate (USGPM)

1350

20

Min

WPD

, lim

ited

by D

iff P

ress

ure

Sw

icth

, Cut

-In P

oint

CG

AP

025

CG

AP05

0

CG

AH

080

CG

AP04

0

CG

AP06

0

CG

AP03

0

9

#

CHAR

T 1

10

#

Table 2 - CGAP / CGAH, Electrical Data (@ARI)

As per UL standard,MCA = Minimum Circuit Ampacity,MCA = 1.25 (LARGEST MOTOR AMP (RLA or FLA) + the SUM OF REMAINING MOTOR AMPS.RLA (ARI) = Rated Load Amp at ARI Rating Point, (3.3C Evap / 54.4C Condensing)WHEN, Compressor is Large Load:MAX FUSE SIZE & MCA = (2.25 * LARGEST COMPR. RLA) + SUM OF REMAINING COMPRESSOR RLA + FAN MOTOR FLA.Note: The standard fuse or circuit breaker size selected must be equal to or less than the calculated value.Also, the selected device rating must be greater than the minimum circuit ampacity.

CGAP 025CGAP 030CGAP 040CGAP 050CGAP 060CGAH 080

708191114132178

Compr. 1 UNITMCAModel Power supply

Fan Motor @ 415V

49577593

108147

Max FuseSize & MCBQty.

223446

RLA(ARI)20.524.016.520.524.031.0

LRA135175130135175215

Qty.224444

KW0.60.60.60.60.60.9

FLA1.51.51.51.51.52.5

380-415 V / 3Ph/50Hz380-415 V / 3Ph/50Hz380-415 V / 3Ph/50Hz380-415 V / 3Ph/50Hz380-415 V / 3Ph/50Hz380-415 V / 3Ph/50Hz

One turn counterclockwise equals to -1C to - 2C superheat decrease. It isrecommended to lower the superheatby increasing the suction pressure bymaking adjustments to the expansionvalve setting prior to attempting to lowerthe LP setting parameter to avoid unittripping on low pressure. Make surethere is enough subcooling.

HOW TO DETERMINE SU-PERHEAT:

1. MEASURE the temperature of thesuction line at the compressor in-let. NEARER to ACCESS VALVE.(where suction pressure CAN BEMEASURED).

2. OBTAIN the suction pressure thatexists in the suction line by readingthe gauge PRESSURE at the suc-tion access VALVE.

3. Convert the pressure obtained above,to saturated evaporator temperatureby using a temperature-pressurechart.

4. Subtract the two temperatures ob-tained in 1 & 3 - the difference isSUPERHEAT. Recomended SU-PERHEAT : 8 - 12F (4.4 - 6.7C)

Water treatment

Untreated or insufficiently treatedwater, if used in this unit, may causescale, slime or algea to accumulateor cause erosion and corrosion. AsTrane does not know the componentsused in the hydraulic network and thequality of the water used, werecommend the the services of aqualified water treatment specialist.

Trane will not accept any liability inregards of damage due to the use ofuntreated or improperly treated wateror from the use of saline or brackishwater. If required, contact your localTrane sales office.

Electrical connectionsCaution:1. The greatest care should be taken

when cutting through passages andinstalling electric wiring. Under nocircumstances should chips ofmetal or cuttings of copper orisolating material fall into the starterpanel or electric components.Relays, contactors, terminals andcontrol wiring should be coveredand protected before powersupplies are connected.

2. Install power supply cabling asshown in wiring diagram. Adequatecable gland should be chosen,ensuring no foreign bodies enterelectrical housing or components.

Caution:1. Cabling must comply with standards

in force. The type and location offuses also must comply with stan-dards. As a safety measure, fusesshould be visibly installed, closeto the unit.

2. Only copper wiring should be used.Using aluminium wires can producegalvanic corrosion and possibly leadto superheat and failure of connec-tion points.

Expansion valves settingIn order to keep the compressor in theoperating envelope, it is mandatory tocontrol the superheat suction atcommissioning. It shall reduce thecompressor discharge gas temp andincrease the saturated suctiontemperature, increasing by the way theunit capacity. The rule to reduce thesuction superheat is to loosen theexpansion valve adjustment screw.

11

# $

- Check the isolation of the motorsusing a 500V DC megohmeter whichmeets manufacturer' s specifications(minimum value 2 megohmeter)

- Check the direction of the rotationusing phasemeter.

Electrical power wiring:- Check all the electrical terminals

tightening,- Set-up compressors overload relays,- Set-up fan-motors overload relays,Electrical control wiring:- Check all the electrical terminals

tightening,- Check all the pressostats,- Check and set-up the control module- Test and start-up without the electri-

cal power, to compressors.Condenser:- Check direction of the rotation of fans,- Check the isolation of the motors

using a 500V DC megohmeter whichmeets manufacturer' s specification(minimum value 500 megohmeter)

Operating parametersstatement:

- Start-up the unit following proceduredescribed in section control systemUSER GUIDE.

- After unit start up, leave in operationfor at least 15 minutes, to ensurepressures are stabilized.

Then check:- voltage,- compressors and fan - motors

currents,

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ] 1. Max. oil level2. Min. oil level

- Check chilled water pressure dropthrough evaporator

- On start-up of each motor in thesystem, check the direction ofrotation and operation of all thecomponents they drive

- Check that there is sufficient demandfor cooling on the day of start-up(around 50% of nominal load)

START-UPFollow the instructions below tocorrectly start-up the unit.

Installation and chiller inspection:- Ensure that all the operations above

(start-up preparation), are followed.- Ensure all water and refrigerant

valves are in service positions,- Ensure that the unit is not damaged,- Ensure that sensors are properly

installed in their bulb-wells andsubmerged in heat conductingproducts,

- Reset all manually set control de-vices,

- Check refrigerating circuits tightness

Checking and setting:Compressors:- Check oil level at rest. The level

should reach at least halfway up in-dicator located on housing. See fig.11 for correct level.

Figure 3 - Compressor oil level

- Check fixing of capillary tubes(protection from vibration and fromwear) and ensure that they are notdamaged,

- Reset all manually set controldevices,

- Check refrigerating circuitstightness

- Check electrical terminals tighteningof the motors and in the control panel,

START UP PREPARATIONInstallation ChecklistComplete this checklist once the unitis installed to verify that all recom-mended procedures have been ac-complished before starting the system.Do not operate the system until allitems covered by this checklist arecomnplete.

UnitInspect unit location for properrequired service clearances.Check type and position of rubberpads.Inspect unit location for proper freeair clearances.Inspect unit location for secure,level mounting position.

Water SystemChilled water circuit ready tooperate, fil led with water,pressure test carried out and airpurged.Chilled water circuit must berinsedChek the presence of waterstrainer ahead of evaporatorThe strainers must be cleanedafter 2 hours of pumps operationCheck the thermometers andmanometers position

SystemCheck chilled water pumpsinterconnection to control panelEnsure that the isolationresistance of all power supplyterminals to ground complies withstandards and regulations in forceCheck that unit voltage andfrequency supplied match ratedinput voltage and frequency

- Check that all electricalconnections are clean and sound-Check that main power supply switchis sound

- Water flow control checking:decrease the water flow and checkthe electrical contact in the controlpanel.

shut down unit and check thedirection of ratation usingphasemeter.

Warning- The chilled water circuit may be under

pressure. Bring down this pressurebefore opening up the system to riseout or fill up the water circuit. Failureto comply with this instruction maycause accidental injury tomaintenance personnel.

- If a cleaning solution is used in thechilled water circuit, the chiller mustbe isolated from the water circuit toavoid all the damage risks of thechiller and evaporator water pipes.

12

# $

- leaving and return chilled watertemperature,

- suction temperature and pressure,- ambient air temperature,- blowing air temperature,- discharge pressure and temperature,- liquid refrigerant temperature and

pressure,- operating parameters:- chilled water pressure drop through

evaporator unit available pressure.- superheat : difference between

suction temperature and dew pointtemperature. Normal superheatshould be within 4 and 7 oC in coolingmode,

- sub-cooling : difference betweenliquid temperature and bubble pointtemperature. Normal subcoolingshould be within 2 and 10oC incooling mode,

Final check:When the unit is operating correctly- Check that the unit is clean and clear

of any debris, tools, etc...- All valves are in operating position,- Close control and starter panel doors

and check panels fixation.

Caution:- For the warranty to apply, any start-up

carried out directly by the customermust be recorded in a detailed report,which must be sent as soon aspossible to the nearest Trane office.

- Do not start-up a motor whoseinsulation resistance is less than 2megaohms

- Phase imbalance should not begreater that 2%.

- The voltage supplied to motorsshould be within 5% of the ratedvoltage on the compressornameplate.

- Excess oil in compressor candamage the compressor. Beforeadding oil, consult Trane technician.Use only Trane productsrecommended.

- The compressors must operate in asingle direction of rotation. Irefrigerant high pressure remainsstable in the 30 seconds aftercompressor start-up, immediately

13

%

The control is through the CARELController, MCH3.Refer to MCH3 - User Guide fr moredetails.

Chilled Water CirculatingPump

1 Once the system has been filled,complete the following chilled watersystem start-up procedure.

2 Ensure all power connection pointhas been done propertly and switchthe MCB into ON position to powerthe control circuitry and controller.

3 The controller will be running inintialization mode and cheeking allconnection switches is properlydone. Once after the initializationmode, the panel display willdisplayed the default screen withchilled water IN temperature andchilled water OUT temperature andChilled unit status.

4 Enable the unit operation by switchingthe On/Off Unit mode from UNIT OFFto UNIT ON.

5 The chilled water pump shall ONbefore the unit operation start.

6 To balance the flow through theevaporator, adjust the flow ratesbetween minimum and maximumvalues given in Table-1.

7 Flow rates above or below thesevalues can cause equipmentdamage or improper unit operation.

8 Measure the evaporator waterpressure drop at the systempressure gauge(s). Compare thereadings to the pressure drop valuesgiven in Table-1 / Chart 1.

Note: Evaporator pressure dropapproximation and is to be used as atool to estimate flow rate and as anaid to waterside system pipingdesign. If an accurate measurementof flow is required, a flow meter mustbe installed in the system.

Unit operations1 Ensure all controller output has

connected to entire contactor andtermination block.

2 Ensure the Error button has notlighted up.

3 Enable the unit operation by switchingthe On/Off Unit mode from UNIT OFFto UNIT ON.

4 Chilled Water Pump motor shall startbefore the unit operation start.

5 Compressor(s) shall ON/OFF insequence base on setting parameter.

6 Condenser Fan shall ON whencompressor is running.

WARNINGROTATING PARTS!UNIT STARTS AUTOMATICALLYMake sure all personnel arestanding clear of the unit beforeproceeding.

WARNING!CONTACTOR IS POWER UP BY240VAC VOLTAGEMake sure all controller outputconnection has been done properlyand tools are clear from the controlpanel before proceeding.

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NOTE:CGAP 040-3 Nos FAN.

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This list must be checked off by the installer to ensure correct installation beforethe unit start up.

UNIT POSITIONCheck clearance around condenserCheck clearance required for maintenance accessCheck type and position of rubbers padsCheck unit is level

CHILLED WATER CIRCUITCheck thermometers and manometers presence and positionCheck water flow rate balancing valve presence and positionCheck presence of strainer ahead of evaporatorChek presence of air-purge valveCheck rinsing and filling of chilled water pipesCheck water pump(s) contactor interconnected to control panelCheck water flowCheck chilled water pressure dropCheck for leaks in chilled water pipes

ELECTRICAL EQUIPMENTCheck installation and rating of mains power switch/fusesCheck electrical connections complied with specificationCheck that electrical connections are in accordance with information onmanufacturer's identification plateCheck direction of rotation using phasemeter

Comments

....................................................................................................................................................................................................

....................................................................................................................................................................................................

....................................................................................................................................................................................................

....................................................................................................................................................................................................

Unit model:

Work Size:

Contact:

Signature / Name:

Serial number:

Telephone:

Fax;

Please return this form to your local Trane Service Agency.

23

24

4. Check the tightness of the refrigerantcircuit.

5. Start-up the unit (see control section)6. Check all interconnected devices

operate properly7. Check oil level and service pressures

after the system has been inoperation for 15 to 20 minutes underfull load.

8. Check that high and low pressuresare correct.

9. Check refrigerant tubing is fixed.

Maintenances and services must becompleted by qualified technicians.Please provide necessarymaintenance periodically for longerusing life and less failure.

Record operating states and saveservice records. It will help techniciansto analyze failure.

Weekly maintenance1. Check compressor oil level at rest.

Oil level should be halfway up ofsight glass located on the housing.Don' t add excess oil. Excess oil inthe compressor can be asdamaging as not enough oil. Beforetopping up, contact a qualifiedtechnician. Use only Tranerecommended oils.

2. Inspect the entire system forundesirable effects, such as noisycompressor, loose access panels,leaks in pipes, or vibratingcontactors.

3. Keep records of temperatures,pressures, service dates and timesor other observations in log book.

Annual maintenance

1. Check water circuit, valve, pipes, andclean filters if necessary. Analyzewater quality. Cleaning may berequired, in which case useprofessional assistance.

2. Clean corroded outer surfaces andrepaint. Check electrical panel sealdoor.

Then following maintenanceinstructions are part of maintenanceoperations required for this equipment.A qualified technician is needed forregular maintenance as part of aregular maintenance contract. Carryout all operations as required byschedule.This will insure long unit service lifeand reduce the possibility of seriousand costly breakdown.Keep service records up to date,showing weekly information on unitoperations. These records can be ofgreat help to maintenance personneldiagnostics. Similarly, if machineoperator keeps a log of changes in unitoperating conditions, problems can beidentified and solutions found beforemore serious problems arise.

ShutdownIf the unit needs to be shut down for ashort period of time, push the "STOP"button of the unit or "OFF" of the remoteswitch. If the unit is shut down for alonger period, make sure the mainpower disconnected. If the water pipingis not protected. against freeze up, drainthe water circuit by the drainage valve.

Seasonal start upIf the unit starts up after shutdown for alonger period of time, the followingpoints should be followed by qualifiedtechnicians:1. Carry out the instruction in "Annual

maintenance".2. Fill up and purge the water circuit.

Insure the stop valve in the watercircuit is open.

3. Insure the liquid line stop valve isopen

3. Check the tightness of the chilledwater circuit. Check circulating pumpoperation and associated devices.

4. Carry out all weekly maintenanceinspections.

5. Check contactors.6. Check adjustment and operation of

each control device.7. Check the tightness of the refrigerant

circuit.8. Check insulation of motor windings.

Caution: Water circuit may be pressurized,

check instruction to reduce circuitpressure before opening watercircuit. Failure to comply with thisinstruction may result in accident orinjury to maintenance personnel.

The unit should be regularly checkedby a qualified technician at least oncea year or every 2,000 operating hoursas a minimum.

Cleaning condenseClean the condenser coils with a brushor jet of water. Please jet water frominside to outside of the unit. If the coilsare too dirty, consult a cleaningprofessional.

Caution;Never use steam of hot water above60oC to clean condenser coils.

Caution:Switch off unit main power supplybefore any service. Failure to followthis safety instruction can lead toaccident death of the maintenancepersonnel and may also destroyequipment.

25

Cleaning plate heatexchangerTrane Company suggests a chemicalcleaning for this. Cleaning solutionshould apply hot phosphoric acidliquid with 15% concentration and 3-6hours recycling cleaning time under50-60C.

Caution:Poisonous or corrosive cleaning liquidmust not be applied for this.

Fig. 4: Cleaning plate heat exchanger

water circulating pump

heating resolution container

check valve (off)

leaving

entering

check valve (off)three way valve

three way valveunit

unit

26

1#"

.

Troubleshooting guideThese are simple diagnostic . If there is a breakdown, the Trane Service Agency should be contacted for confirmation andassistance.

Problems symptoms

A. The compressor will not start up

Compressor terminals are live but motor does not start.

Contactor motor not operational

No current ahead of motor contactor.

Low voltage reading on voltmeter.

Starter coil not excited.

Compressor does not run. Compressor motor "groans".

B. Compress stops

High pressure switch tripped.

Over current thermal relay tripped

Motor temperature thermostat tripped.

Anti-freeze security tripped.

C. Compressor stops just after its startSuction pressure too low. Filter drier iced up.

D. The compressor keeps running without stopping

Temperature too high in areas requiring airconditioning.

Chilled water temperature output too high.

E. Loss of oil in compressor

Oil level too low in indicator.

Gradual fall of oil level.

Suction line too cold. Compressor noisy.

F. Compressor noisy

Compressor knocks.

suction duct abnormally cold.

G. Insufficient cooling capacity

Thermostatic expansion valve "whistles".

Excess pressure drops through filter drier.

Excessive superheat.

Insufficient water flow.

H. Discharge pressure too high

Condenser abnormally hot.

Chilled water leaving temperature too high

Condenser air output too hot.

Probable cause

Motor burned out.

Coil burned out or broken contacts.

a) Power cutb) Mains power supply switched off.Voltage too low.

Regulation circuit open.

Compressor sticking (damaged or sticking components).

Discharge pressure too high.

a) Voltage too low.b) Cooling demand too high, or condensing temperature too high.Not enough cooling fluid.

Water flow to evaporator too low

Filter drier clogged

Excess load on cooling system.

Excess cooling demanded on system.

Not enough oil.

Filter drier clogged.

Liquid flows back to compressor

Components broken in compressor

a) Uneven liquid flow.b) Expansion valve locked in open position.

Not enough refigerant.

Drier filter colgged.

Superheat not properly adjusted.Chilled water pipes obstructed.

Presence of uncondendable liquids in system, or excess of refrigerant.

Overload on cooling system.

Reduced air flow. Air intake temperature higher than specified for unit.

Action recommended

Replace compressor.

Repair or replace.

Check fuses and connection. See why system tripped.

If system is operational, switch on mains power supply.

Contact Power Supply Utility.

Replace compressor.

See instruction for "discharge pressure too high"

a) Contact Power Supply Utility.b) See instruction "discharge pressure too high".Repair leak. Add refrigerant

Check water flow rate, and pressure switch contact in water.

Replace filter drier.

Check thermal insulation and air-tightness of areas requiring air-conditioning.

Check thermal insulation and air-tightness of areas requiring air-conditioning.

Add oil.

Replace filter drier.

Adjust superheat and check bulb fixing of the expansion valve.

Change compressor.

a) Check superheat setting and fixing or expansion valve bulb.b) Repair or replace.

Check refrigerant circuit tightness and add refrigerant

Replace.

Check adjustment of superheat and adjust thermostatic expansion valve.

Clean pipes and strainer.

Purge uncondensable fluids and drain off excess refrigerant.

Reduce load on system. Reduce water flow if necessary.

Clean coil. Check operation of fan motor.

1#"

.

27

Problems symptoms

1. Suction pressure too high

Compressor operates continuously.

Suction duct abnormaly cold.

Refrigerant flows back to compressor.

J. Suction pressure too low

Excessive pressure drop through filter drier.

Refrigerant does not flow through thermostatic expansion valve.

Loss of power

Superheat too low.

K. Insufficient cooling capacity

Low pressure drops through evaporator

Probable cause

Excess cooling demand on evaporator.

a) Expansion valve too far open.b) Expansion valve looked in open position.

Filter drier clogged.

Expansion valve bulb has lost its refrigerant.

Expansion valve obstructed.

Excessive pressure drops though evaporator.

Low water flow rate.

Action recommended

Check system.

Check for superheat and check that expansion valve bule is secure.

a) Check for superheat and check that expansion valve bule is secure.b) Replace.

Replace the filter drier.

Replace the bulb of the expansion valve.

Replace.

Check adjustment of superheat and adjust thermostatic expansion valve.

Check water flow rate. Check state of strainer check for obstruction

in chilled water pipes. Check pressure switch contact in water.

Caution:The above is not a comprehensive analysis of the Scroll compressor refrigeration system. The aim is to give operatorssimple instruction on basic unit processes so that they have the technical knowledge to identify and bring defectiveoperations to the notice of qualified technicians.

CG-SVX15A-E4 (October 2008)

CG-SVN03A-E4 (September 2003)Malaysia

Literature Order Number

File Number

Supersedes

Stocking Location

Trane has a policy of continuous product and product data improvement and reserves the right to chargedesign and specifications without notice. Only qualified technicians should perform the installation andservicing of equipment referred to in this publication.

TraneA business of American Standard Companieswww.trane.com

For more information, contact your local districtoffice

TRANE