Screw Chiller

8/11/2019 Screw Chiller

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2003 American Standard Inc. Al l rights reserved. CGWF-SVX01A-EN

Installation

OperationMaintenance

Scroll Liquid Chillers

Models CGWF/CCAF20-60 Tons

January 2004


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ImportantEnvironmental Concerns!Scientific research has shown that certain man-made chemicals canaffect the earths naturally occurring stratospheric ozone layer whenreleased to the atmosphere. In particular, several of the identifiedchemicals that may affect the ozone layer are refrigerants that containChlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen,Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containingthese compounds have the same potential impact to the environment.Trane advocates the responsible handling of all refrigerantsincludingindustry replacements for CFCs such as HCFCs and HFCs.

Responsible Refrigerant Practices!

Trane believes that responsible refrigerant practices are important to theenvironment, our customers, and the air conditioning industry. Alltechnicians who handle refrigerants must be certified. The Federal CleanAir Act (Section 608) sets forth the requirements for handling,reclaiming, recovering and recycling of certain refrigerants and theequipment that is used in these service procedures. In addition, somestates or municipalities may have additional requirements that mustalso be adhered to for responsible management of refrigerants. Knowthe applicable laws and follow them.

WARNINGContains Refrigerant!System contains oil and refrigerant under high pressure. Recoverrefrigerant to relieve pressure before opening the system. See unitnameplate for refrigerant type. Do not use non-approved refrigerants,refrigerant substitutes, or refrigerant additives.

Failure to follow proper procedures or the use of non-approvedrefrigerants, refrigerant substitutes, or refrigerant additives could resultin death or serious injury or equipment damage.

NOTICE: Warnings and Cautions appear at appropriate sections through-out this literature. Read these carefully.

WARNING: Indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury. It may also be used toalert against unsafe practices.

CAUTION: Indicates a situation that may result in equipment or property-damage only accidents.


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Table of ContentsGeneral Information........................................................................................... 7Literature Change History..................................................................................... 7Unit Identification ................................................................................................. 7Nameplates .......................................................................................................... 7Unit Nameplates................................................................................................... 7Compressor Nameplate ....................................................................................... 7Evaporator Nameplate .......................................................................................... 7Condenser Nameplate.......................................................................................... 8Unit Inspection ..................................................................................................... 8Inspection Checklist ............................................................................................. 8Loose Parts Inventory .......................................................................................... 8Unit Description.................................................................................................... 8Unit Model Number.............................................................................................. 8Installation Overview.......................................................................................... 12

Installation Mechanical.................................................................................... 17

Unit Storage ....................................................................................................... 17Location Requirement ........................................................................................ 17Noise Consideration ........................................................................................... 17Foundation.......................................................................................................... 17Ventilation........................................................................................................... 17Drainage ............................................................................................................. 17Rigging ............................................................................................................... 17Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF Units................... 18Lifting Procedure for 60 Ton Units ..................................................................... 20Alternate Moving Methods................................................................................. 21Access Restrictions ............................................................................................ 21Recommended Clearances ................................................................................ 22Unit Isolation ...................................................................................................... 22

Direct Mounting ................................................................................................. 22Neoprene Isolator Mounting .............................................................................. 22Neoprene Isolator Data ...................................................................................... 22Unit Leveling ...................................................................................................... 23Unit Piping .......................................................................................................... 29General Water Piping Recommendations .......................................................... 29Water System .................................................................................................... 29Water Flow Rates............................................................................................... 29Pressure Drop Measurement............................................................................. 29Evaporator Water Piping..................................................................................... 32Evaporator Water Connections........................................................................... 32Evaporator Piping Components .......................................................................... 32Flow Sensing Devices ........................................................................................ 32Evaporator Drain. ................................................................................................ 33Condenser Water Piping .................................................................................... 33Condenser Water Connections. ......................................................................... 33Condenser Piping Components.......................................................................... 33Condenser Drains. .............................................................................................. 34Water Regulating Valve ...................................................................................... 35Water pressure Relief Valves ............................................................................. 37Low Temperature Operation .............................................................................. 37Pressure Relief Valve Venting ............................................................................ 38Refrigerant Piping (CCAF only) ........................................................................... 40


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Table of Contents

Liquid Line Components and Connections ......................................................... 40Liquid Line Sizing................................................................................................ 40Discharge (hot gas) Lines ................................................................................... 40Leak Test ............................................................................................................ 42System Evacuation ............................................................................................. 42Refrigerant Charging........................................................................................... 42

Installation Electrical........................................................................................ 43General Recommendations ................................................................................ 43Power Supply Wiring .......................................................................................... 43Unit Power Supply.............................................................................................. 43Equipment Grounds............................................................................................ 43Terminal Lugs, Circuit Breakers and Non-Fused Disconnect Switches.............. 43Scroll Compressor Electrical Phasing ................................................................. 47Correcting Improper Electrical Phase Sequence ................................................ 47Unit Voltage ........................................................................................................ 48

Voltage Imbalance .............................................................................................. 48Control Power Supply ......................................................................................... 48Modules Connections for Interconnecting Wiring .............................................. 48Chilled Water Flow Switch ................................................................................. 49Chilled Water Pump Control ............................................................................... 49Condenser Water Loss of Flow Protection ........................................................ 49Condenser Water Pump Starter ......................................................................... 49Programmable Relays......................................................................................... 49External Auto/Stop.............................................................................................. 50Compressor Inhibit/ High Ambient Operation .................................................... 50Condenser Water Temperature Sensor Connections......................................... 50Chilled Water Rest.............................................................................................. 50External Chilled Water Setpoint Option.............................................................. 51

Ice Machine Control Option................................................................................ 51Communications Interface options..................................................................... 51Optional Tracer Communications Interface ........................................................ 51LonTalk Communications Interface for Chillers (LCI-C) Option .......................... 52CCAF - Fan Control ............................................................................................. 54Outdoor Air Temperature Control ....................................................................... 54

Operating System ............................................................................................ 55

Controls Interface ............................................................................................. 57CH530 Communications Overview .................................................................... 57Controls Interface ............................................................................................... 57DynaView ........................................................................................................... 57TechView............................................................................................................ 57DynaView Interface ............................................................................................ 58Key Functions ..................................................................................................... 58Radio Buttons ..................................................................................................... 58Spin Value Buttons ............................................................................................. 58Action Buttons.................................................................................................... 59File Folder Tabs .................................................................................................. 59Display Screens .................................................................................................. 59Basic Screen Format .......................................................................................... 59Keypad/Display Lockout Feature ........................................................................ 60


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Table of ContentsMain Screens ..................................................................................................... 61Reports Screen................................................................................................... 65Settings Screen .................................................................................................. 67Diagnostics Screen............................................................................................. 69TechView Interface ............................................................................................ 69Software Download............................................................................................ 70Instructions for First Time TechView Users ....................................................... 70

Diagnostics ....................................................................................................... 73

Unit Start-up..................................................................................................... 77Pre-Start Checklist .............................................................................................. 77Unit Power Up .................................................................................................. 79Checking Operating Conditions .......................................................................... 79System Superheat.............................................................................................. 80System Subcooling............................................................................................. 80

Unit Shutdown ................................................................................................. 81Normal Unit Shutdown....................................................................................... 81Extended Shutdown Procedure ......................................................................... 81System Restart After Extended Shutdown ........................................................ 82

Unit Maintenance............................................................................................. 83Periodic Maintenance......................................................................................... 83Weekly Maintenance.......................................................................................... 83Monthly Maintenance ........................................................................................ 83Annual Maintenance........................................................................................... 83Maintenance Procedures ................................................................................... 84Mechanical Cleaning .......................................................................................... 84

Chemical Cleaning .............................................................................................. 84Cleaning the Evaporator (Chiller) ........................................................................ 84Water Treatment ................................................................................................ 85

Wiring Schematics ........................................................................................... 89Schematics Page 1&2 ......................................................................................... 90Component Location ...........................................................................................94Field Wiring Diagram ...........................................................................................95Field Layout Diagram........................................................................................... 96


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General Information

Literature Change HistoryNew manual describes the installation, operation and maintenance of CGWF/CCAFUnits.

Unit IdentificationWhen the unit arrives, compare all nameplate data with ordering, submittal, andshipping information. A typical unit nameplate is shown in Figure 1.

Nameplates

Unit NameplatesThe CGWF/CCAF unit nameplate is mounted on the control panel door. The Unitnameplate provides the following information:

Unit model number.

Unit serial number.

Identifies unit electrical requirements.

Lists correct operation charge of R-22 and refrigerant oil.

Lists unit test pressures and maximum operating pressures.

Identifies installation, operation and maintenance literature.

Lists the drawing numbers for the unit wiring diagrams.

Compressor NameplateThe nameplate for the Scroll compressor is mounted on the compressor housing nearthe motor terminal box.

Evaporator NameplateThe evaporator ASME nameplate is mounted on the top of the evaporator supply-endtube sheet. The word nameplate is applied to the insulation just above thenameplate. To view the evaporator nameplate, remove the tape over the area andspread the insulation.

Figure 1 Unit Nameplate


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General Information

Condenser NameplateThe condenser ASME nameplate (30 and 60 ton condensers only) is mounted on thetop of the condenser near the water outlet on 60 ton units and on the side of thecondenser near the water outlet on 30 ton units.

Unit InspectionCarefully inspect chiller while still on shipping conveyance. If unit is damaged or hasbroken free from anchorage, require inspection by transportation inspectors. Filedamage claims with the carrier and notify a Trane sales representative. Themanufacturer is not responsible for damage occurring during transit. Do not install adamaged unit without sales office approval.

Inspection ChecklistTo protect against loss due to damage incurred in transit, complete the followingchecklist upon receipt of the unit: Inspect individual pieces of the shipment before accepting the unit. Check for

obvious damage to the unit or packing material.

Check the unit for concealed damage before it is stored and as soon as possible

after delivery. Concealed damage must be reported within 15 days. If concealed damage is discovered, stop unpacking the shipment. Do not remove

damaged material from receiving location. Take photos of the damage, if possible.The owner must provide reasonable evidence that the damage did not occur afterdelivery.

Notify the carriers terminal of damage immediately by phone and by mail.Request an immediate joint inspection of the damage by the carrier and the con-signee.

Notify a Trane sales representative and arrange for repair. Do not repair the unituntil damage is inspected by the carriers representative.

Loose Parts InventoryCheck all items against shipping list. Water vessel drain plugs, rigging and electricaldiagrams, service literature and optional water temperature sensors are placed insidethe UCP (unit control panel) for shipment before it is shrinkwrapped with waterproofplastic. When ordered, the optional neoprene isolators are secured in place on theshipping skid.

Unit DescriptionTrane Model CGWF/CCAF 20 - 60 ton Scroll Liquid Chillers, utilizing multiple Tranescroll compressors, are designed for installation indoors. Each unit is completelyassembled hermetic package that is factory-piped, wired, leak-tested, dehydrated,charged and tested for proper control operation before shipment.Water inlet and outlet openings are covered before shipment. The units contain anoperating refrigerant charge.The compressors are factory charged with the properamount of refrigerant oil.

Unit Model Number

Table 1 Unit Model Number

FCAT FCODE M/N digit M/N value DescriptionMODL 1-4 Chiller model

CGWF CGWF Water cooled scroll chillerCCAF CCAF Scroll compressor-chiller (condenserless)


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General Information

NTON 5-7 Unit nominal tonnage

20 020 20 nominal tons25 025 25 nominal tons30 030 30 nominal tons40 040 40 nominal tons50 050 50 nominal tons60 060 60 nominal tons

VOLT 8 Unit VoltageDULA G 208-230/60/3 power supply380A D 380/60/3 power supply460A 4 460/60/3 power supply575A 5 575/60/3 power supply400B N 400/50/3 power supply

SHIPCYC 9 Ship cycleMTO (C) Made to orderSTK (C) Packed stock (contact BU)

DSEQ 10-11 Design sequenceA0 A0 Factory/ABU assigned

AGLT 12 Agency listingNONE N No agency listingUL U C/UL listing

CODE 13 Pressure vessel codeASME A ASME codeCAN C Canadian code

SPKG 14 Shipping PackageFLBT A Ship via Flat Bed TruckSHRK B Ship w/Shrink Wrap Bag and SkidSKID C Ship w/Skid

CDTE 15 Condenser temp rangeNA 0 None - CCAF unitsSTD 1 Standard 60-90F [15.6-32.2C] entering water tempHIGH 4 High 90-130F [32.2-54.4C] entering water temp

CDTT 16 Condenser tube materialNA N None - CCAF unitsSTD C Std copper finned tubes

CDCO 17 Condenser water connectionsNA N None - CCAF unitsLHWC L Left hand condenser connectionsRHWC R Right hand condenser connections

EVTL 18 Evap temp rangeSTD 1 Standard cooling 40-60F[4.4-15.6C]

LOWA 2 Ice making 26-39F[-3.3-3.9C]LOWB 3 Low temp 10-25F[-12.2-(-3.9)C]ICE 4 Standard cooling/Ice making 20-60F[-6.7-15.6C]

PCON 19 Power line connection typeTB T Terminal blockDISC D Non-fused disconnect switch

EPRO 20 Short circuit ratingNONE 0 No short circuit ratingSCR 1 With short circuit rating


FCAT FCODE M/N digit M/N value Description


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CIOP 21 Control input options

NONE N No optionsREMS R Remote chilled water setpoint inputREMC C Remote compressor inhibit and/or icemaking inputREMB B Remote CWS and compressor inhibit/icemaking

inputCOOP 22 Control output options

NONE N No optionsPROG P Programmable relays for remote alarm, run, etc.

SENS 23 Auxiliary sensor optionsNONE 0 NoneCDWT 1 Condenser water temp sensors (CGWF only)AMB 2 Outdoor temp sensor - CWR or Amb LockoutBOTH 3 Both condenser and outdoor temp sensor

COMM 24 Communication optionsNONE 0 NoneCOM3 3 Tracer Summit interfaceLCIC 5 LonTalk LCI-C interface

HGBP 25 Hot gas bypassNONE N NO HGBP valve/functionWITH H HGBP function included

SATT 26 Sound attenuatorNONE 0 No sound attenuatorWITH 1 Sound attenuator - Fact installed

SACC 27 Ship-with accessories - isolators, WRV,Filter-driers

NONE X No ship-with accessoriesNIS0 N Neoprene isolators

WRVA A 1.5" 2-way water reg valve x 1 (CGWF only)WRVB B 2" 2-way water reg valve x 1 (CGWF only)WRVC C 2.5" 2-way water reg valve x 1 (CGWF only)WRVD D 1.5" 2-way water reg valve x 2 (CGWF only)WRVE E 2" 2-way water reg valve x 2 (CGWF only)WRVF F 2.5" 2-way water reg valve x 2 (CGWF only)WRAN G Neo isolators + 1.5" WRV x 1 (CGWF only)WRCN H Neo isolators + 2" WRV x 1 (CGWF only)WREN J Neo isolators + 2.5" WRV x 1 (CGWF only)WRBN K Neo isolators + 1.5" WRV x 2 (CGWF only)WRDN L Neo isolators + 2" WRV x 2 (CGWF only)WRFN M Neo isolators + 1.5" WRV x 2 (CGWF only)FD1 P Filter-drier x 1 (CCAF only)FD2 Q Filter-drier x 2 (CCAF only)NFD1 R Neo isolators + 1 Filter-drier (CCAF only)NFD2 T Neo isolators + 2 Filter-driers (CCAF only)

SAC2 28 Ship-with accessories - flow switchesNONE 0 No flow switchesFS1 1 150 psi NEMA-1 flow switch (FS4-3) x 12FS1 2 150 psi NEMA-1 flow switch (FS4-3) x 2FS4 4 150 psi NEMA-4 flow switch (FS8-W) x 12FS4 5 150 psi NEMA-4 flow switch (FS8-W) x 2


FCAT FCODE M/N digit M/N value Description


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General Information

Figure 2 Component Location DWG

UnitNameplate

Condenser

DynaView

WaterInlet

WaterOutlet

ReliefValve

Figure 3 Component Location DWG

EvaporatorWater Inlet

TXV

FilterDryer

EvaporatorWater Outlet

Liquid LineSolenoid Vale

SuctionLine

DischargeService Valve

SightGlass

DischargeLine

CompressorNameplate


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General Information

Installation OverviewFor convenience, Table 2 summarizes responsibilities that are typically associatedwith the CGWF/CCAF chiller installation process.

Refer to the Installation Mechanical and Installation Electrical sections of this manualfor detailed installation instructions. Locate and maintain the loose parts, e.g. isolators, flow sensors or other factory-

ordered, field-installed options, for installation, as required. Loose parts arelocated in the starter/control panel.

Install the unit on a foundation with flat support surfaces, level within 1/4 (6.35mm) and of sufficient strength to support concentrated loading. Place the manu-facturer-supplied neoprene isolators assemblies under the unit.

Install the unit per the instructions outlined in the Mechanical Installation section. Complete all water piping and electrical connections.

NOTE: Field piping must be arranged and supported to avoid stress on theequipment. It is strongly recommended that the piping contractor provide at least 3feet (914 mm) of clearance between the pre-installation piping and the plannedlocation of the unit. This will allow for proper fit-up upon arrival of the unit at the installation site. All necessary piping adjustments can be made at that time. Refer to thecurrent engineering bulletin for further details on installation.

Table 2 Installation Responsibility Chart for CGWF/CCAF Units

Requirement Trane-supplied,Trane-installed

Trane-supplied,Field-installed

Field-supplied,Field-installed

Rigging Safety chainsClevis connectors - Lifting beam

Isolation Neoprene Isolators Isolation padsElectrical Non-fused disconnects (optional) Circuit breakers or fusible

disconnects (optional)Unit-mounted starter Temperature sensor (optional

outdoor air)Terminal lugs

Flow switches (may be field-supplied)

Ground connection(s)

BAS wiring (optional)Control voltage wiringChilled water pump contactor andwiringCondenser water pump contactorand wiringOptional relays and wiring

Water piping Flow switches (may be field-supplied)

Thermometers

Condenser water regulating valve(optional: may be field-supplied)

Water flow pressure gaugesIsolation and balancing valveswater pipingVents and drain valves

Pressure relief valves (for waterboxes as required)PressureRelief

Relief valves Vent line and flexible connector


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General Information Where specified, supply and install valves in the water piping upstream and

downstream of the evaporator and condenser water boxes, to isolate the shellsfor maintenance and to balance/trim the system.

Supply and install condenser water control valve(s) per Trane RLC-EB-4. Supply and install flow switches or equivalent devices in both the chilled water

and condenser water piping. Interlock each switch with the proper pump starterand CH530, to ensure that the unit can only operate when water flow is estab-lished.

Supply and install taps for thermometers and pressure gauges in the water pip-ing, adjacent to the inlet and outlet connections of both the evaporator and thecondenser.

Supply and install drain valves on each water box.

Supply and install vent cocks on each water box.

Where specified, supply and install strainers ahead of all pumps and automatic

modulating valves. Supply and install refrigerant pressure relief piping from the pressure relief to the

atmosphere.

If necessary, supply enough refrigerant and dry nitrogen (75 psig) for pressuretesting.

Start the unit under supervision of a qualified service technician.

Where specified, supply and insulate the evaporator and any other portion of theunit, as required, to prevent sweating under normal operating conditions.

For unit-mounted starters, cutouts are provided at the top of the panel for line-side wiring.

Supply and install the wire terminal lugs to the starter.

Supply and install field wiring to the line-side lugs of the starter.


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Table 3 General Data CGWF

CGWF

Unit Tonnage 20 25 30 40 50 60

General

Refrigerant Type R-22 R-22 R-22 R-22 R-22 R-22

Refrigerant Charge lb (kg) 50 (23) 50 (23) 90 (41) 50/50 (23/23) 50/50 (23/23) 75/75 (34/34)

Oil Type Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil 31

Oil Charge Pints (l) 16 (7.6) 22 (10.4) 28 (13.2) 16/16(7.6/7.6)

22/22(10.4/10.4)

28/28(13.2/13.2)

Operating Weight lb (kg) 1694 (768) 1757 (797) 2249 (1020) 2747 (1246) 2977 (1350) 3905 (1771)

Shipping Weight lb (kg) 1522 (690) 1600 (726) 2014 (914) 2366 (1073) 2626 (1191) 3376 (1531)

Overall Dimensions

Length in (mm) 122.6 (3115) 122.6 (3115) 122.6 (3115) 129.0 (3277) 129.0 (3277) 108.1 (2743)Width in (mm) 31.4 (797) 31.4 (797) 32.2 (818) 31.3 (797) 31.3 (797) 34 (864)

Height in (mm) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1467) 74.6 (1894)

Evaporator

Water Storage gal (l) 11.7 (44) 10.7 (40) 16.4 (62) 25.7 (97) 24 (90) 39.9 (151)

Minimum Flow gpm (l/s) 24 (1.5) 30 (1.9) 36 (2.3) 48 (3.0) 60 (3.8) 84 (5.3)

Maximum Flow gpm (l/s) 72 (4.5) 90 (5.7) 108 (6.8) 144 (9.1) 180 (11.4) 252 (15.9)

Condenser

Water Storage gal (l) 8.9 (34) 8.0 (30) 11.7 (44) 19.9 (75) 18.2 (69) 23.5(89)

Minimum Flow gpm (l/s) 30 (2) 36 (2) 50 (3) 60 (4) 72 (5) 90 (6)

Maximum Flow gpm (l/s) 90 (6) 108 (7) 146 (9) 180 (11) 216 (14) 325 (21)All weights 3%Operating weights include refrigerant, oil, and water charges.


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General Information

Table 4 General Data CCAF

CCAF

Unit Tonnage 20 25 30 40 50 60

General

Refrigerant Type R-22 R-22 R-22 R-22 R-22 R-22

Refrigerant Charge lb(kg) Field Field Field Field Field Field

Oil Type Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil 31

Oil Charge Pints(l) 16 (7.6) 22 (10.4) 28 (13.2) 16/16(7.6/7.6)

22/22(10.4/10.4)

28/28(13.2/13.2)

Operating Weight lb(kg) 1004 (456) 1079 (490) 1274 (579) 1509 (685) 1808 (821) 1982 (900)

Shipping Weight lb(kg) 1430 (649) 1605 (729) 1836 (834) 1792 (814) 2166 (984) 2494 (1133)

Overall Dimensions

Length in (mm) 80.1 (2035) 80.1 (2035) 80.1 (2035) 102.6 (2607) 102.6 (2607) 102.6 (2607)Width in (mm) 29.4 (745) 29.4 (745) 29.4 (745) 31.4 (591) 31.4 (591) 31.4 (591)

Height in (mm) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1487) 57.8 (1487) 57.8 (1487)

Evaporator

Water Storage gal (l) 11.7 (44) 10.7 (40) 16.4 (62) 25.7 (97) 24 (90) 39.9 (151)

Minimum Flow gpm (l/s) 24 (1.5) 30 (1.9) 36 (2.3) 48 (3.0) 60 (3.8) 84 (5.3)

Maximum Flow gpm (l/s) 72 (4.5) 90 (5.7) 108 (6.8) 144 (9.1) 180 (11.4) 252 (15.9)

All weights 3%Operating weights include refrigerant, oil, and water charges.


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Installation Mechanical

Unit StorageExtended storage of the chiller prior to installation requires the followingprecautionary measures:1. Do not remove the protective coverings from the control panel.

2. Store the chiller in a dry, vibration-free and secure area.

Periodically check the pressure in each refrigerant circuit to verify that the refrigerantcharge is intact. If it is not, contact a qualified service organization and the appropriateTrane sales office.

Location Requirement

Noise ConsiderationLocate the unit away from sound-sensitive areas. If necessary, install the optionalisolators under the unit. Refer to Unit Isolators. Install vibration isolators in all pipingand use flexible electrical conduit. Consult an acoustical engineer for criticalapplications.

FoundationProvide rigid non warping mounting pads or a concrete foundation of sufficientstrength and mass to support the chiller operation weight (i.e. including completedpiping, and full operating charges of refrigerant, oil and water). The unit operatingweights are provided in Table 3 and Table 4. Once in place, the chiller should be levelwithin 1/4 (6.3 mm) over the length and width. The Trane Company is notresponsible for equipment problems resulting from an improperly designed orconstructed foundation or for improper installation.

VentilationMake provisions to remove heat generated by unit operation from the equipmentroom. Ventilation must be adequate to maintain an ambient temperature lower than125 F (52.5 C). The condenser and evaporator pressure relief valve(s) must be ventedin accordance with all local and national codes. Refer to Pressure Relief Valves.

DrainageLocate the units near a large capacity drain so that water vessels can be emptiedduring shut down or repairs. Condensers and evaporators are provided with drainconnections. Refer to Unit Piping. All local and national codes apply.

RiggingModel CGWF/CCAF chillers should be moved by lifting, if the crate has beenremoved. Refer to Table 3 and Table 4 for typical unit lifting and operating weights.Figure 4 and Figure 5 show proper lifting methods. When on the shipping skid, theunit can be pushed from one end with a forklift, but should never be lifted using aforklift.Note: Two steel lifting angles, to be used for lifting the unit, are secured to the skidwhen the unit is shipped (20 -50 ton units only). Hardware is provided to mount thelifting angles on the unit.


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WARNINGUnit Lifting Capacity!

The capacity of the lifting equipment sued must exceed etc. Then endwith failure to use properly sized lifting equipment could result in deathor serious injury or equipment damage.

WARNINGImproper Unit Lifting!Follow the lifting procedure detailed below. Failure to follow the properlifting procedure could result in death or serious injury or equipmentdamage.

Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF Units.

1. Remove the two sheet lifting angles from the skid.2. Remove the unit from the shipping skid. If absolutely necessary, the chiller can be

pushed or pulled across a smooth surface as long as it is bolted to the shippingskid.

3. Bolt the lifting angles to the unit as shown in Figure 4. Mount one lifting angle ateach end of the unit using the nuts and bolts provided.

4. Tighten each bolt to 70ft-lbs torque.

5. Verify the lifting angle mounting bolts are tightened to 70ft-lbs torque.

6. Install clevis connectors in the 1-1/4 (32 mm) lifting holes provided on each endof the lifting angles (Figure 4).

7. Attach lifting chains or cables to the clevis connectors. Each cable alone must be

strong enough to lift the chiller.8. Attach cables to the lifting beam. Total lifting weight and centers of gravity are

listed in Table 5. Required lifting beam dimensions are shown in Figure 4. A rig-ging diagram also ships with each unit. Lifting beam crossbars must be positionedso lifting cables do not contact unit piping or control panel enclosure.

CAUTIONUnit Damage!To prevent unit damage, position lifting beam crossbars so that cablesdo not contact the unit.


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Figure 4 Typical Rigging Setup For CGWF 20-50 Ton and 20-60 Ton CCAF Units.

1. Remove lifting angles from the skid. Remove theangle support bolts from the unit legs. Attach the lift-ing angles as shown and torque the 12 mm bolts to 70ft-lbs attaching the lifting angle.

2. Use clevis pins for attachment of chains to liftingangles, lifting chains (cables) may be adjusted forlevel lifting.

3 . Do not Forkli ft Uni t.

4. All units are heavier on the control panel side. UseTable 5 to adjust rigging accordingly.

5. Minimum beam length 4 ft.


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Lifting Procedure for 60 Ton Units

WARNING

Unit Lifting Capacity!The capacity of the lifting equipment sued must exceed etc. Then endwith failure to use properly sized lifting equipment could result in deathor serious injury or equipment damage.

WARNINGImproper Unit Lifting!Follow the lifting procedure detailed below. Failure to follow the properlifting procedure could result in death or serious injury or equipmentdamage.

1. Dismantle shipping crate.

2. Remove the unit from the shipping skid. If absolutely necessary, the chiller can bepushed or pulled across a smooth surface as long as it is bolted to the shippingskid.

3. Attach chains or cables to lifting beam.The total lifting weight, lifting weight distri-bution and required lifting beam dimensions are shown in Figure 5. Lifting beamcrossbars must be positioned so lifting cables do not contact the side of the unit.

CAUTIONUnit Damage!

To prevent unit damage, position lifting beam crossbars so that cablesdo not contact the unit.


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Alternate Moving MethodsIf it is not possible to rig from the previous method shown inFigure 4 and Figure 5,the unit my also be moved by jacking each end high enough to move an equipmentdolly under each end of the unit frame. Once securely mounted on the dollies, theunit may be rolled into position. Jacks should be positioned to lift under the liftingangles installed on the unit by the contractor.

Access RestrictionsAll CGWF/ CCAF units will pass through a standard 36-inch doorway. Typicaldimensions are shown in Figure 7 - Figure 11.

Figure 5 Typical Rigging Setup For CGWF 60 Ton Units.

1. Use clevis pins for attachment of chains to liftingholes, lifting chains (cables) may be adjusted forlevel lifting.

2 . Do not Forkli ft Uni t.3. All units are heavier on the control panel side. Use

Table 5 to adjust rigging accordingly.

4. Minimum beam length 6ft.

Table 5 Center of Gravity Dimensions

Unit Size Location of Center of Gravity (in)

X Y ZCGWF

20 18 24 925 18 25 930 18 26 940 23 26 850 23 27 960 28 31 13

CCAF20 28 31 825 28 30 830 28 28 840 33 29 850 33 27 860 33 26 8


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Recommended ClearancesProvide recommended access clearance for service and maintenance operations.Refer to recommendations provided in Figure 7 - Figure 11. Local codes may takeprecedence over recommendations.

Unit IsolationThere are two mounting methods that will minimize sound and vibration. They are thedirect-mount method and the isolator-mount method.

Direct MountingThe unit can be direct-mounted on an isolated concrete pad or on an isolated concretefooting at each end. Refer to Table 3 and Table 4 for unit operating weights. Amounting hole is provided in the base of the unit frame at each mounting location.Provide a means of securely anchoring the unit to the mounting surface. Level theunit carefully. Refer to Leveling the Unit.

Neoprene Isolator MountingInstall the optional neoprene mounting isolators at each mounting location. Refer toTable 6 for isolator selection, placement and loading information. Isolators are

identified by color and by the isolator part number.Bolt the isolator to the mounting surface. Do not fully tighten the mounting bolts.Mount the unit on the isolators and install a 1/2-inch (13 mm) nut on each isolatorpositioning pin. Maximum isolator deflection should be 1/4-inch. Level the unitcarefully. Refer to Unit Leveling. Now fully tighten isolator mounting bolts.

Neoprene Isolator Data

Figure 6 Isolators and Locations

3

1

4

2

ControlPanel End

CGWF/CCAF

Table 6 RDP 3 Neoprene Isolator Selection

Unit SizeLocation

1 2 3 4CGWF

20 Green Green Green Green25 Green Green Green Green30 Green Green Green Green40 Gray Gray Gray Gray50 Gray Gray Gray Gray60 Gray Gray Gray Gray

CCAF


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Unit LevelingBefore snugging down the mounting bolts, level the unit carefully. Check unit levelend-to-end by using a water level, or by placing a level on the top surface of the unitframe. Unit should be level within 1/4-inch (6.35 mm) over the length. Place the levelon the unit frame and check front to back level. Adjust to within1/4-inch (6.35 m) oflevel front-to-back. Use shims to level the unit.

20 Red Red Red Red25 Red Red Red Red30 Red Red Red Red40 Red Red Red Red50 Green Green Green Green60 Green Green Green Green

Table 6 RDP 3 Neoprene Isolator Selection

Unit SizeLocation

1 2 3 4


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Figure 7 CGWF 20, 25, 30 Ton Unit Dimensions, Recommended Clearances, Mounting Locations,Electrical, Water Connection Size and Locations


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Figure 8 CGWF 40 and 50 Ton Unit Dimensions, Recommended Clearances, Mounting Locations,Electrical, Water Connection Size and Locations


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Figure 9 CGWF 60 Ton Unit Dimensions, Recommended Clearances, Mounting Locations,Electrical, Water Connection Size and Locations


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Figure 10 CCAF 20, 25 and 30 Ton Unit Dimensions, Recommended Clearances, Mounting Locations,Electrical, Water Connection Size and Locations

Size A B C D E F20 Ton 8 1/2" 3' - 11 1/2" 2" 2' - 0" 1' - 3 1/2" 3' - 3"

(216) (1207) (51) (610) (394) (1041)25 Ton 8 1/2" 3' - 11 1/2" 2" 1' - 11 3/4" 1' - 3 1/2" 3' - 10"

(216) (1207) (51) (603) (394) (1041)30 Ton 7 3/4" 3' - 10 3/4" 2 1/2" 2' - 1 7/8" 1' - 5 3/8" 3' - 10"

(197) (1187) (64) (657) (441) (1168)

Notes:

1 . Dimensional tolerances 1/4" (3mm).2 . Tube installation at either end of evaporator.3 . Dimensions in ( ) are millimeters.


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Figure 11 CCAF 40, 50 and 60 Ton Unit Dimensions, Recommended Clearances, Mounting Locations,Electrical, Water Connection Size and Locations

Size A B C D E F40 Ton 5' - 1 3/4" 1' - 3 3/4" 1' - 11 1/4" 2 1/2" 3' - 5" 1' - 4 1/4

(1568) (400) (591) (64) (1041) (413)50 Ton 5' - 1 1/2" 1' - 3 1/2" 2' - 1 1/8" 3" 3' - 10" 1' - 6 1/8"

(1562) (394) (638) (76) (1168) (480)60 Ton 5' - 1 1/2" 1' - 3 1/2" 2' - 0 7/8" 3" 3' - 10" 1' - 6 1/8"

(1562) (394) (632) (76) (1168) (480)

Notes:

1 . Dimensional tolerances 1/4" (3mm).2

. Tube installation at either end of evaporator.3 . Dimensions in ( ) are millimeters.


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Unit Piping

General Water Piping RecommendationsMake water piping connections to evaporator and condenser(s). Isolate and supportpiping to prevent stress on the unit. Use flanged ells or spool-pieces to facilitateservice procedures. Construct piping according to local and national codes. Insulateand flush piping before connecting to unit.

CAUTIONEquipment Damage!To prevent equipment damage, bypass the unit if using an acidicflushing agent.

Use a pipe sealant or teflon tape on all water connections. Minimize heat gain andprevent condensation by insulating all chilled water piping.

CAUTIONPiping Damage!To prevent damage to water piping, do not over-tighten connections.

Water System

Water Flow RatesEstablish balanced water flow through both the evaporator and condenser. Flow ratesshould fall between the minimum and maximum values given inTable 3 and Table 4.Flow rates above or below these values can cause equipment damage or improperunit operation.

Pressure Drop MeasurementMeasure evaporator water pressure drop at the pressure gauge(s) on the systemwater piping. Readings should approximate those shown by the pressure drop chartsin Figure 12 and Figure 13.Note: Evaporator pressure drop is an approximation and is to be used as a tool toestimate flow rate and as an aid to waterside system piping design. If an accuratemeasurement of flow rate is required, an accurate flow meter must be installed in thesystem.


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Figure 12 Evaporator Pressure Drop


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Figure 13 Condenser Pressure Drop


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Evaporator Water Piping

Evaporator Water Connections.Internal NPTF water inlet and outlet connections are used on all 20 through 50 tonCGWF and 20-60 ton CCAF units. 60 ton CGWF use grooved pipe connectors forwater inlet and outlet. Evaporator water inlet and outlet types, sizes and locations areshown in Figure 14.

Evaporator Piping ComponentsFigure 14 illustrates typical recommended evaporator piping components. Pipingcomponents and layout vary, depending on water source and connection locations. Avent is located on top of the evaporator at the water outlet end. Provide additionalvents at high points in the piping to bleed air from the chilled water system. Installpressure gauge(s) to monitor entering and leaving chilled water pressure.

CAUTIONExcessive Water Pressure!

To prevent evaporator damage, do not exceed 300 psi for 20-60 ton CCAFand 20-50 ton CGWF, and 215 psi for 60 ton CGWF evaporator waterpressure.

Provide shutoff valves in the line(s) to the gauge(s) to isolate the gauges when not inuse. Use pipe unions to simplify disassembly for system service. Use vibrationeliminators to prevent transmitting vibrations through the water lines.Install thermometers in the lines to monitor evaporator entering and leaving watertemperatures. Install a balancing cock in the leaving water line. It will be used toestablish a balanced water flow. Both the entering and leaving water lines shouldhave shutoff valves installed to isolate the evaporator for service.

Flow Sensing DevicesChilled water flow switches are optional, but there must be a chilled water flowinterlock provided to the MP to indicate that the evaporator pump is running. Toprovide additional chiller protection, install and wire the flow switch in series with thechilled water pump interlock for the chilled water circuits (refer to Chilled Water FlowInterlock). Specific connection and schematic wiring diagrams shipped with the unit.

Figure 14 Recommended Piping


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Installation MechanicalFlow switches must stop or prevent compressor operation if chilled water flow dropsoff drastically. Follow the manufacturer's recommendations for selection andinstallation procedures. General guidelines for flow switch installation are outlinedbelow:

1. Mount the switch upright with a minimum of 5 pipe diameters straight, horizontalrun on each side. Do not install close to elbows, orifices, or valves.

Note: The arrow on the switch must point in the direction of water flow.

2. To prevent switch fluttering, remove all air from the water systems.

Note: The MP provides a 6-second time delay before shutting the unit down on aloss-of-flow diagnostic. Contact a qualified service organization if nuisancemachine shutdowns persist.

Install a pipe strainer in the evaporator water supply line to protect components fromwater-borne debris.

Evaporator Drain.The evaporator drain connection should be piped to a suitable drain facility to empty

the evaporator during service or shutdown. Provide a shutoff valve in the drain line. Ifthe evaporator drain connection is not piped, remove the drain plug from its shippinglocation in the control panel and install it in the drain connection.

CAUTIONUse Pipe Strainers!To prevent evaporator or condenser damage, pipe strainers must beinstalled in the water supplies to protect components from water borndebris. The Trane Company is not responsible for equipment-only-damage caused by water born debris.

Condenser Water Piping

Condenser Water Connections.Condenser water inlet and outlet types, sizes and locations are given in Figure 7 -Figure 11.

Condenser Piping Components.Condenser piping components and layout vary, depending on water source andconnection locations. Figure 15 illustrates typical piping components for a well water(city water) condensing source. Typical components for a cooling tower condensingsource are ALSO shown in Figure 16.Condenser piping components generally function identically to those in theevaporator piping system. Refer to Evaporator Piping. In addition, cooling towersystems may include a manual or automatic bypass valve that can alter water flowrate to maintain condensing pressure. Well (city) water condensing systems shouldinclude a pressure reducing valve and water regulating valve (Figure 15).A pressure reducing valve should be installed to reduce water pressure entering thecondenser. This is required only if water pressure exceeds 300 psig. This is necessaryto prevent damage to the disc and seat of the water regulating valve that can becaused by excessive pressure drop through the valve.


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CAUTIONExcessive Water Pressure!

To prevent condenser or regulating valve damage, do not exceed 150 psifor 30 and 60 ton units and 300 psi for 20, 25, 40 and 50 ton unitscondenser water pressure.

The optional water regulating valve(s) maintains condensing pressure andtemperature by throttling water flow leaving the condenser in response tocompressor discharge pressure. Adjust the regulating valve(s) for proper operationduring start-up.

Condenser Drains.The condenser shells can be drained by removing the drain plugs from the bottom ofthe condenser heads. Also remove the vent plugs (at the top of the condenser heads)to facilitate complete drainage.When the unit is shipped, the condenser drain plugs are located in the control panel

along with the evaporator drain plug. The condenser drains can be piped to drainfacilities, if desired. If they are not, install the drain plugs in the condenser drainconnections on the condenser.


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Water Regulating ValveThe water regulating valve maintains condensing pressure and temperature bythrottling water flow leaving the condenser in response to compressor dischargepressure, decreasing water flow as pressure falls, and increasing water flow whendischarge pressure rises.Install the valve on the condenser leaving water line (Figure 15). Dual circulated units(40, 50, and 60-ton) require dual regulating valves installed in parallel in the leavingwater line (Figure 15).

Figure 15 Components for Condenser Water Circuit


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Locate the valve after the thermometer and before the shutoff valve (Figure 15). Runthe capillary tubing from the valve(s) to the discharge service valve(s).

CAUTIONRefrigerant Loss!To prevent refrigerant loss, locate capillary tubing and secure it to avoiddamage due to friction or vibration.

Connect the capillary tubing to the access port on the discharge service valve(s).Ensure that the valve is closed to the access port before removing flare cap.

CAUTIONHigh Pressure Refrigerant Gas!Make sure the discharge valve access port is closed before removingflare cap. Improper removal of flare cap may result in instantaneousrelease of high pressure refrigerant causing the cap to become aprojectile and/or liquid refrigerant to contact the skin. Failure to closedischarge valve access port before removing flare cap may result inminor or moderate injury.

Loosen the flare cap slowly to relieve residual pressure and connect the waterregulating valve capillary tubing.Adjust the regulating valve for proper operation during unit start-up.

Figure 16 Typical Water Regulating Valve Installation


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Installation MechanicalWater TreatmentUsing untreated or improperly treated water in these units may result in inefficientoperation and possible tube damage. Consult a qualified water treatment specialist todetermine whether treatment is needed.

CAUTIONProper Water Treatment!The use of untreated or improperly treated water in a Chiller may resultin scaling, erosion, corrosion, algae or slime. It is recommended that theservices of a qualified water treatment specialist be engaged todetermine what water treatment, if any, is required. Trane assume noresponsibility for equipment failures which result from untreated orimproperly treated water, or saline or brackish water.

Water pressure Relief Valves

Install a water pressure relief valve in the condenser and evaporator leaving chilledwater piping (Figure 15). Water vessels with close-coupled shutoff valves have a highpotential for hydrostatic pressure buildup on a water temperature increase. Refer toapplicable codes for relief valve installation guidelines.

CAUTIONInstall Water Relief Valves!To prevent shell damage, install pressure relief valves in both evaporatorand condenser water systems.

Low Temperature OperationThe leaving water temperature cutout setpoint is adjusted using the DynaView orTechView. There is a minimum differential that must exist between the Chilled Water

Setpoint (CWSP) and the Leaving Water Temperature Cutout setpoint (LWTCS). Thisminimum varies depending on the design D T, the number of cooling stages andwhether or not Hot Gas Bypass (HGBP) is installed. The equations to calculateLWTCS are shown below.Leaving Water Temperature Cutout Setpoint (LWTCS) is:20-30 T for units with out HGBP

20-30 T for units with HGBP

40-60 T for units with out HGBP

CWSP T

2------- 2 F +

LWTCS =

CWSP T

2------- 4 F +

LWTCS =

CWSP T

4------- 2 F +

LWTCS =


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40-60 T for units with HGBP

Pressure Relief Valve VentingAll CGWF units utilize two refrigerant-pressure relief valves for each circuit (one highside and one low side) which must be vented to the outdoor atmosphere. The highside relief valves are located at the left end of each condenser at the top (facing thecontrol panel). The low side relief valves are located at the right end of theevaporator.Relief valve connection sizes are 5/8 flare on the condenser and 3/8 flareon the evaporator.CCAF units have evaporator relief valve(s) only.All relief valve venting is the responsibility of the installing contractor.Vent pipe size must conform to the ANSI/ASHRAE Standard 15 for vent pipe sizing. Allfederal, state, and local codes take precedence over any suggestions stated in thismanual.Consult local regulations for any special relief l ine requirements.

CAUTIONProper Vent Piping!Vent piping must be installed to code specifications. Failure to heedspecifications could result in capacity reduction, unit damage and/orrelief valve damage.

Once the relief valve has opened, it will re-close when pressure is reduced to a safelevel. The valve may leak and should be replaced.Pipe each relief valve on the unit into a common vent line. Provide an access valve onthe common line to connect vacuum pump discharge and vent excess refrigerant outof the mechanical room. The access valve must be located at the low point of the ventpiping to enable draining of any condensate that may accumulate in the piping.

Table 7 Percent Glycol and Freeze Solution Temperatures

% GlycolEthylene Glycol Propylene GlycolSolution Freeze Point (F) Solution Freeze Point (F

0 32 325 29 29.310 25.5 26.415 21.5 23.120 16.8 19.325 11.4 14.830 5.1 9.335 -2.3 2.7

40 -10.8 -5.245 -20.7 -14.650 -32.1 -25.854 -42.3 -36.1

CWSP T

4------- 4 F +

LWTCS =


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WARNINGConfined Space Hazards!Do not work in confined spaces where sufficient quantities of arefrigerant or other hazardous, toxic or flammable gas may be leaking.Refrigerant or other gases could displace available oxygen to breathe,causing possible asphyxiation or other serious health risks. Some gasesmay be flammable and or explosive. Evacuate the area immediately andcontact the proper rescue or response authority. Failure to takeappropriate precautions or to react properly to a potential hazard couldresult in death or serious injury.

Table 8 Pressure Relief Valve Data

Valve location Quantity Relief Pressure

(psi)

Rated Capacity per

Relief Valve(lba/min.)

Pipe size

(in)

Condenser20-50 ton

1 per ckt 450 37.6 5/8 flare

Condenser60 ton

1 per ckt 450 37.6 5/8 flare

Evaporator 1 per ckt 300 11.5 3/8 flare


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Refrigerant Piping (CCAF only)Refer to the Trane Reciprocating Refrigeration Manual for refrigerant pipingselection information. Refrigerant pipe size selected must be within the velocity andpressure drop limitations required for proper system operation. It is essential thatrefrigerant piping be properly sized and applied since these factors have a significanteffect on performance.

NOTE: Use Type L refrigerant grade copper tubing only. The use of a lower gradetubing can cause operating problems.

Liquid Line Components and ConnectionsLiquid line connections sizes and locations are shown in Figure 10 - Figure 11.Thermostatic expansion valves, refrigerant sight glass, solenoid valves and schraedervalves are standard components on CCAF liquid lines. A liquid line filter drier must beinstalled for each circuit. Install a liquid line service valve in the liquid line to isolatethe drier for service.

Liquid Line SizingTrane recommends sizing the liquid line diameter as small as possible while

maintaining acceptable pressure drop. This will minimize the required refrigerantcharge and increase compressor life.Liquid risers in a system an additional 0.5 psig pressure drop per each foot of verticalrise. If the riser is length exceeds 15 feet, a larger diameter and/or shorter liquid linemay be required to provide required subcooling at the expansion valve. The line doesnot have to be pitched. Basic liquid line sizing perimeters for these units are:

Liquid lines are not usually insulated. If, however, the line runs through an area ofhigh ambient temperature (i.e. boiler room), subcooling my drop below requiredlevels. Liquid line passing though these warm spaces should be insulated.

Discharge (hot gas) LinesPitch discharge lines in the direction of hot gas flow at the rate of 1/2-inch per each 10feet of horizontal run. Discharge line sizing is based on required velocity to providegood oil movement. Basic discharge line parameters are:

Liquid Velocity 100-250 fpm

Maximum allowable pressure drop 3-6 psig (1F)

Maximum allowable pressure drop 6 psig (1F) 6 psig (1F)

Maximum Velocity 3500 fpm

Minimum Velocity (at minimum load)

Horizontal lines 500 fpm

Vertical lines (up flow) 1000 fpm


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Figure 17 Refrigerant piping Configuration of Typical Dual-Circuit CCAF Unit


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Leak TestOnce refrigerant piping is complete, thoroughly test the system for leaks.

System EvacuationFor field evacuation, use a rotary-style vacuum pump capable of pulling a vacuum of100 microns or less. Follow the pump manufactures instructions for proper use of thepump. The line used to connect the pump to the system should be copper and of thelargest diameter that can practically be used. Using a larger line size with minimumflow resistance can significantly reduce evacuation time.Rubber or synthetic hose are not recommended for unit evacuation because theyhave moisture absorbing characteristics which result in excessive outgassing andpressure rise during the standing vacuum test. This makes it impossible to determineif the unit has a leak, contains excessive moisture, or is experiencing a continual highrate of pressure increase due to the hoses.

NOTE: Insure that all sections of the refrigerant system are properly evacuated.

CAUTION

Equipment Damage!Do not use a megohm meter or apply power to compressor windingsunder vacuum. This may damage motor windings.

Refrigerant ChargingOnce the system is properly installed, leak tested and evacuated, refrigerant chargingcan begin. Liquid refrigerant must be charged into each circuit through the liquid lineaccess valve with the compressor(s) off.

CAUTIONEquipment Damage!To prevent evaporator tube rupture, never charge liquid refrigerant into awater vessel when refrigerant temperature/pressure relationship of thevessel is below freezing.

Charge refrigerant into the system by weight. Use an accurate scale or chargingcylinder to determine the exact charge entering the system. Failure to charge thesystem accurately can lead to under or over-charging and result in unreliableoperation.If system pressure equalize before the full charge enters the system, close thecharging port and proceed to Start-up Procedure. Once the unit is operating, add theremainder of the required charge to the system.


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Installation Electrical

General RecommendationsThe wiring procedures described in this portion of the manual must be accomplishedto obtain proper operation of the basic CGWF/CCAF unit. Electrical wiring instructionsfor all optional features and equipment are described In the Optional ElectricalWiring sections of this manual.

WARNINGHazardous Voltage!Disconnect all electric power, including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure the powercan not be inadvertently energized. Failure to disconnect power beforeservicing could result in death or serious injury.

All wiring must comply with National Electric Code (NEC) and state and localrequirements. Outside the United States, the national and/or local electricalrequirements of the other countries shall apply. The installer must provide properlysized system interconnecting and power supply wiring with appropriate branch circuitprotection. Type and locations of disconnects must comply with all applicable codes.

CAUTIONUse Copper Conductors Only!Unit terminals are not designed to accept other types of conductors.Failure to use copper conductors may result in equipment damage. Allwiring must comply with applicable local and national codes.

Electrical connection locations are shown in Figure 7 - Figure 11. Minimum circuitampacities, recommended fuse sizes and other unit electrical data are provided in

Table 10 and Table 11, and on the unit nameplate. Refer to the Field Wiring andRemote Sensor Layout Schematic shown in the Unit Wiring section.

Power Supply Wiring

Unit Power SupplyThe installer must connect appropriate line power supply (with fused disconnects) tothe terminal block or non-fused, unit mounted disconnect in the power section of theunit control panel. Refer to Figure 2 and Figure 3. Field wiring diagrams, electricalschematics and component location drawings are also attached to the inside of thecontrol panel door.The unit power fused disconnect switch(es) should be located in the general area ofthe unit to comply with NEC or local codes. The unit disconnect can be used as anemergency shutdown device.Normally, manual shutdown of the unit is accomplished at the DynaView. Then, openthe line power and control power (if used) fused disconnects after the pumpdowncycle is complete.

Equipment GroundsProvide proper grounding at the connection points provided in the panel (Figure 22).

Terminal Lugs, Circuit Breakers and Non-Fused Disconnect SwitchesProper starter/control panel line-side lug sizes are specified on the starter submittalsand in Table 9. These lug sizes must be compatible with conductor sizes specified bythe electrical engineer or contractor.


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Figure 18 Electrical Installation

Table 9 Customer Wire Selection

Unit Size Unit Voltage Disconnect Switch Size Connection Wire RangePower wire Selection to Disconnect Switch (1S1)30-50 Ton 208/230 Volt 250 Amp (1) #1-300 MCM20-50 Ton 460 Volt 100 Amp (1) #14-1/0

20-60 Ton 575 Volt 100 Amp (1) #14-1/020-25 Ton 208/230 Volt 100 Amp (1) #14-1/060 Ton 208/230/460 Volt 250 Amp (1) #4-350 MCMPower Wire Selection to Disconnect Switch (1S1) High Condensing Temperature(90-130 F) Units25-50 Ton 208/230 Volt 225 Amp (1) #1-300 MCM60 Ton 208/230 Volt 400 Amp (1) 250-500 MCM20-50 Ton 460 Volt 100 Amp (1) #14-1/020-60 Ton 575 Volt 100 Amp (1) #14-1/060 Ton 460 Volt 250 Amp (1) #4-350 MCM20 Ton 208/230 Volt 100 Amp (1) #14-1/0Power Wire Selection to Main Terminal Block20-60 Ton 460/575 Volt 250 Amp (1) #12-2/020-40 Ton 208/230 Volt 250 Amp (1) #12-2/050-60 Ton 208/230 Volt 250 Amp (1) #6-350 MCM

Control Wire Selection For 30 Volt or Less CircuitsWire Size Maximum Length14 AWG 5000 ft16 AWG 2000 ft18 AWG 1000 ft


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Table 10 Electrical Data CGWF Standard Condensing Temperature Units

Unit Size Unit Wiring Data Compressor Motor DataRatedVoltage

MinimumCircuit Ampac-ity

Max Fuse Size RecommendedDuel Element FuseSize

Qty - Size RLA LRA

20 208/230 77 110 100 2 -10 34 251380 38 50 50 17 142460 32 45 40 14 117575 27 40 40 12 94400/50 32 50 50 14 110

25 208/230 99 150 125 1 -151 - 10

52/34 376/251380 51 70 70 27/17 215/142460 43 60 60 23/14 178/117575 35 50 45 18/12 143/94400/50 42 50 45 22/14 174/110

30 208/230 117 150 150 2 - 15 52 376380 61 80 80 27 215460 52 70 70 23 178575 41 50 50 18 143400/50 50 80 80 22 174

40 208/230 145 175 175 4 - 10 34 251380 72 80 90 17 142460 60 70 70 14 117575 51 60 70 12 94400/50 60 90 90 14 110

50 208/230 185 225 225 2 - 152 - 10

52/34 376/251380 95 110 110 27/17 215/142460 80 100 100 23/14 178/117575 65 80 80 18/12 143/94400/50 78 110 125 22/14 174/110

60 208/230 221 250 250 4 - 15 52 376380 115 125 150 27 215460 98 110 110 23 178575 77 90 90 18 143400/50 94 125 150 22 174

Notes:1. Minimum Circuit Ampacit y is 125% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, per NEC 440-32 and NEC 440-33.2. Maximum Fuse Size is 225% of the largest compressor RLA plus 100% of the remaining compressor(s) RLS, per NEC 440-30.3. Recommended Dual-Element Fuse Size is 175% of t he largest compressor RLA plus 100% of the remaining compressor(s) RLA, Per NEC 430-152.4. Use copper conductors only.5.Compressor motor Voltage utilization range is:Rated Voltage--- Utilization Range208/230 ---188-253380 ---342-418

460 ---414-506575 ---517-633400/50 - 360-440


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Table 11 Electrical Data CCAF and CGWF High Condensing Temperature (90-130 F) Units

Unit Size Unit Wiring Data Compressor Motor DataRated

Voltage

Minimum

CircuitAmpacity

Max Fuse

Size

Recommended

Duel ElementFuse Size

Qty - Size RLA LRA

20 208/230 88 125 110 2 -10 39 251380 45 60 60 20 142460 38 50 50 17 117575 32 45 40 14 94400/50 38 50 50 17 117

25 208/230 112 150 150 1 -151 - 10

58/39 376/251380 59 80 80 31/20 215/142460 50 70 70 26/17 178/117575 40 60 60 21/14 143/94400/50 48 70 70 25/17 178/117

30 208/230 131 175 175 2 - 15 58 376

380 70 100 90 31 215460 59 80 80 26 178575 47 60 60 21 143400/50 56 80 80 25 178

40 208/230 166 200 200 4 - 10 39 251380 85 100 100 20 142460 72 80 90 17 117575 60 70 70 14 94400/50 72 80 90 17 117

50 208/230 209 250 250 2 - 152 - 10

58/39 376/251380 110 125 150 31/20 215/142460 93 110 110 26/17 178/117575 75 90 90 21/14 143/94

400/50 90 110 110 25/17 178/11760 208/230 247 300 300 4 - 15 58 376

380 132 150 150 31 215460 111 125 125 26 178575 89 100 110 21 143400/50 106 125 125 25 178

Notes:1. Minimum Circuit Ampacit y is 125% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, per NEC 440-32 and NEC 440-33.2. Maximum Fuse Size is 225% of the largest compressor RLA plus 100% of the remaining compressor(s) RLS, per NEC 440-30.3. Recommended Dual-Element Fuse Size is 175% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, Per NEC 430-152.4. Use copper conductors only.5.Compressor motor Voltage utilization range is:Rated Voltage--- Utilization Range208/230 ---188-253380 ---342-418460 ---414-506

575 ---517-633400/50 - 360-440


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Scroll Compressor Electrical PhasingIt is important that proper rotation of the scroll compressor be established before themachine is started. Proper motor rotation requires confirmation of the electrical phasesequence of the power supply. The motor is internally connected for clockwiserotation with the inlet power supply phased A,B,C.To confirm the correct phase sequence (ABC), use a Model 45 Associated ResearchPhase indicator or equivalent.Basically, voltages generated in each phase of a polyphase alternator or circuit arecalled phase voltages. In a three-phase circuit, three sine wave voltages aregenerated, differing in phase by 120 electrical degrees. The order in which the threevoltages of a three-phase system succeed one another is called phase sequence orphase rotation. This is determined by the direction of rotation of the alternator. Whenrotation is clockwise, phase sequence is usually called ABC, whencounterclockwise, CBA.This direction may be reversed outside the alternator by interchanging any two of theline wires. It is this possible interchange of wiring that makes a phase sequenceindicator necessary if the operator is to quickly determine the phase rotation of themotor.

Correcting Improper Electrical Phase SequenceProper compressor motor electrical phasing can be quickly determined and correctedbefore starting the unit. Use a quality instrument such as an Associated ResearchModel 45 Phase Sequence Indicator and follow this procedure.

WARNINGHazardous Voltage!During installation, testing, servicing and troubleshooting of thisproduct, it may be necessary to work with live electrical components.Have a qualified licensed electrician or other individual who has beenproperly trained in handling live electrical components perform thesetasks. Failure to follow all electrical safety precautions when exposed tolive electrical components could result in death or serious injury.

1. Turn Chiller off.

2. Open the electrical disconnect or circuit protection switch that provides linepower to the line power terminal block (1TB1) in the control panel (or to the unit-mounted disconnect 1S1).

3. Connect the phase sequence indicator leads to 1TB1 (or 1S1) as follows:

4. Turn power on by closing the unit supply power fused disconnect switch.

5. Read the phase sequence displayed on the indicator. The ABC LED on the faceof the phase indicator will glow if phase sequence is ABC.

6. If the CBA indicator glows instead, open the unit main power disconnect andswitch two line leads on 1TB1 (1S1). Reclose the main power disconnect andrecheck phasing.

7. Reopen the unit disconnect and disconnect the phase indicator.

Phase Seq. Lead 1TB1 TerminalBlack (Phase A) 1Red (Phase B) 2

Yellow (Phase C) 3


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Unit VoltageElectrical power to the unit must meet stringent requirements for the unit to operateproperly. Total voltage supply and voltage imbalance between phases should bewithin the following tolerances.

WARNINGHazardous Voltage!During installation, testing, servicing and troubleshooting of thisproduct, it may be necessary to work with live electrical components.Have a qualified licensed electrician or other individual who has beenproperly trained in handling live electrical components perform thesetasks. Failure to follow all electrical safety precautions when exposed tolive electrical components could result in death or serious injury.

Voltage Supply

Measure each leg of supply voltage at all l ine voltage disconnect switches. Readingsmust fall within the voltage utilization range shown on the unit nameplate. If voltageon any leg does not fall within tolerance, notify the power company to correct thissituation before operating the unit. Inadequate voltage to the unit will cause controlcomponents to malfunction and shorten the life of relay contacts and compressormotors.

Voltage ImbalanceExcessive voltage imbalance between phases in a three-phase system will causemotors to overheat and eventually fail. Maximum allowable imbalance is 2 percent.Voltage imbalance is defined as 100 times the maximum deviation of the threevoltages (three phase) subtracted from the average (without regard to sign), dividedby the average voltage.Example:

If the three voltages measured at the line voltage fused disconnect are 221 volts, 230volts and 227 volts, the average would be:

The percentage of imbalance is then:

In the example above 221 is used because it is the farthest from the average. The 2.2percent imbalance that exists exceeds maximum allowable imbalance by 0.2 percent.This much imbalance between phases can equal as much as 20 percent currentimbalance with a resulting increase in winding temperature that will decreasecompressor motor life.

Control Power SupplyA panel-mounted control power transformer is standard on all units.

Modules Connections for Interconnecting WiringThe wiring procedures described in this portion of the manual must be completedpanel mounted LLIDs. Refer to Filed Wiring on page 95.

221+230+227= 226 Volts

3

100(226-221)= 2.2%

226


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Chilled Water Flow SwitchCH530 has an input that accepts a contact closure from a proof-of-flow device suchas a flow switch or pressure switch. When this input does not prove flow within afixed time relative to transition from Stop to Auto modes of the chiller, or if the flow islost while the chiller is in the Auto mode of operation, the chiller will be inhibited fromrunning by a non-latching diagnosticThe installer must provide a flow sensing device or a pump interlock. Refer also tothe field wiring diagrams attached to the inside of the control panel door.

Chilled Water Pump ControlCH530 has an evaporator water pump output relay that closes when the chiller goesinto the Auto mode. The contact is opened to turn off the pump in the event of mostdiagnostics to prevent the build up of pump heat.

Condenser Water Loss of Flow ProtectionCH530 has an input that accepts a contact closure from a proof-of-flow device suchas a flow switch or pressure switch. When this input does not prove flow within afixed time from when the pump is commanded on, or if the flow is lost while acompressor is running, the chiller will be inhibited from running by a diagnostic.The installer must provide a flow sensing device or a pump interlock. Refer also tothe field wiring diagrams attached to the inside of the control panel door.

Condenser Water Pump StarterCH530 has a condenser water pump output relay that closes to indicate when thecondenser water pump should be started and opens to indicate when the pumpshould stop. If condenser pumps are arranged in a bank with a common header, theoutput can be used to control an isolation valve and/or signal another device that anadditional pump is required.

Programmable RelaysCH530 provides a flexible alarm or chiller status indication to a remote locationthrough a hard wired interface to a dry contact closure. Four relays are available forthis function, and they are provided (generally with a Quad Relay Output LLID) as partof the Alarm Relay Output Option.The events/states that can be assigned to the programmable relays are listed in thefollowing table.

Table 12 Chiller Events/Status Descriptions

Event/State Description

Alarm - Latching This output is true whenever there is any active latching diagnostic that targets the Chiller,Circuit, or any of the Compressors on a circuit.

Alarm - Auto Reset This output is true whenever there is any active non-latching diagnostic that targets theChiller, Circuit, or any of the Compressors on a circuit.

Alarm This output is true whenever there is any active latching or non-latching diagnostic that tar-gets the Chiller, Circuit, or any of the Compressors on a circuit.

Warning This output is true whenever there is any active latching or non-latching informational diag-nostic that targets the Chiller, Circuit, or any of the Compressors on a circuit.

Chiller Limit Mode This output is true whenever the chiller has been running in one of the limit modes (Con-denser, Hot Evaporator Start, Demand or Compressor Inhibit) continuously for the debouncetime. A given limit or overlapping of different limits must be in effect continuously for thedebounce time prior to the output becoming true. It will become false if no limits arepresent for the debounce time.

Compressor Running The output is true whenever any compressors are running.

Maximum Capacity The output is true whenever the chiller has reached maximum capacity continuously for thedebounce time. The output is false when the chiller does not have all its available compres-sors running continuously for the debounce time. See the Maximum Capacity specificationfor more information.


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The CH530 Service Tool (TechView) is used to install and assign any of the abovelisted events or status to each of the four relays provided with this option.The default assignments for the four available relays are listed below.

External Auto/StopCH530 accepts an isolated contact closure input to request STOP or AUTO commandmodes from a remote device. The contact closure status is monitored by a CH530binary input. Contact closure represents an AUTO request, and contact openingrepresents a STOP request.

Compressor Inhibit/ High Ambient OperationCompressor Inhibit prevents the second compressor on all circuits from runningwhich lowers the overall power consumption and cooling capacity of the chiller. Thisfeature may be invoked by an optional hardware input or a BAS command.Reduce Power Consumption: The 20 - 60 Ton chiller does not have a current limitfeature. This feature can be used to lower power consumption by limiting the numberof compressors available to the chiller.High Ambient Operation: To minimize high pressure cutouts in high ambientconditions, a thermostat can be connected to the external input to prevent operationof the 2nd compressor on each circuit.

Condenser Water Temperature Sensor ConnectionsWhen the optional condenser water temperature monitoring feature is specified, apair of sensors are installed in the entering and leaving condenser water boxes.

Chilled Water RestThe MP shall reset the chilled water temperature setpoint based on either returnwater temperature, or outdoor air temperature. The Return Reset option is standard,Outdoor Reset is optional.The following shall be selectable:1. Reset Type Setpoint.

2. RESET RATIO Setpoints.

3. START RESET Setpoints.

4. MAXIMUM RESET Setpoints.

When the chiller is running, if any type of CWR is enabled, the MP will step the CWStoward the desired CWS' at a rate of 1 degree F every 5 minutes until the Active CWSequals the desired CWS'. When the chiller is not running the CWS shall be fully resetimmediately (within one minute). The chiller will then start at the Differential to Startvalue above a fully reset CWS or CWS' for Outdoor, Return, and Constant ReturnReset.

Table 13 Programable RelaysLLID Name LLID Software Relay

DesignationOutput Name

Operating StatusProgrammable Relays

Relay 0 Status Relay 4, J2-1,2,3Relay 1 Status Relay 3, J2-4,5,6Relay 2 Status Relay 2, J2-7,8,9Relay 3 Status Relay 1, J2-10,11,12


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External Chilled Water Setpoint OptionThe MP provides inputs that will accept either 4-20 mA or 2-10 VDC signals to set thechilled water setpoint. This is not a reset function; the input level defines thesetpoint. This input is used with Generic BAS installations.The MP shall accept either a 2-10 VDC or 4-20 mA analog input suitable for customerconnection to set the unit external chilled water setpoint (ECWS).The 2-10 VDC and 4-20 mA shall each correspond to an ECWS range with bothmin_ECWS and max_ECWS configurable in Service Tool.

Ice Machine Control OptionCH530 accepts a contact closure input to initiate Ice Building. When in the icebuilding mode, the chiller will be fully loaded and will continue to operate until the icecontacts open or the return water temperature reaches the Ice Termination Setpoint.If terminated on return setpoint, CH530 will not allow the chiller to restart until the icemaking contact is opened.Ice building operation will be indicated by an "Ice Building" operation mode that can bedisplayed at the unit or communicated over the communications link.Ice Building CommandThis is the command to enter ice building. This setpoint is defined as an Auto/Onsetpoint. There are four possible ways to set this, through DynaView or TechView asthe Front Panel Ice Building Command, through an external interface switch closureto a low voltage binary input, and through a Tracer interface. Setting this to On willcommand the application into ice building if ice building is enabled.

Ice Building Enable/Disable settingThis setting will Enable or Disable the ice building option. It can be set through theDynaView or TechView. This setting does not start or stop ice building. The IceBuilding Command starts and stops ice building.

Ice Building Termination setpointThis setpoint has three possible sources DynaView or TechView as the Front Panel

Ice Termination Setpoint or Tracer. This setpoint has a range of 20F to 32F with adefault of 27F.

Communications Interface options

Optional Tracer Communications InterfaceThis option allows the Tracer CH530 controller to exchange information (e.g.operating setpoints and Auto/Standby commands) with a higher-level control device,such as a Tracer Summit or a multiple-machine controller. A shielded, twisted pairconnection establishes the bi-directional communications link between the TracerCH530 and the building automation system.

Figure 19 External Chilled Water Setpoint

ECWS -vs- Input (VDC)

0

10

20

30

40

50

60

70

0 1 2 3 4 5 6 7 8 9 10 11 12 13

Input (VDC)

E C W S

Outof

RangeOutof Rang

max

min

ECWS -vs- Input (mA)

0

10

20

30

40

50

60

70

0 2 4 6 8 10 12 14 16 18 20 22 24 26

Input (mA)

E C W S Out

of Range

Diagnosti

Outof RangeDiag

max

min


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To prevent control malfunctions, do not run low voltage wiring (


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Alarm Description 1Maximum Capacity

Hot Gas BypassCompressor Running OutputsCondenser Fan Running OutputsEvaporator Water Pump RequestEvaporator Water Flow StatusCondenser Water Pump RequestCondenser Water Flow StatusOutdoor Air TemperatureEvaporator Refrigerant Pressure Per CircuitEvaporator Refrigerant Temperature Per CircuitCondenser Refrigerant Pressure Per CircuitCondenser Refrigerant Temperature Per CircuitCurrent Per LineCompressor StartsCompressor Run TimeNote 1: Alarm Description denotes alarm severity and description of eventSeverity: no alarm, warning, normal shutdown, immediate shutdownNote 2: Regenerating, Refrigeration Circuit On, Pumping Out

Table 15 LonTalk Points List


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CCAF - Fan ControlOn

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