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Summary of Contents for Trane FLEX HP HT
- Page 1 Installation Operation Maintenance FLEX HP HT Air-cooled heat pump with vapour injection scroll compressors R410A refrigerant For hot water production up to 65°C Cooling capacity 50 – 144 kW Heating capacity 54 – 154 kW July 2022 CG-SVX059A-GB Original instructions...
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Page 4: Table Of Contents
Contents 1. OVERVIEW ..........................3 2. SAFETY REGULATIONS ......................3 3. OPERATING LIMITS ......................... 8 4. INSTALLATION ......................... 9 5. ELECTRICAL POWER SUPPLY ..................... 10 6. WATER CONNECTIONS ......................12 7. HYDRAULIC VERSIONS ......................17 8. PUMPS CHARACTERISTICS ....................20 9. -
Page 5: Overview
12 hours a day. The date the machine is operated for the first time means the date reported in the “1st start up form” in the “log book”. This form should be filled in and sent, within 8 days from the start up, to Trane. - Page 6 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 7 Risks for contact with the Vapors don’t take any effect. Splashes or sprinklers can cause chill burns. In those cases it is necessary to eyes rinse the eyes with water or with solution for ocular washings for 10 minutes. The intervention of a doctor is needed. Should it happen, it causes chill burns.
- Page 8 Trane or from official dealers of the companies reported in the list of recommended spare parts. if the unit is to be moved after a year of being in the site or if it has to be dismantled contact Trane. Page 6...
- Page 9 l. WARNING – HIGH PRESSURE SAFETY VALVE No high pressure safety valve is installed on the unit. The unit fail safe is assured by cut-out of the electrical power supply to the coils of the compressors contactors. The cut-out action is carried out by the electrical contact of the dedicated high pressure switch PA highlighted in the figure below “Part of the refrigerant circuit drawing which includes the high pressure switch PA”.
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Page 10: Operating Limits
only with Only CONDENSING with CONTROL ambient (OPTIONAL) temp. kit 3. OPERATING LIMITS 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. OPERATING LIMITS Unit operation is permitted within the limits indicated in the diagram provided in 3.3. -
Page 11: Installation
CHILLER MODE Glycol only with CONDENSING CONTROL (OPTIONAL) Leaving water temperature [°C] Low ambient air temperature kit down to -20°C: Electrical heater in the control box Low temperature resistant electrical cables Hydrofil treated coil Additional coil heater IMPORTANT The low ambient air temperature kit is mandatory for temperatures from -20 °C to -10 °C. 4. -
Page 12: Electrical Power Supply
Minimum space requirements reported in the dimensional drawing shall be respected to avoid: • Noise • Incorrect heat exchange and ventilation • Difficult maintenance or inaccessibility to components It is fundamental to respect minimum distances on all units to ensure optimum ventilation for the condenser coils. Limited installation space could reduce the normal air flow, thus significantly reducing the unit performance and considerably increasing consumption of electrical energy. - Page 13 Vave = (V1 + V2 + V3)/3 Vx = phase with greatest difference from Vave (without regard to the sign) IMPORTANT: If the mains voltage has an imbalance of above 2%, contact the company, which distributes the electrical energy. If the unit functions with a unit voltage imbalance between the phases of above 2% the warranty is invalid.
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Page 14: Water Connections
/ or welding slag inside the heat exchanger. 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. Maximum operating pressure: 6 bar... - Page 15 For optimum operation, the unit needs a water content according to the following values: FLEX HP HT Cooling mode Heating mode Model Q min Q max Q min Q max 191,0...
- Page 16 FLEX HP HT S (SUPER LOW NOISE) Cooling mode Heating mode Model Q min Q max Q min Q max 191,0 14,1 147,3 16,4 153,5 16,3 130,1 18,8 116,1 18,9 99,2 21,2 100,1 20,7 85,2 23,4 41,1 23,6 36,1 10,4...
- Page 17 Trane is not responsible for damage to or malfunctioning of equipment caused by failure to treat water or by improperly treated water.
- Page 18 3. Additional heat insulation and sufficient heating of exposed piping. IMPORTANT: Trane can provide various optional kits (they are not included in the Low ambient kit down to - 10°C) for the protection of all the components of the hydraulic circuit inside the unit (pumps, pipes and tank).
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Page 19: Hydraulic Versions
7. HYDRAULIC VERSIONS Units are available in four hydraulic versions characterized by complete kits of all major hydraulic components for an easier installation, with reduced time, cost and space. single pump single pump and tank double pump double pump and tank Hydronic accessories on request •... - Page 20 Hydrauli kit with 1 pump and water tank – A/B/C Versions Empty plant security pressure switch Gauges Shut off valve Water discharge Evaporator Pump Additional pump water pressure switch Safety valve Check valve Relief valve Water tank Expansion valve Filling group Water differential pressure switch Hydraulic kit with 2 pumps and water tank –...
- Page 21 Empty plant security pressure switch Gauges Shut off valve Water discharge Evaporator Pump Additional pump water pressure switch Safety valve Check valve Relief valve Water tank Expansion valve Filling group Water differential pressure switch IMPORTANT: the flow switch and the water strainer in the customer plant are obligatory in order to keep the warranty IMPORTANT: The desuperheater side pump is always installed in customer plant, an on board unit pump on desuperheater side is not possible not even as an option.
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Page 22: Pumps Characteristics
8. PUMPS CHARACTERISTICS LOW HEAD PRESSURE PUMP (150 kPa) Cooling and Heating mode Pump 1 Pump 2 Pump 3 Pump 4 Pump 5 Expansion Ref. Curve vessel Model 50,3 14,3 Pump 3 58,2 10,0 15,38 Pump 3 67,5 11,6 15,65 Pump 4 1,76 12,7... - Page 23 MEDIUM HEAD PRESSURE PUMP (250 kPa) Cooling and Heating mode Pump 6 Pump 7 Expansion Ref. Curve Model vessel 50,3 14,3 Pump 6 300,0 58,2 15,38 Pump 6 295,0 67,5 15,65 Pump 6 290,0 16,21 Pump 6 285,0 84,3 8,65 Pump 6 280,0 94,1...
- Page 24 HIGH HEAD PRESSURE PUMP (450 kPa) Cooling and Heating mode Pump 8 Pump 9 Expansion Ref. Curve vessel Model 50,3 14,3 Pump 8 11,5 58,2 10,0 15,38 Pump 8 11,5 67,5 11,6 15,65 Pump 9 11,5 12,7 16,21 Pump 9 11,5 84,3 14,5...
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Page 25: Electrical Panel And Electrical Data
Follow proper lock out/tag out procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharges capacitors. Verify with an appropriate voltmeter that all capacitors have discharged. - Page 26 Electrical data FLEX HP HT / FLEX HP HT S (SUPER LOW NOISE) NOMINAL VALUES Ta = 35°C Tw in/out = 12/7°C MAXIMUM VALUES Model Compressors Fans TOTAL TOTAL FLI MAX FLA MAX SA MAX 17,2 30,1 20,2 36,1 168,1...
- Page 27 Auxiliary heaters on coils (OPTIONAL) Model F.L.I. [kW] 10.8 10.8 10.8 14.4 14.4 14.4 *NOTE The auxiliary heaters are supplied with the optional Low ambient air temperature kit In case of selection of this kit, add the resistance absorptions to maximum electrical data Page 25...
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Page 28: Operator Responsabilities
REFRIGERANT SEALS CONTROL Trane units are sent with the complete charge of refrigerant and are at a sufficient pressure to check the seal after installing. If the system were not under pressure, blow refrigerants (vapour) into it until pressure is reached and look for leakage. -
Page 29: Check List - Mandatory Operation Control Before Start-Up
UNIT CUSTOMER: SITE: ADDRESS: POSTCODE: COUNTRY: THE INTENDED PURPOSE OF UNITS IS NOT FOR INDUSTRIAL PROCESS APPLICATION. CONTACT TRANE 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 30 THE CONNECTION WIRES ARE SHIELDED. REMOTE CONTROL DEVICES OR INTERFACES ARE CONNECTED TO THE ELECTRICAL PANEL IN CONFORMITY WITH TRANE WIRING DIAGRAMS 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.
- Page 31 CORRECT DELTA T IS ASSURED AND THE HYDRAULIC PRESSURE IS CONFORM TO THE PLANT AND TO THE WATER PRESSURE DROPS. FOR FURTHER TECHICAL INFORMATIONS PLEASE REFER TO TRANE DOCUMENTATIONS AND PROCEDURE FOR THE FIRST START UP. HYDRAULIC CONNECTIONS TO THE UNIT ARE COMPLIANT WITH THE UNIT NAME PLATE AND DIMENSIONAL DRAWINGS (HOT WATER INLET, HOT WATER OUTLET, COLD WATER INLET, COLD WATER OUTLET, ETC.).
- Page 32 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 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 33 REFRIGERANT CHARGE 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.
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Page 34: Start-Up
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. - Page 35 STARTING UP All the compressors mounted on Trane 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.
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Page 36: Maintenance
The oil temperature must be at least 5°C higher than the saturation temperature of the refrigerant inside the compressor. • Place the unit in the “ON” and wait until the unit is indicated on the display-On. • Turn on the pump (at max speed if with inverter). •... - Page 37 the operating parameters of the unit. The collection of these data will be very useful to technicians if assistance is requested. Compressor Maintenance IMPORTANT! This inspection must be performed by qualified and trained personnel. The analysis of vibration is a great tool for checking the mechanical conditions of the compressor. It is recommended to check the value of the vibration immediately after starting and periodically on an annual basis.
- Page 38 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. Ingoing water temperature sensor –This sensor is located on the evaporator ingoing water connection and is used for monitoring the return water temperature.
- Page 39 IMPORTANT: Only in extreme cases should any type of chemical cleaner or detergent be used on microchannel coils. If it becomes absolutely necessary because water alone did not clean the coil, specify a cleaner that is: • A is pH neutral cleaner. •...
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Page 40: Ordinary Maintenance
ORDINARY MAINTENANCE Activities list week Month (1) Year (2) General: Data collection operation (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 (6) Electric: Check the correct operation of the equipment on the unit Check the wear of contactors - Replace if necessary... -
Page 41: 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 personalised list of accessories according to the commissioned order, including the part number of the equipment. 1 YEAR... -
Page 42: Troubleshooting
TROUBLESHOOTING Who can take corrective action U Symptom Cooling = 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 Defective compressor... - Page 43 Who can take corrective action U Symptom Cooling = User Probable cause Possible remedy S = specialised personnel Pressure switch out of order Check and replace. Machine completely void of See point G. refrigerant Finned coil clogged, airflow rate is Remove dirt from the coil.
- Page 44 Trane – by Trane Technologies (NYSE: TT), a global climate innovator – creates comfortable, energy efficient indoor environments through a broad portfolio of heating, ventilating and air conditioning systems and controls, services, parts and supply. For more information, please visit trane.eu or tranetechnologies.com.
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