Related Manuals for Trane CGCN
Summary of Contents for Trane CGCN
- Page 1 Installation Operation Maintenance Indoor air-cooled chillers and heat pumps Models CGCN/CXCN August 2018 CG-SVX045A-GB Original instructions...
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Page 2: Table Of Contents
Contents General Information............................3 Purpose of this Manual Receiving the unit Unit Identification Warranty Responsibility Mechanical Installation.............................5 Shipping Safety Handling and lifting Operating limits Operating Maps Positioning Minimum space requirements Condensate drainage Anti-vibration Installation................................10 Duct connections EC centrifugal Plug Fans Safety regulations and Certifications Water Piping Water treatment Antifreeze protection on the heat exchangers... -
Page 3: General Information
C. The warranty is valid if all the installation and start-up instructions have been adhered to (both those which may have come from Trane and those coming from current practice), if the “1st start up form” has been filled in and sent to the Trane after sales department. -
Page 4: Responsibility
TRANE written approvals. Responsibility Trane declines all present and future responsibility for any damage to persons, animals or things caused by negligence of operators failing to follow the installation and maintenance instructions in this Manual. All safety equipment must be regularly and periodically checked in accordance with this manual and with local laws and regulations regarding safety and environment protection. -
Page 5: Mechanical Installation
Mechanical Installation Shipping The stability of the unit during shipping must be ensured. If the unit is shipped with a wooden cross-plank on its base, this cross-plank must only be removed after the final destination has been reached. Safety It is essential to observe the following instructions: •... -
Page 6: Operating Limits
Verify the perfect stability during the handling operations of the unit. Do not perform dangerous operations that could damage the unit. Lifting holes Make sure that during transport the unit will not arrive in wrong positions. A momentarily horizontal positioning of the unit can lead to irreversible damage to the compressors. Faultiness arising from incorrect transport is not covered by the manufacturer warranty. -
Page 7: Operating Maps
Unit operation is permitted within the limits indicated in the graphs below. CAUTION! The operation outside the specified limits may cause the activation of the unit protections and damage the unit. In case of doubt, contact your local Trane representative. The operating limits apply to an unit operating at full load conditions. -
Page 8: Positioning
Positioning All CGCN/CXCN units are designed and manufactured for indoor installation only, provided that the area is free from obstacles that could hamper air flow towards the condenser coils. In case the unit is installed in places that are easy accessible to people and animals, it is recommended to install condenser coil and compressor section protection grilles. -
Page 9: Condensate Drainage
Condensate drainage It is critical to easily discharge condensate caused by the heat pump operation, especially during the defrosting cycle. Avoid placing the condensate drain where people transit. Anti-vibration Isolation rubber pads are supplied as standard with the unit, and should be placed between the supporting floor and the unit to isolate the base from the ground. -
Page 10: Installation
Installation Duct connections Duct connections of suction and discharge of the unit and accessories must be made of flexible hose. The duct connection must be flexible enough to prevent transmitting vibrations to the tube network. On all units, a straight duct section connected to a fan must have at least the same cross sectional area as the output panel orifice, and its minimum length must be one and a half times the fan diameter, before any bend or deviation. - Page 11 CAUTION! Unit operation depends on the air temperature. Any recycling of the air fed out by the fans will increase the air intake temperature over the condenser fins and can result in high pressure cutout. In this case the standard operating conditions are modified. Operation of the unit may be affected by an increase in air temperature on the condenser.
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Page 12: Ec Centrifugal Plug Fans
EC Centrifugal Plug Fans Fan Model: K3G630-RB32-71 Motor: M3G150-IF Phases: 3~ Nominal voltage range: 380 – 480 VAC Frequency: 50 - 60 Hertz Fan speed: 1300 min-1. Nominal data in operating point with maximum load and 230 or 400 VAC Max.power input: 2700 W (1) Max. - Page 13 Important: EC fan motor M3G150-IF is represented in fan curve F Operating Fan speed Fan power Current Soundpower or L point (rpm) dB(A) 1300 1780 2,80 1300 2420 3,75 1300 2700 4,15 1300 2640 4,10...
- Page 14 Connection diagram Conn. Designation Function/assignment Supply connection, power supply 3-phase 380-480 VAC, 50/60 Hz Supply connection, power supply 3-phase 380-480 VAC, 50/60 Hz Supply connection, power supply 3-phase 380-480 VAC, 50/60 Hz Ground connection, PE connection Bus connection RS485, RSA, MODBUS-RTU; SELV Bus connection RS485, RSB, MODBUS-RTU;...
- Page 15 Air performance curve - at 50 Hz ρ = 1.15 kg/m³ ± 2 %, Measurement: LU-164207-1 Air performance measured according to ISO 5801 installation category A. For detailed information on the measurement setup, contact ebm-papst. Intake sound level: Sound power level according to ISO 13347 /sound pressure level measured at 1 m distance from fan axis.
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Page 16: Safety Regulations And Certifications
The legal representative of the company appointed by the owner to position and hydraulically, electrically etc. connect the Trane unit to the plant: he or she is responsible for moving and the correct installation of the unit in accordance with the indications in this manual and with the national regulations in force. - Page 17 3 metres. Trane declines any responsibility for damage to things and unauthorised personnel in case of absence of clear and static limiting systems of the risk areas and of the relevant warning and danger signs.
- Page 18 Precautions against residual risks due to the control system • make sure the instructions for use have been understood before carrying out any work on the control panel. • always keep the instruction manual close at hand when working on the control panel. •...
- Page 19 • if the unit is to be moved after a year of being in the site or if it has to be dismantled contact Trane. Manual alarm reset If there is an alarm, the unit must not be manually reset before having located and eliminated the cause of the fault.
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Page 20: Water Piping
The scroll compressors are fitted on shock absorbers. After receiving the unit please check carefully if there are blockages to fasten the compressors during the transportation. If yes, it is necessary to remove these blockages before the CGCN/CXCN unit will be started-up otherwise the warranty is not valid. Acoustic Protection When the sound level must be checked, pay attention to isolation from the base of the unit, properly applying the optional anti-vibration mounts. -
Page 21: Water Treatment
For units equipped with plate heat exchangers the filter should guarantee a filtration of particles until 0,8 mm. Trane is not responsible for damages to or malfunctioning of the equipment caused by failure to treat water or by improperly treated water. -
Page 22: Flow Switch Installation
Flow switch installation To ensure correct water flow through the evaporator, install a flow switch on the water circuit. The flow switch may be either installed on both the inlet pipe of the water on that output. The purpose of the flow switch is to stop the unit in case of an interruption of the water flow while protecting the evaporator from freezing. - Page 23 Screw for load control Note: The flow switch is factory-calibrated with reference to the minimum cut-out value. To increase this value, turn the adjustment screw clockwise. The cut-out value must be >= the minimum flow necessary to ensure the protection of the system. The units without fittings will be supplied with 4 paddles (see drawing palette), which must be cut according to the pipe.
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Page 24: Hydraulic Data
Hydraulic Data Water Flow and Pressure Drop The units have to work with the flow of inertia and tanks provided in the product catalog. Hydronic Group The units are also available in multiple hydraulic versions, characterized by complete kits of all major hydraulic components for an easier installation, with reduced time, cost and space. - Page 25 Ref. Curve Exp Vessel F.L.I. F.L.A. Mod. Mod. [kW] [m^3/h] [kPa] [kW] [kPa] [kPa] CGCN 50 CXCN 55 52,2 108,3 1,77 3,30 CGCN 65 CXCN 70 65,7 11,3 105,3 1,77 3,30 CGCN 80 CXCN 90 81,9 14,1 107,7 1,78 3,80...
- Page 26 Ref. Curve Exp Vessel F.L.I. F.L.A. Mod. Mod. [kW] [m^3/h] [kPa] [kW] [kPa] [kPa] CGCN 50 CXCN 55 52,2 108,3 2,55 4,70 CGCN 65 CXCN 70 65,7 11,3 105,3 2,55 4,70 CGCN 80 CXCN 90 81,9 14,1 107,7 2,55 4,70...
- Page 27 Ref. Curve Exp Vessel F.L.I. F.L.A. Mod. Mod. [kW] [m^3/h] [kPa] [kW] [kPa] [kPa] CGCN 50 CXCN 55 4,25 52,2 108,3 CGCN 65 CXCN 70 4,25 65,7 11,3 105,3 CGCN 80 CXCN 90 4,25 81,9 14,1 107,7 CGCN 95 CXCN 100...
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Page 28: Refrigerant Circuit Safety Valves
CONNECTION SCHEME - STANDARD VERSION Refrigerant safety valves Each system comes with safety valves that are installed on each circuit, both on the high pressure & low pressure pipes. The purpose of the valves is to discharge the refrigerant inside the refrigerating circuit in the event of any malfunction. -
Page 29: Control And Safety Calibrations
water flow rates result in excessive water velocity and possible erosion / corrosion. In the first case low speed 'can lead to underperformance and easy scaling, and in the second case' must install pumps with high prevalence energetically little valid. Control and safety calibrations SCALING CORRECTION SCHEDULES The following table provides information on the organs of action and safety of the unit. -
Page 30: Electrical Installation
Should the wiring diagram not appear on the unit or should it have been lost, please contact your nearest Trane office, who will send you a copy Only use copper conductors. -
Page 31: Unit Operation
Oil compressor load Checking the oil charge All Trane units compressors are charged with oil at the factory. The scroll compressors are equipped with an oil sight glass from which you can control the level. The precise level should be between two marks that indicate the minimum and maximum allowable levels. -
Page 32: Pre-Startup Checks
Pre-startup checks General Once the unit has been installed, use the following procedure to check that is has been done properly: WARNING! Remove the power supply from the unit before performing any checks. Failure to open the power switches at this stage can result in serious injury to the operator or even death. Inspect all the electrical connections to the power circuits and to the compressors including the contactors, fuse carriers and electrical terminals and check that they are clean and well secured. -
Page 33: Electrical Supply
The most appropriate water treatment must be established locally, according to the type of installation and to the characteristics of the process water locally. Trane is not responsible for damage or bad operation of the apparatus resulting from failure to treat water or from incorrectly treated water. -
Page 34: Startup Preliminary Procedures
Refrigerant seals control Trane units are delivered with the complete charge of refrigerant and are at a sufficient pressure to check the seal after installing. If the system is not under pressure, blow refrigerants (vapors) into it until pressure is reached and look for leakage. -
Page 35: Pre-Commissioning Check List
CIRCUIT OR THE ELECTRICAL PANEL OR CHANGES TO THE UNIT OPERATING PARAMETERS) MADE BY A THIRD PERSON WITHOUT A WRITTEN AUTHORIZATION ISSUED BY TRANE. THE UNIT SHALL BE CONFORM TO TRANE WIRING DIAGRAMS AND TECHNICAL DOCUMENTATION) IN CASE OF RELE- VANT DIFFERENCE BETWEEN THE UNIT AND TRANE STANDARD CONFIGURATION PLEASE CONTACT TRANE. - Page 36 ELECTRIC DEVICES ARE INTACT AND DON’T DISPLAY ANY DAMAGE. ELECTRONIC DEVICES ARE INTACT AND DON’T DISPLAY ANY DAMAGE. WATER PUMPS ARE ELECTRICALLY CONNECTED TO THE ELECTRICAL PANEL IN ACCORDANCE WITH THE WIRING DIAGRAMS PROVIDEDBY TRANE. THE ELECTRICAL ABSORBTION AND THE WATER PUMPS OVERHEATING ARE STANDARD. REFRIGERANT CIRCUIT ALL CONNECTIONS ON THE REFRIGERANT CIRCUITS ARE WELL TIGHTENED.
- Page 37 THE PLANT AND TO THE WATER PRESSURE DROPS. FOR FURTHER TECHICAL INFORMATIONS PLEASE REFER TO TRANE DOCUMENTATIONS AND PROCEDURE FOR THE FIRST START UP. HYDRAULIC CONNECTIONS TO THE UNIT ARE COMPLIANT WITH THE UNIT NAME PLATE AND DI- MENSIONAL DRAWINGS.
- Page 38 ALL WATER PIPES ARE GROUND CONNECTED (IN ORDER TO AVOID ABNORMAL VOLTAGES THAT CAN CAUSE DANGEROUS CORROSIONS). THE EVAPORATOR WATER FLOW IS COMPLIANT TO THE TECHNICAL DOCUMENTATION PROVIDED BY TRANE. THE WATER PUMPS ARE CORRECTLY SET UP IN ACCORDANCE WITH THE PLANT WATER FLOW, AVAILABLE HEAD PRESSURE AND PRESSURE DROP.
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Page 39: Refrigerant Replacement Procedure
Refrigerant replacement procedure If the unit has exhausted the refrigerant, it is necessary first of all to establish the causes, before carrying out any replenishment operation. The leak must be looked for and repaired. Oil stains are a good indicator, as they can appear in the vicinity of a leak. However, this is not necessarily always a good search criterion. - Page 40 Refrigerant charge Charge with unit stopped and in vacuum (refrigerant charge in the liquid phase) Completely open the valve for it to close the service connection. Connect the refrigerant cylinder to the service connection without tightening the connection. Half close the liquid shut off valve. If the circuit has been dehydrat- ed and vacuum, load liquid with the cylinder upside down.
- Page 42 WARNING WARNING! The symptoms of a low refrigerant charge are: • Low evaporation pressure • High superheat the intake and exhaust (outside the above limits) • Low value of subcooling. In this case, add refrigerant R410A in the corresponding circuit. The system is planned charging port between the expansion valve and the evaporator.
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Page 43: Refrigerant Loading
Refrigerant loading WARNING! The units are designed to work with R410a refrigerant. DO NOT USE therefore different refrigerants from R410a WARNING! The addition or removal of refrigerant gas must be done in accordance with the laws and regulations in force. WARNING! When you add or remove the refrigerant from the system, ensure the proper flow of water through the evaporator for the entire period of charge / discharge. -
Page 44: Start Up
Start up Preliminary checks Before starting the appliance is very important verify that you have correctly performed all the operations described in the section "PREPARATION OF STARTING." Also check that all mechanical and electrical equipment are tightened properly. WARNING! particular should be paid to the fundamental components (compressor, heat exchangers, fans, electric motors, pumps, terminal blocks) are detected in the case fixing screws loose, proceed to their tightness before start. -
Page 45: Start-Up Procedure
Start-up procedure Unit start up (only by an authorized person) 1. With the switch closed, open the electrical panel and exclude compressor (refer to the wiring diagram on the unit). Close the panel, set switch to "ON" (to give power to the unit) 2. -
Page 46: System Maintenance
System maintenance RNING General The maintenance operations are essential to maintain the efficiency of the refrigeration unit, both from a purely functional and energy consumption. Each unit is equipped with a booklet on the unit, which will be provided by the user, or the person who is authorized on his behalf to the maintenance of the unit, return all records required in order to keep a historical record of the operation of the unit. - Page 47 Standard checks Operation description Recommended frequency Compressors oil level Monthly Clean coil Monthly Inlet temperature (overheating) Monthly Water circuits filling Monthly Fans and compressors motors electrical input Monthly Power supply and auxiliary power voltage Monthly Refrigerant charge through sight glass Monthly Compressors carter heaters operation Monthly...
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Page 48: Unit Test Sheet
Unit test sheet It is advisable to periodically detect the following operating data to verify the correct functionality of the unit in time. These data will also be of great benefit to the technicians who carry out routine and / or extraordinary unit maintenance. -
Page 49: Recommended Spare Parts
Recommended spare parts Following is a list of the recommended parts for several years of operation. Trane is at your disposal to recommend a personalised list of accessories according to the commissioned order, including the part number of the equipment... -
Page 50: Ordinary Maintenance
Ordinary Maintenance - Programmed maintenance Activities list Week Month (1) Year (2) General Data collection operation (3) Visually inspect the unit for any damage and / or looseness Verifying the integrity of the thermal insulation Clean and paint where needed Water Analysis (6) Electric Check the correct operation of the equipment on the unit... -
Page 51: Dehydration Filter Repositioning
Dehydration filter repositioning It is recommended to reposition of filter cartridges Dryer in the case of high pressure drop across the filter same or in case with the value of the subcooling within the limits of acceptability, occurs the passage of bubbles through the sight glass. -
Page 52: Oil Filter Repositioning
ARNING Oil Filter repositioning WARNING! The lubrication system is designed to maintain the majority of the charge of oil inside the compressor. However, during operation, a limited amount of oil circulates freely within the system, transported from the refrigerant. Therefore, the amount of oil to enter into the compressor will have to be equal to that removed and not the total amount of plaque to prevent excessive amount of oil start next. -
Page 53: Disposal
Disposal Unit backflow The unit disposal must be performed by qualified personnel. Pay attention not to disperse harmful liquid or gases. Recover as much refrigerant gas as possible from the unit and any freezing solution in the water circuits. Decommissioning and disposal At disposal, heat exchangers, finned coils, fans or motors may be recovered if working. -
Page 54: Maintenance Contract
It is important, however, to ensure proper and periodical maintenance in accordance with all the procedures listed in this manual. We strongly advise stipulating a maintenance contract with Trane Service in order to ensure efficient and problem-free operation, thanks to the expertise and experience of our personnel. -
Page 55: Important Information Regarding The Refrigerant Used
Important information regarding the refrigerant used This product contains fluorinated greenhouse gases covered by the Kyoto Protocol. Do not vent refrigerants into the atmosphere. Type of refrigerant: R410A GWP (1) 2088 (1) GWP = global warming potential The refrigerant charge is indicated on the name plate of the unit. Mandatory refrigerant leakage inspections apply to stationary equipment (refrigeration, air conditioning and heat pump equipment) in accordance with the EU F-gas Regulation (EU) N 517/2014. -
Page 56: Plant Sketches
Typical plant sketch... -
Page 57: Hydraulic Connections
The installation instructions included in the statements to follow, represent a necessary condition for the validity of the warranty. Trane is at your disposal to examine any differing needs, which still must be approved prior to the operation of the unit. The water flow of the group must be compatible with that of the evaporator. It is also... -
Page 58: Dimensions, Drawings And Weight
Double pumps - low head pressure Double pumps - medium head pressure kg Double pumps - high head pressure CGCN CGCN 50 CGCN 65 CGCN 80 CGCN 95 CGCN 105 CGCN 120 DIMENSIONS AND WEIGHT Length 2.350 2.350 3.346 3.346 4.456... - Page 59 Single pump - high head pressure Double pumps - low head pressure Double pumps - medium head pressure Double pumps - high head pressure CGCN CGCN 135 CGCN 150 CGCN 160 CGCN 185 CGCN 205 CGCN 225 CGCN 245 DIMENSIONS AND WEIGHT Length 4.456 5.456 5.456...
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Page 60: Troubleshooting
U = User S = Specialized personnel only Once the cause has been identified, you are advised to contact a Trane service center or a qualified technician for help. SYMPTOM... - Page 61 SYMPTOM Cooling Heating Who can take Probable cause Possible remedy corrective action D The Pressure switch out of order Check and replace compressor Overcharge of refrigerant Download the excess gas does not start Finned coil clogged, air flow rate is Remove dirt from the coil and because the too low...
- Page 62 HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. © 2018 Trane All rights reserved...