Trane IntelliPak CGAF Series Programming, Troubleshooting Manual

Air-cooled cold generator, "h" and later design sequence, with 3-dtm scroll compressors
Table of Contents

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M
IntelliPak
Air-Cooled Cold Generator
Models
"H" and Later Design Sequence
CGAF-C20
CGAF-C40
CGAF-C25
CGAF-C50
CGAF-C30
CGAF-C60
With 3-D
TM
Scroll Compressors
2005 American Standard Inc. All rights reserved
http://www.trane.com
Programming
Troubleshooting
Guide
Library
Product Section
Product
Model
Literature Type
Sequence
Date
File No.
Supersedes
Trane has a policy of continuous product and product data
improvement and reserves the right to change design and
specifications without notice. Only qualified technicians should
perform the installation and servicing of equipment referred to
in this publication.
CG-SVP01B-EN
Service Literature
Hermetic Scroll Liquid Chillers, Air Cooled
Programming, Trouble Shooting Guide
SV-RF-CG-SVP01B-EN 1/05
CG-SVP01A-EN 4/03
Refrigeration
CG
01B
January 2005

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Summary of Contents for Trane IntelliPak CGAF Series

  • Page 1 CGAF-C60 With 3-D Scroll Compressors Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Only qualified technicians should perform the installation and servicing of equipment referred to 2005 American Standard Inc.
  • Page 2: Literature Change History

    About The Manual Literature Change History The manual is divided into 6 sections. Each section pro- vides the operator with specific information about the sys- tem operating parameters and their related screens. By CG-SVP01B-EN (January 2005) carefully following the screen layout within this manual Original issue of this manual;...
  • Page 3: Table Of Contents

    Liquid Line Temperatures ............20 Interprocessor Communications Bridge Module ..... 6 Temp Measured by Sensor Connected To Trane Communications Interface Module ....... 6 CGM Zone Temp Input ............20 Generic BAS Module ............... 6 Temp Measured by Sensor Connected To Power Disconnecting Switches ..........
  • Page 4 Table of Contents Hot Operation Response Option ........... 24 Ckt 1 Suction Line Pressure Transducer, 0 PSIG and 100 Pumpdown Function Enable/Disable ........24 PSIG Voltages ............... 32 Default Chiller Solution Pump Mode ........24 Ckt 1 Liquid Line Pressure Transducer, 0 PSIG and 400 PSIG Evap Soln Pump Off Delay Time ...........
  • Page 5: Hazard Identification

    Model Number Description eration, specific components, and other options for any spe- cific unit. All Trane products are identified by a multiple-character When ordering replacement parts or requesting service, be model number that precisely identifies a particular type of sure to refer to the specific model number, serial number, unit.
  • Page 6: Glossary Of Terms

    IBTS = Ice Build Terminate Setpoint Trane proprietary network communication protocol. ICS = Integrated Comfort System Comm5 IFW = Informational Warning Trane’s implementation of LonTalk (an open network INFO = Information Only [Diagnostic] communication protocol.) I/O = Inputs/outputs Chilled Solution Temperature Reset...
  • Page 7: Ucm Control System

    ™ The Trane Communication Interface module expands com- 115V Control Circuit Switch (1S1) munications from the unit’s UCM network to a Trane Tracer Control circuit switch (1S1) is provided on all units and is lo- ™ or a Tracer Summit ™...
  • Page 8: Human Interface Module

    General Information Human Interface Module General Operation (1U65 = Local 6U66 = Remote) At power-up, the Human Interface LCD will display one of three initial screens illustrated in the "General Status" sec- The Human Interface (HI) Module illustrated in Figure 1 is the device which enables the customer, building owner, or tion.
  • Page 9: Menu Keys

    General Information Menu Keys SETPOINTS Key Pressing the SETPOINTS key will cause the LCD screen to display the first of the setpoint screens where the operator The six keys illustrated in Figure 2 in the MENU area (STA- will designate default temperature setpoints and setpoint TUS, SETPOINTS, SETUP, CONFIGURATION, DIAGNOS- source information.
  • Page 10: Unit Operation Keys

    General Information + (Plus) Key STOP Key When viewing a setpoint screen, this key will increase the Pressing the STOP key will cause the unit to transition to temperature or pressure value of the setpoint. When work- the stop state. If the current display is editable, pressing the ing with a status menu, it will add the current status display STOP key will cancel the desired edit.
  • Page 11: General Status Display

    General Information General Status Display Anytime the unit is powered up, or the STATUS, AUTO, or STOP keys are pressed, the unit mounted Human Interface will display one of the following three general status display screens. The operator will then be able to enter keystrokes which will allow him to navigate through a set of menus and submenus in order to provide/access various monitoring, setup, and configuration infromation.
  • Page 12: Factory Presets

    General Information Factory Presets If your application requires different settings, turn to the listed page beside the function, press the designated func- The CGM controlled unit has many operating functions tion menu key, then press and hold the NEXT or PREVI- whose settings are preset at the factory, but may be modi- OUS key until its screen appears on the LCD.
  • Page 13 General Information Factory Presets (Continued) Factory Preset Changed See page... To adjust to adjust Press..Ice Building Control Fuctions Ice Building Function Disabled SETUP Ice Building Mode One Time SETUP Ice Rebuild Delay Time 360 Minutes SETUP GBAS 0-5 VDC Module I/O Assignments GBAS (0-5 VDC) Analog Input 1 Assignment Not Assigned SETUP...
  • Page 14 General Information Factory Presets (Continued) Factory Preset Changed See page... To adjust to adjust Press..Actuator Setup Definitions Number 1 Low Ambient Maximum Stroke 30 seconds SETUP Number 1 Low Ambient Minimum Voltage 2.0v SETUP Number 1 Low Ambient Maximum Voltage 10.0v SETUP Number 1 Low Ambient Acting...
  • Page 15: Password Protected Screens

    General Information Password Protected Screens Some of the operating displays on the Human Interface LCD screen are intended to be accessed by qualified users only, and require a password to change. The following screens display the various programming sections that require a password in order to view or to modify the preset operating parameters.
  • Page 16: Compressor Status Submenu

    System Operating Status The screens shown in this section are for example only. STATUS Menu Pressing the + (Plus) key while viewing any of the status display screens will add that screen to the Custom menu. The STATUS menu is used to view various operating condi- When a status screen is displayed for 30 minutes without a tions such as temperatures and humidity levels.
  • Page 17: System Operating Status

    System Operating Status The following screens are displayed for 20 through 60 Ton units. Used on Units: 20 thru 60 Ton Units Compressor Relay K11 Possible Values: K3 - On, Off, Locked, Enabled K4 - On, Off, Locked, 1. Press the NEXT key until the following screen is displayed. K11 - On, Off, Locked, or K12 - On, Off, Locked Compressor Relay K12...
  • Page 18: General System Status Submenu

    System Operating Status 1. Press the NEXT key until the following screen is displayed. The following three screens are applicable when Superheat/ Subcool Module is installed. Used on Units: 40-60 Ton Units with superheat/subcool module Refrigerant Ckt 2 - Temperature Data Possible Values: -40 to 200 F Suction 72.0 F...
  • Page 19: Mcm Heat Tape Control Relay

    System Operating Status This screen is displayed on units with Brazed Plate. MCM Heat Tape Control Relay: Used on Units: All Brazed Plate Units Possible Values: On, Off 1. Press the NEXT key until the following screen is displayed. This screen is displayed when Hot Gas Bypass is installed. Used on Units: With Hot Gas Bypass option CGM Hot Gas Bypass Control Relay: Possible Values: On, Off...
  • Page 20: Temperature Input Status Submenu

    System Operating Status 1. Press the NEXT key until the following screen is displayed. Used on Units: All Units Active Hot Start Load Limit Setpt From Possible Values: Human Interface STP Menu, HUMAN INTERFACE STP MENU is 78.0 F GBAS 0-10 VDC Module, GBAS 0-5 VDC Module, Setpoint Range = 0 - 99.9 F 1.
  • Page 21: Temp Measured By Sensor Connected To Cgm Zone Temp Input

    System Operating Status Used on Units: 40-60 Ton with Superheat/Subcooling Refrigerant Ckt 2 - Temperature Data Module installed Suction 72.0 F Sat Liquid 97.0 F Possible Values: -40.0 to 200 F 1. Press the NEXT key until the following screen is displayed. Used on Units: All Units Temp Measured By Sensor Connected To Possible Values: -40.0 to 200 F...
  • Page 22: Gbas 0-5Vdc Module Status Submenu

    System Operating Status 1. Press the NEXT key until the following screen is displayed. Used on Units: With Current Sensing Module on 40-60 Ton Compressor 2A Phase Currents - Amps Possible Values: 0 to 255 Phase B Phase C 1. Press the NEXT key until the following screen is displayed. Used on Units: With Current Sensing Module on 40-60 Ton Compressor 2B Phase Currents - Amps Possible Values: 0 to 255...
  • Page 23 System Operating Status Used on Units: With GBAS 0-10 VDC Module GBAS (0-10VDC) Demand Limit Input Status Possible Values: Open, Closed Open 1. Press the NEXT key until the following screen is displayed. Used on Units: With GBAS 0-10 VDC Module GBAS (0-10VDC) Binary Output Possible Values: Output = On, Off Assigned:...
  • Page 24: System Programming Setup

    System Programming SETUP After the unit is installed, the CGM must be programmed Start with the first setup screen in the SETUP menu and with certain setup information (chilled solution setpoints, ON program the necessary information by completing the steps and OFF times, system defaults, setpoint sources, etc...) in located below each illustrated window.
  • Page 25 System Programming SETUP Used on Units: All Units with GBAS5V, Demand Limit Definition: NONE GBAS10V or TCI Reduce cooling capacity by this amount Possible Values: None - All Units 1. Press the + or - key until the proper value is displayed. 25% - 2 Ckt Only 2.
  • Page 26 System Programming SETUP Used on Units: All Units Evap Soln Pump Off Delay time 30 Sec Possible Values: 30 to 600 seconds Delay Pump OFF Request By This Amount 1. Press the + or - key until the proper value is displayed. 2.
  • Page 27 System Programming SETUP End of Submenu (NEXT) to Re-enter SETUP 1. Pressing the NEXT key will display the beginning of the Submenu. 2. Press the NEXT key again to advance to the following screen. The following screens are displayed with Ice Building Control Option. Ice Building Control Functions Submenu Press ENTER to Review or Adjust 1.
  • Page 28 System Programming SETUP Used on Units: All Units Saturated Condenser Temp Control Band Possible Values: 0 to 20 F Temporary Low Limit Suppression 10 F 1. Press the + or - key until the proper value is displayed. 2. Press the ENTER key to confirm this choice. 3.
  • Page 29 System Programming SETUP GBAS (0-5VDC) Binary Output 1 Definition OUTPUT IS NOT ASSIGNED 1. Press the + or - key until the proper value is displayed. Used on Units: With GBAS 0-5VDC Module 2. Press the ENTER key to confirm this choice. Possible Values: Not Assigned 3.
  • Page 30 System Programming SETUP 1. Press the NEXT key to display Generic BAS Binary Output 2 Definition screen. GBAS (0-5VDC) Binary Output 2 Definition OUTPUT IS NOT ASSIGNED 2. Press the + or - key until the proper value is displayed. Used on Units: With GBAS 0-5VDC Module 3.
  • Page 31 System Programming SETUP Assign Diag To GBAS (0-10V) Output Any Active Diagnostic (No) 2. Press the + or - key until the proper value is displayed. If "YES" is assigned to "Any Active Diagnostic", pressing the NEXT key Used on Units: With GBAS 0-10VDC Module will advance to the "End of Submenu"...
  • Page 32 System Programming SETUP Device Characteristic Setup Definitions Press ENTER to Review or Adjust 1.To view the factory preset or to modified the factory presets to meet specific application requirements, press the ENTER key to advance to the following screens. If no adjustments are required, press the NEXT key to advance to the "Control Algorithm Tuning Parameters".
  • Page 33 System Programming SETUP Used on Units: With Superheat/Subcooling Option Ckt 1 Suction Line Pressure Transducer Possible Values: 0 PSIG - 0.000 to 4.000 VDC 0 PSIG= 0.118 VDC 100 PSIG= 4.847 VDC 100 PSIG - 1.000 to 5.000 VDC 1. Press the + or - key until the proper value is displayed. 2.
  • Page 34 System Programming SETUP ENTER key to advance to the following screens. If no adjustments are required, press the NEXT key to advance to the beginning of the "Setup" menu. Used on Units: All Units Comfort Cooling Possible Values: 4.0 to 20.0 F Design Delta Temperature Setpoint 10.0 F 2.
  • Page 35: Hi Leaving Solution Setpoint

    System Programming SETPOINTS SETPOINTS Menu When a setpoint screen is displayed for 30 minutes without a key being pressed, the LCD screen will revert to the gen- eral operating status display. If this happens, press the The SETPOINTS menu is used to designate default SETPOINT key again to return to the setpoint menu.
  • Page 36: System Programming Setpoints

    System Programming SETPOINTS 3. Press the NEXT key until the following screen is displayed. Used on Units: With Ice Building Control Option Use Ice Building Terminate Setpoint Possible Values: Human Interface STP Menu From: HUMAN INTERFACE STP MENU GBAS 0-5VDC Module 1.
  • Page 37: Configuration Menu

    System Configuration CONFIGURATION Menu Refer to the Model number stamped on the unit nameplate The CGM controlled unit has many operating functions located on the control panel door while scrolling through the whose settings are preset at the factory. The following con- configuraton screes.
  • Page 38: Superheat/Subcool Module

    System Configuration 3. Press the NEXT key until the following screen is displayed. Used on Units: All Units Configuration - Model Num Digit Possible Values: Installed, Not Installed Current Sensing Module INSTALLED 1. Press the + or - key until the proper value is displayed. 2.
  • Page 39: System Configuration

    System Configuration 1. Press the NEXT key until the following screen is displayed. Used on Units: With CSM Module Software Revision Number Report: Possible Values: 1.0 or Greater Current Sensing Module (CSM) 1.00 1. Press the NEXT key until the following screen is displayed. Used on Units: All Units Software Revision Number Report: Possible Values: 1.0 or Greater...
  • Page 40: Cgm Hot Gas Bypass Control Relay

    System Testing & Troubleshooting SERVICE MODE Menu When a service mode screen is displayed for 30 minutes without a key being pressed, the LCD screen will revert to the general operating status display. If this happens, press The SERVICE MODE menu is used to input operating pa- the SERVICE MODE key again to return to the service rameters for unit operation during a service test.
  • Page 41: Cgm Alarm Output

    System Testing & Troubleshooting The following screen will display on 40 to 60 Ton units. Used on Units: 40 to 60 Ton Compressor Relays Possible Values: On, Off K11 OFF K12 OFF K3 OFF K4 OFF 1. Press the + or - key until the proper value is displayed. 2.
  • Page 42: Cgm Ice Build Relay Output

    System Testing & Troubleshooting 3. Press the NEXT key until the following screen is displayed. Used on Units: With Ice Building Control Option CGM Ice Build Relay Output : Possible Values: On, Off 1. Press the + or - key until the proper value is displayed. 2.
  • Page 43 After pressing the STOP or AUTO key, the following screen is displayed Service Mode, STOP SYSTEM Restart Communicating With Unit. Please Wait and then the following screen is displayed: Updating Unit Data. Please Wait TRANE INTELLIPAK and then the top level status screen is displayed.
  • Page 44: Diagnostics Menu

    System Testing & Troubleshooting DIAGNOSTICS Menu log are stacked in inverse chronological order, with the first diagnostic screen being the most recently reported diagnos- tic. The DIAGNOSTICS menu is used to view diagnostics that have resulted from system failures within the unit. There are When a new diagnostic is displayed, the words “NOT two lists where diagnostics reside;...
  • Page 45 System Testing & Troubleshooting Resetting Active Manual Diagnostics Sending Reset Request and then the following screen will be displayed Resetting Active Manual Diagnostics Updating Unit Data, Please Wait and then the following screen will be displayed Active Diagnostic ---- Info "Please Wait .
  • Page 46 System Testing & Troubleshooting Used on Units: All Units Active Diagnostic ---- Info More The word MORE will only appear if more than one failure has occured. If additional active diagnostics are present, pressing the NEXT key will display them. Possible Values: CGM ICS Temperature Sensor Fail Sat Liquid Temp Sensor Fail Ckt 1...
  • Page 47 System Testing & Troubleshooting Communications Link Problems If one of these messages appear on the Human Interface screen, that Human Interface is not communicating with the unit. Used With: All Units with Local HI LOCAL HI COMMUNICATIONS LOSS Problem: The Unit Mounted (Local) Human interface CHECK COMM LINK WIRING BETWEEN MODULES has lost communications with the CGM.
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  • Page 66 Disconnect switch 1S14 ........... 6 Module I/O Summary ..........62 Emergency Stop ............5 ENTER Key .............. 8 NEXT Key ..............9 External Auto/Stop ........... 5 No Configuration ............7 non-Trane building control systems; See Generic BAS Module Generic Building Automation System ...... 6...
  • Page 67 STATUS Menu ............15 STOP Key ..............9 Superheat & Subcooling Module ......6 TEST START Key (SERVICE) ....... 9 Trane Communications Interface Module ....6 Trane integrated comfort systems; See Trane Communications Interface Module Transformer switch 1S70 ........6 Unit Control Module ..........

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