Related Manuals for Trane CCUF-R454B
Summary of Contents for Trane CCUF-R454B
- Page 1 Installation Operation Maintenance Indoor condenserless chillers with scroll compressors and R454B refrigerant CCUF – R454B Cooling capacity 46 - 634 kW October 2023 CG-SVX061C-GB Original instructions...
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Page 2: Table Of Contents
INDEX 1 OVERVIEW ......................3 2 SAFETY REGULATIONS ..................3 3 OPERATING LIMITS ....................8 4 INSTALLATION...................... 10 5 ACOUSTIC PROTECTION ..................15 6 ELECTRICAL POWER SUPPLY ......Error! Bookmark not defined. 7 WATER CONNECTIONS ..................17 8 REFRIGERANT SCHEME ..................32 9 CONNECTION TO THE REMOTE CONDENSER .......... -
Page 3: Overview
Technician: A person who is directly authorized by Trane or, secondarily, for all EU countries except for Italy, by the distributor of the Trane product, under their own responsibility, to carry out all ordinary or extraordinary maintenance operations, as well as regulations, controls, repairs and parts replacement which may be necessary during the lifetime of the unit. - Page 4 The danger zone must be of a suitable size to avoid any contact, even accidental contact. Trane declines any responsibility for damage to things and unauthorized personnel in case of absence of clear and static limiting systems of the risk areas and of the relevant warning and danger signs.
- Page 5 The best procedure is the recovery and the recycle. If this is not possible the refrigerant must be conferred to an Dismantlement accredited system for its destruction in order to neutralize acid and toxic by-products. 2.5 PRECAUTIONS AGAINST RESIDUAL RISKS Prevention from risks due to the command system •...
- Page 6 • if the unit is to be moved after a year of being in the site or if it has to be dismantled contact Trane . IMPORTANT: No high pressure safety valve is installed on the unit by Trane The unit fail safe is assured by cut-out of the electrical power supply to the coils of the compressors contactors.
- Page 7 DO NOT PULL OUT THE HIGH PRESSURE SWITCHES (TWO PER REFRIGERANT CIRCUIT) IF THE UNIT IS NOT COMPLETELY VOID OF REFRIGERANT. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DEATH OR SERIOUS INJURY 2.10 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. Repeated manual resets may cause the warranty to be annulled.
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Page 8: Operating Limits
OPERATING LIMITS 3.1 STORAGE The units can be stored within the following environmental conditions: Min ambient temperature -10°C Max ambient temperature 53°C Max relative humidity 95% not condensable CAUTION: The storage in a very high humidity space (condensation) can damage electronic components. CAUTION: CCUF units are intended only for indoor usage and storage. - Page 9 In order to calculate performance with glycol solutions multiply main sizes by respective coefficients. IMPORTANT: An oversized water pump as on board unit pump is required for operation with glycol >25%. If any doubt please contact your Trane Sales Office Page 9...
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Page 10: Installation
INSTALLATION 4.1 MOVING AND POSITIONING THE UNIT The units have been designed to be lifted from above by means of eyebolts and holes in the base members. Use retractor bars to keep the lifting wires or chains away from the unit. Figure 2 - Correct lifting procedure for platform 1 units (sizes from 050 to 085) Figure 3 - Correct lifting procedure for platform 2 units (sizes... - Page 11 Correct lifting procedure for platform 3 units (sizes with two refrigerant Figure 4 circuits from 095 to 420) Figure 5 - Correct lifting procedure for platform 4 units (sizes with two refrigerant circuits from 485 to 620) Page 11...
- Page 12 Lifting procedures provided with the unit have to be respected. CAUTION Do not use forklift trucks to lift the unit from below. If equipment for lifting from above is not available, using rollers may move the unit. The surface on which the unit is placed must be flat and strong enough to withstand the weight of the unit while running. In order to reduce the transmission of vibrations to the supporting structures, fit shock absorbers in every fastening point.
- Page 13 4.2 MINIMUM SPACE REQUIREMENTS Dimensional drawing shall be respected to avoid: Difficult maintenance or inaccessibility to components Limited installation space could reduce the normal air flow, thus significantly reducing the unit performance and considerably increasing consumption of electrical energy. The following drawings are views from under the units: Figure 7 - minimum space requirements [mm] Figure 6 - minimum space requirements for platform 2 units (sizes from 100 to 140)
- Page 14 Figure 9 - minimum space requirements [mm] for platform 4 units (sizes form 485 to 620) Side of the unit that can be placed next to the wall. This means that with the unit at a distance less than the optimal one of 700 mm the accessibility to some components is worse but in any case is ensured even if the unit is leaning against the wall.
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Page 15: Acoustic Protection
ACOUSTIC PROTECTION maximum isolation effect, water lines and electrical conduit should also be isolated. Wall sleeves and rubber isolated piping hangers can be used to reduce the sound transmitted through water piping. To reduce the sound transmitted through electrical conduit, use flexible electrical conduit. EU and Local codes on sound emissions should always be considered. - Page 16 6.3 MAIN SWITCHES FEATURES Poli Ampere Type Unit size - CCUF 80 A OT80F3 80 A OT80F3 80 A OT80F3 100 A OT100F3 100 A OT100F3 100 A OT100F3 100 A OT100F3 125 A OT125F3 125 A OT125F3 160 A OT160G03 160 A OT160G03...
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Page 17: Water Connections
We recommend the installation of a filter having a filtering net with holes not exceeding 0.5 mm in diameter. Trane cannot be held responsible for any damage to heat exchangers due to the lack of good quality water filters. - Page 18 7.1.1 Calculation of total minimum water content, total optimal water content and flow rates The chiller needs values of total minimum and total optimal water content according to the following tables: Plant side cold water heat exchanger CCUF Vopt Vmin Q min Q max [m3]...
- Page 19 Trane is not responsible for damage to or malfunctioning of the equipment caused by failure to treat water or by improperly treated...
- Page 20 7.4 HYDRAULIC VERSIONS CCUF units are available in combination with various external hydraulic kits which are supplied separately from the unit and supplied directly by manufacturer. The available modules are the following ones: Single pump hydraulic 2 x single pumps hydraulic kit with or without kit with or without inverter Tank kit...
- Page 21 Terminals to be connected have the same labels on the electrical drawing of the unit and on the electrical drawing of the hydraulic kit. For further support please contact Trane. The hydraulic kit requires a power supply line of its own.
- Page 22 7.4.1 Hydraulic diagram for CCUF units with no pump no tank Temperature Remote Connections Probe drafted at customer care Relief Valve Expansion Vessel Gauges Safety Valve (6 bar) Shut Off Valve Pump Water Charge Water Discharge Plant side Check Valve REMARKS: Water Tank 1 apply the flow switch in a straight pipe far from filters, valves, etc.
- Page 23 7.4.3 Hydraulic diagram for CCUF units and hydraulic module with 1 pump and tank Temperature Probe drafted Relief Valve Single pump hydraulic kit Remote Connections Expansion Vessel at customer care Gauges Safety Valve (6 bar) Shut Off Valve Pump Water Charge Water Discharge Check Valve Water tank hydraulic kit...
- Page 24 7.4.5 Hydraulic diagram for CCUF units and hydraulic module with 2 pumps and tank Temperature Probe drafted Dual pump hydraulic kit Relief Valve Remote Connections Expansion Vessel at customer care Gauges Safety Valve (6 bar) Shut Off Valve Pump Water Charge Water Discharge Check Valve Plant side...
- Page 25 7.5 PUMPS CHARACTERISTICS 7.5.1 CCUF low head pressure pumps characteristics USER SIDE Ref. Curve F.L.I. F.L.A. Mod. [kW] [kPa] [kW] [kPa] [kPa] 1,72 1,72 1,72 2,55 2,55 2,55 2,55 2,55 2,55 4,52 4,52 4,52 4,52 6,09 10,6 6,09 10,6 6,09 10,6 6,09 10,6...
- Page 26 USER SIDE Page 26...
- Page 27 7.5.2 CCUF high head pressure pumps characteristics USER SIDE Ref. Curve F.L.I. F.L.A. Mod. [kW] [kPa] [kW] [kPa] [kPa] 2,55 2,55 2,55 3,44 3,44 4,52 4,52 4,52 4,52 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 10,12...
- Page 28 USER SIDE Page 28...
- Page 29 7.6 CUSTOMER PLANT SKETCHES 7.6.1 Customer plant sketch on the evaporator side of CCUF units with no on board unit pump CUSTOMER PLANT AIR CONDITIONING WATER PUMP Primary Pump Secondary Pump Temperature Probe FANCOIL COLD WATER Flow Switch TANK Drainage Vent Valve Expansion Vessel Filling group...
- Page 30 7.7 CUSTOMER PLANT SKETCHES 7.7.1 Customer plant sketch on the evaporator side CUSTOMER PLANT AIR CONDITIONING WATER PUMP Primary Pump Secondary Pump Temperature Probe FANCOIL COLD WATER Flow Switch TANK Drainage Vent Valve Expansion Vessel Filling group Steel Mesh Strainer Check Valve Safety Valve Interception valve...
- Page 31 7.4 HYDRAULIC VERSIONS. 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. Since no water flow control is installed on board the unit, the installation of the flow switch, always provided as a loose accessory by Trane, in the customer’s plant is mandatory.
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Page 32: Refrigerant Scheme
REFRIGERANT SCHEME REFRIGERANT= R454b Figure 19 IMPORTANT: Shut-off valves (aiming to avoid the refrigerant in the liquid line reaching dangerous pressure values due to direct sun irradiation) featured in the refrigerant scheme above are optional. If they are installed remotely by the customer the above scheme must be complied with concerning their position Page 32... -
Page 33: Connection To The Remote Condenser
The party in charge of the supply of the condenser and of its refrigerant piping is responsible of implementing all the required protections to comply with the PED requirements for the design pressure of the condenser installed. IMPORTANT: The only electrical signals that the Trane CCUF unit provides to the remote condenser are: Enabling signal 0-10 V modulating signal... - Page 34 VERY IMPORTANT: Maximum total length between CCUF unit and the refrigerant condenser is 20 equivalent meters. This means: • One piping bend corresponds to 1 equivalent meter One-way valve corresponds to 4 equivalent meter In case the CCUF condenser-less unit will be placed at a lower level and the refrigerant condenser will be placed at a •...
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Page 35: Electrical Panel And Electrical Data
The electrical panel supply is 400V/3ph+n/50Hz suitable for TN-S system and no additional power supply is necessary. If the unit is powered by a TN-C, TT or IT power supply system the Trane catalogue option “power supply without neutral 400V/3ph/50Hz” must have been ordered and implemented in the unit’s electrical cabinet. - Page 36 Electrical data NOMINAL VALUES MAXIMUM VALUES condenser water temperature in/out 30/35°C, evaporator water temperature in/out 12/7°C Compressors TOTAL TOTAL L.R.A. CCUF S.A. with with soft S.A. with F.L.I. F.L.A. L.R.A. F.L.I. F.L.A. S.A. soft starter F.L.I. F.L.A. S.A. starter soft starter 11,0 19,2 142,0...
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Page 37: Operator Responsabilities
Check that the thermal charge available is appropriate for starting. 12.2 REFRIGERANT CHARGE Trane CCUF units are shipped without any refrigerant charge Danger: Do not use the compressor to vacuum the system. Page 37... -
Page 38: Check List - Mandatory Operation Control Before Start-Up
SITE: ADDRESS: POSTCODE: COUNTRY: THE INTENDED PURPOSE OF CCUF UNITS IS NOT FOR INDUSTRIAL PROCESS APPLICATION. PLEASE CONTACT TRANE TECHNICAL DEPARTMENT IN CASE OF INDUSTRIAL PROCESS APPLICATION. GENERAL COMPLIANCE THE HYDRAULIC CIRCUIT IS COMPLETE AND READY TO BE USED AND THE THERMAL LOAD IS AVAILABLE. - Page 39 ELECTRONIC DEVICES ARE INTACT AND DON’T DISPLAY ANY DAMAGE. AN EXTERNAL WATER PUMP IS ELECTRICALLY CONNECTED TO THE ELECTRICAL PANEL IN ACCORDANCE WITH THE WIRING DIAGRAMS PROVIDED BY TRANE THE ELECTRICAL ABSORPTION AND THE WATER PUMP OVERHEATING ARE STANDARD. REFRIGERANT CIRCUIT COMPLIANCE ALL CONNECTIONS ON THE REFRIGERANT CIRCUITS ARE WELL TIGHTENED.
- Page 40 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.
- Page 41 DATE: AUTHORIZED SERVICE: CUSTOMER: NAME AND SIGNATURE NAME AND SIGNATURE Page 41...
- Page 42 13.1 REFRIGERANT CHARGE 13.1.1 Refrigerant replacement procedure with unit stopped and in vacuum (refrigerant charge in the liquid phase) Open the shut off valve as far as possible so that it closes the service coupling. Connect the refrigerant cylinder to the service coupling without tightening the coupling.
- Page 43 13.1.2 Refrigerant replacement procedure with unit running (refrigerant charge in the vapour phase) Caution: charge vapour only. Do not charge liquid because it may damage the compressor. Connect the refrigerant cylinder to the service valve without tightening the coupling. Drain the connection piping and tighten the coupling.
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Page 44: Start-Up
CONTROL OF THE OIL CHARGE 14.4 All the compressors mounted on Trane CCUF units are factory charged with oil whose chemical characteristic of stability are very good, so it is not necessary to change frequently the lubricant oil. The scroll compressors are equipped with an oil sight glass from which you can control the level. In tandem or trio performances, pay particular attention to oil level. -
Page 45: Maintenance
Every Trane CCUF unit comes with a logbook, in which the user or the person delegated to machine maintenance can keep all the required notes, in order to keep a historical log of the Trane CCUF unit. - Page 46 personnel. In particular, we recommend: 4 annual visits to units that operate about 365 days / year (quarterly) 2 visits per year for units with seasonal operation about 180 days / year (one at the start of the season and another one at mid-season) 1 annual visit for units with seasonal operation of about 90 days / year (starting seasonal) It’s important that during the initial start-up and periodically during operation routine checks are carried out.
- Page 47 IMPORTANT In case a temperature control based on ingoing water temperature is needed please contact Trane before carrying out any trying to set it autonomously.
- Page 48 15.3 ORDINARY MAINTENANCE Activities list week Month (1) Year (2) General: Data collection operation (Note 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 (4) Electric: Check the correct operation of the equipment on the unit Check the wear of contactors - Replace if necessary...
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Page 49: Recommended Spare Parts
RECOMMENDED SPARE PARTS There follows a list of the recommended parts for several years’ running. Trane is at your disposal to recommend a personalized list of accessories according to the commissioned order, including the part number of the equipment. 1 YEAR... -
Page 50: Troubleshooting
TROUBLESHOOTING Who can take corrective action U Symptom Cooling Heating = User Probable cause Possible remedy S = specialised personnel Probe faulty service Check and replace if necessary. A The unit does Lack of consent of the high or low See points D-E not start pressure... - Page 51 Who can take corrective action U Symptom Cooling Heating = User Probable cause Possible remedy S = specialised personnel Pressure switch out of order Check and replace. Machine completely void of See point G. refrigerant Water circulation pump blocked Unlock the pump E The compressor does not start Water circulation pump blocked and...
- Page 52 Water circulation pump defective Check the pump and replace if necessary. Low refrigerant charge See point G. The liquid filter is clogged Replace. N Abnormal noise Compressor noisy Check and replace if necessary. detected in the The panel vibrate Fasten properly. system P The unit does Phases of the supply network...
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Page 53: Improper Uses
For more information, please visit trane.eu or tranetechnologies.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Confidential and proprietary Trane information CG-SVX061C -GB_1023 ©2023 Trane...