Installation Operation Maintenance · avoided, could result in death or serious injury. CAUTION! : Indicates a potentially hazardous situation which, if not avoided, may result in

Installation

Operation

Maintenance

CGCL

Air Cooled Water Chiller With

Centrifugal Fans

Sizes 200 - 250 - 300 - 350 - 400 - 450 -

500 - 600

CGCL-SVX01B-E4

CGCL-SVX01B-E4

General information

ForewordThese instructions are given as aguide to good practice in theinstallation, start-up, operation, andmaintenance by the user, of TraneCGCL chillers. They do not containfull service proceduresnecessary for the continuedsuccessful operation of thisequipment. The services of aqualified technician should beemployed through the medium of amaintenance contract with areputable service company. Readthis manual thoroughly before unitstart-up.

Units are assembled, pressuretested, dehydrated, charged and runtested before shipment.

Warnings and cautionsWarnings and Cautions appear atappropriate sections throughout thismanual. Your personal safety and theproper operation of this machinerequire that you follow themcarefully. The constructor assumesno liability for installations orservicing performed by unqualifiedpersonnel.WARNING! : Indicates a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.CAUTION! : Indicates a potentiallyhazardous situation which, if notavoided, may result in minor ormoderate injury. It may also beused to alert against unsafepractices or for equipment orproperty-damage-only accidents.

Safety

recommendationsTo avoid death, injury, equipment orproperty damage, the followingrecommendations should beobserved during maintenance andservice visits:1. The maximum allowable pressures

for system leak testing on low andhigh pressure side are given in thechapter "Installation". Alwaysprovide a pressure regulator.

2. Disconnect the main power supplybefore any servicing on the unit.

3. Service work on the refrigerationsystem and the electrical systemshould be carried out only byqualified and experiencedpersonnel.

©American Standard Inc. 2006

3CGCL-SVX01B-E4

General information

ReceptionOn arrival, inspect the unit beforesigning the delivery note.

Reception in France only:

In case of visible damage: Theconsignee (or the siterepresentative) must specify anydamage on the delivery note, legiblysign and date the delivery note, andthe truck driver must countersign it.The consignee (or the siterepresentative) must notify TraneEpinal Operations - Claims team andsend a copy of the delivery note.The customer (or the siterepresentative) should send aregistered letter to the last carrierwithin 3 days of delivery.Note: for deliveries in France, evenconcealed damage must be lookedfor at delivery and immediatelytreated as visible damage.

Reception in all countries except

France:

In case of concealed damage: Theconsignee (or the siterepresentative) must send aregistered letter to the last carrierwithin 7 days of delivery, claimingfor the described damage. A copy ofthis letter must be sent to TraneEpinal Operations - Claims team.

WarrantyWarranty is based on the generalterms and conditions of themanufacturer. The warranty is void ifthe equipment is repaired ormodified without the writtenapproval of the manufacturer, if theoperating 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 bythe warranty obligation. If the userdoes not conform to the rules of thismanual, it may entail cancellation ofwarranty and liabilities by themanufacturer.

RefrigerantThe refrigerant provided by themanufacturer meets all therequirements of our units. Whenusing recycled or reprocessedrefrigerant, it is advisable to ensureits quality is equivalent to that of anew refrigerant. For this, it isnecessary to have a precise analysismade by a specialized laboratory. Ifthis condition is not respected, themanufacturer warranty could becancelled.

4 CGCL-SVX01B-E4

General information

Maintenance contractIt is strongly recommended that yousign a maintenance contract withyour local Service Agency. Thiscontract provides regularmaintenance of your installation bya specialist in our equipment.Regular maintenance ensures thatany malfunction is detected andcorrected in good time andminimizes the possibility thatserious damage will occur. Finally,regular maintenance ensures themaximum operating life of yourequipment. We would remind youthat failure to respect theseinstallation and maintenanceinstructions may result in immediatecancellation of the warranty.

TrainingTo assist you in obtaining the bestuse of it and maintaining it in perfectoperating condition over a longperiod of time, the manufacturer hasat your disposal a refrigeration andair conditioning service school. Theprincipal aim of this is to giveoperators and technicians a betterknowledge of the equipment theyare using, or that is under theircharge. Emphasis is particularlygiven to the importance of periodicchecks on the unit operatingparameters as well as on preventivemaintenance, which reduces the costof owning the unit by avoidingserious and costly breakdown.

CGCL-SVX01B-E4 5

Contents

General information 2

General unit characteristics 6

Installation

Unit name plate 8

Installing the unit 8

Duct connections 9

Water to evaporator connection 11

Minimum water volume 11

Water treatment 12

Antifreeze protection 12

Electrical connections 13

General start-up

Start-up preparation 14

Start-up 14

Operation

Unit operation 16

Weekly start up and week-end shutdown 16

Seasonal start-up and shutdown 16

Maintenance

Maintenance instructions 17

Installation checklist 18

Troubleshooting guide 19

6 CGCL-SVX01B-E4

General unit characteristics

Table 1 - CGCL general dataCGCL 200 CGCL 250 CGCL 300 CGCL 350 CGCL 400 CGCL 450 CGCL 500 CGCL 600

R407C R407C R407C R407C R407C R407C R407C R407C

Eurovent Performances (1)

Net cooling capacity (kW) 49.2 61.1 74.0 86.9 101.0 111.0 126.0 152.0Total power input in cooling (kW) 21.9 26.9 34.6 38.3 46.8 55.5 59.7 73.1Evaporator water pressure drop (kPa) 42 41 42 41 39 46 56 68Main power supply 400/3/50Sound power level 300 Pa (dB(A)) 88 84 87 89 91 95 90 94Sound power level 400 Pa (dB(A)) 90 86 89 90 93 96 92 95Sound power level 500 Pa (dB(A)) 91 88 90 92 94 97 93 96

Units Amps

Nominal (4) (A) 48 61.4 76.7 86.1 102.3 117.7 120.8 151.3Start-up amps (A) 150 209 224 234 250 265 268 299Recommended fuse size (Am) (A) Depends on installationMax supply cable size (mm2) 35 35 50 50 95 95 95 95Max. wire length (m) Depends on installation

Compressor

Number (circ 1/ circ 2) 2 2 2 3 3 3 2/2 2/2Type ScrollModel 10T+10T 10T+15T 2x15T 2x10T+15T 10T+2x15T 3x15T 2x(10T+15T) 4x15TNumber of speeds 1 1 1 1 1 1 1 1Number of motors 1 1 1 1 1 1 1 1Rated amps (2)(4) (A) 37 46 55 65 74 83 92 110Locked rotor amps (2) (A) 139 194 203 212 221 230 240 258Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900Sump heater (2) (W) - - - - - - - -

Evaporator

Number 1Type Brazed plateWater volume (total) (l) 4.7 5.9 7.0 8.2 10.5 10.5 12.3 16.1Antifreeze Heater (W) 65 65 65 65 65 65 130 130Water connection type Male ISO R7Water connection diameter 1"1/2 1"1/2 1"1/2 2" 2" 2" 2"1/2 2"1/2

Coil

Type Plate FinTube size (mm) 9.52Tube type SmoothHeight (mm) 914 1219 1219 1219 1219 1219 1626 1626Length (mm) 1829 1829 1829 2743 2743 2743 2743 2743Face Area (m2) 1.67 2.23 2.23 3.34 3.34 3.34 4.46 4.46Number of rows 4Fins per inch (fpf) 180

Fan

Type CentrifugalNumber 1 2 2 2 2 2 3 3Diameter AT 18-18Drive type Belt DriveNumber of speeds 2Number of motors 1

Dimensions

Height (mm) 1997 1997 1997 1997 1997 1997 1997 1997Length (mm) 2268 2268 2268 3230 3230 3230 3230 3230Width (mm) 866 866 866 866 866 866 1216 1216Weight uncrated (kg) 710 830 890 1080 1140 1200 1380 1500Weight crated (kg) 750 870 930 1130 1190 1250 1450 1570

Refrigerant circuit data

Number of circuits 1 1 1 1 1 1 2 2Refrigerant charge A/B (kg) 12/- 15/- 15/- 24/- 24/- 24/- 15/15 15/15Oil charge A/B (l) 7.6/- 10/- 12.4/- 13.8/- 16.2/- 18.6/- 10/10 12.4/12.4

(1) at Eurovent Conditions at nominal airflow (Evap 12°C/7°C - Air. 35°C)(2) per motor(3) per circuit(4) 5°C saturated suction temperature - 60°C saturated discharge temperature

Table 2 - CGCL Fan performanceSize Airflow Total Fan Static Pressure (Pa)

(m3/h) 300 400 500

CGCL 200 15300

Fan Motor Nominal Power Low Speed* (kW) 0.75 1.1 1.1Fan Motor Nominal Power High Speed (KW) 4.0 5.5 5.5Nominal Amps Low speed * (A) 3.2 3.7 3.7Nominal Amps High speed (A) 8.9 11 11Starting Amps * (A) 14 12 12

CGCL 250 17800

Fan Motor Nominal Power Low Speed* (kW) 0.75 1.1 1.5Fan Motor Nominal Power High Speed (KW) 4.0 5.5 7.5Nominal Amps Low speed * (A) 3.2 3.7 5.0Nominal Amps High speed (A) 8.9 11 15.3Starting Amps * (A) 14 12 17

CGCL 300 23800

Fan Motor Nominal Power Low Speed* (kW) 1.5 1.5 2.8Fan Motor Nominal Power High Speed (KW) 7.5 7.5 11.0Nominal Amps Low speed * (A) 5.0 5.0 7.7Nominal Amps High speed (A) 15.3 15.3 21.5Starting Amps * (A) 17 17 33

CGCL 350 26800


CGCL 400 30600

Fan Motor Nominal Power Low Speed* (kW) 2.8 2.8 3.8Fan Motor Nominal Power High Speed (KW) 11 11 15Nominal Amps Low speed * (A) 7.7 7.7 10.1Nominal Amps High speed (A) 21.5 21.5 28.6Starting Amps * (A) 33 33 43

CGCL 450 34500


CGCL 500 39100


CGCL 600 47600


*: Fan motor always starts in Low speed

Unit nominal amps = nominal fan amps (according to static pressure) + compressor nominal amps

Unit starting amps = nominal fan amps (according to static pressure) + compressor starting amps

Table 3 - Pressure drop through condenser coil and air filterUnit Airflow Chiller internal pressure drop (Pa)

m3/h Cds coil AR300 filter A150 Filter M8 FilterCGCL 200 15300 96 100 66 28CGCL 250 17800 77 85 56 22CGCL 300 23800 124 122 84 40CGCL 350 26800 77 85 56 22CGCL 400 30600 96 100 68 28CGCL 450 34500 117 117 80 36CGCL 500 39100 124 95 64 26CGCL 600 47600 163 122 84 40

For minimum clearance, consult the certified submittals, which are available on request from your local Trane sales office.

Available static pressure = Total fan static pressure (from table 2) - Chiller internal pressure drop (from table 3)

IMPORTANT:The setting of the external static pressure supplied by the CGCL chiller must correspond to the actual ductwork (inlet and outlet) pressure drop +/- 50Pa.Failure to comply to this condition could lead to operational problems such as excessive sound levels, vibrations, or early wear of motor, fan or bearings. Adjustment of theairflow through the unit must be performed at chiller commissioning or warranty will not apply.

CGCL-SVX01B-E4 7

General unit characteristics

Installation

Water drain hole

Install a drain hole wide enough todrain away water from the unit inthe event of shut-down or repair.

Clearance

Respect recommended clearancearound the unit to allowmaintenance operation to take placewithout obstruction andrecommended clearance aroundcondenser.

CAUTION!: Unit operation isfunction of the air temperature. Anyrecycling of the air fed out by thefans will increase the air intaketemperature over the condenser finsand can result in high pressure cut-out.In this case the standard operatingconditions are modified.Operation of the unit may beaffected by an increase in airtemperature on the condenser.See submittals

Unit nameplateThe unit nameplate gives thecomplete model reference numbers.The unit power rating is shown, andpower supplies should not deviateby more than 5 % from the ratedpower.

Compressor motor amperage isshown in box I.MAX.The customer's electrical installationmust be able to withstand thiscurrent.

Installing the unitFoundations

No special foundations are required,provided the supporting surface isflat and level, and can withstand theweight or the unit.

Isolation rubber pads

They are supplied as standard withthe machine, and should be placedbetween the supporting floor andthe unit to isolate the base from theground.- 4 pads for the sizes 200 to 300- 6 pads for the sizes 350 to 600- Trane does not allow to install

spring isolators.

8 CGCL-SVX01B-E4

Selection of the Proper Available

Static Pressure:

Static pressure indicated only takesinto account the available pressureof the fan. It is necessary to subtractthe pressure drop of thecomponents from Table 3. Failure todo so will end up in increasingconstraint on the bearings and onthe motor which will result up in adrastic reduction of the lifespan ofthe fan.

For example:CGCL 350 - with 400 Pa available static

pressure fans- with 77 Pa condenser coil- with A150 Filter of 56 Pa

Available Static Pressure =400 Pa -77 Pa - 56 Pa = 267 PaThe tolerance is +/- 50 Pa.In this example the pressure drop ofthe ductwork will have to bebetween 217 Pa and 317 Pa.

Table 4 - Fan speed (rpm) : high speed (low speed)

Available fan static pressure (Pa)

Unit size 300 400 500

200 655 (328) 728 (364) 808 (404)

250 655 (328) 728 (364) 857 (429)

300 650 (325) 768 (384) 857 (429)

350 686 (343) 768 (384) 857 (429)

400 686 (343) 768 (384) 815 (408)

450 812 (406) 831 (416) 931 (466)

500 728 (364) 812 (406) 815 (408)

600 728 (364) 831 (416) 935 (468)

Figure 1 - Handling

Note :

The plates welded at the end of the bases must not be used for handling.

Table 5 - Dimensions of recommended slings and swing-barCGCL 200 250 300 350 400 450 500 600A (mm) 1150 1150 1150 1150 1150 1150 1500 1500B (mm) 2550 2550 2550 2700 2700 2700 2700 2700Weight (kg) 750 870 930 1130 1190 1250 1450 1570

B

A

Duct connectionsDuct connections of suction anddischarge of the unit and accessoriesmust be made of flexible hose. Theduct connection must be flexibleenough to prevent transmittingvibrations to the tube network (seeFigures 2, 3 and 4).

CAUTION!: When fixing the duct tothe condenser inlet, make sure thefixing screws do not pierce the coil.

Figure 2

1. Accessory2.Attachment bolts3.Unit frame4.Sealing strip5.Accessory (filter)

Figure 3 - Inlet

1. Unit body2.Flexible coupling3.Ductwork4.Seal

4

1

2

3

CGCL-SVX01B-E4 9

Installation

5 4

1 2

3

Figure 4 - Outlet

1. Unit body2. Flexible coupling (field supply)3. Ductwork

To prevent a reduction in fanefficiency, which would reduce theair flow and the unit's coolingcapacity, the duct connections mustbe designed and connectedaccording to normal trade practice.

1

2

3

CAUTION! If the duct network doesnot provide the external staticpressure stipulated on selection, itwill have repercussions on the airflow and therefore on the unit'sperformance.

Please refer to "Selection of theProper Available Static Air Pressure".

This type of problem may ifnecessary be referred to the Traneservice office, which may be able toadvise you as to the necessarymodifications, if any.

On all units, a straight duct sectionconnected to a fan must have atleast the same cross sectional areaas the output panel orifice, and itsminimum length must be one and ahalf times the fan diameter, beforeany bend or deviation.

There must be no tight bends,particularly at the fan output wherethe air velocity gradient is high. Alarge proportion of the air initiallyflows at the top of the duct. If a bendis close to the fan it must beinstalled so that its externalcurvature radius is in the trajectoryof the air discharged by the highspeed side of the fan (see figures 5and 6).

10 CGCL-SVX01B-E4

Installation

10 CGCL-SVX01B-E4

Figure 5

RIGHT

Figure 6

WRONG

Installation

CGCL-SVX01B-E4 11

Water to evaporator

connectionBefore making any connections,make sure the labelling for enteringand leaving water corresponds tothe submittals.Install water circulation pumpupstream of the evaporator, insuringthat the evaporator is under positivepressure.Tables for water connectionsdiameter are shown on the certifiedsubmittals.These drawings are available onrequest from your Trane Sales Office.

Figure 7

1. Pressure gauges: show entering and leaving waterpressure (2 pressure ports are available inside of theunit - see item 1 in Figure 7)

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 during maintenance operations.5.Thermometers: indicate chilled water entering and

leaving temperatures (not mandatory).6.Expansion compensators: avoid mechanical stress

between chiller and piping installation.7. Stop valve located on the outlet connection: used to

measure the water pressure inlet or outlet ofevaporator.

8.Strainer: avoid getting heat exchangers dirty. Allinstallation must be equipped with efficient strainerin order that only clean water enters into exchanger.If there is no strainer, reserve will be formulated bythe Trane technician at the start-up of the unit.The strainer used must be able to stop all particleswith a diameter greater than 1.6 mm.

9.Draining and charging: used to drain and charge theplate heat exchanger.

10.Charging valve

10

Minimum water volumeWhy the water volume is an

important parameter?

The water volume is an importantparameter because it allows a stablechilled water temperature and avoidsshort cycle operation of thecompressors.

Parameters which influence the

water temperature stability

• Water loop volume.• Load fluctuation.• Number of capacity steps.• Compressors rotation.• Dead band (adjusted by control

CH530).• Minimum time between 2 starts

of a compressor.

Minimum water volume for a

comfort application

For comfort application we can allowwater temperature fluctuation at partload. The parameter to take intoaccount is the minimum operatingtime of the compressor.In order to avoid lubrication problemon a scroll compressor it must run atleast 2 minutes (120 seconds) beforeit stops.The minimum volume can bedetermined by using the followingformula:Volume = Cooling capacity x Time xhighest capacity step (%) / Specificheat / Dead bandMinimum operating time =120 secondsSpecific heat = 4.18 kJ / kgAverage Dead band = 3°C (or 2°C)

Note:To estimate the biggest step, it

is usually more reliable to make a

selection at lower ambient

temperature where efficiency is

higher and compressors steps

bigger. It is also essential to take

into account the brine specific heat,

in case of the use of glycol.

Table 6 - Recommended water loop volume at Eurovent conditions

This table is estimated with : 35°C ambient air temperature, 12/7°C water temperature, water (no glycol), deadband of 3°C.

Chiller data

Unit size 200 250 300 350 400 450 500 600

Cooling Capacity full load (kW) 49.2 61.1 74.0 86.9 101.0 111.0 126.0 152.0Biggest step (%) 50 60 50 43 38 33 30 25Biggest step (kW) 24.6 36.7 37.0 37.2 37.9 36.6 37.8 38.0

Minimum water loop for comfort application (l) 235 351 354 356 363 350 362 364

Installation

Water treatmentUntreated or insufficiently treatedwater, if used in this unit, may causescale, slime or algae to accumulateor cause erosion and corrosion.As Trane does not know thecomponents used in the hydraulicnetwork and the quality of the waterused, we recommend the services ofa qualified water treatment specialist.The following materials are used inTrane chillers heat exchangers :- Stainless steel plates AISI 316,

1.4401 with copper brazing.- Water piping: copper 99,9 %- Water connections: brass

Trane will not accept any liability inregards of damage due to the use ofuntreated or improperly treatedwater or from the use of saline orbrackish water.If required, contact your local TraneSales Office.

Antifreeze protectionDuring negative ambient airtemperature chilled water pipingmust be fully insulated.Insure that all safeties are taken toprevent frost damage duringnegative ambient air temperature.Following system can be used:- Electrical heater mounted on all

water piping exposed to negativetemperatures.

- Start chilled water pump duringnegative ambient air temperature.

- Add ethylene glycol in the chilledwater.

Figure 8 - Freezing point versus ethylene glycol percentage

1. Liquid2. Freezing without burst effect3. Freezing with burst effect

0

-10

-20

-30

-40

-50

0 10 20 30 40 50 60

3

2

1

% Ethylene glycol

12 CGCL-SVX01B-E4

Installation

Electrical connectionsCAUTION!:

1. The greatest care should be takenwhen cutting through passagesand installing electric wiring.Under no circumstances shouldchips of metal or cuttings ofcopper or isolating material fallinto the starter panel or electriccomponents. Relays, contactors,terminals and control wiringshould be covered and protectedbefore power supplies areconnected.

2. Install power supply cabling asshown in wiring diagram.

Adequate cable gland should bechosen, ensuring no foreign bodiesenter the electrical housing orcomponents.

CAUTION!:

1. Cabling must comply withstandards in force. The type andlocation of fuses must also complywith standards. As a safetymeasure, fuses should be visiblyinstalled, close to the unit.

2.Only copper wiring should beused. Using aluminium wires canproduce galvanic corrosion andpossibly lead to superheat andfailure of connection points.

Trane provides a single powersupply which includes thetransformer.Warranty reserves will be formulatedif a transformer, not supplied byTrane, is installed inside the electricpanel.

CAUTION! Electrical connection toan IT Network is not recommendedif the unit has been provided with aspeed inverter such as the lowambient option (-18°C). Speedinverter generates earth currentleakage that is not suitable for ITnetworks without special designeddevices. For more informationcontact your local Trane Sales Office.

CGCL-SVX01B-E4 13

General start-up

Start-up preparationCarry out all operations on check listand that the unit is correctlyinstalled and ready to operate.The installer must check all thefollowing points before calling in theTrane Servicing Department to putthe equipment into service:- Check position of unit- Check unit is level- Check type and position of rubber

pads- Check clearance required for

maintenance access (See submittals)- Check clearance around condenser

(See Submittals)- Chilled water circuit ready to

operate, filled with water, pressuretest carried out and air purged.

- Chilled water circuit must be rinsed- Check the presence of water

strainer ahead of evaporator- The strainers must be cleaned

after 2 hours of pumps operation- Check the thermometers and

manometers position- Check chilled water pumps

interconnection to control panel- Insure that the isolation resistance

of all power supply terminals toground complies with standardsand regulations in force.

- Check that unit voltage andfrequency supplied match ratedinput voltage and frequency

- Check that all electrical connectionsare clean and sound - Check thatmain power supply switch is sound.

- Check Ethylene glycol % in thechilled water circuit if Ethyleneglycol presence is required.

- Check chilled water pressure dropthrough evaporator is inaccordance with the Trane orderwrite-up.

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

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

- Check that there is sufficientdemand for cooling on the day ofstart-up (around 50% of nominalload)

Start-upFollow the instructions below tocorrectly start-up the unit.

Installation and chiller inspection:

- Ensure that all the operationsabove (start-up preparation), arefollowed.

- Follow the instruction stuck insidethe electrical cabinet:

- Unscrew the screws securing theisolators located under the railssupporting the compressor.

- Put the plexiglass supplied byTrane in front of the power terminal.

- Insure all water and refrigerantvalves are in service positions,

- Insure that the unit is notdamaged,

- Insure that sensors are properlyinstalled in their bulb-wells andsubmerged in heat conductingproduct,

- Check fixing of capillary tubes(protection from vibration andfrom wear) and insure that theyare not damaged,

- Reset all manually set controldevices,

- Check refrigerating circuits tightness

Checking and setting:

Compressors:- Check oil level at rest. The level

should reach at least halfway upindicator located on housing. See fig. 9 for correct level.

Figure 9 - Compressor oil level

1. Max. oil level2.Min. oil level

- Check fixing of capillary tubes(protection from vibration andfrom wear) and insure that theyare not damaged,

- Reset all manually set controldevices,

- Check refrigerating circuitstightness

- Check oil acidity,- Check electrical terminals

tightening of the motors and in thecontrol panel,

- Check the isolation of the motorsusing a 500V DC megohmeterwhich meets manufacturer'sspecifications (minimum value 2meghoms)

- 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 CH530

control- Test and start-up without the

electrical power.Condenser:- Check setting of the safety

pressure valve,- Check direction of the rotation of

fans,- Check the isolation of the motors

using a 500V DC megohmeterwhich meets manufacturer'sspecifications (minimum value 2meghoms)

Operating parameters statement:

- Switch on main power supplyswitch,

- Start the water pump(s),- Start up the unit with CH530 by

pushing "Auto".The unit and the chilled waterpumps contactor must be connectedtogether,- After unit start up, leave in

operation for at least 15 minutes,to insure pressures are stabilized.

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

currents,- leaving and return chilled water

temperature,- suction temperature and pressure,- ambient air temperature,- blowing air temperature,- discharge pressure and temperature.

1

2

14 CGCL-SVX01B-E4

Check that the pressure drop on thecondenser is in the tolerance ofthe fan

- Consult "Selection of the properavailable static pressure"

- If the pressure does not complythen correction must be doneeither by changing pressure dropon the duct or by modifying thepulley or the motor.

- liquid refrigerant temperature andpressure,

- operating parameters:- chilled water pressure drops through

evaporator. It must be in accordancewith Trane order write-up,

- superheat: difference betweensuction temperature and dewpoint temperature. Normalsuperheat must be within 5°Cand 10°C,

- sub-cooling: difference betweenliquid temperature and bubblepoint temperature. Normal sub-cooling should be 2 to 5°Cwith 407C,

- difference between dew pointtemperature in high pressure andcondenser air inlet temperature.

Normal value on standard unit withR407C, should be 20 to 23°C.- difference between outlet water

temperature and dew pointtemperature in low pressure.

Normal value on standard unit,without Ethylene glycol in chilledwater, should be about 3°C withR407C.

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.

CGCL-SVX01B-E4 15

General start-up

WARNING!

- The chilled water circuit may beunder pressure. Bring down thispressure before opening up thesystem to rise out or fill up thewater circuit. Failure to complywith this instruction may causeaccidental injury to maintenancepersonnel.

- If a cleaning solution is used in thechilled water circuit, the chillermust be isolated from the watercircuit to avoid all the damagerisks of the chiller and evaporatorwater pipes.

CAUTION!:

- For the warranty to apply, anystart-up carried out directly by thecustomer must be recorded in adetailed report, which must besent as soon as possible to thenearest Trane office.

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

- Phase imbalance should not begreater than 2%.

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

- Excessive emulsion of the oil inthe compressor shows thatrefrigerant is present in the oil andthe result will be that compressoris not lubricated enough. Shutdown compressor and consultTrane technician.

- Excess oil in compressor candamage the compressor. Beforeadding oil, consult Tranetechnician. Use only Traneproducts recommended.

- The compressors must operate ina single direction of rotation. Ifrefrigerant high pressure remainsstable in the 30 seconds aftercompressor start-up, immediatelyshut down unit and check thedirection of rotation usingphasemeter.

Table 7 - Evaporator pressure dropWater flow (l/s)

P.D. (kPa) CGCL CGCL CGCL CGCL CGCL CGCL CGCL CGCL

200 250 300 350 400 450 500 600

10 1.155 1.449 1.736 1.912 2.282 2.282 2.500 2.70020 1.631 2.045 2.447 2.809 3.343 3.343 3.561 3.85340 2.301 2.886 3.448 4.129 4.898 4.898 5.074 5.49960 2.815 3.530 4.215 5.172 6.125 6.125 6.241 6.77180 3.248 4.072 4.860 6.068 7.177 7.177 7.228 7.848100 3.629 4.550 5.427 6.868 8.116 8.116 8.100 8.800

When ethylene glycol is added in the chilled water circuit the followingadjustment factors have to be taken in account.

Table 8 - Ethylene glycol adjustment factorsLWTE PCT EG Adjustment factors

(%) Flow rate Pressure drop Power Input Cooling Cap.

12 30 1.11 1.20 1.005 0.985 30 1.11 1.24 1.005 0.984 10 1.02 1.08 - -0 20 1.05 1.19 - --4 27 1.08 1.29 - --8 33 1.10 1.46 - --12 37 1.12 1.62 - -

Operation

Control SystemThe control is through the CH530control module.

Unit operation- Check the chilled water pump(s)

operates- Start up unit using CH530. The unit

will operate correctly when thereis sufficient water flow. Thecompressors will start up if theevaporator water leavingtemperature is above the CH530control module setpoint.

Weekly start up

- Check the chilled water pump(s)operates

- Start the unit through the controlmodule.

Week end shutdown

- If the unit needs to be shut downfor a short period of time, stop theunit through the control module.

- If the unit is shut down for alonger period, see under"Seasonal shutdown", below.

- Insure that all safeties are taken toprevent frost damages duringnegative ambient temperature.(see page 5)

- Do not put the general and controldisconnect switches to off.

Seasonal shutdown

- Check water flows and interlocks.- Check Ethylene glycol % in the

chilled water circuit if glycolpresence is required

- Carry out leak test.- Carry out oil analysis- Record operating pressures,

temperatures, amperages andvoltage.

- Check operation ofmachines/compare conditions ofoperation against originalcommissioning data.

- Stop the unit through the controlmodule.

- Insure that all safeties are taken toprevent frost damages duringnegative ambient temperature.(see page 5)

- Fill out the visit log sheet andreview with the operator - Do notput the general and controldisconnect switches to off.

Seasonal start-up



- Check operational set points andperformance.

- Calibrate controls.- Check operation of all safety

devices.- Inspect contacts and tighten

terminals.- Megger the motor compressor

windings.- Record operating pressures,


- Carry out leak test.- Check configuration of unit control

module.- Change the oil as required based

upon results of the oil analysismade during seasonal shutdown


- Fill out the visit log sheet andreview with the operator

16 CGCL-SVX01B-E4

Maintenance

Maintenance InstructionsThe following maintenanceinstructions are part of maintenanceoperations required for thisequipment. A qualified technician isneeded for regular maintenance aspart of a regular maintenancecontract.

Carry out all operations as requiredby schedule. This will insure longunit service life and reduce thepossibility of serious and costlybreakdown.

Keep service records up to date,showing monthly information onunit operations. These records canbe of great help to maintenancepersonnel diagnostics.

Similarly, if machine operator keepsa log of changes in unit operatingconditions, problems can beidentified and solutions found beforemore serious problems arise.

Inspection visit after the first 500

hours of operation from unit start up

- Carry out oil analysis- Carry out leak test.- Inspect contacts and tighten

terminals.- Record operating pressures,



- Fill out inspection visit log sheetand review with the operator

- Check that the condenser pressuredrop and air flow conforms tostart-up measurements.

Monthly preventive visit

- Carry out leak test.- Oil test of acidity- Check Ethylene glycol % in the


- Inspect contacts and tightenterminals.

- Record operating pressures,temperatures, amperages andvoltage.


- Fill out visit log sheet and reviewwith the operator.

Annual preventive visit



- Check operational set points andperformance.

- Calibrate controls.- Check operation of all safety

devices.- Inspect contacts and tighten

terminals.- Megger the motor compressor

windings.- Record operating pressures,


- Carry out leak test.- Check configuration of unit control

module.- Carry out oil analysis- Change the oil as required based

upon results of the oil analysis- Check operation of

machines/compare conditions ofoperation against originalcommissioning data.

- Fill out the annual start up visit logsheet and review with theoperator.

- Check that the condenser pressuredrop and air flow conforms tostart-up measurements.

CAUTION!:

- Please refer to specific Tranedocumentation on oil, availablefrom your nearest Trane office. Oilsrecommended by Trane have beenexhaustively tested in Tranelaboratories to the specificrequirement of Trane chiller andhence the user's requirements.Any use of oils not meetingspecifications recommended byTrane is the responsibility of theuser only, who thereby is liable towarranty loss.

- Oil analysis and oil test aciditymust be carried out by a qualifiedtechnician. Poor interpretation ofresults may cause unit operatingproblems. Also, oil analysis mustfollow the correct procedures, toavoid accidental injury tomaintenance personnel.

- If the condensers are dirty, cleanthem with brush. If the coils aretoo dirty, consult a cleaningprofessional. Never use water toclean condenser coils.

- Contact Trane for information onmaintenance contracts.

WARNING!

- Switch off unit main power supplybefore to any intervention. Failureto follow this safety instruction canlead to accident death of themaintenance personnel and mayalso destroy equipment.

- Never use steam or hot waterabove 55°C to clean condensercoils. The resulting increasingpressure could cause refrigerantlost through the safety valve.

CGCL-SVX01B-E4 17

Maintenance

Installation checklistThis list must be checked off by the installer to ensure correct installationbefore the unit start up.

UNIT POSITION

Check clearance around condenserCheck clearance required for maintenance accessCheck type and position of rubbers pads

CHILLED WATER CIRCUIT

Check thermometers and manometers presence and positionCheck water flow rate balancing valve presence and positionCheck presence of strainer ahead of evaporatorCheck 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 drop through the evaporator

ELECTRICAL EQUIPMENT

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

Comments

………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….............................................................……………………………………………………………………………………………………………………………………………………………………………………………………

Signature:……………………………………………….Name:………...…………………

Order N°: ………………………………………………..

Work site: .....………………………………………………………………………………..

Please return to your local Trane Service Office

18 CGCL-SVX01B-E4

Maintenance

Troubleshooting guideThese are simple diagnostic hints. If there is a breakdown, the Trane Service office should be contacted forconfirmation and assistance.

SymptomA) The compressor does not start up

Compressor terminals are live but motor doesnot startContactor motor not operational.No current ahead of motor contactor.

Current ahead of fuse, but not on contactorside.Low voltage reading on voltameter.Starter coil not excited.

Compressor does not run.Compressor motor" groans".High pressure switch tripped to contacts openon high pressure.Discharge pressure too high.B) Compressor stops

Over current thermal relay tripped.

Motor temperature thermostattripped.

Anti-freeze security tripped.

C) Compressor stops just after its start

Suction pressure too low.Filter drier iced up.

Problem cause

Motor burned out.

Coil burned out or broken contacts.a) Power cut.b) Main power supply switched off.

Fuse blown.

Voltage too low.Control circuit open.

Compressor sticking (damaged or stickingcomponents).Discharge pressure too highDirty coilNot enough airflow

Discharge pressure too high.a) Voltage too low.b) Cooling demand too high, or condensingtemperature too high.

Not enough refrigerant..Water flow to evaporator too low.

Air filters dirty

Filter drier clogged.

Recommended action

Replace compressor

Repair or replace.Check fuses and connection.See why system tripped.If system is operational, switch on main powersupply.Check motor insulation. Replace fuse.

Contact power Supply Utility.Locate regulation device which has tripped outand see why. See instructions concerning thisdevice.Replace compressor.See instructions for "discharge pressure high".

Clean coilIncrease fan speedChange or adjust drive

See instructions for "dischargepressure high".a) Contact Power Supply Utility.b) See instruction "discharge pressure toohigh".Repair leak. Add refrigerant.Check water flow rate, and pressureswitch contact in water.Clean or replace air filters

Replace filter drier.

CGCL-SVX01B-E4 19

20 CGCL-SVX01B-E4

Maintenance

SymptomD) The compressor keeps running

without stopping

Temperature too high in areas requiring air-conditioning.Chilled water temperature output too high.

E) Loss of oil in compressor

Oil level too low in indicator.Gradual fall in oil level.Suction line too cold.

F) Compressor noisy

Compressor knocks.Suction duct abnormally cold.

G) Insufficient cooling capacity

Thermostatic expansion valve "whistles".

Excess pressure drops through filter drierExcessive superheat.

Insufficient water flow.H) Discharge pressure too high

Condenser abnormally hot.

Chilled water leaving temperature too high.

Condenser air output too hot.

Problem cause

Excess load on cooling system.

Excess cooling demand 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 refrigerant.

Drier filter clogged.Superheat not properly adjusted.

Chilled water pipes obstructed.

Presence of uncondensable liquids in system,or excess refrigerant.Overload on cooling system.

Reduced air flow. Air intake temperature higherthan specified for unit

Recommended action

Check thermal insulation and air-tightness ofareas requiring air-conditioning.Check thermal insulation and air-tightness ofareas requiring air-conditioning.

Contact Trane office before to order oilReplace filter drier.Adjust superheat and check bulb fixing of theexpansion valve.

Change compressor.a) Check superheat setting and fixingof expansion valve bulb.b) Repair or replace.

Check refrigerant circuit tightness and addrefrigerant.Replace.Check adjustment of superheat and adjustthermostatic expansion valve.Clean pipes and strainer.

Purge uncondensable fluids and drain offexcess refrigerant.Reduce load on system.Reduce water flow if necessary.Clean or replace air filters. Clean coil. Checkoperation of motor fans. See "Condenser fan"

CGCL-SVX01B-E4 21

Maintenance

Note:

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

Symptom Problem cause Recommended action

I) Suction pressure too high

Compressor operates continuously.Suction duct abnormally cold.

Refrigerant flows back to compressor.

Excess cooling demand on evaporatora) Expansion valve too far open.

b) Expansion valve locked in open position.

Check system.a) Check for superheat and check that expansionvalve bulb is secure.b) Replace.

J) Suction pressure too low

Excessive pressure drop through filter drier.Refrigerant does not flow through thermostaticexpansion valve.

Drier filter clogged.Expansion valve bulb has lost its refrigerant.

Replace the filter drier.Replace the bulb.

Loss of power. Expansion valve obstructed. Replace.

Superheat too low. Excessive pressure drops through evaporator. Check adjustment of superheat and adjustthermostatic expansion valve.

K) Insufficient cooling capacity

Low pressure drops through evaporator Low water flow rate. Check water flow rate. Check state of strainer,check for obstruction in chilled water pipes.Check pressure switch contact in water.

L) Condenser fan

Pulsing noise on fan outlet and duct work

Fan Motor Amps too high

Too much airflow. Fan Available StaticPressure not according duct friction losses

Reduce RPM. Change drive.

Hissing noise at start Belt tension too loose Adjust belt tension.

Vibrations-Noise Fan wheel out of balancePulleys/ belt loosenedShaft bent Worn bearings

Correct balancingTighten the driveChange shaftChange bearings

22 CGCL-SVX01B-E4

Notes

CGCL-SVX01B-E4 23

Notes

Literature Order Number CGCL-SVX01B-E4

Date 0406

Supersedes CGCL-SVX01A-E4_0701

Stocking Location Europe

Trane has a policy of continuous product and product data improvement and reserves the right tochange design and specifications without notice. Only qualified technicians should perform theinstallation and servicing of equipment referred to in this publication.www.trane.com

For more information, contact your local sales office or e-mail us at [email protected]

American Standard Europe BVBARegistered Office: 1789 Chaussée de Wavre, 1160 Brussels - Belgium

Documents

Installation Operation Maintenance · avoided, could result in death or serious injury. CAUTION! : Indicates a potentially hazardous situation which, if not avoided, may result in