Trane IntelliCore CAUK-C20 Installation, Operation And Maintenance Manual

Split system air-cooled condensers - 20 to 120 tons

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Installation, Operation, and Maintenance

IntelliCore™ Split System

Air-Cooled Condensers — 20 to 120 Tons

Model Numbers:

CAUK-C20

CAUK-C25

CAUK-C30

CAUK-C40

CAUK-C50

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 person 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.

November 2024

CAUK-C60

CAUK-C80

CAUK-D10

CAUK-D12

SAFETY WARNING

CAUK-SVX001A-EN

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Page 1 Installation, Operation, and Maintenance IntelliCore™ Split System Air-Cooled Condensers — 20 to 120 Tons Model Numbers: CAUK-C20 CAUK-C60 CAUK-C25 CAUK-C80 CAUK-C30 CAUK-D10 CAUK-C40 CAUK-D12 CAUK-C50 SAFETY WARNING 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.
Page 2: Warnings, Cautions, And Notices
(HCFCs). Not all refrigerants containing these compounds bump cap, fall protection, electrical PPE and arc have the same potential impact to the environment. Trane flash clothing). ALWAYS refer to appropriate advocates the responsible handling of all refrigerants.
Page 3 This document and the information in it are the property of specific handling concerns with R-454B, contact your Trane, and may not be used or reproduced in whole or in local representative. part without written permission. Trane reserves the right to...
Page 4: Table Of Contents
Table of Contents Model Number Description ....5 Final Refrigerant Pipe Connections......35 General Information .
Page 5: Model Number Description
Model Number Description Digit 1 — Unit Type Digit 13 — Not used Digit 25 — Not used C = Condenser 0 = Not used 0 = Not used Digit 2 — Condenser Digit 14 — Not used Digit 26 — Not used A = Air-Cooled 0 = Not used 0 = Not used...
Page 6: General Information
General Information Unit Inspection • The owner must provide reasonable evidence that the damage did not occur after delivery. To protect against loss due to damage incurred in transit, perform inspection immediately upon receipt of the unit. Repair Exterior Inspection Notify the appropriate sales representative before arranging unit installation or repair.
Page 7: General Data
General Information General Data Table 1. General data — CAUK condensers Unit Size (tons) Condenser Fan Data Type/Drive Type Prop/Direct Diameter Power/motor Nominal Total Airflow 14600 20700 20700 26790 36890 40490 56490 73890 76280 Condenser Coil Data Type Microchannel Number of Coils Size 42x71 42x71...
Page 8: A2L Information
• To be repaired only by trained service At all times, Trane’s maintenance and service guidelines shall be followed. If in doubt, contact Trane technical personnel. support for assistance. • Do not puncture refrigerant tubing.
Page 9: Leak Detection
• Verify continuity of earth bonding. 5. Continuously flush or purge with inert gas when using • Replace electrical components with Trane replacement flame to open circuit. parts, or those meeting the same ratings and qualified 6. Open the circuit.
Page 10: Decommissioning
A2L Information • Ensure that contamination of different refrigerants does 2. Isolate system electrically. not occur when using charging equipment. Before attempting the procedure, ensure that: • Hoses or lines shall be as short as possible to minimize a. Mechanical handling equipment is available, if the amount of refrigerant contained in them.
Page 11: Dimensions And Weights
Dimensions and Weights Unit Clearances Locate the unit as close to the applicable system support equipment as possible to minimize refrigerant piping The figure below illustrates the minimum operating and lengths. service clearances for either a single, multiple, or pit Allow adequate clearance for water and refrigerant piping application.
Page 12 Dimensions and Weights Table 2. Unit clearances Clearance (in) Dimension Location 20 to 60 tons 80 to 120 tons Front Back Left (control panel side) Right Distance between units (side-by-side) Pit installation - front and back Pit installation - sides CAUK-SVX001A-EN...
Page 13: Unit Dimensions
Dimensions and Weights Unit Dimensions Unit Dimensions Figure 2. Air-cooled condenser — 20 ton Figure 4. Air-cooled condensing unit - 20 ton NOTES: SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. 4X ⌀ 3/4 MTG HOLES FRONT OF UNIT CLEARANCE 72" . BACK OF UNIT CLEARANCE 72" . FAN GRILLE (BOTTOM OF UNIT) LEFT AND RIGHT SIDE OF UNIT CLEARANCE 48".
Page 14 Dimensions and Weights Figure 3. Air-cooled condenser connections — 20 ton CONTROL PANEL SIDE NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. OPTIONS ONLY COME ON SELECTED UNITS. CONTROL PANEL 7/8" O.D. LIQUID LINE 1-3/8" O.D. DISCHARGE LINE 38 1/8"...
Page 15 Dimensions and Weights Figure 4. Air-cooled condenser — 25 and 30 tons NOTES: 4X ⌀ 3/4" MTG HOLES FAN GRILLE SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. (BOTTOM OF UNIT) FRONT OF 25 AND 30 UNIT CLEARANCE 72" . BACK OF UNIT CLEARANCE 72" . 2X 57-1/2"...
Page 16 Dimensions and Weights Figure 7. Air-cooled condensing unit connections - 25 and 30 tons Figure 5. Air-cooled condenser connections — 25 and 30 tons CONTROL PANEL SIDE NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. OPTIONS ONLY COME ON SELECTED UNITS.
Page 17 Dimensions and Weights Figure 6. Air-cooled condenser — 40 ton NOTES: SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. OPTIONS ONLY COME ON SELECTED UNITS. FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF 6X ⌀ 3/4" MTG HOLES FAN GRILLE UNIT CLEARANCE 48"...
Page 18 Dimensions and Weights Figure 7. Air-cooled condenser connections — 40 ton NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. 7/8" O.D. 27 11/32" 2 7/8" 2. DUAL CIRCUIT UNIT REQUIRES TWO SEPARATE LINES LIQUID LINE SETS (TWO SUCTION) LINES AND TWO LIQUID LINES).
Page 19 Dimensions and Weights Figure 8. Air-cooled condenser — 50 ton NOTES: SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. OPTIONS ONLY COME ON SELECTED UNITS. 6X ⌀ 3/4" MTG HOLES FAN GRILLE FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF (BOTTOM OF UNIT) UNIT CLEARANCE 48"...
Page 20 Dimensions and Weights Figure 9. Air-cooled condenser connections — 50 ton NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. 7/8" O.D. 27-7/16" 2. DUAL CIRCUIT UNIT REQUIRES TWO SEPARATE LINES LIQUID LINE SETS (TWO SUCTION) LINES AND TWO LIQUID LINES). 1-3/8"...
Page 21 Dimensions and Weights Figure 10. Air-cooled condenser — 60 ton NOTES: SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. OPTIONS ONLY COME ON SELECTED UNITS. FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF 6X ⌀ 3/4" MTG HOLES FAN GRILLE UNIT CLEARANCE 48"...
Page 22 Dimensions and Weights Figure 13. Air-cooled condensing unit connections - 60 ton Figure 11. Air-cooled condenser connections — 60 ton NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH 7/8" O.D. 27-7/16" INSTALLER DOCUMENTS BEFORE INSTALLATION. LIQUID LINE 2. DUAL CIRCUIT UNIT REQUIRES TWO SEPARATE LINES 1-3/8"...
Page 23 Dimensions and Weights Figure 14. Air-cooled condensing unit - 80 tons. Figure 12. Air-cooled condenser — 80 ton NOTES: 8X ⌀ 3/4 MTG HOLES FAN GRILLE (BOTTOM OF UNIT) SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. OPTIONS ONLY COME ON SELECTED UNITS. 2X 85-5/8"...
Page 24 Dimensions and Weights Figure 13. Air-cooled condenser connections — 80 ton 88-3/16" 3-15/16" NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. 2. DUAL CIRCUIT UNIT REQUIRES TWO SEPARATE LINES SETS (TWO SUCTION) LINES AND TWO LIQUID LINES). 1-5/8"...
Page 25 Dimensions and Weights Figure 16. Air-cooled condensing unit - 100 and 120 tons. Figure 14. Air-cooled condenser — 100 and 120 tons NOTES: 8X ⌀ 3/4" MTG HOLES FAN GRILLE SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. (BOTTOM OF UNIT) OPTIONS ONLY COME ON SELECTED UNITS.
Page 26 Dimensions and Weights Figure 17. Air-cooled condensing unit connections - 100 and 120 tons Figure 15. Air-cooled condenser connections — 100 and 120 tons 88-3/16" NOTES: 4" 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH 3-15/16" INSTALLER DOCUMENTS BEFORE INSTALLATION. 2.
Page 27: Unit Weights
Dimensions and Weights Unit Weights Table 3. CAUK air-cooled condenser weights Unit Size (tons) Operating Weights (lbs) 1389 1439 1437 1964 2276 2292 3319 4067 4558 CAUK-SVX001A-EN...
Page 28: Installation Mechanical
Installation Mechanical Location Requirements If adjustable isolators (spring) are used, ensure that the proper isolator housing clearance is maintained while Isolation leveling the unit. Isolators are identified by color and/or an isolator part number. Shims under the isolators may be To minimize unit sound and vibration transmission, one of required if the unit cannot be leveled using the isolator the following installation methods should be used:...
Page 29 Installation Mechanical Figure 16. Rigging and center-of-gravity data 8’0” Spreader Bars (field supplied) Control Panel Lifting Brackets Note: See lifting bracket location figure for more detail. Figure 17. Lifting bracket locations 7’ 0” 7’ 0” Lifting Brackets Lifting Brackets 1-13/16” 1-13/16”...
Page 30: Unit Mounting
Installation Mechanical Table 4. CAUK center-of-gravity CG Locations Tons 36.3 32.1 36.8 31.9 36.4 40.8 47.1 49.5 46.6 49.7 46.6 82.7 54.4 108.6 109.7 52.7 Unit Mounting Figure 18. Mounting location Control Control Control Panel Panel Panel 20-30 Ton 40-60 Ton 80-120 Ton Table 5.
Page 31: Unit Isolation
Installation Mechanical Table 6. CAUK point loading weights (lbs) (continued) Mounting Location Unit Size (tons) 487.4 443.7 403.8 360.2 320.3 276.6 601.2 403.4 525.4 327.5 495.9 298.1 432.7 234.9 672.7 440.0 628.3 395.7 621.1 388.4 576.7 344.0 725.3 498.6 686.3 459.6 679.9 453.2...
Page 32: Spring Isolators (20 To 120 Ton Units)
Installation Mechanical Spring Isolators (20 to 120 Ton units) Figure 20. Spring isolators 5/8” 5/8” (15 mm) (15 mm) 2 3/4” 2 3/4” (69 mm) (69 mm) 7 3/4” 4 3/4” (198 mm) (122 mm) 9 1/4” 6 1/2” (234 mm) (165 mm) 10 1/4”...
Page 33: Installation
Install refrigerant rated shutoff valves in the liquid line Thermostatic Expansion Valve (TXV) (s) to isolate the filter drier(s) for service. Trane recommends a balance-ported externally equalized • Install a properly sized filter drier in each liquid line. valve in order to maintain satisfactory superheat control down to lower valve loading conditions and to compensate •...
Page 34 Installation Mechanical Table 10. Expansion valve selection, 20 to 60 ton MCHE (30% bleed) Min Tonnage Max Tonnage Manufacturer Selection Trane Part Sporlan BBIYE 1.5-CP (BP/30) VAL21647 Sporlan BBIYE 2.5-CP (BP/30) VAL21648 Sporlan BBIYE 3-CP (BP/30) VAL21469 Sporlan BBIYE 4.5-CP (BP/30)
Page 35: Refrigerant Piping
Installation Mechanical Refrigerant Piping Connect the liquid line piping to the stubs provided at the liquid line shutoff valves. NOTICE Note: The installer must cut an appropriately-sized opening Compressor Damage! in the unit sheet metal for the refrigerant piping entrance into the unit. POE oil is hygroscopic –...
Page 36: Brazing Procedures
Installation Mechanical NOTICE • Ensure that the tubing surfaces to be brazed are clean, and that the ends of the tubes have been carefully Equipment Damage! reamed to remove any burrs. Drilling or sawing pipe stubs could introduce copper • Make sure the inner and outer tubes of the joint are chips into the system and cause equipment damage.
Page 37 Installation Mechanical Trane condensing units are shipped with a nitrogen holding 3. Disconnect the refrigerant cylinder. Connect a dry charge. If there is no pressure, the unit must be leak tested nitrogen cylinder to the charging port and increase the to determine the location of leak.
Page 38: Installation Electrical
Installation Electrical Electrical Note: Local codes may take precedence. Table 13. CAUK electrical data Condenser Fan Motor Unit Characteristics Unit Size Rated (Ton) Voltage Amps 200/60/3 230/60/3 460/60/3 575/60/3 200/60/3 230/60/3 460/60/3 575/60/3 200/60/3 230/60/3 460/60/3 575/60/3 200/60/3 230/60/3 460/60/3 575/60/3 200/60/3 230/60/3...
Page 39: Wiring Requirements
Installation Electrical Table 13. CAUK electrical data (continued) Condenser Fan Motor Unit Characteristics Unit Size Rated (Ton) Voltage Amps 200/60/3 230/60/3 460/60/3 575/60/3 Voltage Utilization Range is +/- 10% of Rated voltage (use range): 200/60/3 (180-220), 230/60/3 (207-253), 460/60/3 (414-506), 575/60/3 (517-633). Electrical information is for each individual motor.
Page 40: Controls Wiring
Installation Electrical Controls Wiring NOTICE Component Failure! WARNING Resistance in excess of 3 ohms per conductor could Hazardous Voltage! result in component failure due to insufficient AC Failure to disconnect power before servicing could voltage supply. result in death or serious injury. Do not exceed three (3) ohms per conductor for the Disconnect all electric power, including remote length of the run.
Page 41: Operating Principles
Operating Principles Component Locations Condenser Fans Figure 22. Condenser fan locations: 20 to 60 ton units 20 Ton 25 & 30 Ton Low Ambient Low Ambient Control Panel Control Panel 50 & 60 Ton 40 Ton 2M10 2M11 2M10 Low Ambient Low Ambient Control Panel Control Panel...
Page 42: Condenser Fans
Operating Principles Condenser Fans below the set pressure the condenser fan motor will be turned off. When the measured pressure is 15 psi above 20 to 60 Ton Condenser Fans the set pressure, the condenser fan motor will be turned Condenser fan cycling is accomplished through interlocking the fan operation with remote compressor Notes:...
Page 43: Pre-Start
Pre-Start Use the checklist provided below in conjunction with the Each refrigeration circuit for split system applications must “General Unit Requirements,” p. 33 to ensure that the unit be evacuated before the unit can be started. Use a rotary is properly installed and ready for operation. Be sure to type vacuum pump capable of pulling a vacuum of 100 complete all of the procedures described in this section microns or less.
Page 44: Standing Vacuum Test
Pre-Start Standing Vacuum Test Figure 25. Typical vacuum pump hookup Manifold Once 300 microns or less is obtained, close Valve A and leave valves B and C open. This will allow the vacuum gauge to read the actual system pressure. Let the system equalize for approximately 15 minutes.
Page 45: Electrical Phasing
Pre-Start The 2.2% imbalance in this example exceeds the Proper electrical phasing can be quickly determined and maximum allowable imbalance of 2.0%. This much corrected before starting unit by using an instrument such imbalance between phases can equal as much as a 20% as Associated Research Model 45 Phase Sequence current imbalance with a resulting increase in motor Indicator, following steps below...
Page 46: Start-Up
Start-Up Verifying Proper Condenser Fan a. Turn the field supplied disconnect switch or circuit protector switch that provides power to the Rotation condensing unit to the “OFF” position. WARNING b. Interchange any two of the field connected main power wires at the unit terminal block (1XD1) in the Rotating Components! unit control panel.
Page 47 Start-Up • ambient temperature; Record this data on an “operator’s maintenance log” like the one shown in Table 19, p. 48. If the operating • compressor oil level (each circuit); compressor pressures indicate a refrigerant shortage, measure the suction and discharge pressures (each circuit); system superheat and system subcooling.
Page 48 Start-Up CAUK-SVX001A-EN...
Page 49: Maintenance
Maintenance Monthly Maintenance • Check the supply fan belt(s). If the belts are frayed or worn, replace them. Air Handling Equipment • Verify that all wire terminal connections are tight. WARNING • Inspect unit for unusual conditions (e.g., loose access panels, leaking piping connections, etc.) Hazardous Voltage! •...
Page 50: Microchannel Condenser Coil Repair
This unit is built with fall restraint slots located on unit top condenser coil applications, seek pressure coil wand that must be used during servicing. See following figures. extension through the local Trane Parts Center. Figure 27. Fall restraint slot Note: DO NOT use any detergents with microchannel coils.
Page 51 Maintenance Figure 28. Fall restraint slot location 20-30 Ton Units 40-120 Ton Units CAUK-SVX001A-EN...
Page 52: Warranty And Liability Clause
This warranty* is extended by Trane Inc. and applies only implied warranties of merchantability and fitness for to commercial equipment rated 20 Tons and larger and particular use.
Page 53: Wiring Diagrams
Wiring Diagrams Note: Published unit wiring diagrams (individual, separate diagrams for unitary product lines) are available via e-Library. Drawing Description Number SCHEMATIC; SHEET 1, POWER, CA, 80-120T 121348760001 SCHEMATIC; SHEET 1, POWER, CA, 20-60T 121348770001 SCHEMATIC; SHEET 2, CONTROLS, CA, 80-120T 121348780001 SCHEMATIC;...
Page 54 Notes CAUK-SVX001A-EN...
Page 55 Notes CAUK-SVX001A-EN...
Page 56 For more information, please visit trane.com or tranetechnologies.com. Trane has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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