Trane CXAJ065 Maintenance Manual
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Trane CXAJ065 Maintenance Manual

Modular air-cooled water chiller (heat pump) r410a
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Maintenance Manual
Modular Air-cooled Water Chiller
(Heat Pump)
CXAJ/CGAJ065~130
R410A
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of
heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
Improperly installed, adjusted or altered equipment by an unqualified pers on could result in death or serious injury.
When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are
attached to the equipment.
March 2020
SAFETY WARNNING
CG-SVM002A-EN
Confidential and proprietary Trane information

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Summary of Contents for Trane CXAJ065

  • Page 1 Improperly installed, adjusted or altered equipment by an unqualified pers on could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment. March 2020 CG-SVM002A-EN Confidential and proprietary Trane information...

  • Page 2: Table Of Contents

    Contents Safety Precautions........................4 1.Limitations and Warnings ....................6 1-1. Unit Application Range ....................6 1-2. Notes for Long-term Shut Down Between Seasons ............6 1-3. Notes for Starting the Unit..................... 6 1-4. Inspections before Start-up ................... 6 1-5. Anti-freezing Measures in Winter................... 8 2.Nomenclature and Performance Data ................
  • Page 3 6.Commissioning ........................33 6-1. Inspections before Commissioning ................33 6-2. Unit Commissioning ...................... 33 6-3. Controller Operation Instructions ................. 34 6-4. Adjustment and Judgement of Refrigerant Volume ............36 6-5. Judgement of Water Flow in Water System ..............36 6-6. Non-fault Phenomenon ....................36 7.Fault Handling ........................

  • Page 4: Safety Precautions

    • Before maintenance, please confirm that the unit is in the power-off state. • Maintenance can only be carried out by professional maintenance personnel. For maintenance and repair, contact Trane sales office. Improper maintenance and repair may result in water leakage, electric shock or fire.
  • Page 5 • When the unit is repaired in case of refrigerant leakage, please operate the machine after the maintenance personnel confirm that the leakage repair is completed. • Do not start the air conditioning unit when the panel or protective net is removed. Rotating parts in the air conditioning unit may injure people or other articles.

  • Page 6: Limitations And Warnings

    Limitations and Warnings Limitations and Warnings 1-1. Unit Application Range Temperature Range Ambient Temperature Leaving Water Temperature Cooling 18℃ ~ 46℃ 5℃ ~ 15℃ Heating -15℃ ~ 25℃ 30℃ ~ 50℃ 1-2. Notes for Long-term Shut Down Between Seasons • The unit should be connected to power to prevent freezing if it is shut down for a short period of time between seasons. •...
  • Page 7 Limitations and Warnings WARNINGS It is prohibited to conduct parameter change without the guidance from professionals. Wrong parameter changes can cause freezing damage to the unit or lead to abnormalities such as frequent protection. • Voltage range The power supply of the unit must comply with the operation power specified on the nameplate of the unit. The power supply must meet the demand of the unit, with allowable fluctuation range of main voltage: ±10%, and maximum phase unbalance: ±2%.

  • Page 8: Anti-Freezing Measures In Winter

    Limitations and Warnings 18 (Centralized controller shows B2) 19 (Centralized controller shows B3) 20 (Centralized controller shows B4) 21 (Centralized controller shows B5) 22 (Centralized controller shows B6) 23 (Centralized controller shows B7) 24 (Centralized controller shows B8) Type: 0 - cooling + heating 1 - cooling only Two-way valve interlock: 0 - normal 1 - two-way valve interlocking...

  • Page 9: Nomenclature And Performance Data

    Nomenclature and Performance Data Nomenclature and Performance Data 2-1. Nomenclature C X A Model R A M A A Additional options 10 11 12 13 14 15 16 17 18 C X A R A M A A Maintenance code 9 10 11 12 13 14 15 16 17 18 Digit 1 C = Chiller...

  • Page 10: Performance Data

    Nomenclature and Performance Data 2-2. Performance Data Standard-efficiency Model (N type) Model CXAJ065 CXAJ130 CGAJ065 CGAJ130 Rated Cooling Capacity Cooling Rated Input Power 21.6 43.2 21.6 43.2 Rated Operating Current 42.0 81.0 42.0 81.0 Rated Heating Capacity Heating Rated Input Power 41.00...
  • Page 11 Nomenclature and Performance Data High-efficiency Model (H type) Model CXAJ065 CXAJ130 CGAJ065 CGAJ130 Rated Cooling Capacity Cooling Rated Input Power 21.0 40.9 21.0 40.9 Rated Operating Current 78.0 78.0 Rated Heating Capacity Heating Rated Input Power 21.5 40.0 Rated Operating Current 71.0...

  • Page 12: Unit Introduction

    Unit Introduction 3.Unit Introduction 3-1. Cooling System Diagram CXAJ065 System Diagram(F-N,F-H) Fan A1,A2 Compressor 4-way valve SuctionTH3 Discharge temperature sensor TH5 Discharge temperature sensor TH6 Gas-liquid separator Fin coil condenser Evaporator Refrigerant reservoir Heating Cooling...
  • Page 13 Unit Introduction CXAJ130 System Diagram(F-N,F-H) Heating Cooling 4-way valve 4-way valve COMP-A1 COMP-B1 HPS1 HPS2 Fin coil 28.6 condenser COMP-A2 COMP-B2 Gas-liquid Gas-liquid separator separator Drying filter Drying filter EXVA-1 EXVB-1 Inlet waterTH1 Outlet water TH2 Refrigerant Refrigerant reservoir reservoir Evaporator Facing control box, left side is system1,right is system 2 close to left of control box is outlet water, right is inlet water for F-N model, single system is one 25HP compressor, while F-H is 2 12HP compressors...

  • Page 14: Main Components And Function Chart

    Unit Introduction Basic configuration: Model Efficiency Refrigerant R410A R410A R410A R410A Koolman+HW plus Parallel system, compressors can 2 compressors, 2 independent Structure Parallel system, compressors can start separately start separately systems Defrost Defrost in and out judging condition: pressure Compressor VP144-KFE-420 CH290 VP144-KFE-420...

  • Page 15: Unit Appearance And Structure

    Unit Introduction 3-3. Unit Appearance and Structure CXAJ065 （ F-N, F-H ） 序号 零部 Part REMARK 风机板 Plate of fan 出风网 Mesh enclosure of fan 风扇 风扇电 短横条 立柱 Motor of fan 封板 Top plate C 立柱 Column support plate A 压缩机...
  • Page 16 Unit Introduction CXAJ130 （ F-H ） 零部 序号 吊耳 连接 Part REMARK 连接 Lifting 连接 Tube 1 干燥 换向 Tube 2 水盘 Tube 3 低压 Drier&EXV assembly - A 高压 壳管 4-ways-valve assembly - A 壳管 Water pan 储液 Suction tube A 气液...
  • Page 17 Unit Introduction CXAJ130 （ F-N ） Part REMARK Mesh enclosure of fan Plate of fan Support of motor Motor of fan Tube 1 Tube 2 Tube 3 4-ways-valve assembly - A Drier&EXV assembly - A Liquid receiver Support plate of compressor - A Cover plate of shell-tube HX - C Gas-liquild separator Suction tube A...

  • Page 18: Control Box Introduction

    Unit Introduction 3-4. Control Box Introduction CXAJ065 （ F-N, F-H ） RLY1 RLY4 RLY6 RLY9 RLY10 RLY11 RLY12 RLY13 RLY14 RLY15 RLY16 RLY2 RLY3 RLY5 RLY7 RLY8 IND1 LED1 IND2 EXVA-1 IND3 CN30 EXVA-2 IND4 EXVB-1 IND5 CN32 EXVB-2 CN10...
  • Page 19 Unit Introduction CXAJ130 （ F-H ） MCA-1 MCA-2 MCB-1 MCB-2 RLY1 RLY2 RLY4 RLY6 RLY9 RLY10 RLY11 RLY12 RLY13 RLY14 RLY15 RLY16 RLY3 RLY5 RLY7 RLY8 IND1 LED1 IND2 EXVA-1 IND3 CN30 EXVA-2 IND4 EXVB-1 IND5 EXVB-2 CN10 CN31 CN32 IND6 CN12 IND7...
  • Page 20 Unit Introduction CXAJ130 （ F-N ） OVCA-1 OVCB-1 RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 RLY9 RLY10 RLY11 RLY12 RLY13 RLY14 RLY15 RLY16 IND1 LED1 IND2 EXVA-1 IND3 CN30 EXVA-2 IND4 EXVB-1 IND5 CN32 EXVB-2 CN10 CN31 IND6 CN12 IND7 CN11 IND8...

  • Page 21: Unit Installation Requirements

    Unit Installation Requirements Unit Installation Requirements 4-1. Outdoor Unit Installation 1. Select installation location • The unit can be installed on the roof, ground or other places that are easy for installation and with reliable load bearing capacity; • Do not install the unit near other heat sources that can affect the normal operation of the unit; •...

  • Page 22: Installation Of Air Condition Water Pipeline

    Unit Installation Requirements 4-2. Installation of Air Condition Water Pipeline 1. The installation of air condition water pipeline should comply with the following requirements: • The length of the pipeline should be as short as possible; • The diameter of the pipeline should meet the requirement of the unit; •...

  • Page 23: Installation Of Water System

    Unit Installation Unit Installation Requirements Installation of Water System 4-3. Installation of Water System Requirements for Pipeline Prefabrication 1. Requirements for pipeline prefabrication: 1. The diameter of the inlet and outlet water pipes for the water system shall not be smaller than that of the unit •...
  • Page 24 Unit Installation Requirements • Water filter: Y-shaped water filter must be installed within 50cm of the water inlet pipe of the air conditioning unit to prevent impurities in the pipe from blocking the water-side heat exchanger and causing unit failure. The number of meshes for the filter shall be 40. If there is an external pump, the water filter must also be installed at the water inlet of the pump.
  • Page 25 Unit Installation Requirements • Thermal insulation: the chilled water pipe shall be thermally insulated to prevent water dripping due to heat loss and pipe surface condensation. The exterior of the water-side parts in the water system in contact with the air shall be thermally insulated to prevent water dripping due to condensation.

  • Page 26: Electrical Installation

    Electrical Installation Electrical Installation Electrical Installation Safety Precautions Electrical Wiring 5-1. Electrical Wiring and Electric Control Box 1. Connect the power line to the main terminal (TB) of The following contents are related to safety, please the unit distribution box. 1.

  • Page 27: Electrical Specification

    Electrical Installation Electrical Specification Electrical Installation Please refer to the following table for the minimum current, the fuse specification and the electrical specification of 5-2. Electrical Specification motor. Please refer to the following table for the minimum current, the fuse specification and the electrical specification of motor. Min.
  • Page 28 A gnd +V Detail Drawing for Wiring Terminal Dimensional Drawing for Modular Controller 1.Wiring Diagram for Modular controller 1.Wiring diagram for modular controller Modular controller Modular controller TRANE ADC_OT03 VER1.00 Outdoor unit Outdoor unit Outdoor unit Outdoor unit Outdoor unit Outdoor unit...
  • Page 29 Electrical Installation 2.Instructions on ground terminal of 485 control line It is forbidden to connect to the strong current 220V ground terminal for the metal plate of the electric cabinet. 485 grounding port G is the ground terminal for DC power supply of the electric control board. 3.Installation requirements of 485 communication line •...

  • Page 30: Electrical Circuit Diagram

    Electrical Installation Electrical Installation 4.Electrical Circuit Diagram 5-5. Electrical Circuit Diagram CX(G)AJ065 CX(G)AJ065 PKGP-SVX18B-EN...
  • Page 31 Electrical Installation Electrical Installation CX(G)AJ130N CX(G)AJ130 N PKGP-SVX18B...
  • Page 32 Electrical Installatio Electrical Installation CX(G)AJ130H CX(G)AJ130 H PKGP-SVX18B-EN...

  • Page 33: Commissioning

    Commissioning Commissioning 6-1. Inspections before Commissioning • Appearance inspection Check the appearance and internal parts of the unit for any damage. • Fan and motor inspection Check whether the fan is straight and if there is any foreign matter and dirt on the blades and whether the blades are damaged. •...

  • Page 34: Controller Operation Instructions

    Commissioning • Water loop electric heating conditions During heating, when the discharge water temperature ＜ "set heating temperature" – "heater start-up temperature difference", the water loop electric heating will be activated; when the discharge water temperature ≥ "set heating temperature" - "heater stop temperature difference", the water loop electric heating will be turned off.
  • Page 35 Commissioning 4. Customer setting Code in controller Name of parameter MAX. MIN. Regulation accuracy Default setting COOLING SETTING TEMP 15℃ 5℃ 1℃ 7℃ HEATING SETTING TEMP 50℃ 25℃ 1℃ 45℃ Freeze - proofing entre Temp of winter 8℃ 1℃ 1℃ 5℃...

  • Page 36: Adjustment And Judgement Of Refrigerant Volume

    Commissioning 8. Date review Press and then press to view the data. Item Code Inlet water temperature Outlet water temperature Suction temperature A Default Discharge temperature A-1 Discharge temperature A-2 Ambient temperature Suction temperature B Default Discharge temperature B-1 Discharge temperature B-2 Total outlet temperature of modular Suction pressure A (pressure /100kPa) Suction pressure B (pressure /100kPa)

  • Page 37: Fault Handling

    Fault Handling Fault Handling 7-1. Fault Alarm Table If the controller and the control panel are faulty, the code "EE/ED" will be displayed. Code of Code of Input Port Fault Description Single Unit Centralized Fault Handling Controller Controller No.1 analog sensor fault (water inlet temperature) Turn off devices No.2 analog sensor fault (water outlet temperature) Turn off devices...

  • Page 38: Fault Handling For Outdoor Unit

    Fault Handling 7-2. Fault Handling for Outdoor Unit (Refer to outdoor unit fault code table for fault code) 1. Power supply fault Fault phenomenon: Phase sequence protector flashes. Fault reason: Check if the power supply circuit is correct (if there is phase loss or negative phase sequence). 2.
  • Page 39 Fault Handling 5. Pressure sensor fault Fault phenomenon: The alarm indicator on the control panel flashes, the control panel sends 2C 2D 2E 2F alarm. Fault reason: The interface is loose, open-short of the sensor, the main control interface is disconnected or short-circuited. Fault handling process: Fault (pressure sensor fault) Check if the connection between the pressure...
  • Page 40 Fault Handling 9. Reduction in module number Fault reason and handling process is similar with 8), please handle the fault according to 8). 10. Low pressure sensor disconnected Fault phenomenon: The alarm indicator on the control panel flashes, the control panel displays corresponding alarm code. Fault description: The low pressure alarm will be triggered when the low pressure of the system is below 1.5bar (gauge pressure).
  • Page 41 Fault Handling Fault handling process: The air exhaust temperature is too high Error Replace the temperature Check if the temperature sensor is faulty; sensor or the main board. check wirings and main board terminals. Discharge the excessive Error refrigerant, or clean the Check if the refrigerant volume is correct.
  • Page 42 Fault Handling 13. System condenser overheat protection Fault phenomenon: The alarm indicator on the control panel flashes, the control panel displays "98" alarm; Fault description: The protection is activated when the pipeline temperature of system condenser is higher than 68℃. Fault handling process: System condenser overheat protection Error...

  • Page 43: Service Guidance For Key Parts

    Fault Handling 7-3. Service Guidance for Key Parts 1.Compressor Compressor is the most important component in air condition system. The performance of the overall air condition system is closely related to the operating performance of the compressor. • Compressor fault The common faults that can happen to the compressor are listed below: A.
  • Page 44 Fault Handling c. The fan of the outdoor unit does not rotate or rotates at low speed due to reduced capacitance, or blocked air duct, or dirty heat exchanger during heating can all cause incomplete evaporation of refrigerant and leads to liquid hammer; d.
  • Page 45 Fault Handling D. Troubleshooting and fault handling of electronic expansion valve There are two steps for troubleshooting and fault handling of electronic expansion valve. First, inspect the coil of electronic expansion valve. If the coil part is normal, check the valve body. (1) Fault analysis and handling of electronic expansion valve: follow the procedure below.
  • Page 46 Fault Handling (2) Fault analysis and handling of electronic expansion valve: After confirming that the coil part is normal, user should conduct valve body inspection according to the process below. Inspection and repair process of electronic expansion valve body Replace the body: Check if the valve It can be valve leakage due to jamming caused...
  • Page 47 Fault Handling When inspecting the valve body, make sure the coil resistance and connectors are normal, then power on the unit. Hold the valve body with your hands to feel if it is operating. It will take about 6 seconds for the valve body to switch from fully open to fully close. If voltage is applied when the valve body is at fully open or fully close position, you will hear a loud click sound.
  • Page 48 Fault Handling 3.Pressure switch A. Working principle of pressure switch There are two working status of pressure switch: open or close. The opening and closing pressure for different model of pressure switch is dif- ferent, which will be marked on the switch. The opening and closing pressure for high pressure switch is 4.2/3.3Mpa, which means when the pressure reaches 4.2Mpa, the switch will open automatically and disconnect the line;...
  • Page 49 Fault Handling 4.Four-way reversing valve A. Basic structure of four-way reversing valve The four-way reversing valve mainly consists two parts: coil and valve body, as shown below: B. Working principle of four-way reversing valve Working principle: When the solenoid coil is off, the compression spring at the right side will drive the pilot valve to move leftwards; high pressure gas will enter the capillary (1) before entering the piston chamber at right end.
  • Page 50 Fault Handling C. Common faults for four-way reversing valve a. The coil is broken or the voltage does not match with the performance of the coil which prevents the valve element of the pilot valve from operating; b. Partial deformation of the pilot valve due to external reasons which prevents the valve element from operating; c.

  • Page 51: Unit Protection Functions

    Fault Handling 7-4. Unit Protection Functions 1.Extreme low pressure detection If the low pressure of any system is below 1.5bar, the unit will shut down and send alarm. The controller will display (System A) or " " (System B); otherwise the unit will continue running. "...
  • Page 52 Fault Handling If the toggle switch is in "Modular control" position, this function is only valid for number 0 unit. If the pump is overload during anti-freezing operation, it will be stopped immediately. The system will exit anti-freezing mode and the controller will display pump overload alarm.
  • Page 53 The order is reversed for unloading. For CXAJ065/045 unit: Upon each startup of the unit, the compressor with less total working hours of the two compressors will be selected as the first compressor to be started;...

  • Page 54: Unit Defrosting

    Fault Handling 7-5. Unit Defrosting Start pressure and stop pressure: Different start pressures for defrosting corresponding to ambient temperature changes: Stop conditions for defrosting: During the defrosting of any system, if the air exhaust pressure is >2967kPa for 10s, or the defrosting operation period is > "Maximum defrosting operation time", or the high pressure switch trips, or the discharge water temperature ≤...

  • Page 55: Attached Table

    Attached Table Attached Table The effective sensing range for 10K temperature sensor is -40℃ to 110℃, see the table below for corre- sponding resistance: Rmin Rnom Rmax Rmin Rnom Rmax Rmin Rnom Rmax T [℃] T [℃] T [℃] [KΩ] [KΩ] [KΩ] [KΩ]...
  • Page 56 Attached Table The effective sensing range for 100K temperature sensor is -30℃ to 140℃, see the table below for cor- responding resistance: Rmin Rnom Rmax Rmin Rnom Rmax Rmin Rnom Rmax T [℃] T [℃] T [℃] [KΩ] [KΩ] [KΩ] [KΩ] [KΩ] [KΩ]...
  • Page 57 For more information, please visit trane.com 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. We are committed to using environmentally conscious print practices.

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