Trane CXAJ series Installation, Operation And Maintenance Manual
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Trane CXAJ series Installation, Operation And Maintenance Manual

Trane CXAJ series Installation, Operation And Maintenance Manual

Modular air-cooled chiller (heat pump) unit
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Installation, Operation and
Maintenance
Modular Air-Cooled Chiller (Heat Pump) Unit
CXAJ/CGAJ
Only qualified personnel may install and maintain the unit. The installation, start-up and maintenance of heating,
ventilating and air-conditioning unit will be hazardous, and the operator shall have specific knowledge and training.
Improper installation, adjustment or change of the unit by an unqualified person will result in death or serious injury.
When operating the unit, pay attention to all precautions in the documents and the tags and labels attached to the
unit.
Jan. 2016
Safety Warning
690134220001
PKGP-SVX06A-EN

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Summary of Contents for Trane CXAJ series

  • Page 1 Installation, Operation and Maintenance Modular Air-Cooled Chiller (Heat Pump) Unit CXAJ/CGAJ 690134220001 Safety Warning Only qualified personnel may install and maintain the unit. The installation, start-up and maintenance of heating, ventilating and air-conditioning unit will be hazardous, and the operator shall have specific knowledge and training. Improper installation, adjustment or change of the unit by an unqualified person will result in death or serious injury.

  • Page 2: Table Of Contents

    Table of Contents General Information ………………………………………………………………………………… 3 Safety Precautions …………………………………………………………………………………… 4 Nomenclature ………………………………………………………………………………………… 5 Dimensions …………………………………………………………………………………………… 6 Performance Data …………………………………………………………………………………… 7 Unit Installation ……………………………………………………………………………………… 9 Electrical Installation ……………………………………………………………………………… 15 Wiring Diagram …………………………………………………………………………………… 17 Pre-Start-up ………………………………………………………………………………………… 22 Unit Operation …………………………………………………………………………………… 29 Module Control System …………………………………………………………………………...

  • Page 3: General Information

    This manual does not purport to cover the differences among various units or all problems that may be encountered in the installation, and impossibly provides guidance for all possibilities in the installation. If you want to get more information or face any special problem that is not explained in this manual, please contact your local Trane sales office.

  • Page 4: Safety Precautions

    Safety Precautions In order to avoid electrical shock or fire, and other • Never sit on the direct air duct at any time. Sitting on the direct air duct is not conducive to your health and injuries that may be caused, the following rules should safety.

  • Page 5: Nomenclature

    Nomenclature Model: Additional options: Maintenance code: Digit 1 C= Chiller Digit 2 X=Heat pump G=cooling only Digit 3 A=air cooled Digit 4 J= modular type Digit 5,6,7 Model (cooling capacity) 045 (45kW) 065 (65kW) 130 (130kW) Digit 8 Voltage/Hertz/Phase 5=380V/50Hz/3PH Digit 9 Design Sequence Digit 10...

  • Page 6: Dimensions

    Dimensions CXAJ045/065 (N/H type) 2155 WARNING HAZARDOUS VOLTAGE ! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death. m3/h m3/h 1987 dB(A) DN125 1521 2038 2145 CXAJ130 (N/H type) 2020 2155 m3/h...

  • Page 7: Performance Data

    Performance Data Performance data for Modular Air-cooled Chiller (Heat Pump) Unit (N Type) Model CXAJ045 CXAJ065 CXAJ130 CGAJ045 CGAJ065 CGAJ130 Nominal cooling capacity Cooling Input power 14.2 20.4 40.8 14.2 20.4 40.8 Operating current 33.0 41.4 82.8 33.0 41.4 82.8 Nominal heating capacity Heating Input power...
  • Page 8 Performance Data TecŠical Parameter Table for Modular Air-cooled Chiller (Heat Pump) Unit (H Type) Model CXAJ045 CXAJ065 CXAJ130 CGAJ045 CGAJ065 CGAJ130 Nominal cooling capacity Cooling Input power 14.2 19.2 38.8 14.2 19.2 38.8 Operating current 33.0 37.2 75.2 33.0 37.2 75.2 Nominal heating capacity Heating...

  • Page 9: Unit Installation

    72 hours, and simultaneously inform the local Trane sales office. Please thoroughly inspect the unit within 7 days after arrival of the goods. If any damage is found, please immediately notify the carrier and the local Trane sales office.
  • Page 10 Unit Installation Installation Space Diagram ≥1.2M ≥1.2M AIR OUT ≥1.2M AIR IN AIR IN WARNING WARNING DISCONNECT ALL ELECTRIC POWER HAZARDOUS VOLTAGE ! DISCONNECT ALL ELECTRIC POWER HAZARDOUS VOLTAGE ! INCLUDING REMOTE DISCONNECTS INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. BEFORE SERVICING. servicing can cause severe personal Failure to disconnect power before servicing can cause severe personal...
  • Page 11 Unit Installation Single-module Combination Diagram (Reverse Return Connection) WATER OUTLET PUMP WATER INLET Note: CXAJ/CGAJ045/065 single-module combination includes 8 reverse return connection units at most, and CXAJ/ CGAJ130 single-module combination includes 4 reverse return connection units at most. Single-module Combination Diagram (Direct Return Connection) WATER OUTLET PUMP...
  • Page 12 Unit Installation Blind flange The water pipe interface blind flange necessary for the installation of the end unit is show in the diagram below: Name: blind flange Material: No.20 Specification: 5", PN1.6 Water pipeline • Clean all chilled water pipelines. •...
  • Page 13 • Never use the untreated or improperly treated system water for fear of damaging the unit. Otherwise, TRANE will not be responsible for the unit damage therefrom. • After the installation of water pipeline is completed, please firstly close the shutoff valves 2 and 3, open the shutoff valves 1 and 4, the open the water pump, and flush the debris in the water pipe residual in the water pipe with water onto the filter;...
  • Page 14 Unit Installation System Connection Diagram Feed-water Overflow Direct Return Disdirect Return Expansion tank Connection Connection Drain valve Tree-way valve Backup other pump is recommended Pressure gauge Thermometer Exhaust valve Pump Filter Shockproof hose Drain valve Flow switch Electric heater Shutoff valve Drain valve Principle Description 1.

  • Page 15: Electrical Installation

    Electrical Installation Electrical Wiring • Connect the power wire to the main terminal board (TB) of the distribution box for the unit. • Connect the control panel with the main control board of the unit through the control panel (indoor mounted) connecting cable. See pages 18-24. •...
  • Page 16 Electrical Installation Electrical Data Minimum Full- Rated Rated Rated Rated Rated Rated Rated Rated Minimum specification load current current current current Recommended Maximum Power current current current current circuit of copper current of No.1 of No.2 of No.3 of No.4 fuse specification Model...

  • Page 17: Wiring Diagram

    Wiring Diagram The following wiring diagrams are for reference only. The accompanied wiring diagrams shall prevail.
  • Page 18 Wiring Diagram...
  • Page 19 Wiring Diagram...
  • Page 20 Wiring Diagram...
  • Page 21 Wiring Diagram...

  • Page 22: Pre-Start-Up

    Pre-Start-up Voltage Range The power supply of the unit must comply with the operating power supply marked on the nameplate of this unit, and the supply voltage and the voltage imbalance between phases must be within the following scope. The voltage between phases shall be measured, and the voltage reading must be within the allowable voltage tolerance ( ±...
  • Page 23 Pre-Start-up Inspection Items before Start-up • Inspect the connection of all wires. All electrical contacts shall keep clean and tight. • Inspect whether the supply voltage of the unit is normal. • Fill with water in the chilled water circuit. Keep the exhaust valve of the system open when filling with water.
  • Page 24 Pre-Start-up Figure 2. Characteristic Diagram for Water Pressure Drop N Type H Type CX(G)AJ045 CX(G)AJ045 Internal Pressure Drop of Unit Water Pressure Drop Curve 4.64 5.42 6.19 6.97 7.74 8.51 9.29 10.06 10.84 4.64 5.41 6.18 6.95 7.72 8.49 9.26 10.03 10.80 Water Flow m Water Flow m CX(G)AJ065...
  • Page 25 Pre-Start-up Make sure the water flow in the reasonable range ( 60%--130% rated water flow) Before unit start-up or commissioning, set the functions and operating parameters according to the following methods. The unit function setting is mainly defined through the jumper, the dial switch and the system bit.
  • Page 26 Pre-Start-up Auto: （135） 0 　 Need manual start-up (by default) when powering on 1 　 Allow automatic start-up (in case of power-down in running state) when powering on Defrost:（136, only single unit controller） 0 　 “Manual defrosting” disabled (by default) 1 　...
  • Page 27 Pre-Start-up 17 (the centralized controller displays B1) 18 (the centralized controller displays B2) 19 (the centralized controller displays B3) 20 (the centralized controller displays B4) 21 (the centralized controller displays B5) 22 (the centralized controller displays B6) 23 (the centralized controller displays B7) 24 (the centralized controller displays B8) The bits 6-8 of this switch is used for setting the functions of the unit.
  • Page 28 Pre-Start-up Default Switch Setting N Type Mode Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 Modular IP Void Void Void Mode Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 MODE TYPE ENSAVE CONTROL CXAJ045/065 CXAJ045/065 CXAJ130 CGAJ130 Bit1-5 of SW1, Bit8 of SW2 need adjust by actual jobsite H Type Mode Bit1...

  • Page 29: Unit Operation

    Unit Operation Start Steps • Power on the unit, press MODE button on the Single Unit Controller to select cooling or heating after 120 seconds, and then press ON/OFF button on the Single Unit Controller to start the unit. • When the unit operates for over 30 minutes and the system steadily operates, inspect the following items to ensure the normal operation of the unit: 1.
  • Page 30 Unit Operation drainage opening at the bottom of the water pump and the shell and tube heat exchanger to ensure that the circulating water is drained off. 4. Turn off the power switches of the unit and water pump. Cautions •...
  • Page 31 Unit Operation Function of antifreezing in winter When the unit is in the standby mode in winter and the water temperature is lower than the set antifreezing temperature in winter, the unit automatically starts antifreezing operation, and “AP” is displayed. Thus, when the unit is in the standby mode in winter when it is easy to freeze, the power supply of the unit shall be switched on.
  • Page 32 Unit Operation The fault code is “98”. In the cooling mode, when the fin temperature of any system is lower than or equal to 58 ℃ , the compressor of this system is allowed to run. Ambient temperature over range protection (H Type Unit Only) The ambient temperature range for the unit to reasonably run is 15 to 48 ℃...
  • Page 33 Unit Operation Single system When the system is started, the water pump operates immediately. Two minutes later, the water pump continues to operate. When the water return temperature is over 15 ℃ , the compressor will be started. If the cooling requirement is reached, the water return temperature will be reduced to 10 ℃...
  • Page 34 Unit Operation When the system is unloaded, if the water outlet temperature is lower than or equal to 6 ℃ , one compressor will be shut down; if the water outlet temperature is lower than or equal to 5.5 ℃ , two compressors will be shut down;...

  • Page 35: Module Control System

    Module Control System System Introduction The module control system is a highly intelligent centralized control system. It can manage the loading and unloading controls of multiple outdoor unit modules, the centralized control of multiple outdoor units is mainly performed by the Centralized Controller, and one Centralized Controller can control 25 units at most.
  • Page 36 Module Control System Description: S1 ……… Keyboard lock; if this icon is displayed, the keyboard will be locked; S2-S5 …… icon for compressors 1-4 Running; S6-S9 …… icon for compressors 1-4 Defrosting ; S10-S11 … icon for electrical heaters 1-2 Running; S12 ………...
  • Page 37 Module Control System S44-S48 … Respectively expressing cooling, dehumidification, heating, ventilating and automatic modes; Keys Description: ∧ ……… After the centralized controller selects the single-unit operation mode, press this key to set the temperature. The temperature will rise by 1 degree. See the following description for other functions.
  • Page 38 Module Control System this key is used for fault resetting; When adjusting the time (or setting the week timing), press this key to adjust the minute. This key can be also used as a number key. ……… Timing key. This key is used for the timing setting of comfort function. It can be also ○...
  • Page 39 Module Control System Wiring Diagram of Centralized Controller Centralized Controller TRANE ADC_OT03 VER1.00 MODULE MODULE MODULE LINE LINE LINE N-COM N-COM N-COM NEGETIVE ADC_OD_CO1 NEGETIVE ADC_OD_CO1 NEGETIVE ADC_OD_CO1 EN-SAVE EN-SAVE EN-SAVE OVHT/HP2 OVHT/HP2 OVHT/HP2 FREZ/LP2 FREZ/LP2 FREZ/LP2 FLOW FLOW FLOW...
  • Page 40 Module Control System the network, and adjust the mode and the temperature; Timing operation (comfort control): the centralized controller can respectively set the temperature values at different times of each day to meet the needs of comfort level according to the working days and the holidays within one week. Network monitoring: the centralized controller can monitor all units on the network.
  • Page 41 Module Control System Flash display In case the controller is connected with the network but there is any key operation: After the control panel is connected to the network, firstly search for the control panel. In the searching process, the square brackets will be still displayed at the number position of the air conditioning unit and will be displayed in a mobile way.
  • Page 42 Module Control System Single-unit operation If the key ④ (Single Unit) is pressed, 00 will be displayed at the number position of the air conditioning unit and flash. At this time, press the number key to input the number of unit to be controlled, and then press OK.
  • Page 43 Module Control System be simultaneously displayed. If there are many offline units, the unit numbers will be display in turn. Flash Unit fault display If the unit on the network is faulty, the number of unit which is faulty on the network will be displayed at the unit number position, the alarm symbol and the fault code will be displayed in the temperature display area, as shown in the following figure.
  • Page 44 Module Control System Note 2: if the parameters is temperature parameter, the unit “C” or “F” will be displayed; if the parameters are time or other parameters, the units will not be displayed; Note 3: the decimal part of the parameter will not be displayed. “66”...
  • Page 45 Module Control System Forbid to operate by the remote telephone. If the remote telephone operation is valid, the centralized controller will display the phone icon (as shown in the figure below). At this time, press ⑨ for 3 seconds to cancel the remote telephone operation.
  • Page 46 Module Control System For H Type unit, all slave units on the network are subject to the water outlet temperature of No.0 unit. The host unit is provided with the system pump and the basic input and output. The host unit is connected with the water pump and detects the water flow switch; the slave units are not connected with the water pump but still connected with the water flow switch for detecting the water flow switch.
  • Page 47 Module Control System Condition 1 Determine on the basis of the set temperature. Condition 2 Determine on the basis of increasing the set temperature by 0.5 degree (refrigeration). Condition 3 Determine on the basis of increasing the set temperature by 1.0 degree (refrigeration).

  • Page 48: Building Control System

    Building Control System Mini-ICS system is a highly intelligent centralized control system developed by Trane for Unitary (small and medium sized) units. Mini-ICS system can manage the linkage control of multiple indoor units and outdoor units, the loading and unloading control of multiple indoor unit modules, the centralized control of multiple outdoor units as well as the centralized control of multiple indoor units;...
  • Page 49 Up to 15 Modbus modules RS458 communication wire See Operation Manual for CXAJ Series Modbus Module for the specific wiring and operation of Modbus module. Control of electrical heater (installed by the user as required) In the heating mode of the unit, when the water return temperature is lower than the set value 5 ℃...

  • Page 50: Troubleshooting

    Troubleshooting Fault Alarm Table for Controller (N Type) If the single unit controller and the control panel are faulty, the code “EE” will be displayed. 13 fault input alarm switches and 1 fault output alarm switch are arranged for the single-compressor system. Input Port Fault Description Type...
  • Page 51 Troubleshooting 17 fault input alarm switches, 1 fault output alarm switch and 1 operating status output switch are arranged for the double-compressor system. Input Port Fault Description Type Code Fault Handling Short circuit / open circuit of water inlet Turn off all external devices temperature sensor Short circuit / open circuit of water Turn off all external devices...
  • Page 52 Troubleshooting Fault Alarm Table for Controller (H Type) Code of Code of Input Port Fault Description Single unit Centralized Fault Handling controller Controller No.1 analog sensor fault (water inlet Switch off temperature) No.2 analog sensor fault (water outlet Switch off temperature) No.3 analog sensor fault (suction Switch off...
  • Page 53 Troubleshooting Switch off the compressor of the system A. If this fault CN13 Low pressure overrun occurs twice, switch off and give an alarm. Switch off the compressor of the system B. If this fault CN14 Low pressure overrun 2 occurs twice, switch off and give an alarm.
  • Page 54 Troubleshooting Fault Analysis and Handling Method The compressors cannot be started and make sounds Possible Cause Handling Method Inspect the following items: (1) The power supply is not a. The main power switch is not turned on. connected b. The fuse is blown out. Inspect the following items: (2) There is no refrigeration a.
  • Page 55 Troubleshooting The compressors make sounds but cannot be started Possible Cause Handling Method Inspect the following items: a. Certain fuse is blown out. (1) The compressor voltage is b. The supply voltage is too low. too low. c. The electromagnetic contactor of the compressor is faulty. d.
  • Page 56 Troubleshooting The compressor operates without stop Possible Cause Handling Method (1) The unit energy cannot bear load (cannot reach the unloading Inspect the cause of excessive load water temperature). (2) The temperature probe or the Replace the temperature probe. control circuit is poor. Replace or repair the control circuit.
  • Page 57 Troubleshooting The compressor noise is too high Possible Cause Handling Method (1) The parts inside the compressor are damaged or broken (the Replace the compressor. compressor makes a tap-tap). Inspect and adjust the superheat. (2) Liquid backflow. Inspect whether the refrigerant is charged (3) There is liquid refrigerant in the compressor when starting (the excessively.
  • Page 58 Troubleshooting The suction pressure is too high Possible Cause Handling Method (1) The cooling load is too high (i.e. the water supply temperature is See the section E. high). (2) The expansion valve excessively supplies liquid (i.e. the Adjust the superheat setting, and inspect superheating capacity is too low, and the liquid overflows to the whether the temperature sensor is installed in compressor).
  • Page 59 Troubleshooting The low pressure is too low -- heating condition Possible Cause Handling Method (1) The refrigerant is insufficient. Charge the refrigerant. (2) The air flow entering into the coil is too low or the Clean the coil, and inspect whether the fan motor function is air is too cold.

  • Page 60: Maintenance

    Maintenance Shutdown If the system is required to be shut down for a short time, just press the key “ON/OFF” on the control panel. If the system is required to be shut down for a long time, the main power supply shall be switched off.
  • Page 61 Cleaning of shell and tube heat exchanger Trane recommends to clean the shell and tube heat exchanger by the chemical cleaning method. The cleaning agent shall be hot phosphoric acid solution, and its use conditions are as follows: 50-60 ℃...
  • Page 62 Please visit www.trane.com。 Trane constantly improves and innovates its products. The data in this document will be changed without prior notice. © 2014Trane All rights reserved PKGP-SVX06A-EN (Jan.

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