trane hong kong - installation operation maintenance · 2016. 8. 24. · centrifugal fans sizes 200...

Installation

Operation

Maintenance

CGCL

Air Cooled Water Chiller With

Centrifugal Fans

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

500 - 600

CGCL-SVX01A-E4

To be used with the manual of SMM Module

Reference L80IM022E

CGCL-SVX01A-E4

General information

ForewordThese installation, operation andmaintenance instructions are givenas a guide to good practice in theinstallation, putting into service,operation, and maintenance by theuser, of Trane CGCL chillers. They donot contain full service proceduresnecessary for the continuedsuccessful operation of thisequipment; The services of aqualified technician should beemployed through the medium of amaintenance contract with a reputableservice company.

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 to misuse, lack ofmaintenance or failure to complywith the manufacturer's instructionsor recommendations is not coveredby the warranty obligation. If theuser does not conform to the rulesof chapter "Maintenance", it mayentail cancellation of warranty andliabilities by Trane.

ReceptionOn arrival, inspect the unit beforesigning the delivery note. Specifyany damage on the delivery note,and send a registered letter ofprotest to the last carrier of thegoods within 72 hours of delivery.Notify the local Trane Sales Office atthe same time.

The unit should be totally inspectedwithin 7 days of delivery. If anyconcealed damage is discover, senda registered letter of protest to thecarrier within 7 days of delivery andnotify the local Trane Office.

Units are shipped with therefrigerant operating or holdingcharge and should be examined withan electronic leak detector todetermine the hermetic integrity ofthe unit. The refrigerant charge is notincluded in the standard TraneWarranty Cover.

General

informationAbout this manual

Caution appears at appropriateplaces in this instruction manual.Your personal safety and the properoperation of this machine requirethat you follow them carefully. Theconstructor assumes no liability forinstallations or servicing performedby unqualified personnel.

About the unit

These CGCL units are assembled,pressure tested, dehydrated, chargedand run tested before shipment. Theinformation contained in this manualapplies to units designated CGCL.

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.

©American Standard Inc. 2001

CGCL-SVX01A-E4 3

Contents

Foreword 2

Warranty 2

Reception 2

General Information 2

Refrigerant 2

Installation

General unit characteristics 4

Unit name plate 6

Installation instructions 6

Handling 6

Duct connection 7

Water to evaporator connection 9

Minimum water volume 9

Water treatment 11

Antifreeze protection 11

Electrical connections 12

General start-up

Preparation 13

Start-up 13

Operation 15

Control and unit operation 15

Weekly start up and week-end shutdown 15

Start up and seasonal shutdown 15

Maintenance 16

Maintenance instructions 16

Installation checklist 17

Troubleshooting guide 18

Control parameters of the SMM control module 21

Safety recommendations 23

Maintenance contract 23

Training 23

4 CGCL-SVX01A-E4

General unit characteristics

Table 1 - CGCL general dataCGCL CGCL CGCL CGCL CGCL CGCL CGCL CGCL

200 250 300 350 400 450 500 600

R407C R407C R407C R407C R407C R407C R407C R407C

Performances (1)

Cooling Capacity kW 48.9 60.7 73.5 86.3 100.1 109.8 125.0 149.7Power input kW 19.9 24.7 28.0 34.7 42.7 47.0 50.6 59.7Pressure 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 94 90 94Sound Power Level 400 Pa dB(A) 90 86 89 90 93 95 92 95Sound Power Level 500 Pa dB(A) 91 88 90 92 94 96 93 96

System Data

Refrigerant Circuit - - - 1 2Compressor

Number 2 3 4Type ScrollModel 10T+10T 10T+15T 2x15T 2x10T+15T 10T+2x15T 3x15T 2x(10T+15T) 4x15TSpeeds number 1 1 1 1 1 1 1 1Motors Number 1 1 1 1 1 1 1 1Nominal Amps A 37 46 55 65 74 83 92 110Starting Amps A 138 193 202 212 221 230 239 257Motor RPM rpm 2900 2900 2900 2900 2900 2900 2900 2900

Heat Exchanger

Number 1Type Brazed plateModel V45-40 V45-50 V45-60 V45-70 V45-90 V45-90 DV47-102 DV47-134Water volume (total) l 4.7 5.9 7.0 8.2 10.5 10.5 12.3 16.1Antifreeze Heater W 65 130

Water Connections

Type: ISO R7 MaleDiameter 1 1/2" 2" 2 1/2"

Coil

Type Plate FinTube size mm 9.52Tube type SmoothHeight mm 914 1219 1219 1626Length mm 1829 1829 2743 2743Face Area m2 1.67 2.23 3.34 4.46Rows 4.0 4.0 4.0 4.0Fins per inch (fpf) 180.0 180.0 180.0 180.0

Control VA VA 800Fan

Type CentrifugalNumber 1 2 3Diameter mm AT 18-18Drive type Pulley + BeltSpeeds number 2Air flow m3/h Refer to table 2Static pressure Pa Refer to table 2Motors Number 1Motor kW Refer to table 2Nominal Amps A Refer to table 2Starting Amps A Refer to table 2Motor RPM (Low/High) rpm Refer to table 2

Dimensions

Height mm 1997 1997 1997Length mm 2268 3230 3230Width mm 866 866 1216Weight uncrated kg 700 820 880 1080 1140 1200 1380 1500Weight crated kg 740 860 920 1130 1190 1250 1450 1570

System Data

Refrigerant circuit 1 1 1 1 1 1 2 2R407C Refrigerant Charge

Circuit A kg 12 15 15 23 23 23 15 15Circuit B kg - - - - - - 15 15

(1) Water temp 12/7°C outside air temp 35°C(2) Without fan - refer to table 2 for fan amps

CGCL-SVX01A-E4 5

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

(m3/h) 300 400 500

CGCL 200 15300

High speed * (kW) 0.75 1.1 1.1High 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

High speed * (kW) 0.75 1.1 1.5High 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

High speed * (kW) 1.5 1.5 2.8High 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

High speed * (kW) 2.8 2.8 3.8High 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 start in Low speed

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

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

Table 3 - Pressure drop through condenser coil and air filterUnit Airflow 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 Trane Agency.

6 CGCL-SVX01A-E4

Unit nameplate

The 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.

Installation instructionsFoundations

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

Anti-vibration rubber pads

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

spring isolators.

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 is functionof the air temperature. Any recyclingof the air fed out by the fans willincrease the air intake temperatureover the condenser fins and canresult 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

HandlingFigure 1

Note :

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

Table 4 - 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) 950 1100 1200 1450 1550 1600 1900 2000

B

A

Duct connections

Duct 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).

Warning: When fixing the duct to thecondenser inlet, make sure the fixingscrews do not pierce the coil.

Figure 2

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

Figure 3

CGCL-SVX01A-E4 7

Installation of air inlet and

discharge ducting

5 4

1 2

3

4

1

2

3

Figure 4

1. Unit body2. Flexible couplig (field supply)3. Ductwork4. Seal

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

8 CGCL-SVX01A-E4

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

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, astraight duct section connected to afan must have at least the samecross sectional area as the outputpanel orifice, and its minimumlength must be one and a half timesthe fan diameter, before any bend ordeviation.

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).

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

Figure 5

RIGHT

Figure 6

WRONG

Water to evaporator connection

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 agency.

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

- Number of capacity step.- Minimum time between two starts

of a compressor.- Water loop volume.- Load fluctuations.

CGCL-SVX01A-E4 9

Minimum water volume for a

comfort application

For comfort application we can allowwater temperature fluctuation at partload.

The parameter to take into accountis the minimum operating time ofthe compressor.

In order to avoid any lubricationproblem, scroll compressor mustrun for at least 2 minutes (120seconds) before it stops.

The minimum volume can bedetermined by using the followingformula :Volume = Cooling capacity xTime/Number of steps/Specificheat/Dead band.Minimum operating time = 12seconds.Specific heat = 4.18 kj/kg.Dead band recommended = 3°C.With these value the formulabecomes :Volume = Cooling capacity steps.For the CGCL running in followingconditions :Air temperature 35°C, water 12/7°C,this gives the following volumes.

Table 5 - Evaporator water contentUnit size Water volume (l)

CGCL 200 4.7CGCL 250 5.9CGCL 300 7.0CGCL 350 8.2CGCL 400 10.5CGCL 450 10.5CGCL 500 12.3CGCL 600 16.1

If the total water volume of theinstallation is below the abovementioned values it is necessary touse a hydraulic module.

Figure 7

1. Pressure gauges: show entering and leaving waterpressure.

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 circulating

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

leaving temperatures.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 to get heat exchangers dirty. Allinstallation must be equipped with efficient strainerin order that only clean water enters into exchanger.If there is no stainer, reserve will be formulated bythe Trane technician at the start-up of the unit. Thestrainer used must be able to stop all particles with adiameter greater than 1 mm.

9 Draining: used as the draining the plate heatexchanger.

1

7

6

5

8

9

2

3

4

Minimum water volume for a

process application or for a chiller

which has to run all year long.

For process application we have tominimise the water temperaturefluctuation at part load.In order to avoid any problem scrollcompressor must run at least 2minutes (120 seconds) before itstops and with a minimum timebetween two starts of 5 minutes (300 seconds).The water volume has to be able toprovide the cooling capacity whilethe unit is shut down.

The minimum volume can bedetermined by using the followingformula :Volume = Cooling capacity xTime/Number of steps/Steps/Specificheat/Dead band.Minimum time = 180 seconds (300-120).Specific heat = 4.18 kj/kgDead band recommended = Functionof the process.With these value the formulabecomes : Volume = Coolingcapacity x 43/Number of capacitysteps/Dead band.An hydraulic module can, onrequest, be provided by Trane.

Water treatment

Untreated 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 treatmentspecialist.The following materials are used inTrane chillers heat exchangers :- Stainless steel plates AISI 316,

1.4401 witch copper brasing.- Water piping: copper 99,9 %- Water connections: brass

Trane will not accept any ability 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 protection.During negative ambient airtemperature chilled water pipingmust be fully insulated.Insure that all safeties are taken toprevent frost damage duringnegative ambiant air temperature.Following system can be used:- Electrical heater mounted on all

water piping exposed to negativetemperatures.

- Start chilled water pump duringnegative ambiant 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

10 CGCL-SVX01A-E4

Electrical connections

Caution:1. The greatest care should be taken

when 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 with

standards 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.

As an option, Trane provides theunique power supply which includesthe transformer. If the transformer isnot ordered, it is necessary to foreseethe power supply of the electronicmodule separately.Warranty reserves will be formulatedif a transformer, not supplied byTrane, is installed inside the electricpanel.

CGCL-SVX01A-E4 11

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 (See table 6).

- 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 SMM

module- 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 pushing button"I"

of control module. The green LEDmust be lit, the SMM controlmodule must be in"cooling mode"

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,

1

2

12 CGCL-SVX01A-E4

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

pressure,- 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.

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 in thecompressor shows that refrigerantis present in the oil and the resultwill be that compressor is notlubricated enough. Shut downcompressor and consult Tranetechnician.

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

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

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 damage risksof the chiller and evaporator waterpipes.

Table 6 - 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 ethylen glycol is added in the chilled water circuit the followingadjustment factors have to be taken in account.

Table 7 - Ethylen 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 - -

CGCL-SVX01A-E4 13

Operation

Control SystemThe control is through the SMMcontrol module.

Unit operations- Check the chilled water pump(s)

operates- Start up unit pushing button"I" of

the SMM control module. The unitwill operate correctly when thereis sufficient water flow. Thecompressors will start up if theevaporator water leavingtemperature is above the SMMcontrol module setpoint.

Weekly start up

- Check the chilled water pump(s)operates

- Push button"I" of the module toallow chiller operation.

Week end shutdown

- If the unit needs to be shut downfor a short period of time, pushbutton "O" of the 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.

- Push button"O" of the module.- Insure that all safeties are taken to

prevent 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

14 CGCL-SVX01A-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

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.

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 operating

problems. 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 ServiceFirst forinformation on maintenancecontracts.

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-SVX01A-E4 15

Installation check list

This 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

16 CGCL-SVX01A-E4

Troubleshooting guide

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

Problems symptomsA) 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

High pressure switch tripped.

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 causeMotor burned out.

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

Fuse blown.

Voltage too low.Regulation circuit open.

Compressor sticking (damaged or stickingcomponents).Discharge pressure too high

Discharge pressure too high.a) Voltage too low.b) Cooling demand too high, or condensingtemperature too high.Not enough cooling fluid.Water flow to evaporator too low.Air filters dirty

Filter drier clogged.

Action recommendedReplace 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".

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.

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

CGCL-SVX01A-E4 17

Problems symptomsD) 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.Compressor noisyF) 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

Action recommended

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.

18 CGCL-SVX01A-E4

Problems symptomsI) Suction pressure too high

Compressor operates continuously.Suction duct abnormally cold.

Refrigerant flows back to compressor.

J) Suction pressure too low

Excessive pressure drop through filter drier.Refrigerant does not flow through thermostaticexpansion valve.Loss of power.Superheat too low.

K) Insufficient cooling capacity

Low pressure drops through evaporator

Problem cause

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

b) Expansion valve locked in open position.

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

Expansion valve obstructed.Excessive pressure drops through evaporator.

Low water flow rate.

Action recommended

Check system.a) Check for superheat and check thatexpansion valve bulb is secure.b) Replace.

Replace the filter drier.Replace the bulb.

Replace.Check adjustment of superheat and adjustthermostatic expansion valve.

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

Caution :

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

CGCL-SVX01A-E4 19

Control parameters of the SMM

control module

To cancel a manually reset default press key 1.

AA01 Active water set pointA02 Evaporator water outlet mix temperatureA03 Circuit 1 evaporator water outlet temperatureA04 Circuit 2 evaporator water outlet temperatureA05 Air temperatureA06 Number of compressor A1 operating hoursA07 Number of compressor A1 startsA08 Number of compressor B1 operating hoursA09 Number of compressor B1 startsA10 Number of compressor A2 operating hoursA11 Number of compressor A2 startsA12 Number of compressor B2 operating hoursA13 Number of compressor B2 startsBB01 Evaporator outlet temperature set pointB02 Hot water outlet temperature set pointB03 Auxiliary water outlet temperature set pointB04 Circuit 1 ON validationB05 Circuit 2 ON validationB06 Operating modeB07 Remote control validationB08 Auxiliary set point validationB09 Current date display

B091 DayB092 MonthB093 Year

B10 Current time displayB101 HoursB102 MinutesB103 Seconds

B11 Set this parameter to 0.0°CB12 Set this parameter to 0.0°CB13 Set this parameter to 0.0°CCC01 Default displayC02 Current default resetDD01 Cooling set point reset typeD02 Cooling reset starting valueD03 Cooling reset value rangeD04 Cooling reset rangeD05 Heating set point reset typeD06 Heating reset starting valueD07 Heating reset value rangeD08 Heating reset rangeD09 Generic input typeD10 Evaporator pump stop timerD11 Evaporator water pumpD12 Compressor lead-lagD13 Default 1 report typeD14 Default 2 report typeD15 Serial link address

20 CGCL-SVX01A-E4

EE01 Circuit 1 evaporator saturated temperatureE02 Circuit 1 evaporator saturated pressureE03 Circuit 1 condenser saturated temperatureE04 Circuit 1 condenser saturated pressureE05 Circuit 2 evaporator saturated temperatureE06 Circuit 2 evaporator saturated pressureE07 Circuit 2 condenser saturated temperatureE08 Circuit 2 condenser saturated pressureE09 Evaporator water inlet temperatureE10 Condenser water outlet temperatureE11 Condenser water inlet temperature

CGCL-SVX01A-E4 21

22 CGCL-SVX01A-E4

Notes

CGCL-SVX01A-E4 23

Notes

The manufacturer has a policy of continuousproduct improvement, and reserves the rightto alter any details of the products at any timewithout notice.

This publication is a general guide to install,use and properly maintain our products. Theinformation given may be different from thespecification for a particular country or for aspecific order. In this event, please refer toyour nearest office.

Safety recommendationsTo avoid accidents and damage, thefollowing recommendations shouldbe observed during maintenanceand service visits:1. The maximum allowable

pressures for system leak testingon low and high pressure side aregiven in the chapter “Installation”.Always provide a pressureregulator.

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

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

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.

TrainingThe equipment described in thismanual is the result of many yearsof research and continuousdevelopment. To assist you inobtaining the best use of it andmaintaining it in perfect operatingcondition over a long period of time,the manufacturer has at yourdisposal a refrigeration and airconditioning 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.

Literature Order Number CGCL-SVX01A-E4

Date 07/01

New

Stocking LocationThe Trane CompanyAn American Standard Companywww.trane.com

For more information contactyour local sales office ore-mail us at [email protected]

Since The Trane Company has a policy of continuous product improvement, it reserves the right to changedesign and specifications without notice.

For additional information, contact:Distributor / Installer stamp

Société Trane – Société Anonyme au capital de 61 005 000 Euros – Siege Social: 1 rue des Amériques –88190 Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188Numéro d’identification taxe intracommunautaire: FR 83 3060501888

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