CG-SVX07A-E4 1005

Installation
Operation
Maintenance
Cooling only:
CGAN 209-210-211-212-213-214
CG-SVX07A-E4
General information
Foreword
Warnings and cautions
These instructions are given as a
guide to good practice in the
installation, start-up, operation, and
maintenance by the user, of Trane
CGAN 209-214 chillers. They do not
contain full service procedures
necessary for the continued
successful operation of this
equipment. The services of a
qualified technician should be
employed through the medium of a
maintenance contract with a
reputable service company. Read
this manual thoroughly before unit
start-up.
Warnings and Cautions appear at
appropriate sections throughout
this manual. Your personal safety
and the proper operation of this
machine require that you follow
them carefully. The constructor
assumes no liability for installations
or servicing performed by
unqualified personnel.
Units are assembled, pressure
tested, dehydrated, charged and run
tested before shipment.
For information about the unit
controller, refer to the controller's
user guide.
WARNING! : Indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION! : Indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be
used to alert against unsafe
practices or for equipment or
property-damage-only accidents.
Safety recommendations
To avoid death, injury, equipment or
property damage, the following
recommendations should be
observed during maintenance and
service visits:
1. The maximum allowable
pressures for system leak testing
on low and high pressure side
are given in this manual. Always
provide a pressure regulator.
2. Disconnect the main power
supply before any servicing on
the unit.
3. Service work on the refrigeration
system and the electrical system
should be carried out only by
qualified and experienced
personnel.
2
CG-SVX07A-E4
General information
Reception
Warranty
On arrival, inspect the unit before
signing the delivery note.
Warranty is based on the general
terms and conditions of the
manufacturer. The warranty is void
if the equipment is repaired or
modified without the written
approval of the manufacturer, if the
operating limits are exceeded or if
the control system or the electrical
wiring is modified. Damage due to
misuse, lack of maintenance or
failure to comply with the
manufacturer's instructions or
recommendations is not covered by
the warranty obligation. If the user
does not conform to the rules of
this manual, it may entail
cancellation of warranty and
liabilities by the manufacturer.
Reception in France only:
In case of visible damage: The
consignee (or the site
representative) must specify any
damage on the delivery note,
legibly sign and date the delivery
note, and the truck driver must
countersign it. The consignee (or the
site representative) must notify
Trane Epinal Operations - Claims
team and send a copy of the
delivery note. The customer (or the
site representative) should send a
registered letter to the last carrier
within 3 days of delivery.
Note: for deliveries in France, even
concealed damage must be looked
for at delivery and immediately
treated as visible damage.
Reception in all countries except
France:
In case of concealed damage: The
consignee (or the site
representative) must send a
registered letter to the last carrier
within 7 days of delivery, claiming
for the described damage. A copy of
this letter must be sent to Trane
Epinal Operations - Claims team.
CG-SVX07A-E4
Refrigerant
The refrigerant provided by the
manufacturer meets all the
requirements of our units. When
using recycled or reprocessed
refrigerant, it is advisable to ensure
its quality is equivalent to that of a
new refrigerant. For this, it is
necessary to have a precise analysis
made by a specialized laboratory. If
this condition is not respected, the
manufacturer warranty could be
cancelled.
3
General information
4
Maintenance contract
Training
It is strongly recommended that you
sign a maintenance contract with
your local Service office. This
contract provides regular
maintenance of your installation by
a specialist in our equipment.
Regular maintenance ensures that
any malfunction is detected and
corrected in good time and
minimizes the possibility that
serious damage will occur. Finally,
regular maintenance ensures the
maximum operating life of your
equipment. We would remind you
that failure to respect these
installation and maintenance
instructions may result in
immediate cancellation of the
warranty.
To assist you in obtaining the best
use of it and maintaining it in
perfect operating condition over a
long period of time, the
manufacturer has at your disposal a
refrigeration and air conditioning
service school. The principal aim of
this is to give operators and
technicians a better knowledge of
the equipment they are using, or
that is under their charge. Emphasis
is particularly given to the
importance of periodic checks on
the unit operating parameters as
well as on preventive maintenance,
which reduces the cost of owning
the unit by avoiding serious and
costly breakdown.
CG-SVX07A-E4
Contents
General information
2
General data
6
Installation
11
Unit nameplate
Foundations
Isolation and Sound Emission
Isolating rubber pads
Neoprene Isolator Installation (option)
Clearance
Lifting and Moving Instructions
Drainage
Water treatment
Water connections
Minimal installation water content
Winter freeze protection
Expansion valves settings
Electrical connections
General start-up
11
11
11
12
12
12
14
15
15
16
19
21
22
23
24
Start-up preparation
24
Start-up
25
Operation
30
Control system
Unit operation
Weekly start-up
Weekend shutdown
Seasonal shutdown
Seasonal start-up
Maintenance
30
30
30
30
31
31
32
Troubleshooting guide
CG-SVX07A-E4
35
5
General Data
Table 1 - General data CGAN Standard R407C
CGAN
209
Standard
R407C
Eurovent Performances (1)
Net Cooling Capacity
(kW)
287.7
Total Power input in cooling
(kW)
107.4
COP
2.68
Evaporator water pressure drop
(kPa)
33
Available head pressure (5) Low head
pressure /standard head pressure
(kPa)
104 / 161
Main Power supply
400/3/50
Sound Power Level (5)
(dBA)
95
System Data
Number of refrigerant circuits
2
Number of capacity steps
4
Minimum capacity
(%)
23
Units Amps
Nominal (4)
(A)
247
Start-up Amps
Standard unit
(A)
509
With soft starter option
(A)
381
Short circuit unit capacity
(kA)
15
Max supply cable size
(mm²)
150
Min supply cable size
(mm²)
240
Compressor
Number
4
Type
Model
2 X (25T+30T)
Rated Amps (compA/CompB)
(A)
52/62.5
Locked rotor Amps (compA/CompB)
(A)
272/310
Motor RPM
(rpm)
2900
Power factor (compA/CompB)
0.87/0.87
Sump Heater
(W)
150
Evaporator
Number
1
Type
Water volume (total)
(l)
26.8
Antifreeze Heater
(W)
200
Unit water connection
Chilled water
(Inch/mm)
4" (100)
Type
Fan
Type
Number
6
Diameter
(mm)
760
Drive type
Number of speeds
1
Air flow
(m3/h)
117300
Motor HP (2)
(kW)
9.4
Rated Amps (2)
(A)
19.6
Motor RPM
(rpm)
915
Dimensions
Height
(mm)
2323
Length
(mm)
5135
Width
(mm)
2230
Operating Weight
(kg)
2680
Shipping Weight
(kg)
2650
Refrigerant Charge (3)
Circuit 1/Circuit 2
(kg)
41/41
Oil Charge per circuit
Circuit 1/Circuit 2
(l)
12.6/12.6
(1)
(2)
(3)
(4)
(5)
6
CGAN
210
Standard
R407C
CGAN
211
Standard
R407C
CGAN
212
Standard
R407C
CGAN
213
Standard
R407C
CGAN
214
Standard
R407C
315.6
120.4
2.62
35
350.2
130.2
2.69
34
389.2
139.4
2.79
42
428.1
155.8
2.75
43
462.1
171.6
2.69
50
93 / 155
400/3/50
95
105 / 149
400/3/50
95
84 / 133
400/3/50
96
69 / 120
400/3/50
96
62 / 119
400/3/50
96
2
4
25
2
5
19
2
6
17
2
6
15
2
6
17
269
282
326
359
392
531
403
15
150
240
544
416
15
185
240
551
443
15
185
240
621
493
15
240
240
654
526
15
240
240
4
5
6
6
2 X (30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
6
Scroll
3 x 25T+2 x 30T 2 x (25T+25T+25T)
52/62.5
52/52
272/310
272/272
2900
2900
0.87/0.87
0.87/0.87
150
150
1
1
29.2
200
35.6
200
4" (100)
4" (100)
1
Brazed plate
35.6
200
3 x 25T+3 x 30T 2 x (30T+30T+30T)
52/62.5
62.5/62.5
272/310
310/310
2900
2900
0.87/0.87
0.87/0.87
150
150
1
1
42.0
200
42.0
200
4" (100)
4" (100)
4" (100)
8
760
8
760
8
760
Victaulic
Propeller
6
760
7
760
1
117300
9.4
19.6
915
1
131000
11.0
22.8
915
1
144700
12.6
26.1
915
1
141900
12.6
26.1
915
1
139100
12.6
26.1
915
2323
5135
2230
2710
2680
2323
5135
2230
3070
3030
2323
5135
2230
3370
3330
2323
5135
2230
3490
3450
2323
5135
2230
3590
3550
41/41
56/41
56/56
60/56
60/60
12.6/12.6
18.9/12.6
18.9/18.9
18.9/18.9
18.9/18.9
Direct drive
at Eurovent Conditions (Evap 12°C/7°C - Air. 35°C)
total
per circuit
Max rated conditions.
Dual Pump Option
CG-SVX07A-E4
General Data
Table 2 - General data CGAN Super Quiet R407C
CGAN
209
Super Quiet
R407C
Eurovent Performances (1)
Net Cooling Capacity
287.5
Total Power input in cooling
104.8
COP
2.74
Evaporator water pressure drop
(kPa)
33
Available head pressure (5) Low head
pressure / standard head pressure
(kPa)
104 / 161
Main Power supply
400/3/50
Sound Power Level (5)
(dBA)
90
System Data
Number of refrigerant circuits
2
Number of capacity steps
4
Minimum capacity
(%)
23
Units Amps
Nominal (4)
(A)
247
Start-up Amps
Standard unit
(A)
509
With soft starter option
(A)
381
Short circuit unit capacity
(kA)
15
Max supply cable size
(mm²)
150
Min supply cable size
(mm²)
240
Compressor
Number
4
Type
Model
2 X (25T+30T)
Rated Amps (compA/CompB)
(A)
52/62.5
Locked rotor Amps (compA/CompB)
(A)
272/310
Motor RPM
(rpm)
2900
Power factor (compA/CompB)
0.87/0.87
Sump Heater (compA/CompB)
(W)
150
Evaporator
Number
1
Type
Water volume (total)
(l)
26.8
Antifreeze Heater
(W)
200
Unit water connection
Chilled water
(Inch/mm)
4" (100)
Type
Fan
Type
Number
8
Diameter
(mm)
760
Drive type
Number of speeds
1
Air flow
(m3/h)
115400
Motor HP (2)
(kW)
4.5
Rated Amps (2)
(A)
10.9
Motor RPM
(rpm)
690
Dimensions
Height
(mm)
2323
Length
(mm)
5135
Width
(mm)
2230
Operating Weight
(kg)
2850
Shipping Weight
(kg)
2820
Refrigerant Charge (3)
Circuit 1/Circuit 2
(kg)
41/41
Oil Charge per circuit
Circuit 1/Circuit 2
(l)
12.6/12.6
(1)
(2)
(3)
(4)
(5)
CGAN
210
Super Quiet
R407C
CGAN
211
Super Quiet
R407C
CGAN
212
Super Quiet
R407C
CGAN
213
Super Quiet
R407C
CGAN
214
Super Quiet
R407C
315.3
117.8
2.68
35
344.6
130.5
2.64
33
377.5
142.7
2.65
40
412.3
162.7
2.53
40
442.3
181.8
2.43
44
93 / 155
400/3/50
90
106 / 150
400/3/50
90
87 / 136
400/3/50
90
74 / 125
400/3/50
90
69 / 124
400/3/50
91
2
4
25
2
5
19
2
6
17
2
6
15
2
6
17
269
282
326
359
392
531
403
15
150
240
544
416
15
185
240
551
443
15
185
240
621
493
15
240
240
654
526
15
240
240
4
5
6
6
2 X (30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
6
Scroll
3 x 25T+2 x 30T 2 x (25T+25T+25T)
52/62.5
52/52
272/310
272/272
2900
2900
0.87/0.87
0.87/0.87
150
150
1
1
29.2
200
35.6
200
4" (100)
4" (100)
8
760
8
760
1
115400
4.5
10.9
690
1
Brazed plate
35.6
200
3 x 25T+3 x 30T 2 x (30T+30T+30T)
52/62.5
62.5/62.5
272/310
310/310
2900
2900
0.87/0.87
0.87/0.87
150
150
1
1
42
200
42
200
4" (100)
4" (100)
8
760
8
760
8
760
1
112600
4.5
10.9
690
1
109700
4.5
10.9
690
1
107100
4.5
10.9
690
1
104500
4.5
10.9
690
2323
5135
2230
2880
2850
2323
5135
2230
3220
3180
2323
5135
2230
3490
3450
2323
5135
2230
3620
3580
2323
5135
2230
3720
3680
41/41
56/41
56/56
60/56
60/60
12.6/12.6
18.9/12.6
18.9/18.9
18.9/18.9
18.9/18.9
4" (100)
Victaulic
Propeller
Direct drive
at Eurovent Conditions (Evap 12°C/7°C - Air. 35°C)
total
per circuit
Max rated conditions.
Dual Pump Option
CG-SVX07A-E4
7
General Data
Table 3 - General data CGAN Standard R22
Eurovent Performances (1)
Net Cooling Capacity
Total Power input in cooling
COP
Evaporator water pressure drop
(kPa)
Available head pressure (5) Low head
pressure / standard head pressure
(kPa)
Main Power supply
Sound Power Level (5)
(dBA)
System Data
Number of refrigerant circuits
Number of capacity steps
Minimum capacity
(%)
Units Amps
Nominal (4)
(A)
Start-up Amps
Standard unit
(A)
With soft starter option
(A)
Short circuit unit capacity
(kA)
Max supply cable size
(mm²)
Min supply cable size
(mm²)
Compressor
Number
Type
Model
Rated Amps (compA/CompB)
(A)
Locked rotor Amps (compA/CompB)
(A)
Motor RPM
(rpm)
Power factor (compA/CompB)
Sump Heater
(W)
Evaporator
Number
Type
Water volume (total)
(l)
Antifreeze Heater
(W)
Unit water connection
Chilled water
(Inch/mm)
Type
Fan
Type
Number
Diameter
(mm)
Drive type
Number of speeds
Air flow
(m3/h)
Motor HP (2)
(kW)
Rated Amps (2)
(A)
Motor RPM
(rpm)
Dimensions
Height
(mm)
Length
(mm)
Width
(mm)
Operating Weight
(kg)
Shipping Weight
(kg)
Refrigerant Charge (3)
Circuit 1/Circuit 2
(kg)
Oil Charge per circuit
Circuit 1/Circuit 2
(l)
(1)
(2)
(3)
(4)
(5)
8
CGAN
209
Standard
R22
CGAN
210
Standard
R22
CGAN
211
Standard
R22
CGAN
212
Standard
R22
CGAN
213
Standard
R22
CGAN
214
Standard
R22
282.1
101.3
2.78
31
311.6
117.2
2.66
34
343.6
123.6
2.78
33
376.1
130.1
2.89
39
415.5
148.9
2.79
41
453.6
167.3
2.71
49
102 / 159
400/3/50
95
91 / 153
400/3/50
95
103 / 147
400/3/50
95
81 / 130
400/3/50
96
65 / 115
400/3/50
96
58 / 115
400/3/50
96
2
4
23
2
4
25
2
5
19
2
6
17
2
6
15
2
6
17
247
269
282
326
359
392
509
381
15
150
240
531
403
15
150
240
544
416
15
185
240
551
443
15
185
240
621
493
15
240
240
654
526
15
240
240
4
4
5
6
6
2 X (25T+30T)
52/62.5
272/310
2900
0.87/0.87
150
2 X (30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
3 x 25T+3 x 30T
52/62.5
272/310
2900
0.87/0.87
150
2 x (30T+30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
1
1
1
1
1
35.6
200
42
200
42
200
4" (100)
4" (100)
4" (100)
8
760
8
760
8
760
6
Scroll
3 x 25T+2 x 30T
2 x (25T+25T+25T)
52/62.5
52/52
272/310
272/272
2900
2900
0.87/0.87
0.87/0.87
150
150
1
Brazed plate
26.8
200
29.2
200
35.6
200
4" (100)
4" (100)
4" (100)
Victaulic
Propeller
6
760
6
760
7
760
1
117300
9.4
19.6
915
1
117300
9.4
19.6
915
1
131000
11.0
22.8
915
1
144700
12.6
26.1
915
1
141900
12.6
26.1
915
1
139100
12.6
26.1
915
2323
5135
2230
2680
2650
2323
5135
2230
2710
2680
2323
5135
2230
3070
3030
2323
5135
2230
3370
3330
2323
5135
2230
3490
3450
2323
5135
2230
3590
3550
41/41
41/41
56/41
56/56
60/56
60/60
12.6/12.6
12.6/12.6
18.9/12.6
18.9/18.9
18.9/18.9
18.9/18.9
Direct drive
at Eurovent Conditions (Evap 12°C/7°C - Air. 35°C)
total
per circuit
Max rated conditions.
Dual Pump Option
CG-SVX07A-E4
General Data
Table 4 - General data CGAN Super Quiet R22
Eurovent Performances (1)
Net Cooling Capacity
Total Power input in cooling
COP
Evaporator water pressure drop
(kPa)
Available head pressure (5) Low head
pressure
(kPa)
Main Power supply
Sound Power Level (5)
(dBA)
System Data
Number of refrigerant circuits
Number of capacity steps
Minimum capacity
(%)
Units Amps
Nominal (4)
(A)
Start-up Amps
Standard unit
(A)
With soft starter option
(A)
Short circuit unit capacity
(kA)
Max supply cable size
(mm²)
Min supply cable size
(mm²)
Compressor
Number
Type
Model
Rated Amps (compA/CompB)
(A)
Locked rotor Amps (compA/CompB)
(A)
Motor RPM
(rpm)
Power factor (compA/CompB)
Sump Heater (
(W)
Evaporator
Number
Type
Water volume (total)
(l)
Antifreeze Heater
(W)
Unit water connection
Chilled water
(Inch/mm)
Type
Fan
Type
Number
Diameter
(mm)
Drive type
Number of speeds
Air flow
(m3/h)
Motor HP (2)
(kW)
Rated Amps (2)
(A)
Motor RPM
(rpm)
Dimensions
Height
(mm)
Length
(mm)
Width
(mm)
Operating Weight
(kg)
Shipping Weight
(kg)
Refrigerant Charge (3)
Circuit 1/Circuit 2
(kg)
Oil Charge per circuit
Circuit 1/Circuit 2
(l)
(1)
(2)
(3)
(4)
(5)
CGAN
209
Super Quiet
R22
CGAN
210
Super Quiet
R22
CGAN
211
Super Quiet
R22
CGAN
212
Super Quiet
R22
CGAN
213
Super Quiet
R22
CGAN
214
Super Quiet
R22
282.0
98.6
2.86
30
311.4
114.6
2.72
33
339.1
123.6
2.74
33
366.7
133.0
2.76
36
405.0
155.2
2.61
36
441.9
177.5
2.49
44
108 / 165
400/3/50
90
96 / 158
400/3/50
90
111 / 155
400/3/50
90
91 / 138
400/3/50
90
74 / 126
400/3/50
90
69 / 124
400/3/50
91
2
4
23
2
4
25
2
5
19
2
6
17
2
6
15
2
6
17
247
269
282
326
359
392
509
381
15
150
240
531
403
15
150
240
544
416
15
185
240
551
443
15
185
240
621
493
15
240
240
654
526
15
240
240
4
4
5
6
6
2 X (25T+30T)
52/62.5
272/310
2900
0.87/0.87
150
2 X (30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
3 x 25T+3 x 30T
52/62.5
272/310
2900
0.87/0.87
150
2 x (30T+30T+30T)
62.5/62.5
310/310
2900
0.87/0.87
150
1
1
1
1
1
35.6
200
42
200
42
200
4" (100)
4" (100)
4" (100)
8
760
8
760
8
760
6
Scroll
3 x 25T+2 x 30T 2 x (25T+25T+25T)
52/62.5
52/52
272/310
272/272
2900
2900
0.87/0.87
0.87/0.87
150
150
1
Brazed plate
26.8
200
29.2
200
35.6
200
4" (100)
4" (100)
4" (100)
Victaulic
Propeller
8
760
8
760
8
760
1
115400
4.5
10.9
690
1
115400
4.5
10.9
690
1
112600
4.5
10.9
690
1
109700
4.5
10.9
690
1
107100
4.5
10.9
690
1
104500
4.5
10.9
690
2323
5135
2230
2850
2820
2323
5135
2230
2880
2850
2323
5135
2230
3220
3180
2323
5135
2230
3490
3450
2323
5135
2230
3620
3580
2323
5135
2230
3720
3680
41/41
41/41
56/41
56/56
60/56
60/60
12.6/12.6
12.6/12.6
18.9/12.6
18.9/18.9
18.9/18.9
18.9/18.9
Direct drive
at Eurovent Conditions (Evap 12°C/7°C - Air. 35°C)
total
per circuit
Max rated conditions.
Dual Pump Option
CG-SVX07A-E4
9
General Data
Table 5 - General data - Hydraulic module (option)
Rated Amps (1)
(A)
Motor RPM
(rpm)
14,7
2900
Water strainer diameter
(inches)
4
Expansion tank volume
(l)
50
User volume expansion capacity (2)
(l)
3000
Max. water-side operating pressure
without hydraulic module
(kPa)
1000
with hydraulic module
(kPa)
400
Hydraulic module additional weight (1)
(kg)
300
Water tank volume (option)
(l)
600
Water tank additional shipping weight
(kg)
240
(1) For dual pump standard head pressure
(2) Hydrostatic pressure 3 bar at 45°C with -12°C mini
10
CG-SVX07A-E4
Installation
Unit nameplate
Foundations
The unit nameplate gives the
complete model reference numbers.
The unit power rating is shown, and
power supplies should not deviate
by more than 5 % from the rated
power. Compressor motor
amperage is shown in box I.MAX.
The customer's electrical
installation must be able to
withstand this current.
Provide rigid, non-warping
mounting pads or a concrete
foundation of sufficient strength
and mass to support the unit
operating weight (that is, including
completed piping, and full operating
charges of refrigerant, oil, and
water). Refer to General Data
section for operating weights. After
it is in place, the unit must be level
within 6 mm over its length and
width.
Trane is not responsible for
equipment problems resulting from
an improperly designed or
constructed foundation.
Isolation and Sound
Emission
The most effective form of isolation
is to locate the unit away from any
sound-sensitive area. Structurally
transmitted sound can be reduced
by elastomeric vibration
eliminators. Spring isolators are not
recommended. Consult an
acoustical engineer in critical sound
applications.
For maximum isolation effect,
isolate water lines and electrical
conduit. Wall sleeves and rubber
isolated piping hangers can be used
to reduce the sound transmitted
through water piping. To reduce the
sound transmitted through electrical
conduit, use flexible electrical
conduit. National and local codes
on sound emissions should always
be considered. Because the
environment in which a sound
source is located affects sound
pressure, unit placement must be
carefully evaluated. Sound-power
levels for Trane air-cooled chillers
are available on request.
Figure 1 - Unit isolation recommendations
4
1
3
4
3
1
2
1
2
3
4
=
=
=
=
Flex conduit control power
Concrete base
Neoprene isolators
Elastomeric vibration eliminators
CG-SVX07A-E4
11
Installation
Isolating rubber pads
Clearance
8 pads are supplied as standard
with the unit and should be placed
between the supporting floor and
the unit to isolate from the ground.
Respect recommended clearance
around the unit to allow
maintenance operation to take place
without obstruction and
recommended clearance around
condenser.
Also as on option pads might be
replaced by neoprene isolators
which are to be mounted on site as
it is indicated on the submittals.
Trane does not recommend
installing spring isolators.
Neoprene Isolator
Installation (option)
Secure the isolators to the
mounting surface using the
mounting slots in the isolator base
plate. DO NOT fully tighten the
isolator mounting bolts at this time.
See unit submittals for isolator
placement, maximum weights, and
isolator diagrams. Align the
mounting holes in the base of the
unit with the threaded positioning
pins on the top of the isolators.
Lower the unit onto the isolators
and secure the isolator to the unit
with a nut. The maximum isolator
deflection should be 6 mm. Level
the unit carefully. Fully tighten the
isolator mounting bolts.
12
Vertical clearance
Vertical condenser air discharge
must be unobstructed. While it is
difficult to predict the degree of
warm air recirculation, a unit
installed as shown in Figure 2
would have its capacity and
efficiency significantly reduced and
could possibly encounter nuisance
high head pressure tripouts.
Performance data is based on free
air discharge.
Figure 2 - Vertical air discharge
CG-SVX07A-E4
Installation
Lateral clearance
Walled enclosure installations
The condenser coil inlet must not
be obstructed. Thanks to its
W-shaped condenser coil design,
AquaStream2® lateral clearance is
one of the best of the market - it can
be as low as 1.2 m. A unit installed
closer than the minimum
recommended distance to a wall or
other vertical riser may experience
a combination of coil starvation and
warm air recirculation, resulting in
unit capacity and efficiency
reductions and possible excessive
head pressures.
When the unit is placed in an
enclosure or small depression, the
top of the fans should be no lower
than the top of the enclosure or
depression. If they are,
consideration should be given to
ducting the top of the unit. Ducting
individual fans, however, is not
recommended. Such applications
should always be reviewed with the
local Trane sales engineer.
The recommended lateral
clearances are given in the certified
drawings for multiple chiller
installation up to 3 units. For
applications with more than
3 chillers, check with the local Trane
sales engineer.
CAUTION!
Unit operation is function of the air
temperature. Any recycling of the
air fed out by the fans will increase
the air intake temperature over the
condenser fins and can result in
high pressure cut-out.
In this case the standard operating
conditions and performance are
modified. Operation of the unit may
be affected by an increase in air
temperature on the condenser.
When the units are positioned in a
windy area, avoid all the risks of aircooled recycling. Refer to certified
drawings.
Figure 3 - Lateral clearance recommendations
1.2 m
CG-SVX07A-E4
13
Installation
Lifting and Moving
Instructions
A specific lifting method is
recommended as follows:
1. 4 lifting points are built into the
unit.
2. Slings and spreader bar to be
provided by rigger and attached
to the lifting points.
3. Minimum rated lifting capacity
(vertical) of each sling and
spreader bar shall be no less
than the tabulated unit shipping
weight.
CAUTION!
4. This unit must be lifted with the
utmost care. Avoid shock load by
lifting slowly and evenly.
CAUTION!
Refer to lifting and moving
instructions for unit weight and
additional installation instructions
contained inside the control panel.
Other lifting arrangements may
cause equipment damage or serious
personal injury.
Figure 4 - Rigging and handling
2400
4000
A
C
B
Pull-out hook
Table 6 - Unit dimensions (maximum, mm)
A
B
C
Unit without
hydraulic
module
Can be identified by the absence of any
water pump
2423
2280
4849
Unit with
hydraulic
module
Can be identified by the presence of
a single or dual pump and the absence of
the 600 litre water tank on the water side
2423
2250
4849
Unit with
hydraulic
module and
buffer tank
Can be identified by the presence of
the 600 litre water tank on the water side.
2423
2250
4849
14
CG-SVX07A-E4
Installation
Drainage
Provide a large-capacity drain for
water vessel drain-down during
shutdown or repair. All local and
national codes apply.
Trane will not accept any ability in
regards of damage due to the use
of untreated or improperly treated
water or from the use of saline or
brackish water. If required, contact
your local Trane sales office.
The vent on the top of the water
tube is provided to prevent a
vacuum, by allowing air into the
evaporator for complete drainage.
Thoroughly flush all water piping to
the unit before making the final
piping connections to the unit.
Water treatment
If using an acidic commercial
flushing solution, construct a
temporary bypass around the unit
to prevent damage to internal
components of the evaporator.
Untreated or insufficiently treated
water, if used in this unit, may
cause scale, slime or algae to
accumulate or cause erosion and
corrosion. As Trane does not know
the components used in the
hydraulic network and the quality of
the water used, we recommend the
services of a qualified water
treatment specialist.
The following materials are used in
Trane chillers heat exchangers:
• Stainless steel plates AISI 316,
1.4401 with copper brazing.
• Water piping: steel
• Water connections: brass
CAUTION!
To avoid possible equipment
damage, do not use untreated or
improperly treated system water.
CAUTION!
Trane assumes no responsibility for
equipment failures which results
from untreated or improperly
treated water or saline or brackish
water.
Water connections
Before making any water
connection, make sure the labeling
for entering and leaving water
corresponds to the submittals.
Figure 5 - Victaulic connections
CG-SVX07A-E4
15
Installation
CAUTION!
CAUTION!
The chilled-water connections to
the evaporator are to be Victaulic
type connections. Do not attempt
to weld these connections, because
the heat generated from welding
can cause microscopic and
macroscopic fractures on the unit
piping. An optional Victaulic pipe
stub and coupling is available for
welding on flanges.
A pipe strainer must be installed in
the entering water line. Failure to
do so can allow waterborne debris
to enter the brazed plate
evaporator. The strainer must be
cleanable without dismounting and
designed to filter particles bigger
than 1.6 mm. Units with hydraulic
module are already fitted with this
type of strainer.
To prevent damage to chilled-water
components, do not allow
evaporator pressure (maximum
working pressure) to exceed
10.0 bar on units without hydraulic
module and 4 bar on units with
hydraulic module.
CGAN units are available in
3 versions:
• Without hydraulic module (with
or without contactors)
• With hydraulic module (single or
dual pump)
• With hydraulic module and buffer
tank.
Use rubber vibration eliminators to
prevent vibration transmission
through the water lines. If desired,
install thermometers in the lines to
monitor entering and leaving water
temperatures.
On all installation the following
components will always be
necessary to be mounted on the
piping:
Install a balancing valve in the
leaving-water line to control water
flow balance.
Install shutoff valves on both the
entering and leaving-water lines so
that the evaporator or hydraulic
module can be isolated for service.
16
CG-SVX07A-E4
Installation
WARNING!
Units with hydraulic module and
buffer tank content all safety and
operation devices and only require
the supply and return piping to be
connected using expansion
compensators. Units without
hydraulic module have to be
connected according to Figure 6.
Figure 6 - Hydraulic module schematics
A = Circuit with hydraulic module
B = Circuit without hydraulic module
CW = Chilled water loop
FT = Water flow switch
TT = Temperature sensor
Pi = Gauge
1 = Single or double water pump
2 = Water strainer
3 = Relief valve
4 = Expansion tank
6 = Manual air vent
7 = Manual water vent
8 = Automatic air vent
9 = Stop butterfly valve
10 = Insulated evaporator
12 = Optional buffer tank
13 = Antifreeze protection
14 = Schraeder ¼ SAE male
CG-SVX07A-E4
17
Installation
Figure 7 - Unit without hydraulic module and buffer tank - typical water circuit
10
Figure 8 - Unit with hydraulic module and buffer tank - typical water circuit
2
1 = Pressure gauges: show entering and leaving water pressure (2 pressure ports are
available inside of the unit - see item 1 in Figure 7)
2 = Balancing valve: adjusts water flow.
3 = Air purge allows to remove the air from the water circuit during fill up.
4 = Stop valves: isolate chillers and water circuiting pump during maintenance
operations.
5 = Thermometers: indicate chilled water entering and leaving temperatures
(not mandatory).
6 = Expansion compensators: avoid mechanical stress between chiller and piping
installation.
7 = Stop valve located on the outlet connection: used to measure the water pressure
inlet or outlet of evaporator.
8 = Strainer: avoid to get heat exchangers dirty. All installation must be equipped
with efficient strainer in order that only clean water enters into exchanger. If
there is no strainer, reserve will be formulated by the Trane technician at the
start-up of the unit.
The strainer used must be able to stop all particles with a diameter greater
than 1.6 mm.
9 = Draining and charging: used to drain and charge the plate heat exchanger.
10 = Charging valve
To protect the environment, it is compulsory to recover and process glycol
brines.
18
CG-SVX07A-E4
Installation
Minimal installation water
content
The minimum volume can be
determined by using the following
formula:
The water volume is an important
parameter because it allows a
stable chilled water temperature
and avoids short cycle operation of
the compressors.
Volume = Cooling capacity x Time x
highest capacity step (%) / Specific
heat / Dead band
Parameters which influence the
water temperature stability
• Water loop volume.
• Load fluctuation.
• Number of capacity steps.
• Compressors rotation.
• Dead band (adjusted by control
CH530).
• Minimum time between 2 starts
of a compressor.
Specific heat = 4.18 kJ / kg
Minimum water volume for a
comfort application
Minimum operating time =
120 seconds
Average Dead band = 3°C (or 2°C)
Note: To estimate the biggest step,
it is usually more reliable to make a
selection at lower ambient
temperature where efficiency is
higher and compressors steps
bigger. It is also essential to take
into account the brine specific heat,
in case of the use of glycol.
For comfort application we can
allow water temperature fluctuation
at part load. The parameter to take
into account is the minimum
operating time of the compressor.
In order to avoid lubrication
problem on a scroll compressor it
must run at least 2 minutes
(120 seconds) before it stops.
Table 7 - Minimum water loop for comfort applications
This table is estimated with: Ambient 35°C, Water 12°/7°C, Water (0% glycol),
deadband of 3°C
Unit size
Chiller data
Minimum water loop
CG-SVX07A-E4
CGAN
209
210
211
212
213
214
Capacity (kW)
288
316
350
389
428
462
Biggest step (%)
27
25
22
17
18
17
Comfort (l)
751
755
745
621
745
737
19
Installation
Minimum water volume for a
process application
For process application we have to
minimize the water temperature
fluctuation at part load. In order to
avoid problem on a scroll
compressor it must run at least
2 minutes (120 seconds) before it
stops and the minimum time
between two starts is 5 minutes
(300 seconds). The water volume
has to be able to provide the
cooling capacity while the unit is
shut down. The minimum volume
can be determined by using the
following formula:
Volume = Cooling capacity x Time x
highest capacity step (%) / Specific
heat / Dead band
For the CGAN running in following
conditions: Air temperature 35°C,
water 12/7°C, this gives the
following volumes. If the total water
volume of the installation is below
the above mentioned values it is
necessary to use a buffer tank.
Minimum time = 180 seconds (300120)
Specific heat =4.18 kJ / kg
Dead band = 2°C (request)
With these values the formula
becomes:
Volume = Cooling capacity x 43 x
highest capacity step (%) / Dead
band
Increasing the dead band is like
adding water volume to the loop.
With these values the formula
becomes for water:
Volume = Cooling capacity X 43 x
highest capacity step (%)/ dead
band
20
CG-SVX07A-E4
Installation
Winter freeze protection
During negative ambient air
temperature chilled water piping
must be fully insulated.
Ensure that all safeties are taken to
prevent frost damage during
negative ambient air temperature.
CAUTION!
Table 8 - Freeze protection recommendations
Freeze protection heater
Type of pump control
Without electrical
heater digit 36=X
With electrical
heater digit 36=1
Following systems can be used:
• Electrical heater mounted on all
water piping exposed to negative
temperatures.
• Start chilled water pump during
negative ambient air
temperature.
• Add ethylene glycol in the chilled
water.
• Drain water-circuit, however be
aware of corrosion process when
drained.
Advice
No pump
controled
digit 35=X
No winter freeze
protection.
Electric heat function.
For areas where ambient
temperature might go
below freezing
temperatures use glycol
or freeze protection
devices.
Remote pump
control
digit 35=A, B
Pump winter freeze
protection
(not recommended).
Electric heat function
with pump winter
freeze protection.
It is recommended to
deactivate the pump
protection and use only
heater protection.
Pump installed
in the unit
digit 35=C to F
Pump winter freeze
protection.
Electric heat function
with pump winter
freeze protection.
It is recommended to use
pump protection or even
both modes together.
When using the freeze protection by
pump activation during the cold
season, water must be able to
circulate freely. Check that no
closure valve or other device might
block waterflow.
°C
Figure 9 - Freezing point versus ethylene glycol percentage
%
% = % ethylene glycol
°C = Brine temperature
1 = Liquid
2 = Freezing without burst effect
3 = Freezing with burst effect
CG-SVX07A-E4
21
Installation
Expansion valves settings
Electrical connections
In order to keep the compressor in
the operating envelope, it is
mandatory to control the superheat
suction at commissioning. It shall
reduce the compressor discharge
gas temp and increase the saturated
suction temperature, increasing by
the way the unit capacity. The rule
to reduce the suction superheat is
to loosen the expansion valve
adjustment screw. One turn
counterclockwise equals to -1°C to
- 2°C superheat decrease. It is
recommended to lower the
superheat by increasing the suction
pressure by making adjustments to
the expansion valve setting prior to
attempting to lower the LP setting
parameter to avoid unit tripping on
low pressure. Always make sure
there is enough subcooling. This
can be especially convenient for
units with Ethylene Glycol and
Propylene Glycol.
CAUTION!
1. The greatest care should be
taken when cutting through
passages and installing electric
wiring. Under no circumstances
should chips of metal or cuttings
of copper or isolating material
fall into the starter panel or
electric components. Relays,
contactors, terminals and control
wiring should be covered and
protected before power supplies
are connected.
2. Install power supply cabling as
shown in wiring diagram.
Adequate cable gland should be
chosen, ensuring no foreign bodies
enter the electrical housing or
components.
See "General start-up" section for
recommended settings.
CAUTION!
1. Cabling must comply with local
standards. The type and location
of fuses must also comply with
standards.
2. Only copper wiring should be
used. Using aluminium wires can
produce galvanic corrosion and
possibly lead to superheat and
failure of connection points.
Soft starter recommended setting
Acceleration time: 0.5 seconds full
speed
Start-up torque: 50%
Deceleration time: 0 seconds
Use adjustment setting button.
22
CG-SVX07A-E4
Installation
CG-SVX07A-E4
155mm
L1 L2 L3
PE
65
65
Figure 10 - Main power supply connection
23
General start-up
Start-up preparation
Carry out all operations on check list
so that the unit is correctly installed
and ready to operate.
The installer must check all the
following points before calling in
the Trane Servicing Department to
put the equipment into service:
• Check position of unit
• Check unit is level
• Check type and position of
rubber pads
• Check clearance required for
maintenance access (Refer to
certified drawings)
• Check clearance around
condenser (Refer to certified
drawings)
• Chilled water circuit ready to
operate, filled with water,
pressure test carried out and air
purged.
• Chilled water circuit must be
rinsed
• Check the presence of water
strainer ahead of evaporator
• The strainers must be cleaned
after 2 hours of pumps operation
• Check the thermometers and
manometers position
• Check chilled water pumps
interconnection to control panel
• Ensure that the isolation
resistance of all power supply
terminals to ground complies
with standards and regulations in
force.
• Check that unit voltage and
frequency supplied match rated
input voltage and frequency
• Check that all electrical
connections are clean and sound
• Check that main power supply
switch is sound.
• Check Ethylene glycol or
Propylene glycol % in the chilled
water circuit.
• Water flow control checking:
decrease the water flow and
check the electrical contact in the
control panel.
• Check chilled water pressure
drop through evaporator (unit
without hydraulic module) or unit
available pressure (unit with
hydraulic module) are in
accordance with the Trane order
write-up (Figure 12).
• On start-up of each motor in the
system, check the direction of
rotation and operation of all the
components they drive.
• Check that there is sufficient
demand for cooling on the day of
start-up (around 50% of nominal
load)
WARNING! For leak test, maximum
pressure on HP and LP side is
21 bar.
24
CG-SVX07A-E4
General start-up
Start-up
Follow the instructions below to
correctly start-up the unit.
Installation and chiller inspection:
• Ensure that all the operations
above (start-up preparation), are
followed.
Follow the instruction stuck inside
the electrical cabinet:
• Ensure all water and refrigerant
valves are in service positions,
• Ensure that the unit is not
damaged,
• Ensure that sensors are properly
installed in their bulb-wells and
submerged in heat conducting
product,
• Check fixing of capillary tubes
(protection from vibration and
from wear) and ensure that they
are not damaged,
• Reset all manually set control
devices,
• Check refrigerating circuits
tightness
Checking and setting:
Compressors:
• Check oil level at rest. The level
should reach at least halfway up
indicator located on housing. See
Figure 11 for correct level.
Figure 11 - Compressor oil level
• Check fixing of capillary tubes
(protection from vibration and
from wear) and ensure that they
are not damaged,
• Reset all manually set control
devices,
• Check refrigerating circuits
tightness
• Check electrical terminals
tightening of the motors and in
the control panel,
• Check the isolation of the motors
using a 500V DC megohmeter
which meets manufacturer's
specifications (alert value
2 megohms)
• Check the direction of the
rotation using phasemeter.
Electrical power wiring:
• Check all the electrical terminals
tightening,
• Set-up compressors overload
relays,
• Set-up fan-motors overload
relays,
Electrical control wiring:
• Check all the electrical terminals
tightening,
• Check all the pressostats,
• Check and set-up the TRACER
CH530 control module
• Test and start-up without the
electrical power.
Condenser:
• Check direction of the rotation of
fans,
1 = Maximum oil level
2 = Minimum oil level
CG-SVX07A-E4
25
General start-up
Operating parameters statement:
• Check that the unit is clean and
clear of any debris, tools, etc…
• All valves are in operating
position,
• Switch on main power supply
switch,
• Start the water pump(s) and
check there is no cavitation.
• Start-up the unit following
procedure described in the
controller user guide
The unit and the chilled water
pumps contactor must be
connected together,
• After unit start up, leave in
operation for at least 15 minutes,
to ensure pressures are
stabilized.
26
Then check:
• voltage,
• compressors and fan-motors
currents,
• leaving and return chilled water
temperature,
• suction temperature and
pressure,
• ambient air temperature,
• blowing air temperature,
• discharge pressure and
temperature,
• liquid refrigerant temperature
and pressure,
• operating parameters:
• chilled water pressure drop
through evaporator (if no
hydraulic module is installed) or
unit available pressure. It must
be in accordance with Trane
order write-up,
• superheat: difference between
suction temperature and dew
point temperature. Normal
superheat should be within 4 and
7 °C with R407C in cooling mode,
• sub-cooling: difference between
liquid temperature and bubble
point temperature. Normal
subcooling should be within 2
and 10°C with R407C in cooling
mode,
• difference between dew point
temperature in high pressure and
condenser air inlet temperature.
Normal value on standard unit
with R407C, should be 15 to
23°C.
• difference between outlet water
temperature and dew point
temperature in low pressure.
Normal value on standard unit,
without Ethylene glycol in chilled
water, should be about 3°C +
superheat with R407C.
Final check:
When the unit is operating correctly
• Close control and starter panel
doors and check panels fixation.
CAUTION!
• For the warranty to apply, any
start-up carried out directly by
the customer must be recorded
in a detailed report, which must
be sent as soon as possible to
the nearest Trane sales office.
• Do not start-up a motor whose
insulation resistance is less than
0.5 megohms
• Phase imbalance should not be
greater than 2%.
• The voltage supplied to motors
should be within 5% of the rated
voltage on the compressor
nameplate.
• Excessive emulsion of the oil in
the compressor shows that
refrigerant is present in the oil
and the result will be that
compressor is not lubricated
enough. Shut down compressor
and wait for 60 minutes for the
sump heaters to heat oil and
start again. Should this not work,
consult Trane technician.
• Excess oil in compressor can
damage the compressor. Before
adding oil, consult Trane
technician.
Use only Trane products
recommended.
• The compressors must operate
in a single direction of rotation. If
refrigerant high pressure remains
stable in the 30 seconds after
compressor start-up,
immediately shut down unit and
check the direction of rotation
using phasemeter.
CG-SVX07A-E4
General start-up
WARNING!
• The chilled water circuit may be
under pressure. Bring down this
pressure before opening up the
system to rise out or fill up the
water circuit. Failure to comply
with this instruction may cause
accidental injury to maintenance
personnel.
• If a cleaning solution is used in
the chilled water circuit, the
chiller must be isolated from the
water circuit to avoid all the
damage risks of the chiller and
evaporator water pipes.
Figure 12 - Pressure drop without hydraulic module
50
20
5
CG-SVX07A-E4
10
20
50
27
General start-up
Figure 13 - Chiller Available pressure (Hydraulic module standard head pump)
250
200
kPa
150
100
209
210
211
50
213
214
212
0
5
10
15
20
25
30
35
l/s
Figure 14 - Chiller Available pressure (Hydraulic module low head pump)
180
211
160
140
120
kPa
100
80
60
40
210
20
209
0
5
10
15
20
212
25
213
214
30
l/s
28
CG-SVX07A-E4
General start-up
The correction factor found in
Table 9 and Table 10 may be used to
calculate the actual general data of
the unit. You may apply both of
those factors (first Table 9 then
Table 10)
In case of application with negative
temperature at the evaporator or
usage of another type of fluid:
please contact your local Trane sales
engineer. A relief valve is located at
pump suction limiting water circuit
pressure at 4 bar. Nitrogen pressure
inside of the expansion tank must
be equal to the geometric height of
the installation + 0.5 bar. In order to
avoid air entering in the water
circuit, expansion tank must be
inflated with nitrogen. Pressure
must be checked yearly. For a good
pump operation, pump suction
pressure must be between 0.5 and
3.5 bar when pump runs.
This table is valid for evaporator
leaving water temperature between
+5°C and +15°C.
Table 9 - Performance data adjustment altitude and delta T factors (1)
Elevation
Chilled
Water Temp.
Delta T
Sea Level
Cooling
Power
capacity
input
factor
factor
Flow
rate
factor
Cooling
capacity
factor
600 m
Power
input
factor
Flow
rate
factor
Cooling
capacity
factor
1200 m
Power
input
factor
Flow
rate
factor
Cooling
capacity
factor
1800 m
Power
input
factor
Flow
rate
factor
4 °C
0.997
0.999
1.246
0.987
1.012
1.233
0.975
1.027
1.217
0.960
1.045
1.200
5 °C
1.000
1.000
1.000
0.989
1.013
0.989
0.977
1.028
0.977
0.963
1.047
0.963
6 °C
1.003
1.001
0.835
0.992
1.014
0.826
0.979
1.030
0.816
0.965
1.048
0.804
7 °C
1.004
1.002
0.717
0.993
1.016
0.710
0.981
1.031
0.701
0.966
1.049
0.690
8 °C
1.006
1.003
0.629
0.995
1.016
0.622
0.982
1.032
0.614
0.968
1.050
0.605
(1) with fouling factor of 0.044 m²/°C/kW
Table 10 - Performance data adjustment with glycol
Correction factors to apply in case of the use of Glycol in the water loops
Glycol Concentration
Fluid Type
Water in Evaporator
Ethylene Glycol
Mono-Propylene Glycol
(1)
(2)
Performance
Evaporator
Evaporator
Cooling
Capacity
Factor
Power
input
Factor
Flow
rate
Factor (1)
Pressure
drop
Factor (2)
0%
10%
20%
30%
10%
20%
30%
1.00
0.99
0.98
0.97
0.99
0.97
0.96
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.02
1.05
1.10
1.01
1.03
1.05
1.00
1.02
1.06
1.10
1.05
1.10
1.17
Flow rate with capacity modification
Pressure drop to be used after flow rate factor rate
CG-SVX07A-E4
29
Operation
Control system
The control is through the TRACER
CH530 control module.
Unit operation
• Check the chilled water pump(s)
operates
• Start up the unit following
procedure described in the
controller user guide. The unit
will operate correctly when there
is sufficient water flow. The
compressors will start up if the
evaporator water leaving
temperature is above the control
module setpoint.
30
Weekly start-up
• Check the chilled water pump(s)
operates
• Start up the unit following
procedure described in the
controller user guide.
Weekend shutdown
• If the unit needs to be shut down
for a short period of time, stop
the unit following procedure
described in the controller user
guide (See "Clock" menu)
• If the unit is shut down for a
longer period, see "Seasonal
shutdown".
• Ensure that all safeties are taken
to prevent frost damages during
negative ambient temperature.
• Do not put the general
disconnect switches to off, except
if the unit is drained. Trane does
not recommend draining the
unit, due to the fact that it
increases tube corrosion.
CG-SVX07A-E4
Operation
CG-SVX07A-E4
Seasonal shutdown
Seasonal start-up
• Check water flows and interlocks.
• Check glycol % in the chilled
water circuit if glycol presence is
required
• Carry out leak test.
• Carry out oil analysis
• Record operating pressures,
temperatures, amperages and
voltage.
• Check operation of machines and
compare conditions of operation
against original commissioning
data.
• Stop the unit following
procedure described in the
controller user guide.
• Ensure that all safeties are taken
to prevent frost damages during
negative ambient temperature.
• Fill out the visit log sheet and
review with the operator
• Do not put the general
disconnect switch to off, except
if the unit is drained. Trane
does not recommend draining
the unit, due to the fact that it
increases tube corrosion.
• Check water flows and interlocks.
• Check Ethylene glycol % in the
chilled water circuit if glycol
presence is required
• Check operational set points and
performance.
• Check operation of all safety
devices.
• Inspect contacts and tighten
terminals.
• Megger the motor compressor
windings.
• Record operating pressures,
temperatures, amperages and
voltage.
• Carry out leak test.
• Check configuration of unit
control module.
• Change the oil as required based
upon results of the oil analysis
made during seasonal shutdown
Get the 8 condition measurements
at the same time, on each circuit.
• HP
• LP
• Suction temperature
• Discharge temperature
• Liquid temperature
• Water entering temperature
• Water leaving temperature
• Outdoor ambient temperature
Then calculate the sub-cooling and
superheat. No diagnosis can be
accurate with one of these records
missing.
• Check operation of
machines/compare conditions of
operation against original
commissioning data.
• Fill out the visit log sheet and
review with the operator
31
Maintenance
The following maintenance
instructions are part of maintenance
operations required for this
equipment. A qualified technician is
needed for regular maintenance as
part of a regular maintenance
contract.
Carry out all operations as required
by schedule. This will ensure long
unit service life and reduce the
possibility of serious and costly
breakdown.
Keep service records up to date,
showing monthly information on
unit operations. These records can
be of great help to maintenance
personnel diagnostics. Similarly, if
machine operator keeps a log of
changes in unit operating
conditions, problems can be
identified and solutions found
before more serious problems arise.
32
Inspection visit after the first
500 hours of operation from unit
start up
• Carry out oil analysis
• Carry out leak test.
• Inspect contacts and tighten
terminals.
• Record operating pressures,
temperatures, amperages and
voltage.
• Check operation of
machines/compare conditions of
operation against original
commissioning data.
• Fill out inspection visit log sheet
and review with the operator
• Check and clean the strainer
For medium to highly critical
applications, a monthly preventive
visit is recommended.
Monthly preventive visit
• Carry out leak test.
• Oil test of acidity
• Check Ethylene glycol % in the
chilled water circuit if glycol
presence is required
• Inspect contacts and tighten
terminals.
• Record operating pressures,
temperatures, amperages and
voltage.
• Check operation of
machines/compare conditions of
operation against original
commissioning data.
• Fill out visit log sheet and review
with the operator.
• Check and clean the strainer.
CG-SVX07A-E4
Maintenance
Annual preventive visit
• Check and clean the strainer.
• Check water flows and interlocks.
• Check expansion tank pressure.
• Check glycol % in the chilled
water circuit if glycol presence is
required
• Check operational set points and
performance.
• Calibrate controls and pressure
transducer.
• Check operation of all safety
devices.
• Inspect contacts and tighten
terminals.
• Megger the motor compressor
windings.
• Record operating pressures,
temperatures, amperages and
voltage.
• Carry out leak test.
• Check configuration of unit
control module.
• Carry out oil analysis
• Change the oil as required based
upon results of the oil analysis
• Check operation of machines and
compare conditions of operation
against original commissioning
data.
• Fill out the annual start up visit
log sheet and review with the
operator.
CG-SVX07A-E4
CAUTION!
• Please refer to specific Trane
documentation on oil, available
from your nearest Trane sales
office. Oils recommended by
Trane have been exhaustively
tested in Trane laboratories to the
specific requirement of Trane
chiller and hence the user's
requirements. Any use of oils not
meeting specifications
recommended by Trane is the
responsibility of the user only,
who thereby is liable to warranty
loss.
• Oil analysis and oil test acidity
must be carried out by a
qualified technician. Poor
interpretation of results may
cause unit operating problems.
Also, oil analysis must follow the
correct procedures, to avoid
accidental injury to maintenance
personnel.
• If the condensers are dirty, clean
them with a soft brush and
water. If the coils are too dirty,
consult a cleaning professional.
Never use high pressure water to
clean condenser coils.
• Contact Trane Service for
information on maintenance
contracts.
WARNING!
• Switch off unit main power
supply before any intervention.
Failure to follow this safety
instruction can lead to death or
may also damage equipment.
• Never use steam or hot water
above 60°C to clean condenser
coils. The resulting increasing
pressure could cause refrigerant
loss through the safety valve.
Pump maintenance
Pumps motor bearings and
mechanical seals have a designed
life expectancy of 20000-25000
hours of operation. For critical
applications it might be necessary
to change the components as a
preventive measure.
33
Maintenance
This list must be checked off by the installer to ensure correct installation
before the unit start up.
UNIT POSITION
!
Check clearance around condenser
!
Check clearance required for maintenance access
!
Check type and position of rubbers pads
!
Check unit is level
CHILLED WATER CIRCUIT
!
Check manometers presence and position
!
Check water flow rate balancing valve presence and position
!
Check presence of strainer ahead of evaporator
!
Check presence of air-purge valve
!
Check rinsing and filling of chilled water pipes
!
Check water pump(s) contactor interconnected to control panel
!
Check water flow
!
Check chilled water pressure drop or unit available pressure (units with
hydraulic module)
!
Check for leaks in chilled water pipes
ELECTRICAL EQUIPMENT
!
Check installation and rating of mains power switch/fuses
!
Check electrical connections complied with specification
!
Check that electrical connections are in accordance with information on
manufacturer's identification plate
!
Check direction of rotation using phasemeter
Comments
..................................................................................................................................
..................................................................................................................................
..................................................................................................................................
..................................................................................................................................
..................................................................................................................................
Signature: ................................Name: ....................................................................
Order N°:..................................................................................................................
Work site: .................................................................................................................
Please return to your local Trane Service Office
34
CG-SVX07A-E4
Maintenance
Troubleshooting guide
These are simple diagnostic hints.
This is not a comprehensive
analysis of the Scroll compressor
refrigeration system.
The aim is to give operators simple
instructions on basic unit processes
so that they have the technical
knowledge to identify and bring
defective operations to the notice of
qualified technicians.
If there is a breakdown, the Trane
Service office should be contacted
for confirmation and assistance.
Problems symptoms
Problem causes
Action recommended
Motor burned out.
Replace compressor
A) The compressor does not start up
Compressor terminals are live but motor does not
start
Contactor motor not operational.
Coil burned out or broken contacts.
Repair or replace.
No current ahead of motor contactor.
a) Power cut.
Check fuses and connection.
b) Main power supply switched off.
See why system tripped.
If system is operational, switch on main power
supply.
Current ahead of fuse, but not on contactor side.
Fuse blown.
Check motor insulation. Replace fuse.
Low voltage reading on voltameter.
Voltage too low.
Contact power Supply Utility.
Starter coil not excited.
Regulation circuit open.
Locate regulation device which has tripped out and
see why.
See instructions concerning this device.
Compressor does not run.
Compressor sticking (damaged or sticking
components).
Replace compressor.
Discharge pressure too high
See instructions for "discharge pressure high".
Compressor motor "groans".
High pressure switch tripped to contacts open on
high pressure.
Discharge pressure too high.
B) Compressor stops
High pressure switch tripped.
Discharge pressure too high.
See instructions for "discharge pressure high".
Over current thermal relay tripped.
a) Voltage too low.
a) Contact Power Supply Utility.
b) Cooling demand too high, or condensing
temperature too high.
b) See instruction "discharge pressure too high".
Motor temperature thermostat tripped.
Not enough cooling fluid.
Repair leak. Add refrigerant.
Anti-freeze security tripped.
Water flow to evaporator too low.
Check water flow rate, and flow switch contact in
water
Filter drier clogged.
Replace filter drier.
Temperature too high in areas requiring airconditioning.
Excess load on cooling system.
Check thermal insulation and air-tightness of areas
requiring air-conditioning.
Chilled water temperature output too high.
Excess cooling demand on system.
Check thermal insulation and air-tightness of areas
requiring air-conditioning.
C) Compressor stops just after its start
Suction pressure too low.
Filter drier iced up.
D) The compressor keeps running without
stopping
E) Loss of oil in compressor
Oil level too low in indicator.
Not enough oil.
Contact Trane before ordering oil
Gradual fall in oil level.
Filter drier clogged.
Replace filter drier.
Suction line too cold.
Liquid flows back to compressor.
Adjust superheat and check bulb fixing of the
expansion valve.
CG-SVX07A-E4
35
Maintenance
F) Compressor noisy
Compressor knocks.
Components broken in compressor.
Change compressor.
Suction duct abnormally cold.
a) Uneven liquid flow.
a) Check superheat setting and fixing of expansion
valve bulb.
b) Expansion valve locked in open position.
b) Repair or replace.
Not enough refrigerant.
Check refrigerant circuit tightness and add
refrigerant.
G) Insufficient cooling capacity
Thermostatic expansion valve "whistles".
Excess pressure drops through filter drier
Drier filter clogged.
Replace.
Excessive superheat.
Superheat not properly adjusted.
Check adjustment of superheat and adjust
thermostatic expansion valve.
Insufficient water flow.
Chilled water pipes obstructed.
Clean pipes and strainer.
Condenser abnormally hot.
Presence of uncondensable liquids in system, or
excess refrigerant.
Purge uncondensable fluids and drain off excess
refrigerant.
Chilled water leaving temperature too high.
Overload on cooling system.
H) Discharge pressure too high
Reduce load on system.
Reduce water flow if necessary.
Condenser air output too hot.
Reduced air flow. Air intake temperature higher
than specified for unit
Clean or replace air filters. Clean coil. Check
operation of motor fans.
Compressor operates continuously.
Excess cooling demand on evaporator
Check system.
Suction duct abnormally cold.
a) Expansion valve too far open.
a) Check for superheat and check that expansion
valve bulb is secure.
Refrigerant flows back to compressor.
b) Expansion valve locked in open position.
b) Replace.
Excessive pressure drop through filter drier.
Filter drier clogged.
Replace the filter drier.
Refrigerant does not flow through thermostatic
expansion valve.
Expansion valve bulb has lost its refrigerant.
Replace the bulb.
Loss of power.
Expansion valve obstructed.
Replace.
Superheat too low.
Excessive pressure drops through evaporator.
Check adjustment of superheat and adjust
thermostatic expansion valve.
Low water flow rate.
Check water flow rate. Check state of strainer,
check for obstruction in chilled water pipes.
I) Suction pressure too high
J) Suction pressure too low
K) Insufficient cooling capacity
Low pressure drops through evaporator
36
CG-SVX07A-E4
Notes
CG-SVX07A-E4
37
Notes
38
CG-SVX07A-E4
Notes
CG-SVX07A-E4
39
Literature Order Number
CG-SVX07A-E4
Date
1005
New
Literature Stocking Location
Europe
www.trane.com
Trane has a policy of continuous product and product data improvement and reserves the right to
change design and specifications without notice. Only qualified technicians should perform the
installation and servicing of equipment referred to in this publication.
For more information, contact your local
sales office or e-mail us at [email protected]
American Standard Europe BVBA
Registered Office: 1789 Chaussée de Wavre, 1160 Brussels - Belgium