Table of Contents
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TM
IntelliPak
Air-Cooled Cold Generator
Models
"K" and Later Design Sequence
CGAF-C20
CGAF-C40
CGAF-C25
CGAF-C50
CGAF-C30
CGAF-C60
With 3-D
TM
Scroll Compressors
Ó
2005 American Standard Inc. All rights reserved
http://www.trane.com
Installation
Operation
Maintenance
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 de-
sign and specifications without notice. Only qualified
technicians should perform the installation and servic-
ing of equipment referred to in this publication.
CG-SVX02B-EN
Hermetic Scroll Liquid Chillers, Air Cooled
Installation, Operation & Maintenance
SV-RF-CG-SVX02B-EN 105
Note: The installation of this equipment must
comply with all National, State and Local
Codes.
Service Literature
Refrigeration
CG
02B
January 2005
CG-SVX02A-EN 403
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Table of Contents
Related Manuals for Trane IntelliPak CG-SVX02B-EN
Summary of Contents for Trane IntelliPak CG-SVX02B-EN
- Page 1 Codes. CGAF-C30 CGAF-C60 With 3-D Scroll Compressors Trane has a policy of continuous product and product data improvement and reserves the right to change de- sign and specifications without notice. Only qualified Ó 2005 American Standard Inc. All rights reserved technicians should perform the installation and servic- http://www.trane.com...
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Page 2: About The Manual
About the Manual Literature Change History ing the instructions, the risk of improper operation and/or component damage will be minimized. CG-SVX02B-EN (November 2004) It is important that periodic maintenance be performed to First issue of manual; provides Installation, Operation, and help assure trouble free operation. -
Page 3: Table Of Contents
Table of Contents Disconnect Switch External Handle ......28 About the Manual Main Unit Power Wiring ..........28 Literature Change History ..........2 Power Wire Sizing and Protection Device Equations ... 30 Overview of Manual ............2 Field Installed Control Wiring ......... 32 Controls Using 115 VAC .......... -
Page 4: General Information
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 5: Unit Description
The Trane Communication Interface module expands communications from the unit’s UCM network to a Trane Tracer For “Ship with” items, refer to the Unit Component “Layout” 100™ or a Tracer Summit™ system and allows external setpoint and “Ship with”... - Page 6 General Information Lead/Lag (Standard) on that circuit will be locked out and a manual reset diag- When Lead-Lag is enabled, for each capacity add request, nostic is initiated. the CGM will begin sequencing the compressors “On” that Evaporator Freeze Protection have: Is accomplished by Freeze Protection Cutout (FPC) a.
- Page 7 For 25, 30, 50 and 60 ton units, the Saturated Condenser General Information OA Temp Suppression Setpoint (SCTOATSS) is a Human Interface settable parameter (default: 40°F, range: 30 - are de-energized immediately without regard to the 50°F, Disabled: above 50°F) which determines how many condenser fan minimum on time.
- Page 8 General Information only the solution pump output will be energized. 5 minutes Compressor Motor Winding Thermostats (Standard) later, an auto-reset diagnostic (Evap Solution Flow Proving A thermostat is embedded in the motor windings of each Switch) will be generated. Once the flow switch input Scroll compressor.
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Page 9: Unit Component "Layout" And "Shipwith" Locations
General Information External Auto/Stop (Optional) The unit can be Stopped and Started by a remote customer 1. when the unit is stopped (Unit Stop or External Auto/ provided field installed binary input device (such as a time Stop) clock) connected to the CGM. When the input is opened (Stop), the unit will stage the compressors and the solution 2. -
Page 10: Module Mounting Locations
General Information Module Mounting Locations & Screw Hole... -
Page 11: Installation
Follow the instructions under “Unit Isolation” for proper iso- dence that the damage did not occur after delivery. lator placement and installation. [ ] Notify the appropriate Trane office before installing or re- Check with a roofing contractor for proper waterproofing pairing a damaged unit. - Page 12 Figure 1 Typical Installation Clearances for Single, Multiple or Pit Applications...
- Page 13 Figure 2 C20 Ton Unit Dimensional Data & Recommended Clearances...
- Page 14 Figure 2 C25 Ton Unit Dimensional Data & Recommended Clearances...
- Page 15 Figure 2 C30 Ton Unit Dimensional Data & Recommended Clearances...
- Page 16 Figure 2 C40 Ton Unit Dimensional Data & Recommended Clearances...
- Page 17 Figure 2 C50 Ton Unit Dimensional Data & Recommended Clearances...
- Page 18 Figure 2 C60 Ton Unit Dimensional Data & Recommended Clearances...
- Page 19 Installation Table 1 Typical Unit Weights & Point Loading Data Unit Condenser Operating Operating Weight Distribution @ Unit Mounting Points Size Fin Mat’l. Weight Alum. 1870 — — Copper 2085 — — Alum. 2085 — — Copper 2370 — — Alum.
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Page 20: Rigging
Installation Rigging 6. Level the unit carefully. Refer to the “Leveling the Unit” A Rigging illustration and Center-of-Gravity dimensional section. data table is shown in Figure 3. Refer to the typical unit op- erating weights table before proceeding. 7. After the unit is level, tighten the isolator base mounting bolts to secure them to the mounting surface. - Page 21 Installation Figure 4 Typical Neoprene Isolator Selection & Location Unit Neoprene Isolator Part Number @ Mounting Location Size Material Location 1 Location 2 Location 3 Location 4 Location 5 Location 6 RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-RED RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-GRN RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-GRN RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRN RDP-4-BLK RDP-3-GRN RDP-3-GRY RDP-3-RED RDP-3-GRN RDP-3-RED...
- Page 22 Installation Figure 5 Typical Spring Isolator Selection & Location Spring Isolator Part Number @ Mounting Location Unit Location 1 Location 2 Location 3 Location 4 Location 5 Location 6 Size C20 CP-1-28 CP-1-31 CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-26 CP-1-26 C25 CP-1-31 CP-1-31 CP-1-27 CP-1-28 CP-1-27 CP-1-28 CP-1-26 CP-1-27 C30 CP-1-32 CP-2-27 CP-1-27 CP-1-27 CP-1-31 CP-1-31 CP-1-26 CP-1-26 CP-1-27 CP-1-28 CP-1-25 CP-1-25 C40 CP-1-28 CP-1-28 CP-1-28 CP-1-31 CP-1-28 CP-1-28 CP-1-28 CP-1-28 CP-1-27 CP-1-28 CP-1-27 CP-1-28 C50 CP-1-31 CP-1-32 CP-1-31 CP-1-32 CP-1-31 CP-1-31 CP-1-31 CP-1-31 CP-1-28 CP-1-31 CP-1-28 CP-1-31...
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Page 23: Shipping Fasteners
Installation Shipping Fasteners 1. Remove the four anchor bolts (2 front and 2 rear), used to secure the shipping brace to the unit’s base rail. Compressor Shipping Hardware 2. Remove the three self-tapping screws that secure each Figure 6 illustrates the location of each tiedown bolt and shipping brace to the compressor mounting rails. -
Page 24: General Unit Requirements
(chiller units only). [ ] Check the unit for shipping damage and material short- age; file a freight claim and notify Trane office. [ ] Install proper grounding wires to an earth ground. [ ] Verify that the installation location of the unit will provide Field Installed Control Wiring Requirements the required clearance for proper operation. -
Page 25: Chilled Water Access Holes
Installation Isolate the water pumps from the system to avoid vibration transmission. To minimize heat gain and prevent condensa- Water Pressure Gauges tion, insulate all water piping. Use an appropriate pipe seal- Install pressure gauge(s) at the chiller barrel to monitor the ant on all threaded connections. - Page 26 Figure 7A Typical Water Access Holes for 20 through 60 Ton Units Figure 7B Figure 7C Edge Protector Installation Clearance Requirements Around Water Pipe...
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Page 27: Final Water Piping Connections
Installation Figure 8 Typical Water Piping Recommendations Figure 9 2. Connect the water pipe to the chiller. Required Flow Switch Illustration 3. Install the drain plug, (if no drain is used) or ensure the drain shutoff valve is closed. 4. While filling the chiller system with solution, vent the air from the system at the highest points. - Page 28 Also, tection. Refer to Tables 2A and 2B. the low pressure control may need to be changed. Contact the local Trane representative. ® 2. Use friction tape to secure the heat tape to the solution pipe.
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Page 29: Field Installed Power Wiring
Installation An overall layout of the field required power wiring is illus- Field Installed Power Wiring trated in Figure 11. These diagrams are representative of standard applications and are for general reference only. Al- An overall dimensional layout for the field installed wiring ways refer to the wiring diagram that shipped with the unit entrance into the unit is illustrated in Figure 2. - Page 30 Installation Figure 11 Typical Field Installed Power Wiring Refer to the Wiring Diagram Notes at the end of this Section Table 3 Customer Connection Wire Range...
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Page 31: Power Wire Sizing And Protection Device Equations
Installation Power Wire Sizing and Protection Device Equations To correctly size the main power wiring for the unit, use the appropriate calculation(s) listed below. Read the load definitions that follow and use Calculation #1 for determining the MCA (Minimum Circuit Ampacity), MOP (Maximum Over current Pro- tection), and RDE (Recommended Dual Element fuse size) for each unit. - Page 32 Installation Table 4 Unit Electrical Data Min. Max. Unit Rated Ckt. Fuse Compressor Motor (Each) Cond. Fan Motors (Each) Size Voltage Amp. Size Qty. Qty. 200/60/3 39.4 230/60/3 39.4 CGAF 460/60/3 17.2 575/60/3 13.2 380/50/3 17.2 0.75 415/50/3 17.2 0.75 200/60/3 39.3/56.9 269/409...
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Page 33: Field Installed Control Wiring
Installation Field Installed Control Wiring d. Do not run the AC low voltage wiring in the same conduit with the high voltage power wiring. Before installing any connecting wiring, refer to Figure 2 for Install appropriately sized 24 volt AC/DC control wiring for the electrical access locations provided on the unit. -
Page 34: Controls Using Dc Communication Links
Installation Note: Resistance in excess of 2.5 ohms per 1. Refer to the Tracer installation literature to determine conductor can cause deviations in the accuracy of proper communication link termination connections at the the controls. Tracer unit. Multiple UCM’s on the communication link can be connected in a “daisy chain”... -
Page 39: System Pre-Start Procedures
With the designs of specialized motors such as those used the vent, located on the top of the chiller barrel. Close in the Trane scroll compressor, operating temperature, effi- the vent when the chiller barrel is full of water. ciency, performance, and reliability has been taken into ac- count in the total performance of the compressor. -
Page 40: Electrical Phasing
System Pre-Start Procedures At low operating voltage and high operating load, the imbal- The compressor motor is internally connected for clockwise ance may be around 4 percent. At high operating voltage rotation with the incoming power supply phased as and low operating load, the imbalance may be as high as A, B, C. -
Page 41: System Start-Up
System Start-Up Sequence of Operation Evaporator Freeze Protection Diagnostic The evaporator freeze protection integrator (EFZ) will start integrating when the leaving solution temperature or enter- Chiller Control for Comfort Applications ing solution temperature is less than the low solution tem- The CGM controls the leaving solution temperature (LST) to perature cutout setpoint. - Page 42 System Start-Up Ice Building can be terminated by: Opening the customer provided field installed remote On Time device, or Seconds = 3600 / 4 X Max Cycle Rate X (1-Load Value Ice building stopped from ICS communications. Fraction) Off Time If at any time the unit is switched from the Ice Building Seconds = 3600 / 4 X Max Cycle Rate X Load Value mode to normal comfort operation, the unit will transition to...
- Page 43 System Start-up Zone Temp Reset: • If Zone Temperature is above the Start Temp, or if Zone Temperature Sensor has failed, calculated reset amount is zero (0). • If Zone Temperature is equal or below the End Temp, calculated reset amount is equal to selected Max Amount. •...
- Page 44 System Start-Up Table 8A Chilled Solution Reset Schedule based on Zone Temperature Active Leaving Solution Setpoint Zone Reset Cooling Reset Amount = Maximum LSS = ALSS + Maximum Adjustable Factory Reset Preset = 5 3 - 16 F Reset Amount = Zero (0) LSS = ALSS Zone End Temperature...
- Page 45 System Start-Up Table 8C Chilled Solution Reset Schedule based on Entering Solution Temperature Active Leaving Solution Setpoint Entering Solution Reset Reset Amount = Maximum LSS = ALSS + Maximum Adjustable Factory Reset Preset = 5 3 - 16 F Reset Amount = Zero (0) LSS = ALSS EST - LST...
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Page 46: Chilled Water Circulating Pump
System Start-Up Sequence of Operation WARNING Low Ambient Dampers Rotating Components! Low Ambient Dampers are available as a factory installed option or can be field-installed. Dampers are used to extend During installation, testing, servicing and troubleshoot- the operation of these units from the standard operational ing of this product it may be necessary to measure the temperatures to a minimum of 0 F without hot gas bypass... - Page 47 System Start-Up Figure 13 Evaporator Water-Pressure Drop for CGAF-C20 Through C60 Units (English) Note 1 - Factor to convert “Feet of Water” to “Lbs. per Sq. Inch” (PSI): 2.3 Feet of Water = 1 PSI...
- Page 48 System Start-Up Figure 14 Performance Adjustments and Solution Freezing Points (Use Only When Leaving Brine Temperature is Between 40 F & 50...
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Page 49: Verifying Proper Fan Rotation
System Start-Up Verifying Proper Fan Rotation c. Interchange any two of the field connected main power wires at the unit terminal block 1TB1 or the 1. Close the main power disconnect switch or circuit protec- factory mounted disconnect switch 1S14. tor switch that provides the supply power to the unit’s ter- minal block 1TB1 or the unit mounted disconnect switch Note: Interchanging “Load”... - Page 50 System Start-Up Figure 15 Condenser Fan Locations 8. Open the Human Interface access door, located in the Note: Pump operation is dependent upon proper unit control panel, and press the SERVICE MODE key to solution flow proving switch operation. Please see display the first service screen.
- Page 51 System Start-Up ignated in this step has elapsed. Press the ENTER key WARNING to confirm this choice. Rotating Components! During installation, testing, servicing and troubleshoot- WARNING ing of this product it may be necessary to measure the speed of rotating components. Have a qualified or li- Rotating Components! censed service individual who has been properly trained in handling exposed rotating components, per-...
- Page 52 System Start-Up b. The efficiency of the evaporator. b. Using a Refrigerant / Temperature chart, convert the pressure reading to a corresponding saturated vapor c. The amount of protection the compressor is temperature. receiving against flooding or overheating. c. Measured the suction line temperature as close to The recommended range for superheat is 10 to 16 degrees the expansion valve bulb, as possible.
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Page 53: Compressor Crankcase Heaters
Compressor Oil “W” in the miscellaneous digit of the model number), a The scroll compressor uses Trane OIL-42 without substi- damper is factory installed over the lead condenser fan for tution. The appropriate oil charge for a 9 and 10 Ton scroll each refrigeration circuit. - Page 54 System Start-Up [ ] Program the Night Setback (NSB) panel (if applicable) for proper unoccupied operation. Refer to the programming WARNING instructions for the specific panel. Hazardous Voltage! [ ] Verify that the Remote panel “System” selection switch, Disconnect all electric power, including remote discon- “Fan”...
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Page 55: Service & Maintenance
Service & Maintenance The scroll compressor uses Trane OIL-42 without substi- Compressor Operational Sounds tution. The appropriate oil charge for a 9 and 10 Ton scroll compressor is 8.5 pints. For a 14 and 15 Ton scroll com- Because of the scroll compressor design, it emits a higher pressor, use 13.8 pints. -
Page 56: Fuse Replacement Data
Service & Maintenance Table 12 Compressor Circuit Breaker Data Unit Number of Compressor Rated Compressor Compressor Must Hold Must Trip Size Compressors Capacities Voltage (AMPS) (AMPS) 39.4 43.2 49.7 39.4 43.2 49.7 380/415 17.2 18.9 21.7 17.2 18.9 21.7 13.2 15.1 17.4 39.3 , 56.9... -
Page 57: Monthly Maintenance
Service & Maintenance Monthly Maintenance Note: Over lubrication can be just as harmful as not enough grease. Before completing the following checks, turn all system con- trol circuit switches to the “Off” position. Use a hand grease gun to lubricate these bearings; add grease until a light bead appears all around the seal. -
Page 58: Coil Cleaning
Service & Maintenance Coil Cleaning 5. Pour the cleaning solution into the sprayer. If a high-pres- sure sprayer is used: Regular coil maintenance, including annual cleaning, en- hances the unit’s operating efficiency by minimizing: a. do not allow sprayer pressure to exceed 600 psi. compressor head pressure and amperage draw;... -
Page 59: Annual Maintenance
Service & Maintenance Annual Maintenance Final Process [ ] Perform all weekly and monthly maintenance proce- For future reference, you may find it helpful to record the dures. unit data requested below in the blanks provided. [ ] Have a qualified service technician check the setting and (1) Complete Unit Model Number: function of each control and inspect the condition of and ______________________________________... -
Page 60: Warranty And Liability Clause
WARRANTY AND LIABILITY CLAUSE COMMERCIAL EQUIPMENT RATED 20 TONS AND LARGER AND RELATED ACCESSORIES PRODUCTS COVERED - This warranty* is extended THE WARRANTY AND LIABILITY SET by American Standard Inc. and applies only to com- FORTH HEREIN ARE IN LIEU OF ALL mercial equipment rated 20 Tons and larger and OTHER WARRANTIES AND LIABILITIES, related accessories. -
Page 61: Index
Index AC Conductors...32; See Table 5 Edge Protector...25; See Figure 7B Air Handling Equipment...55 “efficiency check point” setting...6 Air Vents...24 Electrical Service Sizing Data...31 Align the mounting holes...19 Emergency Stop...8 Evaporator Nameplate...4 Evaporator Data...44; See Table 9 Evaporator water inlet and outlet types...23 Balancing Valves...24 Evaporator Water-Pressure Drop...45;... - Page 62 Superheat & Subcooling Module...5 Neoprene Isolator Selection...20; See Figure 4 Neoprene Isolators...19 “temporary low limit suppression” setting...6 Thermometers...24 “OAKITE 161”...56 Trane Communications Interface Module...5 “OAKITE 166”...56 Trane OIL-42...51 Operator’s Maintenance Log...52; See Table 11 Typical Compressor Locations; See Figure 16 Optional Flow Switch...26 Typical Compressor Terminal Block...51;...