Trane CGAF 100 SE, CGAF 90 SE, CGAF 130 SE, CGAF 150 SE, CGAF 140 SE Installation Operation & Maintenance

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Installation Operation Maintenance

CGAF / CXAF

Air-cooled Scroll Chillers and Heat Pumps 260 - 670 kW

CG-SVX039B-GB

Original instructions

Table of Contents

General Information ............................................................................................................... 3

Unit Description ...................................................................................................................... 5

Unit Model Number ............................................................................................................... 6

Pre-Installation ........................................................................................................................ 8

General Data ......................................................................................................................... 10

Table 1 – General data CGAF 090-190 standard efﬁciency ...........................................................................................................................10

Table 2 – General data CGAF 080-190 high efﬁciency ..................................................................................................................................13

Table 3 – General data CGAF 080-190 extra efﬁciency .................................................................................................................................16

Table 4 – General data CGAF 090-150 standard efﬁciency (shell & tube) ...................................................................................................18

Table 5 – General data CXAF 080-190 standard efﬁciency ...........................................................................................................................21

Table 6 – General data CXAF 080-190 high efﬁciency ...................................................................................................................................24

Typical CGAF / CXAF Components location ...................................................................... 27

Installation Requirements ................................................................................................... 29

Evaporator Piping ................................................................................................................. 31

Installation Mechanical ........................................................................................................ 34

Schematic pump package .................................................................................................... 35

Evaporator Waterside ........................................................................................................... 37

General Electrical Recommendations ................................................................................. 40

Installer-Supplied Components ........................................................................................... 42

Operating Principles ............................................................................................................. 43

Operating Map ...................................................................................................................... 47

Total Heat Recovery (THR) Optional .................................................................................. 48

Table 7 – General data Total Heat Recovery (THR) CGAF 080-190 ................................................................................................................48

Table 9 – Refrigerant Charge (THR Option) CGAF 080-190 ...........................................................................................................................50

Partial Heat Recovery Optional .......................................................................................... 51

Table 10/11/12 – General data for Partial Heat Recovery CGAF 080-190 SE/HE/XE .....................................................................................52

Optional Free-Cooling .......................................................................................................... 53

Table 13 – General data Free Cooling Option 080-190 ..................................................................................................................................53

Controls / Tracer TD7 Operator Interface............................................................................. 60

Pre-Start Checkout ............................................................................................................... 61

Unit Start Up Procedures ..................................................................................................... 63

Periodic Maintenance ........................................................................................................... 65

Compressor Service Information ........................................................................................ 68

Condenser Coils MCHE Maintenance ................................................................................. 70

Integrated Pump Maintenance ............................................................................................ 71

BPHE Evaporator Maintenance ........................................................................................... 72

Log Check Sheet ................................................................................................................... 73

Recommended service routine frequencies ....................................................................... 74

Additional services ............................................................................................................... 75

CG-SVX039B-GB

General Information

Foreword

These instructions are given as a guide to good practice in the installation, start-up, operation, and maintenance by the user, of Trane CGAF - Chillers and CXAF – Heat Pumps manufactured in France.

A separate manual is available for the use and maintenance of the unit’s control, Tracer™ UC800. 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.

Note: All the Chiller / Heat Pump Units are assembled, pressure tested, dehydrated, charged and tested in accordance with factory standard before shipment.

Warnings and Cautions

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.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Figure 1 – Warning pictograms

1 = Risk that unit is powered up

2 = Risk hazard due to fan rotation

3 = Risk hazard of burns on compressors or refrigeration

piping

4 = Unit contains refrigerant gas. See speciﬁc warnings.

5 = Risk of residual voltage when speed drive, capacitor or

softstarter options are present

6 = Unit under pressure

7 = Risk to cut, particularly on heat exchanger ﬁns

8 = Read instructions before installation

9 = Disconnect all electric power before servicing

10 = Read technical instructions

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 the chapter “Installation”. Ensure that the pressures are within the speciﬁed limits by using appropriate devices.

2. Disconnect all power supplies before the start of any service activity on the unit.

3. Service work on the refrigeration system and the electrical system should be carried out only by qualiﬁed and experienced personnel.

4. To avoid any risk, it is recommended to place the unit on an area with limited access.

The following pictograms can be found on the unit. Take necessary precautions to avoid damage and injury.

Reception

On arrival,

• Inspect the unit before signing the delivery note.

• Specify any visible damage on the delivery note.

• Notify the local TRANE sales ofﬁce at the same time. Note: The delivery note must be clearly signed after

inspection and countersigned by the driver.

Also send a registered letter of protest to the last carrier of the goods within 7 days of delivery.

Concealed damage also shall be notiﬁed by a registered letter of protest to the last carrier of the goods within 7 days of delivery. Notify the local TRANE sales ofﬁce at the same time.

Important notice: No shipping claims will be accepted by TRANE if the above mentioned procedure is not respected.

For more information, refer to the general sales conditions of your local TRANE sales ofﬁce.

Note: For unit’s delivered in France, scheduled time for unit inspection and notifying through registered letter in case of visible and concealed damage is only 72 hours.

CG-SVX039B-GB

General Information

Loose Parts Inventory

Check all the accessories and loose parts that are shipped with the unit against the shipping list. Included in these items will be the water vessel drain plugs, rigging and electrical diagrams, service literature, which are placed inside the control panel and/or starter panel for shipment. If optional elastomeric isolators are ordered with the unit they are shipped mounted on the horizontal support frame of the chiller / heat pump. The isolators’ location and distribution weight diagram is placed with the service literature inside the starter/ control panel.

Warranty

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.

Startup MUST be performed by Trane, or an authorized agent of Trane, to VALIDATE this WARRANTY.

Training

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.

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.

Maintenance contract

It is strongly recommended that you sign a maintenance contract with your local Service Agency.

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.

CG-SVX039B-GB

Sintesis Advantage Chillers CGAF and Heat pumps CXAF are air cooled scroll compressor units designed for outdoor Installation. The CGAF units are cooling only units and CXAF units are reversible and can work in cooling and heating mode.

The units have two independent refrigerant circuits, two or three compressors per circuit. Units are packaged with an evaporator and condenser.

Each Unit is completely assembled, hermetic packaged, refrigerant circuit factory piped, electrical components wired, leak tested, dehydrated, charged and tested.

The chilled water inlet and outlet openings are covered for shipment.

Units feature Trane’s exclusive Tracer UC800 Control logic and controls. It monitors the control variables that govern the operation of the unit. Control logic can correct these variables, when necessary, to optimize operational efﬁciencies, avoid unit shut down, and keep producing chilled or hot Water.

These units comes with various options and can be customized depending on Capacity, efﬁciencies, acoustic levels, applications requirements at the time of order placement.

Unit received and its options can be cross-checked with the serial and model number provided in unit name plate and description provided under unit model number description provided in manual.

Unit Description

Nameplates

The CGAF / CXAF outdoor unit nameplates are applied to the exterior of the control panel. A compressor nameplate is located on each compressor.

Unit Nameplate

The unit nameplate provides the following information:

• Unit model and size description

• Unit serial number

• Identiﬁes unit electrical requirements

• Lists correct operating charges of refrigerant and refrigerant oil

• Lists unit test pressures

Compressor Nameplate

The compressor nameplate provides following information:

• Compressor model number.

• Compressor serial number.

• Compressor electrical characteristics.

• Utilization range.

• Recommended refrigerant.

CG-SVX039B-GB

Unit Model Number Description

Digit 1, 2, 3, 4 – Unit model

CGAF = Air-Cooled Scroll – Chiller CXAF = Air-Cooled Scroll – Heat Pump

Digit 5-7 – Unit Nominal Tonnage

080 = 80 Tons 090 = 90 Tons 100 = 100 Tons 110 = 110 Tons 130 = 130 Tons 140 = 140 Tons 150 = 150 Tons 165 = 165 Tons 180 = 180 Tons 190 = 190 Tons

Digit 8 – Unit voltage

D = 400V/50Hz/3ph G = 400V/50Hz/3ph Compatible with IT Neutral

Digit 9 – Manufacturing Location

E = Europe

Digit 10, 11 – Design sequence

** = Factory assigned

Digit 12 – Efﬁciency

N = Standard Efﬁciency H = High Efﬁciency A = Extra Efﬁciency

Digit 13 – Agency listing

C = CE Marking

Digit 14 – Pressure vessel code

2 = PED (Pressure equipment directive)

Digit 15 – Acoustic level

X = Standard noise (SN) L = Low noise (LN) E = Extra Low Noise (XLN)

Digit 16 – Unit Application

X = Standard Ambient [-10°C; +46°C] L = Low Ambient [-20°C; +46°C] H = High Ambient [-10°C; +52°C] D = Wide Ambient [-20°C; + 52°C] 1 = Comfort application, cooling mode [10°C; 46°C] and

heating mode [-15°C; 20°C]

3 = Process application, cooling mode [-20°C; 46°C]

Heating mode [-15°C; 35°C]

Digit 17 – Relief valve option

W = Without

Digit 20 – Evaporator Conﬁgurations

B = Brazed plate heat exchanger T = Shell & Tube heat exchanger

Digit 21 – Thermal Insulation

N = Standard

Digit 22 – Condenser Coating

N = Aluminum Micro Channel C = E-Coated Micro Channel B = Aluminum Fin w/o slit E = Epoxy Coated Aluminum Fin

Digit 23 – Heat Recovery

X = No Heat Recovery P = Partial Heat Recovery T = Total Heat Recovery (full equipment)

Digit 24 – Hydraulic module

X = Pump signal On/Off 1 = Dual pump standard pressure 2 = Single pump standard pressure 3 = Dual pump high pressure 4 = Single pump high pressure

Digit 25 – Free Cooling

X = No Free Cooling F = Total Free-Cooling Direct H = Total Free-Cooling Glycol free

Digit 26 – Disconnect switch

B = With circuit breaker

Digit 27 – Under/Over Voltage

X = None 1 = Included 2 = Included with ground fault protection

Digit 28 – Human Interface language

C = Spanish D = German E = English F = French H = Dutch I = Italian M = Swedish P = Polish R = Russian T = Czech U = Greek V = Portuguese 2 = Romanian 6 = Hungarian 8 = Turkish

Digit 18 – Water connection

X = Grooved pipe connection W = Grooved pipe + welded coupling 2 = Grooved pipe with coupling and Flange adapter

Digit 19 – Evaporator Application

N = Standard cooling [4°C; 20°C] P = Low Temperature process [-12°C; 4°C] C = Ice Making [-7°C; 20°C] with hardwired interface

Digit 29 – Smart com protocol

X = None B = BACnet interface M = Modbus interface L = LonTalk interface

Digit 30 – Communication customer

X = None A = External set point & capacity outputs

CG-SVX039B-GB

Unit Model Number Description

Digit 31 – Flow switch

X = None F = Field installed ﬂow switch

Digit 32 – Electrical Panel Protection

X = Enclosure with deadfront protection 1 = Enclosure with IP 20 internal protection

Digit 33 – Master Slave

X = Without A = With

Digit 34 – Unit User Interface

L = Standard, Local UI supplied (TD7)

Digit 35 – Energy meter

X = No energy meter M = Energy meter installed

Digit 36 – Mini Chiller Plant Control

X = No Mini PC

Digit 37 – Variable Primary Flow

X = Constant speed pump (no AFD) A = Pump ﬂow controlled by 3 ways Duty Valve F = Constant Speed Pump -AFD Adjustment T = Variable Speed Pump - Constant delta T

Digit 38 – Open for future use = X

Z = Slovenian 2 = Romanian 3 = Serbian 4 = Slovak 5 = Croatian 6 = Hungarian 8 = Turkish

Digit 44 – Shipping package

X = Standard protection A = Containerization package

Digit 45 – Refrigerant

X = None A = R410A Factory full Refrigerant charge 8 = R410A Factory Refrigerant Pre-Charge

Digit 46 – Isolator Valve per Manifold Compressor

X = None

Digit 47 – Power Factor Correction Capacitors

A = With X = None

Digit 48 – Open for future use = X

Digit 49 – Freeze Protection (Factory Installed)

X = None 2 = With freeze protection

Digit 39 – Open for future use = X

Digit 40 – Power socket

X = None P = Included (230V - 100W)

Digit 41 – Factory tests

X = No ﬁnal performances test B = Visual inspection with customer E = Performance test without customer

Digit 42 – Installation accessory

X = None 1 = Neoprene Isolators 4 = Neoprene pads

Digit 43 – Literature language

B = Bulgarian C = Spanish D = German E = English F = French H = Dutch I = Italian K = Finnish L = Danish M = Swedish N = Norwegian P = Polish R = Russian T = Czech U = Greek V = Portuguese

Digit 50 – Buffer Tank

X = No Tank 1 = With Tank

Digit 51 – Water Strainer

X = No strainer A = Factory installed strainer

Digit 52 – Louvered panels

X = None

Digit 53 – Open for future use = X

Digit 54 – Starter type

A = Across the line starter/Direct On Line B = Soft starter

Digit 55 – Annunciation Relay

X = None A = With

Digit 56 – Fan type

1 = AC fan 2 = EC fan 3 = EC with Axitop

Digit 57 – Night Noise Setback (NNSB)

X = Without 1 = With NNSB

Digit 58 – Design special

X = Standard S = Special requirement

CG-SVX039B-GB

Pre-Installation

Inspection checklist

When the unit is delivered, verify that it is the correct unit and that it is properly equipped. Compare the information which appears on the unit nameplate with the ordering and submittal information. Inspect all exterior components for visible damage. Report any apparent damage or material shortage to the carrier and make a “unit damage” notation on the carrier’s delivery receipt. Specify the extent and type of damage found and notify the appropriate Trane Sales Ofﬁce. Do not proceed with installation of a damaged unit without sales ofﬁce approval.

Mandatory Start-up Checklist

This checklist is not intended to be a substitution for the contractor’s installation instruction. This checklist is intended to be a guide for the Trane technician just prior to unit ‘start-up’. Many of the recommended checks and actions could expose the technician to electrical and mechanical hazards. Refer to the appropriate sections in the unit manual for appropriate procedures, component speciﬁcations and safety instructions. Except where noted; it is implied that the technician is to use this checklist for inspection / veriﬁcation of prior task completed by the general contractor at installation.

1. Unit clearances adequate for service and to avoid air recirculation, etc

2. Unit exterior inspected. CGAF / CXAF condenser coil will not be obstructed at any time by snow or ice during winter conditions

3. Unit properly grounded

4. Crankcase heaters working for 24 hours prior to arrival of Trane technician performing start up

5. Correct voltage supplied to unit and electric heaters (imbalance not to exceed 2%)

6. Unit power phasing (A-B-C sequence) proper for compressor rotation

7. Copper power wiring meets sizing requirement in job submittal

8. All automation and remote controls installed/ wired

9. All wiring connections tight

10. Prove chilled water side Interlock and Interconnecting

11. Wiring Interlock and externals (chilled water pump)

12. Field installed control wiring landed on correct terminals (external start/stop, emergency stop, chilled water reset…)

13. Verify all refrigerant and oil valves are open/back seated

14. Compressor oil levels (1/2 -3/4 high in glass) proper

15. Verify chilled water strainer is clean and free of debris and evaporator chilled water circuits are ﬁlled

16. A pressure switch device to detect lack of water is not included in the pump package. Installation of this type of device is highly recommended to avoid sealing damage due to operation of pump without enough water

1 7. Close the fused-disconnect switches that supplies

power to the chilled water pump starter

18. Start the chilled water pump to begin circulation of the water. Inspect piping for leaks and repair as necessary. Check the physical presence of the water pressure switch

19. With water circulating through the system, adjust water ﬂow and check water pressure drop through evaporator

20. Return chilled water pump to auto

21. Verify all the chiller controller Menu Items

22. All panels/doors secured prior to start-up

23. All coil ﬁns inspected and straightened

24. Rotate fans before starting unit to inspect for potential audible and visual signs of rubbing. Start unit

25. Press AUTO key. The unit will start if the chiller control calls for cooling and the safety interlocks are closed

26. Check the evaporator and the condenser refrigerant pressure on the chiller controller

27. Conﬁrm Superheat and sub-cooling values are normal

28. Compressor operation normal and within amperage rating

29. Operating log completed

30. Press stop key

31. Inspect fans again after being under load to ensure no signs or rubbing exist

32. Verify the chilled water pump runs for at least 1 minute (possibility to conﬁgure maxi 10 mn) after the chiller is commanded to stop (for normal chilled water systems)

Unit storage

If the chiller is to be stored for more than one month prior to installation, observe the following precautions:

• Store the unit in a secured area, to avoid intentional damages.

• Close the suction, discharge and liquid-line isolation valves.

• Store the chiller in a dry, vibration-free, secure area.

• At least every three months, attach a gauge and manually check the pressure in the refrigerant circuit.

• If the refrigerant pressure is below 13 bar at 20°C (or 10 bar at 10°C), call a qualiﬁed service organization and the appropriate Trane sales ofﬁce.

Note: If the unit is stored before servicing near a construction site it is highly recommended to protect micro channel coils from any concrete and iron element. Failure to do so may considerably reduce reliability of the unit.

CG-SVX039B-GB

Pre-Installation

Installation requirements and contractor responsibilities

A list of the contractor responsibilities typically associated with the unit installation process is provided.

Type of requirement

Foundation • Meet foundation requirements

Rigging

Isolation

Electrical

Water piping

Insulation • Insulation • Insulation (Piping)

Water piping connection elements • Grooved pipe

Trane-supplied Trane-installed

• Disconnect Switch

• Unit mounted starter

• Flow Switch

• Water Strainer (Optional)

Trane-supplied Field-installed

• Neoprene Pads

• Isolators (Optional)

• Grooved pipe couplings (or) Flanged Adopters

Field-supplied Field-installed

• Safety chains

• Clevis connectors

• Lifting beams

• Neoprene Pads

• Isolators (Customer Supplied)

• Wiring sizes per submittals and local codes and regulations

• Terminal lugs

• Ground connection(s)

• BAS Wiring (optional)

• Control voltage wiring

• Chilled water pump contactor and wiring including interlock

• Option relays and wiring

• Taps for thermometers and gauges

• Thermometers

• Water ow pressure gauges

• Isolation and balancing valves in water piping

• Vents and drains

• Pressure relief valves

• Pressure switch device to detect lack of water

CG-SVX039B-GB

General Data

Table 1 – General data CGAF 090-190 Standard Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE

Net Cooling Capacity (1) (kW) 318 351 391 431 473 519 558 621 661

Net Total Power input (1) (kW) 105 120 138 157 160 183 202 211 230

Unit electrical data (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15 15 15 15

Power Cable Cross Section (max) mm² 1*240 1*240 1*240 1*240 2*300 2*300 2*300 2*300 2*300

Disconnect switch size (A) 400 400 500 500 630 630 630 800 800

Digit 56=1

Maximum Power input (kW) 142.6 162.2 176.0 189.9 221.9 241.5 255.4 272.1 286.0

Max. amps (A) 237.8 270.0 292.1 314.2 368.9 401.1 423.2 451.2 473.3

Unit start up amps (w/o soft starter digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Displacement power factor (dpf) 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87

Digit 56=2 or Digit 56=3

Maximum Power input (kW) 145.7 165.2 179.1 193.0 226.0 245.6 259.5 277.2 291.1

Max. amps (A) 238.4 270.6 292.7 314.8 369.7 401.9 424.0 452.2 474.3

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Displacement power factor (dpf) 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.89

Compressor

Compressor Number per Circuit # 2 2 2 2 3 3 3 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (Digit 56=1) (4)

Rated Amps Circuit 1 / Circuit 2 (Digit 56=2 or Digit 56=3) (4)

Locked Rotor Amps Circuit 1 / Circuit 2 (4) (A)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 168/168 168/168 168/168 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1 1 1 1

Type Stainless steel Copper Brazed plate Heat exchanger

Evaporator model

Evaporator Water Content volume (l) 31.0 35.7 40.4 48.6 48.6 56.7 64.9 73.1 81.3

Nominal water connection size (Grooved coupling) - Without HYM

Nominal water connection size (Grooved coupling) - With HYM

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 123 115 98 92 142 137 124 164 155

Motor Power (kW) 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Single pump - High head pressure option

Max available Head Pressure (kPa) 251 247 234 232 249 252 245 234 226

Motor Power (kW) 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 123 115 98 92 142 137 124 164 155

Motor Power (kW) 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

(A) 495.1 527.3 631.4 653.5 626.3 658.5 762.5 790.4 812.6

(A) 367.1 399.3 466.2 488.3 498.3 530.5 597.3 625.2 647.4

(A) 495.7 527.9 632.0 654.1 627.1 659.3 763.3 791.4 813.6

367.7 399.9 466.8 488.9 499.1 531.3 598.1 626.2 648.4

25+30/

25+30

28.4+38.2/

28.4+38.2

35.4+46.0/

(A)

35.4+46.0

35.1+45.5/

35.1+45.5

260+320/

260+320

DFX650x106 DFX650x122 DFX650x138 DFX650x166 DFX650x166 DFX650x194 DFX650x222 DFX650x250 DFX650x278

(in) (mm)

4" -

114.3

4" -

114.3

30+30/

30+30

38.2+38.2/

38.2+38.2

47.0+47.0/

47.0+47.0

46.5+46.5/

46.5+46.5

320+320/

320+320

4" -

114.3

4" -

114.3

30+40/

30+40

38.2+45.2/

38.2+45.2

48.3+59.8/

48.3+59.8

47.7+59.0/

47.7+59.0

320+413/

320+413

4" -

114.3

4" -

114.3

40+40/ 40+40

45.2+45.2/

45.2+45.2

61.7+61.7/

61.7+61.7

60.7+60.7/

60.7+60.7

413+413/

413+413

4" -

114.3

4" -

114.3

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

35.5+48.1+48.1/

35.5+48.1+48.1

35.1+47.5+47.5/

35.1+47.5+47.5

260+320+320/

260+320+320

5" -

139.7

5" -

139.7

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

48.2+48.2+48.2/

48.2+48.2+48.2

47.5+47.5+47.5/

47.5+47.5+47.5

320+320+320/

320+320+320

5" -

139.7

5" -

139.7

30+30+40/

30+30+40

38.2+38.2+45.2/

38.2+38.2+45.2

49.2+49.2+61.0/

49.2+49.2+61.0

48.5+48.5+60.1/

48.5+48.5+60.1

320+320+413/

320+320+413

5" -

139.7

5" -

139.7

30+40+40/

30+40+40

38.2+45.2+45.2/

38.2+45.2+45.2

47.6+59.0+59.0/

47.6+59.0+59.0

47.1+58.2+58.2/

47.1+58.2+58.2

320+413+413/

320+413+413

5" -

139.7

5" -

139.7

40+40+40/

40+40+40

45.2+45.2+45.2/

45.2+45.2+45.2

60.1+60.1+60.1/

60.1+60.1+60.1

59.2+59.2+59.2/

59.2+59.2+59.2

413+413+413/

413+413+413

5" -

139.7

5" -

139.7

CG-SVX039B-GB

General Data

Table 1 – General data CGAF 090-190 Standard Efﬁciency (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE

Twin pump - High head pressure option

Max available Head Pressure (kPa) 251 247 234 232 249 252 245 234 226

Motor Power (kW) 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Expansion Tank Volume (l) 50 50 50 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Optional water Buffer tank volume (l) 607 607 607 607 777 777 777 777 777

Antifreeze Heater without pump package and without buffer tank

Antifreeze Heater with pump package and without buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Antifreeze Heater with pump package and with buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Condenser

Type Full aluminum Micro channel heat exchanger

Quantity of coil # 6 6 6 6 8 8 8 10 10

Face area per circuit (m²) 8.88 8.88 8.88 8.88 11.84 11.84 11.84 14.80 14.80

Condenser Fan

Quantity # 6 6 6 6 8 8 8 10 10

Diameter (mm) 800

Fan / motor Type Propeller fan : Fixed speed AC motor / Variable speed EC motor

Digit 56=1

Fan / motor Type Fixed speed AC motor

Airow per fan m3/h 15859 15778 15680 15580 15686 15684 15609 15730 15670

Max Power Input per Motor Kw 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44

Max Amps per Motor A 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9

Motor RPM (rpm) 900 900 900 900 900 900 900 900 900

Digit 56=2 or Digit 56 =3

Fan / motor Type Variable speed EC motor

Airow per fan m3/h 17411 17331 17235 17136 17240 17239 17165 17283 17225

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0

Motor RPM (SN - Digit 15=X or LN Digit 15=L and Digit 56=2)

Motor RPM (XLN - Digit 15=E and Digit 56=2)

Motor RPM (SN - Digit 15=X or LN Digit 15=L and Digit 56=3)

Motor RPM (XLN - Digit 15=E and Digit 56=3)

Dimensions

Unit Length (mm) 3395 3395 3395 3395 4520 4520 4520 5645 5645

Unit Width (mm) 2200 2200 2200 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

(l) 1750 1750 1750 1750 1750 1750 1750 1750 1750

(W) 360 420 420 420 540 640 640 640 640

1000 /

(W)

1060

1880 /

(W)

1940

(rpm) 850 850 860 920 860 900 940 890 920

840 840 840 840 840 840 840 840 840

850 850 880 940 860 920 960 900 940

800 800 800 800 800 800 800 800 800

(mm) +146 +146 +146 +146 +146 +146 +146 +146 +146

(mm) +425 +425 +425 +425 +370 +370 +370 +370 +370

1060 /

1120

1940 /

2000

1060 /

1120

1940 /

2000

1060 /

1120

1940 /

2000

1240 /

1300

2690 /

2750

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

CG-SVX039B-GB

General Data

Table 1 – General data CGAF 090-190 Standard Efﬁciency (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE

Weights

Shipping Weight (3) (kg) 2085 2195 2260 2325 2835 3010 3075 3440 3515

Operating Weight (3) (kg) 2145 2260 2330 2400 2915 3100 3175 3550 3630

Option Additional shipping weight

Single pump - Standard head pressure (kg) 215 220 225 225 230 230 295 310 305

Single pump - High head pressure (kg) 260 265 265 260 305 305 305 320 320

Twin pump - Standard head pressure (kg) 300 305 325 320 325 325 440 450 450

Twin pump - High head pressure (kg) 385 390 385 385 460 460 465 480 475

Axitop option (kg) 60 60 60 60 80 80 80 100 100

XLN option (kg) 115 115 115 115 150 150 150 150 150

Pump VFD option (kg) 70 70 70 70 70 70 70 70 70

Partial heat recovery option (Digit 19 = N)

Partial heat recovery option (Digit 19 = P)

Water Buffer tank option (kg) 250 250 250 250 330 330 330 330 330

System data

Nb of refrigerant circuit # 2 2 2 2 2 2 2 2 2

Minimum cooling load % (6) % 23 25 21 25 15 17 15 14 17

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l)

POE Oil type OIL058E / OIL057E

(kg) 45.00 45.00 65.00 65.00 75.00 75.00 75.00 75.00 75.00

(kg) 45.00 45.00 45.00 45.00 75.00 75.00 75.00 75.00 75.00

(kg) 18 / 18 19 / 19

13.4 /

13.4

13.4 /

13.4

19.5 /

19.5

13.4 /

13.4

20.5 /

20.5

13.4 /

13.4

30 / 30 32 / 32 33 / 33 38 / 38 39 / 38

23.1 /

22.1

23.1 /

23.1

23.1 /

23.1

23.1 /

23.1

23.1 /

23.1

(1) Indicative performance at Evaporator water temperature : 12°C / 7°C - Condenser air temperature 35°C - for detailed performances, on a given unit,

consult Order Write Up. (2) Under 400V/3/50Hz. (3) Rated Condition without Pump Package. (4) Electrical & system data are indicative and subject to change without notice. Please refer to unit nameplate data. (5) If the power line of the unit is protected by fuses gG of the same size as the disconnect switch.

CG-SVX039B-GB

General Data

Table 2 – General data CGAF 080-190 High Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Net Cooling Capacity (1) (kW) 293 334 371 416 459 498 548 587 641 682

Net Total Power input (1) (kW) 90 102 115 132 149 155 176 193 205 222

Unit electrical data (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15 15 15 15 15

Power Cable Cross Section (max) mm² 1*240 1*240 1*240 1*240 1*240 2*240 2*300 2*300 2*300 2*300

Disconnect switch size (A) 315 400 400 500 500 630 630 630 800 800

Digit 56=1

Maximum Power input (kW) 123.0 145.5 165.0 178.9 192.8 224.8 244.4 258.3 275.0 288.9

Max. amps (A) 205.6 243.6 275.8 297.9 320.0 374.7 406.9 429.0 457.0 479.1

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Displacement power factor (dpf) 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 0.87

Digit 56=2

Maximum Power input (kW) 126.1 149.6 169.1 183.0 196.9 229.9 249.5 263.4 281.1 295.0

Max. amps (A) 206.2 244.4 276.6 298.7 320.8 375.7 407.9 430.0 458.2 480.3

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Power factor 0.88 0.88 0.88 0.88 0.89 0.88 0.88 0.88 0.89 0.89

Compressor

Compressor Number per Circuit # 2 2 2 2 2 3 3 3 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (Digit 56=1) (4)

Rated Amps Circuit 1 / Circuit 2 (Digit 56=2) (4)

Locked Rotor Amps Circuit 1 / Circuit 2 (4) (A)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 112/112 168/168 168/168 168/168 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1 1 1 1 1

Type Stainless steel Copper Brazed plate Heat exchanger

Evaporator model

Evaporator Water Content volume (l) 40.4 40.4 48.6 56.7 64.9 73.1 81.3 81.3 81.3 86.0

Nominal water connection size (Grooved coupling) - Without HYM

Nominal water connection size (Grooved coupling) - With HYM

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 155 136 119 103 92 146 134 122 161 149

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Single pump - High head pressure option

Max available Head Pressure (kPa) 280 266 254 242 237 257 253 249 231 220

Motor Power (kW) 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 155 136 119 103 92 146 134 122 161 149

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

(A) 419.0 500.9 533.1 637.2 659.3 632.1 664.3 768.3 796.2 818.4

(A) 315.0 372.9 405.1 472.0 494.1 504.1 536.3 603.1 631.0 653.2

(A) 419.6 501.7 533.9 638.0 660.1 633.1 665.3 769.3 797.4 819.6

315.6 373.7 405.9 472.8 494.9 505.1 537.3 604.1 632.2 654.4

(A)

(in) -

(mm)

(in) -

(mm)

25+25/ 25+25

28.4+28.4/

28.4+28.4

34.9+34.9/

34.9+34.9

34.6+34.6/

34.6+34.6

260+260/

260+260

DFX650

x138

4" -

114.3

4" -

114.3

25+30/

25+30

28.4+38.2/

28.4+38.2

34.1+44.3/

34.1+44.3

34.0+44.1/

34.0+44.1

260+320/

260+320

DFX650

x138

4" -

114.3

4" -

114.3

30+30/

30+30

38.2+38.2/

38.2+38.2

44.9+44.9/

44.9+44.9

44.6+44.6/

44.6+44.6

320+320/

320+320

DFX650

x166

4" -

114.3

4" -

114.3

30+40/

30+40

38.2+45.2/

38.2+45.2

45.9+56.6/

45.9+56.6

45.4+56.1/

45.4+56.1

320+413/

320+413

DFX650

x194

4" -

114.3

4" -

114.3

40+40/

40+40

45.2+45.2/

45.2+45.2

57.9+57.9/

57.9+57.9

57.3+57.3/

57.3+57.3

413+413/

413+413

DFX650

x222

4” -

114.3

4” -

114.3

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

34.4+46.2+46.2/

34.4+46.2+46.2

34.2+45.8+45.8/

34.2+45.8+45.8

260+320+320/

260+320+320

DFX650

x250

5" -

139.7

5" -

139.7

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

46.2+46.2+46.2/

46.2+46.2+46.2

45.8+45.8+45.8/

45.8+45.8+45.8

320+320+320/

320+320+320

DFX650

x278

5" -

139.7

5" -

139.7

30+30+40/

30+30+40

38.2+38.2+45.2/

38.2+38.2+45.2

47.0+47.0+58.1/

47.0+47.0+58.1

46.4+46.4+57.4/

46.4+46.4+57.4

320+320+413/

320+320/

413

DFX650

x278

5" -

139.7

5" -

139.7

30+40+40/

30+40+40

38.2+45.2+45.2/

38.2+45.2+45.2

46.1+56.9+56.9/

46.1+56.9+56.9

45.6+56.3+56.3/

45.6+56.3+56.3

320+413+413/

320+413+413

DFX650

x278

5" -

139.7

5" -

139.7

40+40+40/

40+40+40

45.2+45.2+45.2/

45.2+45.2+45.2

57.7+57.7+57.7/

57.7+57.7+57.7

57.1+57.1+57.1/

57.1+57.1+57.1

413+413+413/

413+413+413

DFX650

x294

5" -

139.7

5" -

139.7

CG-SVX039B-GB

General Data

Table 2 – General data CGAF 080-190 High Efﬁciency (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Twin pump - High head pressure option

Max available Head Pressure (kPa) 280 266 254 242 237 257 253 249 231 220

Motor Power (kW) 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Expansion Tank Volume (l) 50 50 50 50 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Optional water Buffer tank volume (l) 607 607 607 607 607 777 777 777 777 777

Antifreeze Heater without pump package and without buffer tank

Antifreeze Heater with pump package and without buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Antifreeze Heater with pump package and with buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Condenser

Type Full aluminum Micro channel heat exchanger

Quantity of coil # 6 8 8 8 8 10 10 10 12 12

Face area per circuit (m²) 8.88 11.84 11.84 11.84 11.84 14.80 14.80 14.80 17.76 17.76

Condenser Fan

Quantity # 6 8 8 8 8 10 10 10 12 12

Diameter (mm) 800

Fan / motor Type Propeller fan : Fixed speed AC motor / Variable speed EC motor

Digit 56=1

Fan / motor Type Fixed speed AC motor

Airow per fan m3/h 15925 16020 15956 15879 15803 15840 15839 15782 15858 15809

Max Power Input per Motor Kw 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44

Max Amps per Motor A 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9 2.9

Motor RPM (rpm) 900 900 900 900 900 900 900 900 900 900

Digit 56=2

Fan / motor Type Variable speed EC motor

Airow per fan

(SN - Digit 15=X or LN - Digit 15=L)

Airow per fan (XLN - Digit 15=E) m3/h 17360 17453 17390 17315 17240 17276 17276 17220 17294 17246

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (SN - Digit 15=X or LN Digit 15=L)

Motor RPM (XLN - Digit 15=E) 840 840 840 840 840 840 840 840 840 840

Dimensions

Unit Length (mm) 3395 4520 4520 4520 4520 5645 5645 5645 6770 6770

Unit Width (mm) 2200 2200 2200 2200 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

Weights

Shipping Weight (3) (kg) 2015 2410 2540 2615 2675 3205 3385 3425 3790 3855

Operating Weight (3) (kg) 2085 2480 2615 2700 2770 3315 3500 3540 3910 3975

Option Additional shipping weight

Single pump - Standard head pressure (kg) 215 230 225 235 235 245 240 305 330 325

Single pump - High head pressure (kg) 265 275 270 270 270 320 315 315 340 340

Twin pump - Standard head pressure (kg) 305 315 315 335 335 345 340 450 475 470

Twin pump - High head pressure (kg) 385 400 395 395 395 480 475 475 500 495

XLN option (kg) 115 115 115 115 115 150 150 150 150 150

Pump VFD option (kg) 70 70 70 70 70 70 70 70 70 70

(l) 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750

(W) 420 420 420 520 520 640 640 640 640 640

1060 /

(W)

1120

1940 /

(W)

2000

(rpm) 850 850 850 860 920 860 900 940 890 920

(mm) +146 +146 +146 +146 +146 +146 +146 +146 +146 +146

(mm) +425 +425 +425 +425 +425 +370 +370

1060 /

1120

1940 /

2000

1060 /

1120

1940 /

2000

1160 /

1220

2040 /

2100

1160 /

1220

2040 /

2100

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

+370 +370 +370

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

CG-SVX039B-GB

General Data

Table 2 – General data CGAF 080-190 High Efﬁciency (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Partial heat recovery option (Digit 19 = N) / (Digit 19 = P)

Water Buffer tank option (kg) 250 250 250 250 250 330 330 330 330 330

System data

Nb of refrigerant circuit # 2 2 2 2 2 2 2 2 2 2

Minimum cooling load % (6) % 25 23 25 21 25 15 17 15 14 17

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l)

POE Oil type OIL058E / OIL057E

(1) Indicative performance at Evaporator water temperature: 12°C / 7°C - Condenser air temperature 35°C - for detailed performances, on a given unit, consult

Order Write Up.

(2) Under 400V/3/50Hz. (3) Rated Condition without Pump Package. (4) Electrical & system data are indicative and subject to change without notice. Please refer to unit nameplate data. (5) If the power line of the unit is protected by fuses gG of the same size as the disconnect switch.

(kg)

45.00 /

45.00

22.0 /

22.0

13.4 /

13.4

45.00 /

45.00

27.5 /

27.5

13.4 /

13.4

45.00 /

45.00

27.5 /

27.5

13.4 /

13.4

65.00 /

45.00

28.5 /

28.5

13.4 /

13.4

65.00 /

45.00

29 / 29 39 / 39 39 / 39 39 / 39 43 / 43

13.4 /

13.4

75.00 /

75.00

23.1 /

22.1

75.00 /

75.00

23.1 /

23.1

75.00 /

75.00

23.1 /

23.1

75.00 /

75.00

23.1 /

23.1

75.00 /

75.00

43.5 /

43.5

23.1 /

23.1

CG-SVX039B-GB

General Data

Table 3 – General data CGAF 080-190 Extra Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

XE XE XE XE XE XE XE XE XE XE

Net Cooling Capacity (1) (kW) 295 335 373 419 464 502 553 593 647 689

Net Total Power input (1) (kW) 87 99 112 128 145 151 172 188 200 216

Unit electrical data (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15 15 15 15 15

Power Cable Cross Section (max) mm21*240 1*240 1*240 1*240 1*240 2*300 2*300 2*300 2*300 2*300

Disconnect switch size (A) 315 400 400 500 500 630 630 630 800 800

Maximum Power input (kW) 126.1 149.6 169.1 183.0 196.9 229.9 249.5 263.4 281.1 295.0

Unit rated amps (A) 206.2 244.4 276.6 298.7 320.8 375.7 407.9 430.0 458.2 480.3

Unit start up amps (w/o soft starter - Digit 54=A) (4)

Unit start up amps (with soft starter - Digit 54=B) (4)

Displacement power factor (dpf) 0.88 0.88 0.88 0.88 0.89 0.88 0.88 0.88 0.89 0.89

Compressor

Compressor Number per Circuit # 2 2 2 2 2 3 3 3 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (4) (A)

Locked Rotor Amps Circuit 1 / Circuit 2 (4) (A)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 112/112 168/168 168/168 168/168 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1 1 1 1 1

Type Stainless steel Copper Brazed plate Heat exchanger

Evaporator model

Evaporator Water Content volume (l) 40.4 40.4 48.6 56.7 64.9 73.1 81.3 81.3 81.3 86.0

Nominal water connection size (Grooved coupling) - Without HYM

Nominal water connection size (Grooved coupling) - With HYM

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 155 136

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Single pump - High head pressure option

Max available Head Pressure (kPa) 280 266 254 241 232 252 257 245 229 218

Motor Power (kW) 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 155 136 119 102 87 141 137 115 159 146

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11.0 11.0 11.0

Rated Amps (A) 11.0 11.0 11.0 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Twin pump - High head pressure option

Max available Head Pressure (kPa) 280 266 254 241 232 252 257 245 229 218

Motor Power (kW) 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28.0 28.0 28.0 28.0 28.0

Expansion Tank Volume (l) 50 50 50 50 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Optional water Buffer tank volume (l) 607 607 607 607 607 777 777 777 777 777

Antifreeze Heater without pump package and without buffer tank

Antifreeze Heater with pump package and without buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

(A) 419.6 501.7 533.9 638.0 660.1 633.1 665.3 769.3 797.4 819.6

315.6 373.7 405.9 472.8 494.9 505.1 537.3 604.1 632.2 654.4

(in) -

(mm)

(in) -

(mm)

25+25/ 25+25

28.4+28.4/

28.4+28.4

34.6+34.6/

34.6+34.6

260+260/

260+260

DFX650

x138

4" -

114.3

4" -

114.3

25+30/ 25+30

28.4+38.2/

28.4+38.2

33.9+44.1/

33.9+44.1

260+320/

260+320

DFX650

x138

4" -

114.3

4" -

114.3

30+30/

30+30

38.2+38.2/

38.2+38.2

44.6+44.6/

44.6+44.6

320+320/

320+320

DFX650

x166

4" -

114.3

4" -

114.3

30+40/

30+40

38.2+45.2/

38.2+45.2

45.4+56.1/

45.4+56.1

320+413/

320+413

DFX650

x194

4" -

114.3

4" -

114.3

40+40/ 40+40

45.2+45.2/

45.2+45.2

57.2+57.2/

57.2+57.2

413+413/

413+413

DFX650

x222

4” -

114.3

4” -

114.3

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

34.2+45.7+45.7/

34.2+45.7+45.7

260+320+320/

260+320+320

DFX650

x250

5" -

139.7

5" -

139.7

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

45.7+45.7+45.7/

45.7+45.7+45.7

320+320+320/

320+320+320

DFX650

x278

5" -

139.7

5" -

139.7

30+30+40/

30+30+40

38.2+38.2+45.2/

38.2+38.2+45.2

46.4+46.4+57.3/

46.4+46.4+57.3

320+320+413/

320+320/413

DFX650

x278

5" -

139.7

5" -

139.7

30+40+40/

30+40+40

38.2+45.2+45.2/

38.2+45.2+45.2

45.6+56.3+56.3/

45.6+56.3+56.3

320+413+413/

320+413+413

DFX650

x278

5" -

139.7

5" -

139.7

119 102 87 141 137 115 159 146

(l) 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750

(W) 420 420 420 520 520 640 640 640 640 640

(W)

1060 /

1120

1060 /

1120

1060 /

1120

1160 /

1220

1160 /

1220

1340 /

1400

1340 /

1400

1340 /

1400

1340 /

1400

40+40+40/

40+40+40

45.2+45.2+45.2/

45.2+45.2+45.2

57.0+57.0+57.0/

57.0+57.0+57.0

413+413+413/

413+413+413

DFX650

x294

5" -

139.7

5" -

139.7

1340 /

1400

CG-SVX039B-GB

General Data

Table 3 – General data CGAF 080-190 Extra Efﬁciency (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

XE XE XE XE XE XE XE XE XE XE

Antifreeze Heater with pump package and with buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Condenser

Type Full aluminum Micro channel heat exchanger

Quantity of coil # 6 8 8 8 8 10 10 10 12 12

Face area per circuit (m²) 8.88 11.84 11.84 11.84 11.84 14.80 14.80 14.80 17.76 17.76

Condenser Fan

Quantity # 6 8 8 8 8 10 10 10 12 12

Diameter (mm) 800

Fan / motor Type Propeller fan : Variable speed EC motor

Airow per fan m3/h 17476 17569 17506 17430 17355 17392 17391 17335 17410 17362

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (SN - Digit 15=X or LN Digit 15=L)

Motor RPM (XLN - Digit 15=E) (rpm) 800 800 800 800 800 800 800 800 800 800

Dimensions

Unit Length (mm) 3395 4520 4520 4520 4520 5645 5645 5645 6770 6770

Unit Width (mm) 2200 2200 2200 2200 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

Weights

Shipping Weight (3) (kg) 2075 2490 2620 2695 2755 3305 3485 3525 3910 3975

Operating Weight (3) (kg) 2145 2560 2695 2780 2850 3415 3600 3640 4030 4095

Option Additional shipping weight

Single pump - Standard head pressure (kg) 215 230 225 235 235 245 240 305 330 325

Single pump - High head pressure (kg) 265 275 270 270 270 320 315 315 340 340

Twin pump - Standard head pressure (kg) 305 315 315 335 335 345 340 450 475 470

Twin pump - High head pressure (kg) 385 400 395 395 395 480 475 475 500 495

XLN option (kg) 115 115 115 115 115 150 150 150 150 150

Pump VFD option (kg) 70 70 70 70 70 70 70 70 70 70

Partial heat recovery option (Digit 19 = N)

Partial heat recovery option (Digit 19 = P)

Water Buffer tank option (kg) 250 250 250 250 250 330 330 330 330 330

System data

Nb of refrigerant circuit # 2 2 2 2 2 2 2 2 2 2

Minimum cooling load % (6) % 25 23 25 21 25 15 17 15 14 17

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l)

POE Oil type OIL058E / OIL057E

1940/

(W)

2000

(rpm) 850 850 850 880 940 860 920 960 900 940

(mm) +146 +146 +146 +146 +146 +146 +146 +146 +146 +146

(mm) +425 +425 +425 +425 +425 +370 +370 +370 +370 +370

(kg) 45.00 45.00 45.00 65.00 65.00 75.00 75.00 75.00 75.00 75.00

45.00 45.00 45.00 45.00 45.00 75.00 75.00 75.00 75.00 75.00

22.0 /

(kg)

22.0

13.4 /

13.4

1940/

2000

27.4 /

27.4

13.4 /

13.4

1940/

2000

27.6 /

27.6

13.4 /

13.4

1940/

2000

28.4 /

28.4

13.4 /

13.4

2040/

2100

29.4 /

29.4

13.4 /

13.4

2040/

2100

39.0 /

39.0

23.1 /

22.1

2790/

2850

39.0 /

39.0

23.1 /

23.1

2790/

2850

39.0 /

39.0

23.1 /

23.1

2790/

2850

43.0 /

43.0

23.1 /

23.1

2790/

2850

43.5 /

43.5

23.1 /

23.1

(1) Indicative performance at Evaporator water temperature: 12°C / 7°C - Condenser air temperature 35°C - for detailed performances, on a given unit,

consult Order Write Up.

CG-SVX039B-GB

General Data

Table 4 – General data CGAF 090-150 Standard Efﬁciency – Shell & Tube

CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150

SE SE SE SE SE SE

Net Cooling Capacity (1) (kW) 319 349 384 418 483 510

Net Total Power input in cooling (1) (kW) 105 120 139 159 168 184

Unit electrical data (1) (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15

Power Cable Cross Section (max) mm

Disconnect switch size (A) 400 400 500 500 630 630

Digit 56=1

Maximum Power input (kW) 154.6 174.2 188.1 201.9 228.2 257.5

Unit rated amps (A) 258.8 291.0 313.1 335.2 381.0 429.3

Unit start up amps (w/o soft starter digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Displacement power factor (dpf) 0.87 0.87 0.87 0.87 0.87 0.87

Digit 56=2 or Digit 56=3

Maximum Power input (kW) 156.7 176.2 190.1 204.0 231.2 260.6

Max. amps (A) 259.4 291.4 313.5 335.6 381.6 430.0

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

Displacement power factor (dpf) 0.88 0.88 0.88 0.88 0.88 0.88

Compressor

Compressor Number per Circuit # 2 2 2 2 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (Digit 56=1) (4)

Rated Amps Circuit 1 / Circuit 2 (Digit 56=2 or Digit 56=3) (4)

Locked Rotor Amps Circuit 1 / Circuit 2 (4) (A)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1

Type Shell & Tube Heat exchanger

Evaporator model 3511 3511 3511 3511 3519 3519

Evaporator Water Content volume (l) -- -- -- -- -- --

Unit Connections

Without pump package and no strainer

Inlet / Outlet 8" / 8" 8" / 8" 8" / 8" 8" / 8" 8" / 8" 8" / 8"

Without pump package but strainer

Inlet / Outlet 4" / 8" 4" / 8" 4" / 8" 4" / 8" 5" / 8" 5" / 8"

With pump package but no balance valve

Inlet / Outlet 4" / 8" 4" / 8" 4" / 8" 4" / 8" 5" / 8" 5" / 8"

With pump package and balance valve

Inlet / Outlet 4" / 4" 4" / 4" 4" / 4" 4" / 4" 5" / 5" 5" / 5"

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 124 109 147 130 122 107

Motor Power (kW) 5.5 5.5 7.5 7.5 7.5 7.5

Rated Amps (A) 11 11 14.4 14.4 14.4 14.4

Single pump - High head pressure option

Max available Head Pressure (kPa) 254 242 223 205 234 224

Motor Power (kW) 11 11 11 11 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 28 28

1*240 1*240 1*240 1*240 2*300 2*300

(A) 516.1 548.3 652.4 674.5 638.4 686.7

(A) 388.1 420.3 487.2 509.3 510.4 558.7

(A) 516.5 548.7 652.8 674.9 639.0 687.3

388.5 420.7 487.6 509.7 511.0 559.3

(A)

25+30/

25+30

28.4+38.2/

28.4+38.2

35.4+46.0/

35.4+46.0

35.1+45.5/

35.1+45.5

260+320/

260+320

30+30/

30+30

38.2+38.2/

38.2+38.2

47.0+47.0/

47.0+47.0

46.5+46.5/

46.5+46.5

320+320/

320+320

30+40/

30+40

38.2+45.2/

38.2+45.2

48.3+59.8/

48.3+59.8

47.7+59.0/

47.7+59.0

320+413/

320+413

40+40/

40+40

45.2+45.2/

45.2+45.2

61.7+61.7/

61.7+61.7

60.7+60.7/

60.7+60.7

413+413/

413+413

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

35.5+48.1+48.1/

35.5+48.1+48.1

35.1+47.5+47.5/

35.1+47.5+47.5

260+320+320/

260+320+320

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

48.2+48.2+48.2/

48.2+48.2+48.2

47.5+47.5+47.5/

47.5+47.5+47.5

320+320+320/

320+320+320

CG-SVX039B-GB

General Data

Table 4 – General data CGAF 090-150 Standard Efﬁciency – Shell & Tube (continued)

CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150

SE SE SE SE SE SE

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 124 109 147 130 122 107

Motor Power (kW) 5.5 5.5 7.5 7.5 7.5 7.5

Rated Amps (A) 11 11 14.4 14.4 14.4 14.4

Twin pump - High head pressure option

Max available Head Pressure (kPa) 254 242 223 205 234 224

Motor Power (kW) 11 11 11 11 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 28 28

Expansion Tank Volume (l) 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Antifreeze Heater without pump package

Without lter option (digit 51=X) (W) 200 200 200 200 200 200

With lter option (digit 50=A) (W) 320 320 320 320 440 440

Antifreeze Heater with single pump package

With balance valve (Digit 37=A) (W) 1160 1160 1160 1160 1340 1340

Without balance valve (Digit 37=X) (W) 900 900 900 900 1020 1020

Antifreeze Heater with dual pump package

With balance valve (Digit 37=A) (W) 1220 1220 1220 1220 1140 1140

Without balance valve (Digit 37=X) (W) 960 960 960 960 1080 1080

Condenser

Type Full aluminum Micro channel heat exchanger

Quantity of coil # 6 6 6 6 8 8

Face area per circuit (m²) 8.88 8.88 8.88 8.88 11.84 11.84

Condenser Fan

Quantity # 6 6 6 6 8 8

Diameter (mm) 800

Fan / motor Type

Digit 56=1

Fan / motor Type Fixed speed AC motor

Airow per fan m3/h 15859 15778 15680 15580 15686 15684

Max Power Input per Motor Kw 1.44 1.44 1.44 1.44 1.44 1.44

Max Amps per Motor A 2.9 2.9 2.9 2.9 2.9 2.9

Motor RPM (rpm) 900 900 900 900 900 900

Digit 56=2

Fan / motor Type Variable speed EC motor

Airow per fan m3/h 17295 17215 17120 17021 17125 17124

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3.0 3.0 3.0 3.0 3.0 3.0

Motor RPM (rpm) 840 840 840 840 840 840

Digit 56 = 3

Fan / motor Type Variable speed EC motor with Axitop

Airow per fan m3/h 17411 17331 17235 17136 17240 17239

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3

Motor RPM (rpm) 800 840 840 840 840 840

Dimensions

Unit Length (mm) 3395 3395 3395 3395 4520 4520

Unit Width (mm) 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

(l) 1750 1750 1750 1750 1750 1750

Propeller fan : Fixed speed AC motor / Variable speed EC motor / Variable speed EC

motor with Axitop

(mm) +146 +146 +146 +146 +146 +146

(mm) +425 +426 +427 +428 +370 +370

CG-SVX039B-GB

General Data

Table 4 – General data CGAF 090-150 Standard Efﬁciency – Shell & Tube (continued)

CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150

SE SE SE SE SE SE

Weights

Shipping Weight (3) (kg) 2375 2475 2525 2555 3235 3380

Operating Weight (3) (kg) 2470 2570 2620 2650 3379 3524

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l) 12.8 / 12.8 12.8 / 12.8 12.8 / 12.8 12.8 / 12.8 23.1 / 23.1 23.1 / 23.1

POE Oil type OIL058E / OIL057E

(1) Indicative performance at Evaporator water temperature: 12°C / 7°C - Condenser air temperature 35°C - for detailed performances, on a given unit,

(kg) 20 / 20 20 / 20 20 / 20 20 / 20 30 / 30 30 / 30

CG-SVX039B-GB

General Data

Table 5 – General data CXAF 080-190 Standard Efﬁciency

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE SE

Net Cooling / Heating Capacity (1) (kW)

278 /

276

Net Total Power input (1) (kW) 87 102 117 133 151 164 179 196 209 225

Unit electrical data (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15 15 15 15 15

Power Cable Cross Section (max) mm² 1*240 1*240 1*240 1*240 1*240 1*240 2*300 2*300 2*300 2*300

Disconnect switch size (A) 315 400 400 400 500 500 630 630 630 800

Digit 56=1

Maximum Power input (kW) 122 141 161 179 193 225 244 258 275 289

Max. amps (A) 154 175 201 223 252 274 300 329 347 375

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

(A) 419 495 528 637 659 632 664 768 796 818

(A) 315 367 400 472 494 504 536 603 631 653

Displacement power factor (dpf) 0.84 0.84 0.84 0.86 0.86 0.86 0.86 0.85 0.86 0.86

Digit 56=2 or Digit 56 =3

Maximum Power input (kW) 130 150 169 183 197 230 249 263 281 295

Unit rated amps (A) 153 173 196 223 250 272 298 326 342 369

Unit start up amps (w/o soft starter Digit 54=A) (4)

Unit start up amps (with soft starter Digit 54=B) (4)

(A) 426 502 534 638 660 633 665 769 797 820

322 374 406 473 495 505 537 604 632 654

Displacement power factor (dpf) 0.83 0.84 0.85 0.86 0.86 0.86 0.86 0.86 0.87 0.87

Compressor

Compressor Number per Circuit # 2 2 2 2 2 3 3 3 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll

(A)

25+25/

25+25

28.4+28.4/

28.4+28.4

35.4+35.4/

35.4+35.4

35.1+35.1/

35.1+35.1

260+260/ 260+260

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (Digit 56=1) (4)

Rated Amps Circuit 1 / Circuit 2 (Digit 56=2 or Digit 56=3) (4)

Locked Rotor Amps Circuit 1 / Circuit 2 (4) (A)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 112/112 168/168 168/168 168/168 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1 1 1 1 1

Type Stainless steel Copper Brazed plate Heat exchanger

Evaporator model

DFX650

x138

Evaporator Water Content volume (l) 40.4 40.4 48.6 56.7 64.9 73.1 81.3 81.3 81.3 86

Nominal water connection size (Grooved coupling) - Without HYM

Nominal water connection size (Grooved coupling) - With HYM

(in) -

(mm)

(in) -

(mm)

4" -

114.3

4" -

114.3

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 153 141 137 166 157 141 143 182 163 154

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11 11 11

Rated Amps (A) 11 11 11 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Single pump - High head pressure option

Max available Head Pressure (kPa) 266 254 252 242 232 252 258 249 230 221

Motor Power (kW) 11 11 11 11 11 15 15 15 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28 28 28 28 28

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 153 141 137 166 157 141 143 182 163 154

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11 11 11

Rated Amps (A) 11 11 11 14.4 14.4 14.4 14.4 20.8 20.8 20.8

306 /

313

25+30/

25+30

28.4+38.2/

28.4+38.2

35.4+46.0/

35.4+46.0

35.1+45.5/

35.1+45.5

260+320/

260+320

DFX650

x138

4" -

114.3

4" -

114.3

338 /

343

30+30/

30+30

38.2+38.2/

38.2+38.2

47.0+47.0/

47.0+47.0

46.5+46.5/

46.5+46.5

320+320/

320+320

DFX650

x166

4" -

114.3

4" -

114.3

384 /

389

30+40/

30+40

38.2+45.2/

38.2+45.2

48.3+59.8/

48.3+59.8

47.7+59.0/

47.7+59.0

320+413/

320+413

DFX650

x194

4" -

114.3

4" -

114.3

421 /

421

40+40/

40+40

45.2+45.2/

45.2+45.2

61.7+61.7/

61.7+61.7

60.7+60.7/

60.7+60.7

413+413/

413+413

DFX650

x222

4” -

114.3

4” -

114.3

467 /

481

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

35.5+48.1+48.1/

35.5+48.1+48.1

35.1+47.5+47.5/

35.1+47.5+47.5

260+320+320/

260+320+320

DFX650

x250

5" -

139.7

5" -

139.7

496 /

508

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

48.2+48.2+48.2/

48.2+48.2+48.2

47.5+47.5+47.5/

47.5+47.5+47.5

320+320+320/

320+320+320

DFX650

x278

5" -

139.7

5" -

139.7

527 /

538

30+30+40/

30+30+40

38.2+38.2+45.2/

38.2+38.2+45.2

49.2+49.2+61.0/

49.2+49.2+61.0

48.5+48.5+60.1/

48.5+48.5+60.1

320+320+413/

320+320/413

DFX650

x278

5" -

139.7

5" -

139.7

585 /

599

30+40+40/

30+40+40

38.2+45.2+45.2/

38.2+45.2+45.2

47.6+59.0+59.0/

47.6+59.0+59.0

47.1+58.2+58.2/

47.1+58.2+58.2

320+413+413/

320+413+413

DFX650

x278

5" -

139.7

5" -

139.7

619 /

631

40+40+40/

40+40+40

45.2+45.2+45.2/

45.2+45.2+45.2

60.1+60.1+60.1/

60.1+60.1+60.1

59.2+59.2+59.2/

59.2+59.2+59.2

413+413+413/

413+413+413

DFX650

x294

5" -

139.7

5" -

139.7

CG-SVX039B-GB

General Data

Table 5 – General data CXAF 080-190 Standard Efﬁciency (continued)

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE SE

Twin pump - High head pressure option

Max available Head Pressure (kPa) 266 254 252 242 232 252 258 249 230 221

Motor Power (kW) 11 11 11 11 11 15 15 15 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28 28 28 28 28

Expansion Tank Volume (l) 50 50 50 50 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Optional water Buffer tank volume (l) 607 607 607 607 607 777 777 777 777 777

Antifreeze Heater without pump package and without buffer tank

Antifreeze Heater with pump package and without buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Antifreeze Heater with pump package and with buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Condenser

Type Fin-tube heat exchanger

Quantity of coil # 8 8 8 8 8 10 10 10 12 12

Face area per circuit (m²) 9.3 9.3 9.3 9.29 9.29 11.61 11.61 11.61 13.93 13.93

Condenser Fan

Quantity # 8 8 8 8 8 10 10 10 12 12

Diameter (mm) 800

Digit 56=1

Fan / motor Type Fixed speed AC motor

Airow per fan m3/h

Max Power Input per Motor Kw 0.89 0.89 0.89 1.44 1.44 1.44 1.44 1.44 1.44 1.44

Max Amps per Motor A 2.22 2.22 2.22 2.9 2.9 2.9 2.9 2.9 2.9 2.9

Motor RPM (rpm) 686 686 686 900 900 900 900 900 900 900

Digit 56=2

Fan / motor Type Variable speed EC motor

Airow per fan m3/h

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (rpm) 700 770 820 860 890 900 900 900 960 960

Digit 56=3

Fan / motor Type Variable speed EC motor with Axitop

Airow per fan m3/h

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (rpm) 660 730 780 820 850 860 860 860 910 910

Dimensions

Unit Length (mm) 4520 4520 4520 4520 4520 5645 5645 5645 6770 6770

Unit Width (mm) 2200 2200 2200 2200 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

Weights

Shipping Weight (3) (kg) 2765 2864 2999 3081 3141 3768 3944 3984 4438 4507

Operating Weight (3) (kg) 2835 2934 3078 3168 3235 3876 4060 4100 4554 4628

(l) 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750

(W) 420 420 420 520 520 640 640 640 640 640

1060 /

(W)

1120

1940 /

(W)

2000

(mm) 146 146 146 146 146 146 146 146 146 146

(mm) 425 425 425 425 425

1060 /

1120

1940 /

2000

1060 /

1120

1940 /

2000

1060 /

1220

2040 /

2100

1060 /

1220

2040 /

2100

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

370 370 370 370 370

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

1340 /

1400

2790 /

2850

CG-SVX039B-GB

General Data

Table 5 – General data CXAF 080-190 Standard Efﬁciency (continued)

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE SE

Option Additional shipping weight

Single pump - Standard head pressure (kg) 225 225 225 235 235 245 245 310 325 325

Single pump - High head pressure (kg) 270 270 270 270 270 320 320 320 335 335

Twin pump - Standard head pressure (kg) 315 315 315 335 335 345 345 455 470 470

Twin pump - High head pressure (kg) 395 395 395 395 395 480 480 480 495 495

Axitop option (kg) 80 80 80 80 80 100 100 100 120 120

XLN option (kg) 115 115 115 115 115 150 150 150 150 150

Pump VFD option (kg) 70 70 70 70 70 70 70 70 70 70

Water Buffer tank option (kg) 250 250 250 250 250 330 330 330 330 330

System data

Nb of refrigerant circuit # 2 2 2 2 2 2 2 2 2 2

Minimum cooling load % (6) % 25 23 25 22 25 15 17 15 14 17

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l) 14 / 14 14 / 14 14 / 14

POE Oil type OIL058E / OIL057E

(1) Indicative performance at Evaporator water temperature : 12°C / 7°C - Condenser air temperature 35°C for cooling & Condenser water temperature:

40°C / 45°C - Evaporator air temperature 7°C (6°C) - for detailed performances, on a given unit, consult Order Write Up. (2) Under 400V/3/50Hz. (3) Rated Condition without Pump Package. (4) Electrical & system data are indicative and subject to change without notice. Please refer to unit nameplate data. (5) If the power line of the unit is protected by fuses gG of the same size as the disconnect switch.

(kg) 42 / 42 42 / 42 42 / 42 43 / 43 43 / 43 59 / 58 60 / 59 60 / 59 69 / 68 69 / 68

14.1 /

14.1

14.2 /

14.2

21 / 21 21 / 21

21.1 /

21.1

21.2 /

21.2

21.3 /

21.3

CG-SVX039B-GB

General Data

Table 6 – General data CXAF 080-190 High Efﬁciency

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Net Cooling / Heating Capacity (1) (kW)

278 /

278

Net Total Power input (1) (kW) 87 102 117 132 150 164 179 194 206 223

Unit electrical data (2) (3) (4)

Short Circuit Unit Capacity (9) (kA) 15 15 15 15 15 15 15 15 15 15

Power Cable Cross Section (max) mm21*240 1*240 1*240 1*240 1*240 1*240 2*300 2*300 2*300 2*300

Disconnect switch size (A) 315 400 400 400 500 500 630 630 630 800

Digit 56=1

Maximum Power input (kW) 122 141 161 179 193 225 244 258 275 289

Unit rated amps (A) 153 178 204 226 255 278 304 332 351 379

Unit start up amps (w/o soft starter - Digit 54=A) (4)

Unit start up amps (with soft starter - Digit 54=B) (4)

(A) 419 495 528 637 659 632 664 768 796 818

315 367 400 472 494 504 536 603 631 653

Displacement power factor (dpf) 0.84 0.84 0.84 0.86 0.86 0.86 0.86 0.85 0.86 0.86

Digit 56=2 or Digit 56 =3

Maximum Power input (kW) 130 150 169 183 197 230 249 263 281 295

Unit rated amps (A) 153 176 200 226 253 276 301 329 346 373

Unit start up amps (w/o soft starter - Digit 54=A) (4)

Unit start up amps (with soft starter - Digit 54=B) (4)

(A) 426 502 534 638 660 633 665 769 797 820

322 374 406 473 495 505 537 604 632 654

Displacement power factor (dpf) 0.83 0.84 0.85 0.86 0.86 0.86 0.86 0.86 0.87 0.87

Compressor

Compressor Number per Circuit # 2 2 2 2 2 3 3 3 3 3

Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll

(A)

25+25/

28.4+28.4/ 25+30/

35.3+35.3/

35.3+35.3

35.2+35.2/

35.2+35.2

260+260/

260+260

Model Circuit 1 / Circuit 2

Max Comp Power input Circuit 1 / Circuit 2 kW

Rated Amps Circuit 1 / Circuit 2 (Digit 56=1)(4)

Rated Amps Circuit 1 / Circuit 2 (Digit 56=2 or Digit 56=3) (4)

Locked Rotor Amps Circuit 1 / Circuit 2 (4)

Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900

Oil sump heater Circuit 1 / Circuit 2 (W) 112/112 112/112 112/112 112/112 112/112 168/168 168/168 168/168 168/168 168/168

Evaporator

Quantity # 1 1 1 1 1 1 1 1 1 1

Type Stainless steel Copper Brazed plate Heat exchanger

Evaporator model

DFX650

x138

Evaporator Water Content volume (l) 40.4 40.4 48.6 56.7 64.9 73.1 81.3 81.3 81.3 86

Nominal water connection size (Grooved coupling) - Without HYM

Nominal water connection size (Grooved coupling) - With HYM

Maximum pressure on water side without pump package

(in) (mm)

4" -

114.3

4" -

114.3

(BarA) 10 10 10 10 10 10 10 10 10 10

Hydraulic Module Components

Single pump - Standard head pressure option

Max available Head Pressure (kPa) 153 141 137 166 157 141 143 182 163 154

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11 11 11

Rated Amps (A) 11 11 11 14.4 14.4 14.4 14.4 20.8 20.8 20.8

Single pump - High head pressure option

Max available Head Pressure (kPa) 266 254 252 242 232 252 258 249 230 221

Motor Power (kW) 11 11 11 11 11 15 15 15 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28 28 28 28 28

Twin pump - Standard head pressure option

Max available Head Pressure (kPa) 153 141 137 166 157 141 143 182 163 154

Motor Power (kW) 5.5 5.5 5.5 7.5 7.5 7.5 7.5 11 11 11

Rated Amps (A) 11 11 11 14.4 14.4 14.4 14.4 20.8 20.8 20.8

307 /

315

25+30/

25+30

36.1+46.8/

36.1+46.8

35.6+46.2/

35.6+46.2

260+320/

260+320

DFX650

x138

4" -

114.3

4" -

114.3

338 /

346

30+30/

30+30

38.2+38.2/

38.2+38.2

48.0+48.0/

48.0+48.0

46.8+46.8/

46.8+46.8

320+320/

320+320

DFX650

x166

4" -

114.3

4" -

114.3

384 /

401

30+40/

30+40

38.2+45.2/

38.2+45.2

47.9+59.2/

47.9+59.2

47.8+59.1/

47.8+59.1

320+413/

320+413

DFX650

x194

4" -

114.3

4" -

114.3

421 /

436

40+40/

40+40

45.2+45.2/

45.2+45.2

60.7+60.7/

60.7+60.7

60.3+60.3/

60.3+60.3

413+413/

413+413

DFX650

x222

4” -

114.3

4” -

114.3

466 /

495

25+30+30/

25+30+30

28.4+38.2+38.2/

28.4+38.2+38.2

36.5+47.4+47.4/

36.5+47.4+47.4

36.3+47.0+47.0/

36.3+47.0+47.0

260+320+320/ 260+320+320

DFX650

x250

5" -

139.7

5" -

139.7

493 /

523

30+30+30/

30+30+30

38.2+38.2+38.2/

38.2+38.2+38.2

48.1+48.1+48.1/

48.1+48.1+48.1

47.7+47.7+47.7/

47.7+47.7+47.7

320+320+320/ 320+320+320

DFX650

x278

5" -

139.7

5" -

139.7

525 /

557

30+30+40/

30+30+40

38.2+38.2+45.2/

38.2+38.2+45.2

48.9+48.9+60.6/

48.9+48.9+60.6

48.5+48.5+60.0/

48.5+48.5+60.0

320+320+413/ 320+320+413

DFX650

x278

5" -

139.7

5" -

139.7

581 /

617

30+40+40/

30+40+40

38.2+45.2+45.2/

38.2+45.2+45.2

47.9+59.2+59.2/

47.9+59.2+59.2

47.1+58.3+58.3/

47.1+58.3+58.3

320+413+413/

320+413+413

DFX650

x278

5" -

139.7

5" -

139.7

615 /

651

40+40+40/

40+40+40

45.2+45.2+45.2/

45.2+45.2+45.2

60.+60.2+60.2/

60.2+60.2+60.2

59.2+59.2+59.2/

59.2+59.2+59.2

413+413+413/

413+413+413

DFX650

x294

5" -

139.7

5" -

139.7

CG-SVX039B-GB

General Data

Table 6 – General data CXAF 080-190 High Efﬁciency (continued)

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Twin pump - High head pressure option

Max available Head Pressure (kPa) 266 254 252 242 232 252 258 249 230 221

Motor Power (kW) 11 11 11 11 11 15 15 15 15 15

Rated Amps (A) 20.8 20.8 20.8 20.8 20.8 28 28 28 28 28

Expansion Tank Volume (l) 50 50 50 50 50 50 50 50 50 50

Max User water loop Volume for factory mounted expansion tank (1)

Maximum pressure on water side without pump package

Optional water Buffer tank volume (l) 607 607 607 607 607 777 777 777 777 777

Antifreeze Heater without pump package and without buffer tank

Antifreeze Heater with pump package and without buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Antifreeze Heater with pump package and with buffer tank (Single Water Pump digit 24=2 or 4 / Dual Water Pump digit 24=1 or 3)

Condenser

Type Fin-tube heat exchanger

Quantity of coil # 8 8 8 8 8 10 10 10 12 12

Face area per circuit (m²) 9.3 9.3 9.3 9.29 9.29 11.61 11.61 11.61 13.93 13.93

Condenser Fan

Quantity # 8 8 8 8 8 10 10 10 12 12

Diameter (mm) 800

Digit 56=1

Fan / motor Type Fixed speed AC motor

Airow per fan m3/h

Max Power Input per Motor Kw 0.89 0.89 0.89 1.44 1.44 1.44 1.44 1.44 1.44 1.44

Max Amps per Motor A 2.22 2.22 2.22 2.9 2.9 2.9 2.9 2.9 2.9 2.9

Motor RPM (rpm) 686 686 686 900 900 900 900 900 900 900

Digit 56=1

Fan / motor Type

Airow per fan m3/h

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (rpm) 700 770 820 860 890 900 900 900 960 960

Digit 56=3

Fan / motor Type

Airow per fan m3/h

Max Power Input per Motor Kw 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95

Max Amps per Motor A 3 3 3 3 3 3 3 3 3 3

Motor RPM (rpm) 660 730 780 820 850 860 860 860 910 910

Dimensions

Unit Length (mm) 4520 4520 4520 4520 4520 5645 5645 5645 6770 6770

Unit Width (mm) 2200 2200 2200 2200 2200 2200 2200 2200 2200 2200

Std Unit Height (mm) 2526 2526 2526 2526 2526 2526 2526 2526 2526 2526

Axitop EC Fan Unit - (Additional height

conguration)

Pump Package Option - (Additional length

conguration)

Weights

Shipping Weight (3) (kg) 2815 2914 3059 3141 3201 3848 4024 4064 4523 4592

Operating Weight (3) (kg) 2885 2984 3138 3228 3295 3956 4140 4180 4639 4713

Option Additional shipping weight

Single pump - Standard head pressure (kg) 225 225 225 235 235 245 245 310 325 325

Single pump - High head pressure (kg) 270 270 270 270 270 320 320 320 335 335

Twin pump - Standard head pressure (kg) 315 315 315 335 335 345 345 455 470 470

Twin pump - High head pressure (kg) 395 395 395 395 395 480 480 480 495 495

(l) 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750

(W) 420 420 420 520 520 640 640 640 640 640

1060/

(W)

1120

1940/

(W)

2000

(mm) 146 146 146 146 146 146 146 146 146 146

(mm) 425 425 425 425 425 370

1060/

1120

1940/

2000

1060/

1120

1940/

2000

1160/

1220

2040/

2100

Variable speed EC motor with Axitop

1160/

1220

2040/

2100

Variable speed EC motor

1340/

1400

2790/

2850

1340/

1400

2790/

2850

370 370 370 370

1340/

1400

2790/

2850

1340/

1400

2790/

2850

1340/

1400

2790/

2850

CG-SVX039B-GB

General Data

Table 6 – General data CXAF 080-190 High Efﬁciency (continued)

CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF

080 090 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Axitop option (kg) 80 80 80 80 80 100 100 100 120 120

XLN option (kg) 115 115 115 115 115 150 150 150 150 150

Pump VFD option (kg) 70 70 70 70 70 70 70 70 70 70

Water Buffer tank option (kg) 250 250 250 250 250 330 330 330 330 330

System data

Nb of refrigerant circuit # 2 2 2 2 2 2 2 2 2 2

Minimum cooling load % (6) % 25 23 25 22 25 15 17 15 14 17

Standard/Partial Heat Recovery Unit

R410A refrigerant charge Circuit 1 / Circuit 2

Oil charge Circuit 1 / Circuit 2 (l) 14 / 14 14 / 14 14 / 14

POE Oil type OIL058E / OIL057E

(1) Indicative performance at Evaporator water temperature : 12°C / 7°C - Condenser air temperature 35°C for cooling & Condenser water temperature:

(kg) 49 / 49 49 / 49 49 / 49 50 / 50 50 / 50 67 / 70 68 / 71 68 / 71 77 / 80 78 / 81

14.1 /

14.1

14.2 /

14.2

21 / 21 21 / 21

21.1 /

21.1

21.2 /

21.2

21.3 /

21.3

CG-SVX039B-GB

Typical CGAF / CXAF Components location

Top view

CG-SVX039B-GB

Typical CGAF / CXAF Components location

CG-SVX039B-GB

Installation Requirements

Location Requirements

Sound consideration

The most effective form of acoustical 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. Rubber isolated piping hangers can be used to reduce the sound transmitted through water piping. To reduce sound transmitted through electrical conduit, use ﬂexible electrical conduit.

EU and Local Regulations codes on sound emissions should always be considered. Since the environment in which a sound source is located affects the sound pressure, unit placement must be carefully evaluated.

Clearances

When installing the unit, provide enough space around the unit to allow the installation and maintenance personnel unrestricted access to all service points.

Unobstructed ﬂow of condenser air is essential to maintain chiller capacity and operating efﬁciency. When determining unit placement, give careful consideration to ensuring a sufﬁcient air ﬂow across the condenser coils heat-transfer surface.

In case of enclosure around the unit, the height of the enclosure must not be higher than the unit itself. If the enclosure is higher than the unit, restrictive airﬂow louvers should be ﬁtted to ensure fresh air supply.

Installation Responsibilities

Generally contractor must do the following Items when installing a CGAF / CXAF unit:

1. Install the unit on a ﬂat foundation strong enough to support unit loading and level (within 5 mm across the length and width of the unit).

2. Install the units as per instructions contained in this manual.

3. Where speciﬁed, provide and install valves in the water piping upstream and downstream of the evaporator water connections, to isolate the evaporator for maintenance, and to balance and trim the system.

4. Furnish and install a water ﬂow prove device and/ or auxiliary contacts to prove chiller water ﬂow.

5. Furnish and install water pressure gauges in the inlet and outlet of the evaporator water box.

6. Supply and install an air vent cock to the top of the evaporator or evaporator piping.

7. Furnish and install strainers ahead of all pumps and automatic modulating valves.

8. Provide and install ﬁeld wiring according to schematics provided in the control panel.

9. Install heat tape and insulate the chilled water lines and any other portion of the system, as required, to prevent sweating under normal operating conditions or freezing during low ambient temperature conditions.

10. Ensure that the compressor and compressor heaters have been operating for a minimum of 24 hours before starting. Failure to do so may result in equipment damage.

11. Start the unit under supervision of a qualiﬁed service technician.

Lifting and Moving Instructions

A speciﬁc lifting method is recommended, which can be described as follow:

1. Lifting points are built into the unit, see lifting instruction label on the unit.

2. Slings and spreader bar must be provided by crane operator and attached on the lifting points.

3. Use the 4 rigging points which are built into the unit.

4. The minimum lifting capacity of each sling as well as the spreader bar must be higher than the tabulated unit shipping weight.

CAUTION! Lift and handle with care. Avoid shocks while handling.

Details of lifting instruction and container pull out are given in the drawings speciﬁc for lifting and handling shipped with the unit.

WARNING! Heavy Objects! Ensure that all the lifting equipment used is properly rated for weight of the unit being lifted. Each of the cables (chains or slings), hooks, and shackles used to lift the unit must be capable of supporting the entire weight of unit. Lifting cables (chains or slings) may not be the same length. Adjust as necessary for even unit lift. Other lifting arrangements could cause equipment or property damage. Failure to follow instructions above or properly lift unit could result in unit dropping and possibly crushing operator/ technician which could result in death or serious injury.

WARNING! Improper Unit Lift! Test lift unit approximately 10 cm to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level. Failure to properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury and possible equipment or property- only damage.

CG-SVX039B-GB

Installation Requirements

117.6

159

9.6

Dimension and Weights

Dimensions details, dimensions of hydraulic connections, electrical connections, isolator positioning, speciﬁc features for heat recovery and free cooling are included in submittals and diagrams provided in documentation package.

Center of Gravity

See instructions on lifting drawings available on request.

Unit Isolation and Leveling

Provide a foundation with sufﬁcient strength and mass to support the unit operating weight (that is, including completed piping, full operating charges of refrigerant and oil, and water). Refer to unit operating weights. The unit must be leveled within 5 mm over its length and width. Use shims as necessary to level the unit. For additional reduction of sound and vibration, install the optional elastomeric isolators.

Elastomeric Isolators Installation (Optional)

Isolators are ready to install. Mountings have to be placed on a rigid and level foundation. External equipment should not transmit additional vibration to the chiller. The position of elastomeric isolator and weight per point are given in the Neoprene isolators installation drawing which is supplied with the chiller. Wrong placement along the unit may result in excessive deﬂection.

Isolator Pads Installation (Optional)

Isolators are ready to install. Mountings have to be placed on a rigid and level foundation. External equipment should not transmit additional vibration to the chiller. The position of pads isolator is given in the pad isolators installation or selection drawing which is supplied with the chiller.

Figure 3 – Isolator pads

450

1. Secure the isolators to the mounting surface using the mounting slots in the isolator’s base plate. Do NOT fully tighten the isolators mounting bolts at this time. See the isolators submittals for isolators location, maximum weights, and isolators diagrams.

2. Align the mounting holes in the base of the unit with the threaded positioning pins on the top of the isolators.

3. Install the unit on the isolators and secure the isolators to the unit with a nut. The maximum isolators deﬂection should be 13 mm.

4. Level the unit carefully. Fully tighten the isolator mounting bolts.

Figure 2 – Elastomeric Isolator

40.6

127

63.5

14.2 16

12.7

CG-SVX039B-GB

Evaporator Piping

Evaporator water connections are grooved. Thoroughly ﬂush all water piping to the unit before making the ﬁnal piping connections to the unit.

Components and layout will vary slightly, depending on the location of connections and the water sources.

CAUTION Equipment Damage! If using an acidic commercial ﬂushing solution, construct a temporary bypass around the unit to prevent damage to internal components of the evaporator.

CAUTION Proper Water Treatment! The use of untreated or improperly treated water in a chiller may result in scaling, erosion, corrosion, algae or slime. It is recommended that the service of a qualiﬁed water treatment specialist be engaged to determine what water treatment, if any, is required. Trane assumes no responsibility for equipment failures which results from untreated or improperly treated water or saline or brackish water.

Drainage

Locate the unit near a large capacity drain for water vessel draining down during shutdown or repair. Condensers and evaporators are provided with drain connections. Refer to “Water Piping.” All local and national codes apply.

Water Treatment

In the evaporator the following material are in contact with water:

• Plate material: AISI 316 EN 10028-7 - 1.4401 +2B/2R

• Connection: AISI 316 EN 10272 -

1.4401/1.4404/1.4435/1.4436 - 1E

• Braze alloy: EN-13388, ISO Copper CU-HCP

In Shell and Tube evaporator the following material are in contact with water:

• Copper tube

• Carbon steel

• Polypropylene bafﬂes

• EPDM rubber gaskets on bafﬂes

• Stainless steel rivets

• Tie rod in carbon steel with galvanized ﬁnish

For the heater, the copper ring gasket’s.

When the unit is supplied with hydraulic module, the following additional materials are in contact with water:

• Pump frame and connections are made of cast

iron

• Water pipes are made of carbon steel

• Pipe sealings are made of EPDM rubber

(ethylene propylene diene monomer rubber)

• Pump sealings are made of silicon carbide

• Straine

r is made of stainless steel

Dirt, scale, products of corrosion, and other foreign material will adversely affect heat transfer between the water and system components. Foreign matter in the chilled-water system can also increase pressure drop and consequently, reduce water ﬂow. Proper water treatment must be determined locally, depending on the type of system and local water characteristics.

Neither salt nor brackish water is recommended for use in Trane air-cooled chillers. Use of either will lead to an unpredictably shorter life cycle. Trane encourages the employment of a reputable water treatment specialist, familiar with local water conditions, to assist in this determination and in the establishment of a proper water treatment program.

If calcium chloride is used for water treatment, an applicable corrosion inhibitor must also be used. Failure to do so may result in damage to system components. Do not use untreated or improperly treated water.

Equipment damage may occur.

Piping

Piping components include all devices and controls used to provide proper water system operation and unit operating safety. A typical CGAF / CXAF evaporator piping is shown below.

Figure 4 – Unit typical water circuit

1 = Pressure gauges: show entering and leaving water

pressure 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.

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.

CG-SVX039B-GB

Evaporator Piping

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 trainer used must be able to stop all particles with a diameter greater than 1 mm.

9 = Draining: used as the draining the plate heat

exchanger.

10 = Do not start the unit with low water volume or not

enough pressurized circuit.

Note: A pressure switch device to detect lack of water is not included in the pump package. Installation of this type of device is highly recommended to avoid sealing damage due to operation of pump without enough water.

An air vent is located on top of the evaporator at the chiller water outlet. Be sure to provide additional air vents at the highest points in the piping to remove air from the chilled water system. Install necessary pressure gauges to monitor the entering and leaving chilled water pressure.

Provide shut off valves in lines to the gauges to isolate them from the system when they are not in use. 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.

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 can be isolated for service.

It is mandatory to place a ﬂow switch device at the outlet of the unit and to link it with the control of the unit (see wiring diagrams shipped with the unit).

CAUTION! The chilled-water connections to the evaporator are to be “grooved pipe” type connections. Do not attempt to weld these connections, because the heat generated from welding can cause microscopic and macroscopic fractures on the heat exchanger connection that can lead to premature failure of the connection. An optional grooved pipe stub and coupling should be used for welding on ﬂanges.

Entering Chilled Water Piping

• Air vents to bleed the air from the system (to be placed on the highest point)

• Water pressure gauges with shutoff valves

• Vibration eliminators

• Shutoff (isolation) valves

• Thermometers if desired (temperature readings available on chiller controller display)

• Clean-out tees

• Pipe strainer

Leaving Chilled Water Piping

• Air vents to bleed the air from the system (to be placed on the highest point)

• Water pressure gauges with shut off valves

• Vibration eliminators

• Shutoff (isolation) valves

• Thermometers (temperature readings available on the chiller controller display)

• Clean-out tees

• Balancing valve

• Flow Proving Device

Pressure Gauges

Install ﬁeld-supplied pressure components. Locate pressure gauges or taps in a straight run of pipe; avoid placing them near elbow (at least at 10 pipe diameter from discontinuity). To read manifold pressure gauges, open one valve and close the other (depending on the side of the desired reading), this eliminate errors resulting from differently calibrated gauges installed at unmatched elevations.

Evaporator Flow Switch

Speciﬁc connection and schematic wiring diagram are shipped within the unit. Some piping and control schemes, particularly those using a single water pump for both chilled and hot water, must be analyzed to determine how and/or if a ﬂow sensing device will provide the desired operation.

To prevent damage to chilled-water components, do not allow evaporator pressure (maximum working pressure) to exceed 10 Bar. The maximum service pressure depends on free cooling type and potential pump package option. The value of max service pressure is indicated on unit nameplate.

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Evaporator Piping

Flow Switch Installation – Typical Requirements

1. Mount the switch upright, with a minimum of 10 pipes diameters of straight horizontal run on each side. Do not install close to elbows, oriﬁces, or valves. The arrow on the switch must point in the direction of the ﬂow. For additional information, consult the ﬂow switch information sheet coming with the part.

2. To prevent switch ﬂuttering, remove all air from the water system. Tracer UC800 provides a 6 second time delay after a “loss-of-ﬂow” diagnostic before shutting the unit down. Contact a Trane service representative if nuisance machine shutdowns persist.

3. Adjust the switch to open when water ﬂow falls below nominal values. Evaporator data is given on the General Information Section. Flow Switch contacts are closed on proof of water ﬂow.

CAUTION! Control voltage from the chiller to the ﬂow proving device is 110V AC.

Note: In case of winter water drainage for freeze protection, it is mandatory to disconnect the evaporator’s heaters to protect them from burning due to overheat. It is also mandatory to fulﬁll the drainage, using pressurized air, and ensure that no water stays in the evaporator during winter season.

The minimum volume can be determined by using the following formula: Volume = Cooling capacity x Time x highest capacity step (%) / Speciﬁc heat / Dead band Minimum operating time = 120 seconds Speciﬁc heat = 4.18 kJ / kg 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. Process applications will need more water volume to minimize the water temperature ﬂuctuation at part load.

Expansion tank (option)

The factory-installed expansion tank initial pressure should be adjusted about 0.2 bar lower than the static pressure of the circuit at the pump inlet. The expansion tank volume has been selected for typical loop volume. It is recommended to check the expansion tank volume with the installation information. The following data is required: C = Water capacity of the circuit e = Expansion coefﬁ cient (difference between max and min water temperature, in operation or not) Pi = Initial pressure of the expansion tank Pf = Final pressure: Max is given by the pressure relief valve

Minimal installation water content

The water volume is an important parameter because it allows as table chilled water temperature and avoids short cycle operation of the compressors. Parameters which inﬂuence the water temperature stability

− Water loop volume

− Load ﬂuctuation

− Number of capacity steps

− Compressors rotation

− Dead band (adjusted on chiller controller)

− Minimum time between 2 starts of a compressor

Minimum water volume for a comfort application

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.

Minimum Volume of expansion tank = (C x e)/(1-Pi/Pf) Expansion coefﬁcient of water various temperatures

°C e

0 0.00013

10 0.00027

20 0.00177

30 0.00435

40 0.00728

50 0.01210

Water loop and expansion tank volume

- Water loop CGAF 080 HE/XE, CGAF 090: 607 l

- Water loop CGAF 140-190: 777 l

Expansion tank volume (option): 50 l

Note: Maximum pressure of the circuit is 400 kPa with pump package and 1000 kPa without.

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Installation - Mechanical

125

5 50

Evaporator Pressure Drop (kPa)

Water Flow Rates (L/s)

Evaporator Water Pressure Drop

1-106

2-122

3-138

4-166

5-194

6-222

7-250

8-278

9-294

10-3511

11-3519

3025 4015

100

BPHE - 1 to 9 - DFX650 Number of plates Shell & Tube - 10 & 11

3025 4015

100

BPHE - 1 to 9 - DFX650 Number of plates Shell & Tube - 10 & 11

3025 4015

100

BPHE - 1 to 9 - DFX650 Number of plates Shell & Tube - 10 & 11

3025 4015

100

BPHE - 1 to 9 - DFX650 Number of plates Shell & Tube - 10 & 11

Figure 5 – CGAF / CXAF Evaporator Water Pressure Drop (BPHE, Shell & Tube)

Note: Water pressure drop are for pure water. Limit of water ﬂow are limit of the curves.

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Schematic pump package

Installation – Mechanical

Chiller can be ordered with an optional integrated hydraulic module. In this case, chiller will be provided with the following components factory mounted and tested:

• Centrifugal water pump, Low pressure or High pressure (option)

• Water strainer to protect the pump against impurities in the circuit

• Expansion module with expansion vessel and pressure relief valve sufﬁcient to ensure the expansion of the water loop ability

• Thermal insulation for antifreeze protection

• Balancing valve (Optional) for equilibrate the ﬂow of water circuit

• Drain valve

• Temperature sensor

Pump package schematics is supplied in the documentation set shipped with the unit.

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Schematic pump package

100

150

200

250

5 10 15 20 25 30 35 40 45 50

Avaiable Pressure(kPa)

Water Flow Rates (L/s)

Standard Head - Standard Efficiency

1. 80-90SE

2. 100SE

3. 110SE

4. 130-140SE

5. 150SE

6. 165SE

7. 180SE

8. 190SE

9. 90/100-SE-T

10. 110/130-SE-T

11. 140/150-SE-T

Max Flow 80SE

1 to 8 - BPHE Evaporat or 9 to 11 - Shell & Tube Evaporator

100

150

200

250

300

350

5 10 15 20 25 30 35 40 45 50

Avaiable Pressure(kPa)

Water Flow Rates (L/s)

High Head - Standard Efficiency

1. 80-090SE

2. 100SE

3, 110SE

4. 130SE

5. 140SE

6. 150SE

7. 165SE

8. 180SE

9. 190SE

10. 90/100/110/130-SE-T

11. 140/150-SE-T

Max Water Flow 80SE

1 to 9

- BPHE Evaporator

10 & 11 - Shell & Tube Evaporator

Pump Curves

In the ﬁgures below are described pump curves (Standard Head and High head) for the whole CGAF / CXAF unit range.

Figure 6 – Pump Curve - Sizes 090-190 –Standard / High Head - BPHE / Shell & Tube Evaporator

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Evaporator Waterside

Freeze Protection

Depending on the ambient temperature the unit may be exposed to freeze, there are multiple options for freeze protection. They are listed in order of highest ambient (least freeze protection) to the lowest ambient (most freeze protection).

For all chiller running with water under cold ambient temperature (below 0°C), it is extremely important to keep full water ﬂow in the evaporator for an extended time after last compressor stops. This will protect brazed plate evaporator from freezing by refrigerant migration. This is why evaporator water pump output relay must be used to control the chilled water pump. This is not mandatory if glycol is used with protection down to lowest ambient expected.

1. Water pump and heaters

a. Heaters are factory installed on brazed plates

evaporator. They will protect it from freezing in ambient temperatures down to -18°C.Heaters are installed on the water piping and on the pumps of units equipped with hydraulic module.

b. Install heat tape on all water piping, pumps, and other

components that may be damaged if exposed to freezing temperatures. Heat tape must be designed for low ambient temperature applications. Heat tape selection should be based on the lowest expected ambient temperature.

c. Tracer™ UC800 controller can start the pump(s) when

freezing conditions are detected. For this option the pumps must be controlled by the CGAF / CXAF unit and this function validated on the chiller / Heat pump controller.

d. Water circuit valves need to stay open at all times.

Note: Water pump control and heater combination will protect the evaporator down to any ambient temperature provided power is available to the pump and the UC800 controller. This option will NOT protect the evaporator in the event of power failure to the chiller unless backup power is supplied to the necessary components.

2. Freeze inhibitor

a. Freeze protection can be accomplished by adding

sufﬁcient glycol to protect against freezing down to the lowest ambient expected.

b. See “evaporator glycol requirement” section for

guidance on determining the glycol concentration.

Note: Use of glycol type antifreeze reduces the cooling capacity of the unit and must be considered in the design of the system speciﬁcations.

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CAUTION! When using freeze inhibitor, never ﬁll the system with pure glycol. Always ﬁll the system with diluted solution. Maximum concentration of glycol is 40%. Higher glycol concentration will damage pump seal.

3. Drain water circuit

For ambient temperatures below -20°C and for those installation not including either option 1 or 2 above described a. Shut off power supply to unit and to all heaters. b. Purge the water circuit c. Blow out the evaporator to ensure that no liquid is left

inside the evaporator and the water lines. Drain the pump.

Note: It is not recommended to drain the water circuit for the following reasons.

1. The water circuit will rust and its lifetime could be reduced.

2. Water will remain in the bottom of the plate heat

exchangers and freeze damage could occur

CAUTION! Evaporator damage!

If insufﬁcient concentration or no glycol is used, the evaporator water pumps must be controlled by the UC800 to avoid severe damage to the evaporator due to freezing. A power loss of 15 minutes during freezing can damage the evaporator. It is the responsibility of the installing contractor and/or the customer to ensure that a pump will start when called upon by the chiller controls. Please consult TRANE service for unit setting and % of glycol required.

With factory-ﬁtted disconnect switch option, evaporator trace heating is taken from the live side of the isolator. As a consequence, the heaters are energized as long as the main switch is closed. Supply voltage to the heating tapes is 400V.

• Avoid the use of very low or near minimum chilled ﬂuid ﬂow rates through the chiller. Higher velocity chilled ﬂuid ﬂow reduces freeze risk in all situations.

• Flow rates below limits have increased freeze potential and have not been considered by freeze protection algorithms.

• Avoid applications and situations that result in a requirement for rapid cycling or repeated starting and stopping of the chiller. Keep in mind that chiller control algorithms may prevent a rapid compressor restart after shutting down when the evaporator has been operating near or below the LERTC (Low Refrigerant Temperature Cutout) limit.

• Maintain refrigerant charge at appropriate levels. If charge is in question, contactTrane service. A reduced or low level of charge can increase the likelihood of freezing conditions in the evaporator and/or LERTC diagnostic shutdowns.

The warranty will be void, in case of freezing due to the lack of use of either of these protections.

Evaporator Waterside (not for free cooling version)

Low refrigeration temperature setpoint and antifreeze setpoint on CGAF unit control

CAUTION! The chiller is provided with standard factory

settings. It can be necessary to modify the Low Pressure saturation Temperature and the Antifreeze Setpoint on the unit control. Based on the following examples, it is necessary to modify on the unit control the following settings:

• The LP saturation temperature

• The antifreeze setpoint

Examples for:

• 7°C, the LP setting must be -4°C where the antifreeze setting shall be 2°C

• 2°C, the LP setting must be -9°C where the antifreeze setting shall be -4°C

• -12°C, the LP setting must be -23°C where the antifreeze setting shall be -17°C

Figure 7 – LP setting Vs. Leaving Water Temperature setpoint

Freeze protection with glycol

It is mandatory to use a freeze inhibitor for leaving water setpoint less or equal to 5°C. On the glycol recommended concentration ﬁgure, you must select concentration on or above the curve. For example, for

-4°C brine temperature, a concentration of 25% ethylene glycol is not sufﬁcient. The concentration must be 28% ethylene glycol or 33% propylene glycol.

Using glycol with hydraulic module

If the glycol brine percentage is not at the recommended percentage (greyed area), corrosion inhibitor present in the glycol may not be efﬁcient enough. For instance, a glycol concentration of 15% will provide freeze protection to the unit down to -5°C, but it might generate additional corrosion.

Lp setting -

Lp setting

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Evaporator Waterside (not for free cooling version)

Figure 8 – Glycol percentage recommendation curve

1 = Critical risks of freezing

2 = Efﬁcient freeze protection

3 = Ethylene glycol

4 = Propylene glycol

% = Glycol percentage (mass concentration)

°C = Glycol or water temperature

CAUTION!

1. Additional glycol beyond the recommendations will adversely affect unit performance. The unit efﬁciency will be reduced and the saturated evaporator temperature will be reduced. For some operating conditions this effect can be signiﬁcant.

2. If additional glycol is used, then use the actual % glycol to establish the low refrigerant cutout set point with Trane

service advice.

3. The minimum low refrigerant cutout set point allowed is - 20.6°C. This minimum is established by the solubility limits of the oil in the refrigerant.

4. With glycol application, ensure that there is no ﬂuctuation of brine ﬂow versus Order Write Up value, as a reduction of ﬂow will adversely affect unit performance and behaviour.

5. Full unit simulation is required for proper prediction of unit performance for speciﬁc operating conditions.

For information on speciﬁc conditions, contact Trane.

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General Electrical Recommendations

Electrical Parts

When reviewing this manual keep in mind.

• All ﬁeld-installed wiring must be in accordance with local regulations, CE directives and guidelines. Be sure to satisfy proper equipment grounding requirements according CE

• The following standardized values - Maximum Amps - Short Circuit Amps - Starting Amps are displayed on unit nameplate.

• All ﬁeld-installed wiring must be checked for proper terminations, and for possible shorts or grounds.

Note: Always refer to wiring diagrams shipped with chiller or unit submittal for speciﬁc electrical schematic and connection information.

Important: To prevent control malfunctions, do not run low voltage wiring (<30V) in conduit with conductors carrying more than 30 volts.

WARNING! Hazardous Voltage with Capacitor!

Disconnect all electric power, including remote disconnects and discharge all motor start/run and AFD (Adaptive Frequency TM Drive) capacitors before servicing. Follow proper lockout/tagout 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

• DC bus capacitors retain hazardous voltages after input power has been disconnected. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized

• After disconnecting input power, wait ﬁve (5) minutes for units which are equipped with EC fans and wait twenty (20) minutes for units which are equipped with variable frequency drive (0V DC) before touching any internal components.

• Failure to follow these instructions could result death or serious injury

For additional information regarding the safe discharge of capacitors, see “Adaptive Frequency™ Drive (AFD3) Capacitor Discharge” and BAS-SVX19B-E4.

Hazardous Voltage – Pressurized Burning Fluid!

Before removing compressor terminal box cover for servicing, or servicing power side of control panel, CLOSE COMPRESSOR DISCHARGE SERVICE VALVE and disconnect all electric power including remote disconnects. Discharge all motor start/run capacitors. Follow lockout/tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged.

The compressor contains hot, pressurized refrigerant. Motor terminals act as a seal against this refrigerant. Care should be taken when servicing NOT to damage or loosen motor terminals.

Do not operate compressor without terminal box cover in place.

Failure to follow all electrical safety precautions could result in death or seriously injure.

CAUTION! To avoid corrosion, overheating or general damage, at terminal connections, unit is designed for copper mono-conductors only. In case of multiconductor cable, an intermediate connection box must be added. For cable with alternative material, bi-material connecting devices are mandatory. Cable routing inside control panel should be made case by case by installer.

Do not allow conduit to interfere with other components, structural members or equipment. Control voltage (115V) wiring in conduit must be separate from conduit carrying low voltage (<30V) wiring. To prevent control malfunctions, do not run low voltage wiring (<30V) in conduit with conductors carrying more than 30V.

WARNING! The Warning Label is displayed on the equipment and shown on wiring diagrams and schematics. Strict adherence to these warnings must be observed. Failure to do so may result in personal injury or death.

CAUTION! Units must not be linked to the neutral wiring of the installation. Units are compatible with the following neutral operating conditions:

TNS IT TNC TT

Standard Standard** Special Standard*

* Differential protection should be suited for industrial machinery with current leak which can be higher than 500 mA (several motors and frequency drives).

** Filter RFI disconnect on VPF and EC fan.

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General Electrical Recommendations

Electrical data

To get the following electrical data details: Refer to General Data tables for each unit conﬁguration and size.

− Maximum Power input (kW)

− Unit rated amps (Max comp + Fan + Control)

− Unit start up amps (Starting Amps of the largest comp + RLA of 2nd comp + RLA of all fans+ control)

− Compressor Power factor

− Disconnect switch size (A)

− Short Circuit Rating for all sizes =15 kA

Wiring diagrams are shipped with unit and can be found in the unit control panel.

Note: Rating is made for 400 V, 3 phases, 50 Hz power supply.

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Installer-Supplied Components

Customer wiring interface connections are shown in the electrical schematics and connection diagrams that are shipped with the unit. The installer must provide the following components if not ordered with the unit:

• Power supply wiring (in conduit) for all ﬁeldwired connections

• All control (interconnecting) wiring (in conduit) for ﬁeld supplied devices

• Fused-disconnect switches

Power Supply Wiring

All power supply wiring must be sized and selected accordingly by the project engineer in accordance with standard IEC 60364. All wiring must comply with local codes. The installing (or electrical) contractor must provide and install the system interconnecting wiring, as well as-the power supply wiring. It must be properly sized and equipped with the appropriate fusedisconnect switches. The type and installation location(s) of the fused-disconnect switches must comply with all applicable codes.

Cut holes into the sides of the control panel for the appropriately-sized power wiring conduits. The wiring is passed through these conduits and connected to the terminal blocks.

To provide proper phasing of 3 phase input, make connections as shown in ﬁeld wiring diagrams and as stated on the yellow WARNING label in the starter panel. Proper equipment grounds must be provided to each ground connection in the panel.

CAUTION! Customer wiring interface connections are shown in the electrical schematics and connection diagrams that are shipped with the unit. The installer must provide the following components if not ordered with the unit.

WARNING! To prevent injury or death, disconnect all electrical power sources before completing wiring connections to the unit.

CAUTION! The use of copper mono-conductors is the preferred solution to avoid corrosion and overheating at terminal connections.

Control Power Supply

Chiller is provided with control power transformer, it is not necessary to provide additional control power voltage to the unit.

Heater Power Supply

The evaporator shell is insulated from ambient air and protected from freezing for temperature down to -20°C by two thermostatically-controlled immersion heaters combined with evaporator pumps activation through Tracer UC800. Whenever the ambient temperature drops below 0°C the thermostat energizes the heaters and the Tracer UC800 activates the pumps. If ambient

temperatures below -20°C are expected, contact your Trane local ofﬁce.

CAUTION! The control panel main processor does not check for loss of power to the heat tape nor does it verify thermostat operation. A qualiﬁed technician must frequently verify power to the heat tape and conﬁrm operation of the heat tape thermostat, to avoid catastrophic damage to the evaporator.

CAUTION! With factory-ﬁtted disconnect switch, trace heating is taken from the live side of the isolator so power remains on. Supply voltage to the heating tapes is 400V.

Don’t energize heaters without water. In case of winter water drainage for freeze protection, it is compulsory to disconnect the evaporator heaters to protect them from burning due to overheat.

Water Pump Power Supply

Provide power-supply wiring with fused disconnect switch(es) for the chilled water pump(s).

Interconnecting Wiring

Chilled-Water Flow (Pump) Interlock

CGAF/CXAF requires a ﬁeld-supplied, control-voltage contact input through a ﬂow proving switch (6S51) and an auxiliary contact (6K51). Connect the proving switch and auxiliary contact to terminal 2 connector J2 cards (1A11). Refer to the ﬁeld wiring diagram for details.

Chilled-Water Pump Control

An evaporator water-pump output relay closes when the chiller is given a signal to go into the AUTO mode of operation from any source. The contact is opened to turn off the pump in the event of most machine-level diagnostics, to prevent the buildup of pump heat.

CAUTION! The evaporator water pump output relay must be used to control the chilled water pump and to beneﬁt from the water pump timer function at startup and shutdown of the chiller. This is required when the chiller is in operation under freezing conditions, especially if the chilled water loop does not contain glycol.

CAUTION! Refer to Freeze Protection section for information about the evaporator circulating pump.

Alarm and Status Relay Outputs (Programmable Relays)

See CGAF / CXAF User Guide for alarm and status relay outputs.

EDLS and ECWS Analog Input Signal Wiring Details

See CGAF / CXAF User Guide for EDLS and ECWS.

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Operating Principles

This section contains an overview of the operation of CGAF / CXAF air-cooled liquid chiller / Heat Pump equipped with microcomputer-based control systems. It describes the overall operating principles of the CGAF chiller / CXAF Heat Pump.

Note: To ensure proper diagnosis and repair, contact a qualiﬁed service organization if a problem could occur.

General

The Model CGAF / CXAF units are scroll compressor(s), single or dual circuit, air-cooled liquid chillers. These units are equipped with unit-mounted starter/control panels and operate with R410A refrigerant.

The basic components of a CGAF / CXAF unit are:

• Unit-mounted panel containing starter and Tracer UC800 controller and Input/Output LLIDS

• Scroll compressors

• Brazed plate / Shell & Tube evaporator

• Air-cooled MCHE / Fin & tube condenser with sub cooler

• Electronic Expansion Valve (EEXV)

• Related interconnecting piping

Refrigerant Cycle

The refrigeration cycle of the Model CGAF chiller / CXAF Heat Pump is conceptually similar to other Trane aircooled chiller products. The CGAF chiller / CXAF Heat Pump uses a brazed plate / Shell & Tube evaporator and an air-cooled MCHE / Fin & tube condenser. The compressors use suction gas cooled motors and an oil management system to provide almost oil-free refrigerant to the condenser and evaporator for maximum heat transfer while lubricating and sealing compressor rotors and bearings. The lubrication system helps to assure long compressor life and contributes to quiet operation.

Refrigerant condenses in the MCHE / Fin & tube air-cooled heat exchanger. Liquid refrigerant is metered into the brazed plate or Shell and Tube evaporator using an electronic expansion valve to maximize chiller efﬁciency at full and part load operation.

The CGAF chiller / CXAF Heat Pump is equipped with a unit-mounted starter and control panel. Microprocessor based unit control modules (Trane Tracer™UC800) provide accurate chilled water control and providing monitoring, protection and adaptive limit functions. The adaptive nature of the controls intelligently prevent the chiller from operating outside of its limits, or compensates for unusual operating conditions while keeping the chiller running rather than simply shutting off the chiller. If problems do occur, the UC800 controls provide diagnostic messages to help the operator in troubleshooting.

Oil System

The oil is efﬁciently separated inside the scroll compressor and will remain in the scroll compressor during all run cycles. Between 1-2% of the oil circulates around with the refrigerant.

See compressor section for oil level information.

Condenser and Fans

The air cooled micro-channel condenser coils use all aluminum brazed ﬁn construction and Fin & tube condenser coils use Copper tube and aluminum ﬁn construction.

The MCHE coil is composed of three components: the ﬂat micro channel tube, the ﬁns located between the micro-channel tubes, and two refrigerant manifolds. Coils can be cleaned with high pressure water (see Condenser Coils maintenance for instructions).

Whereas Fin & Tube coil is composed of four components: the holding frame, Circular tube, U-bends joining the tube ends, the aluminum ﬁns located above the tubes, and two refrigerant Headers. Coils can be cleaned with high pressure water (see Condenser Coils maintenance for instructions).

The condenser coils has an integral sub-cooling circuit. Condensers are factory proof and leak tested at 45 bars.

Direct-drive vertical-discharge airfoil condenser AC/EC fans are dynamically balanced.

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Operating Principles

This section describes the overall ﬂow chart principle for CGAF / CXAF. Detailed information for a given order is supplied with order package documentation.

Figure 9 – Example of Typical Refrigerant System Schematic & Oil Lube Circuit Schematic for CGAF - BPHE

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Operating Principles

Figure 10 – Example of Typical Refrigerant System Schematic & Oil Lube Circuit Schematic for CGAF S&T

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Operating Principles

Figure 11 – Example of Typical Refrigerant System Schematic & Oil Lube Circuit Schematic for CXAF - BPHE

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Figure 12 – Operating Map for CGAF / CXAF

-30

-20

-10

-20 -10 0 10 20

Ambient Temperature/C

Leaving Water Temperature / C

CXAF - Cooling Map SE/HEat

EC Fan

AC Fa n

AC/EC Fan Min.Load

-20

-15

-10

-5

5 10 15 20 25 30 35 40 45 50 55 60

Ambient Temperature/C

Leaving Water Temperature / C

CXAF - Heating Map Full Load

SE EC Fan

SE AC Fan

HE at AC & EC Fa n

HEat

-20

-15

-10

-5

5 10 15 20 25 30 35 40 45 50 55 60 65

Ambient Temperature/C

Leaving Water Temperature / C

CXAF - Heating Map Min. Load

SE EC Fan

SE AC Fan

HEa t AC & E C Fan

HEat

Operating Map

Notes:

- Minimum start-up/operation at low ambient air temperature based on wind speed lower than 2m/s.

- Maximum ambient operation is for unit at 12°C/7°C operating conditions.

- The curve of limit current may vary from one machine size to another, but it will always be a parallel curve to that

CG-SVX039B-GB

shown in the operating map.

Total Heat Recovery

The total heat recovery option includes:

− A Common braze plate heat exchanger for both refrigeration circuits installed in serial between with the compressor discharge and air-cooled condenser, allowing mix of liquid and gas at the outlet leaving to condenser coil.

− MCHE Condenser coil with EC fan motor only to maintain the discharge pressure above the THR water outlet condensing temperature.

CAUTION! Discharge gas temperature can reach 130°C, may resulting in overheating of the heat recovery water if there is no appropriate ﬂow.

CAUTION! For the ﬁrst start, Total Heat Recovery water temperature sensors should be checked to make sure that they are not reversed.

CAUTION! A ﬁeld-installed safety or relief valve on the water side is required with the total heat recovery to prevent risks resulting from a failure of the unit control.

− A 3-way modulating valve factory installed on the water side to manage the leaving water temperature and required high discharge pressure.

− Two temperature sensors for inlet and outlet hot water temperature control.

− Freeze protection heaters (option).

Piping recommendations

A 1 to 1.6 mm strainer must be installed close to the total heat recovery heat exchanger entering water line to protect the heat exchanger.

Insulate water lines and other portions of the heat recovery water loop to prevent heat loss and potential injury due to exposure to a hot surface.

The heat exchanger is used both as a desuperheater and a condenser of compressors discharge gas. Refrigerant leaves the total heat recovery braze plates heat exchanger as a mixture of gas and liquid. The air-cooled condenser is used to ﬁnalize the condensation and provide a subcooled refrigerant to the expansion valve.

Main stream of refrigerant ﬂow in these units is through ﬁlter drier keeping bypass opening to 10% with THR Off. This avoid oil distillation in dead branch. During THR operation bypass valve open 100% allowing 65% of refrigerant ﬂow via bypass line to maintain pressure.

The heating capacity is driven by the cooling demand on the chiller, the ambient temperature and the temperature of the heat recovery loop. The heating capacity is

Do not use untreated or improperly treated water in the heat recovery water loop since it will cause inefﬁcient operation and potential damage to the unit such as: reduced heat transfer between water and refrigerant, increased water pressure drop and reduced water ﬂow.

CAUTION! : Proper Water Treatment! The use of untreated or improperly treated water in a chiller may result in scaling, erosion, corrosion, algae, or slime. It is recommended that the services of a qualiﬁed water treatment specialist be engaged to determine what water treatment, if any, is required. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

optimized by a smart control of the condensing temperature using the fans.

Water circulating inside the heat recovery heat exchanger should never be used in food processing or as drinking water. It must be used through a direct loop to heat or preheat water.

Note: Ambient temperature shall be lower than THR leaving water temperature set point to operate allowing 45% up to 116% evaporator heat recovery

Note: If the total heat recovery heat exchanger is drained, the heater must be turned off to avoid damaging the total heat recovery heat exchanger. The heater should only be on when the heat recovery heat exchanger has water in it.

Freeze protection (option)

The heat recovery condenser is insulated and a factoryinstalled heater is installed and will protect the heat exchanger from freezing in ambient temperatures down to -18°C. When the ambient temperature drops to approximately 5°C, the main controller energizes the heaters.

Note: The inlet and outlet piping should be protected against freezing by one of the following methods:

− Install heat tape on all ﬁeld installed water piping.

− Add freeze inhibit ﬂuid to the total heat recovery water loop.

Table 7 – General Data for Total Heat recovery (THR) Option CGAF 080-190

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

080 090 100 110 130 140 150 165 180 190

Heat Exchanger Type Stainless steel Copper Brazed plate Heat exchanger

THR Heat Exchanger model DB400

Water connection size (in) -

(mm)

Water content volume L 15.2 15.2 18.5 18.5 18.5 25.3 25.3 25.3 31.2 31.2

Additional Shipping Weight kg 155 155 165 165 165 210 210 210 245 265

Freeze protection – Electric heater

Max Power input (kW) 0.28 0.28 0.28 0.34 0.34 0.34 0.34 0.34 0.34 0.34

Max Amps (A) 0.7 0.7 0.7 0.85 0.85 0.85 0.85 0.85 0.85 0.85

3"OD –

x74

76.1

DB400

x74

3"OD –

76.1

DB400

x90

3"OD –

76.1

DB400

x90

3"OD –

76.1

DB400

x90

3"OD –

76.1

DB400

x122

3"OD –

76.1

DB400

x122

3"OD –

76.1

DB400

x122

3"OD –

76.1

DB400

x150

3"OD –

76.1

DB400

x150

3"OD –

76.1

CG-SVX039B-GB

Total Heat Recovery

30 , 33.0

49 , 52.0

55 , 52.0

55 , 7.2

30 , 7.2

10.0

20.0

30.0

40.0

50.0

60.0

25 30 35 40 45 50 55 60

Amb Temperat ure (C)

THR LWT (C)

Figure 13 – Refrigerant Schematic THR option

THR should not be used for glycol application on evaporator side. Minimum THR start-up water temperature should be higher than 5°C. THR should be used when leaving evaporator temperature is between 5 and 15.5°C.

Table 8 – Operating Map (THR) CGAF 080-190

Standard

Application

Min. outdoor air temperature 7.2 7.2

Max. outdoor air temperature 49 52

Min. leaving evaporator water temperature

Max. leaving evaporator water temperature

Min. leaving THR water temperature

Max. leaving THR water temperature

ambient

(°C) (°C)

4.4 4.4

15.6 15.6

30 30

55 55

High ambient

THR 3-way valve description

The 3-way valve is divided into 2 mains parts: the actuator and the valve body.

Valve body

2 types of valve are used (DN50, DN65) with a Kvs respectively of 40, **.

Kvs –value is showing the capacity of media ﬂow of a valve, it characterizes the volume ﬂow (m3/h) of water by measuring a differential pressure (bar). This value is related to full stroke.

The 3-way valve body is connected to the system in 3 points A, B, AB as below:

Actuator overview

- Supply voltage: 24 Vac

- Actuator setting

• W1(input signal failure): 100%, actuator will adjust to 100% position when signal input fails (THR BP bypassed)

• W2(input signal range): LED “OFF” for 2~10V

• W3 (direction of action): LED “ON” 2V for A-AB close, 10V for A-AB full open

Figure 14 – Total Heat Recovery Operation Map

CG-SVX039B-GB

Total Heat Recovery

250

2 4 8 16 32

Pressure Drop (kPa)

Water Flow Rates (L/s)

TOTAL HEAT RECOVERY (THR) & BPHE (THR) - CGAF SE/HE/XE

1 - 080/090 - SE /HE/XE

2 - 100/110/130 - SE/HE/XE

3 - 140/150/165 - SE/HE/XE

4 - 180/190 SE/HE/XE

5 - BPH E 080/090/100/110/130/140/1 50/165/180/190 - SE /HE/XE

1 to 4 - Total THR Pressure Drop 5 - BPHE (THR) Pressure Drop

Refrigerant charge

When a total heat recovery is installed, refrigerant charge (kg) are as shown in the table below.

Table 9 – Refrigerant Charge (THR Option) CGAF 080-190

Refrigerant charge THR Option

CGAF-CXAF sizes 80 90 100 110 130 140 150 165 180 190

SE 45=A Quantity circuit 1/2 -- 36 34 34 36 43 45 46 60 61

HE/XE 45=A Quantity circuit 1/2 36 40 41 41 42 61 61 61 63 64

Figure 15 – Total heat recovery water loop pressure drop Total THR & BPHE (THR) Curve

Figure 16 – Partial / Total heat recovery pipe recommendations

CG-SVX039B-GB

Partial Heat Recovery Option

Heat recovery option is made with a plate heat exchanger in series with the air-cooled condenser. This heat exchanger beneﬁts the discharge gas superheat as well as a part of the condensing gas heat to be transferred to hot water system. The chiller can simultaneously produce chilled water and hot water.

The heating capacity is driven by the cooling demand on the chiller, the ambient temperature and the temperature of the heat recovery loop.

The partial heat recovery includes:

• One common brazed plate heat exchanger for both refrigerant circuit.

• Two temperature sensors to read the inlet/ outlet hot water temperature information on the unit control display.

• Freeze protection heater (option).

Note: Unit can recover only the compressor power input in Partial heat recovery mode.

Water circulating inside the heat recovery heat exchanger should never be used for food process or drinking water. It must be used through a direct loop to heat or preheat water.

Note: If the partial heat recovery heat exchanger is drained, the heater must be turned off to avoid damaging the partial heat recovery heat exchanger. The heater should only be on when the heat recovery heat exchanger has water in it.

CAUTION! Discharge gas temperature can reach 130°C, may resulting in overheating of the heat recovery water if there is no appropriate ﬂow.

Note: Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Partial heat recovery freeze protection (option)

Note: The inlet and outlet piping should be protected against freezing by one of the following methods:

• Install heat tape on all ﬁeld installed water piping

• Add freeze inhibit ﬂuid to the partial heat recovery water loop.

Figure 17 – Water pressure drop - heat recovery heat exchanger

Partial heat recovery piping

A ﬁeld-installed safety or relief valve on the water side is required with the partial heat recovery to prevent risks resulting from a failure of the thermostat.

A 1 to 1.6 mm strainer must be installed close to the partial heat recovery heat exchanger entering water line to protect the heat exchanger.

The partial heat recovery water temperature entering the unit should be at least 40°C.

Insulate water lines and other portions of the heat recovery water loop to prevent heat loss and potential injury due to exposure to a hot surface.

For recommended partial heat recovery piping, see ﬁgure.

CG-SVX039B-GB

Partial Heat Recovery Option

Table 10 – General Data for Partial Heat recovery CGAF 090-190 Standard Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

90 100 110 130 140 150 165 180 190

SE SE SE SE SE SE SE SE SE

Partial Heat recovery (PHR) option

Heat-Exchanger Type Stainless steel Copper Brazed plate Heat exchanger

Digit 19=N or C

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 2.40 2.40 4.32 4.32 5.76 5.76 5.76 5.76 5.76

Digit 19=P

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 1.44 1.44 1.44 1.80 4.32 4.32 4.32 4.32 4.32

Antifreeze Heater Max Power Input (Standard Digit 19=N or C / Process Digit 19=P)

Antifreeze Heater Max Amps (Standard Digit 19=N or C / Process Digit 19=P)

B12MT/

(in) -

2” - 60.3 2” - 60.3 2” - 60.3 2” - 60.3

(mm)

B12MT/

(in) -

1”1/2 -

(mm)

(W) 60 / 60 60 / 60 120 / 60 120 / 60

0.15 /

(A)

Table 11 – General Data for Partial Heat recovery CGAF 080-190 High Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

HE HE HE HE HE HE HE HE HE HE

Partial Heat recovery (PHR) option

Heat-Exchanger Type Stainless steel Copper Brazed plate Heat exchanger

Digit 19=N or C

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 1.80 2.40 2.40 4.32 4.32 5.76 5.76 5.76 5.76 5.76

Digit 19=P

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 1.44 1.44 1.44 1.44 1.80 4.32 4.32 4.32 5.76 5.76

Antifreeze Heater Max Power Input (Standard Digit 19=N or C / Process Digit 19=P)

Antifreeze Heater Max Amps (Standard Digit 19=N or C / Process Digit 19=P)

B12MT/

D-60

(in) -

1"1/2 -

(mm)

B12MT/

D-48

(in) -

1"1/2 -

(mm)

(W) 60 / 60 60 / 60 60 / 60 120 / 60 120 / 60 120 / 120120 / 120120 / 120120 / 120120 / 120

0.15 /

(A)

B12MT/

D-80

B12MT/

D-48

1”1/2 -

48.3

0.15

B12MT/

D-80

2" - 60.3 2" - 60.3 2" - 60.3 2" - 60.3

48.3

B12MT/

D-48

1"1/2 -

48.3

0.15

/0.15

D-80

D-48

48.3

0.15 /

0.15

B35TM4/

D-48

B12MT/

D-48

1”1/2 -

48.3

0.3 /

0.15

B12MT/

D-80

B12MT/

D-48

1"1/2 -

48.3

0.15

/0.15

B35TM4/

B12MT/

1"1/2 -

B35TM4/

B12MT/

2” - 60.3 2” - 60.3 2” - 60.3 2” - 60.3

D-48

48.3

0.3 /

0.15

B35TM4/

D-48

B35TM4/

D-60

0.3 /

0.3 / 0.3 0.3 / 0.3 0.3 / 0.3 0.3 / 0.3 0.3 / 0.3

0.15

B35TM4/

D-48

B12MT/

D-60

2" - 60.3 2" - 60.3 2" - 60.3 2" - 60.3

0.3 /

0.15

B35TM4/

D-64

2”1/2 -

76.1

B35TM4/

D-64

120 /

120

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-48

0.3 /0.3 0.3 /0.3 0.3 / 0.3 0.3 / 0.3 0.3 / 0.3

D-64

2”1/2 -

76.1

D-64

120 /

120

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-48

B35TM4/

D-64

2”1/2 -

76.1

B35TM4/

D-64

120 /

120

B35TM4/

D-64

2"1/2 -

76.1

D-48

B35TM4/

D-64

2”1/2 -

76.1

B35TM4/

D-64

2”1/2 -

76.1

120 /

120

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-64

2”1/2 -

76.1

B35TM4/

D-64

2”1/2 -

76.1

120 /

120

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-64

2"1/2 -

76.1

Table 12 – General Data for Partial Heat recovery CGAF 080-190 Extra Efﬁciency

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

80 90 100 110 130 140 150 165 180 190

XE XE XE XE XE XE XE XE XE XE

Partial Heat recovery (PHR) option

Heat-Exchanger Type Stainless steel Copper Brazed plate Heat exchanger

Digit 19=N or C

B12MT/

B35TM4/

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 1.80 2.40 2.40 4.32 4.32 5.76 5.76 5.76 5.76 5.76

Digit 19=P

Heat-Exchanger Model

Water connection size (Thread connection)

Water content volume (l) 1.44 1.44 1.44 1.44 1.80 4.32 4.32 4.32 5.76 5.76

Antifreeze Heater Max Power Input (Standard Digit 19=N or C / Process Digit 19=P)

Antifreeze Heater Max Amps (Standard Digit 19=N or C / Process Digit 19=P)

D-60

D-80

(in) -

1"1/2 -

(mm)

(in) -

(mm)

(W) 60 / 60 60 / 60 60 / 60 120 / 60 120 / 60 120 / 120120 / 120120 / 120120 / 120120 / 120

(A)

2" - 60.3 2" - 60.3 2" - 60.3 2" - 60.3

48.3

B12MT/

D-48

1"1/2 -

48.3

0.15

/0.15

B12MT/

D-48

1"1/2 -

48.3

0.15

/0.15

D-48

1"1/2 -

48.3

0.15 /

0.15

B35TM4/

D-48

B12MT/

D-48

1"1/2 -

2" - 60.3 2" - 60.3 2" - 60.3 2" - 60.3

48.3

0.3 /

0.15

B35TM4/

D-48

D-64

2"1/2 -

76.1

B12MT/

B35TM4/

D-60

D-48

0.3 /

0.3 /0.3 0.3 /0.3 0.3 / 0.3 0.3 / 0.3 0.3 / 0.3

0.15

D-64

2"1/2 -

76.1

B35TM4/

D-48

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-48

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-64

2"1/2 -

76.1

CG-SVX039B-GB

B35TM4/

D-64

2"1/2 -

76.1

B35TM4/

D-64

2"1/2 -

76.1

Optional Free-Cooling

Table 13 – General data for free cooling option sizes 080-190

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

080 090 100 110 130 140 150 165 180 190

Free Cooling Heat-Exchanger Type Full aluminum Micro channel heat exchanger

Fan / motor Type Propeller fan : Fixed speed AC motor / Variable speed EC motor

Digit 56=1

Fan / motor Type Propeller fan : Fixed speed AC motor

Power per Motor kW 1.49 1.49 1.49 1.49 1.49 1.49 1.49 1.49 1.49 1.49

Motor RPM RPM 900 900 900 900 900 900 900 900 900 900

Digit 56=2

Fan / motor Type Propeller fan : Variable speed EC motor

Power per Motor (Digit12 = N) kW 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27 2.27

Motor RPM (Digit12 = N) RPM 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Power per Motor (Digit12 = H) kW 2.28 1.67 1.67 2.28 2.28 2.28 2.28 2.28 2.28 2.28

Motor RPM (Digit12 = H) RPM 1000 910 910 1000 1000 1000 1000 1000 1000 1000

Digit 56=3

Fan / motor Type Propeller fan : Variable speed EC motor

Power per Motor kW 2.07 1.61 1.61 2.07 2.07 2.07 2.07 2.07 2.07 2.07

Motor RPM RPM 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Water connection size

Additional Width mm 245 245 245 245 245 245 245 245 245 245

Direct Free Cooling Option (4)

Total Free Cooling Option Total Free Cooling (Digit 25 = F)

Digit 12=N

Coils quantity - 4 4 4 4 6 6 6 8 8

FC Pump Max Motor Power kW - 2.3 2.3 2.3 2.3 2.56 2.56 2.56 3 3

FC Pump Rated Amps A - 4.3 4.3 4.3 4.3 5.8 5.8 5.8 6.15 6.15

Summer nominal water ow L/s - 16.0 17.6 19.5 21.4 23.7 25.9 27.8 31.1 33.0

Summer unit pressure drop kPa - 117.5 118.8 126.1 126.4 106.7 105.0 104.1 115.0 118.0

Direct Free Cooling Capacity kW - 215.0 215.3 215.8 214.8 337.2 337.3 337.5 464.0 489.7

Winter customer pressure drop kPa - 88.0 85.1 87.3 66.7 75.2 68.1 62.3 60.7 55.6

Antifreeze Heater** W - 240 240 240 240 240 240 240 240 240

Additional shipping weight kg - 325 325 325 325 455 455 455 565 565

Additional water content L - 67.33 67.33 67.33 67.33 81.09 81.09 81.09 94.86 94.86

Digit 12=H or Digit 12=A

Coils quantity 4 6 6 6 6 8 8 8 10 10

FC Pump Max Motor Power kW 2.3 2.56 2.56 2.56 2.56 3 3 3 3 3

FC Pump Rated Amps A 4.3 5.8 5.8 5.8 5.8 6.15 6.15 6.15 6.15 6.15

Summer nominal water ow L/s 14.8 17.0 18.8 21.0 23.1 25.1 27.6 29.4 32.3 34.3

Summer unit pressure drop kPa 75.3 97.1 98.8 107.4 117.5 77.1 83.8 94.9 113.2 121.4

Direct Free Cooling Capacity kW 214.8 332.3 332.9 333.6 332.1 463.8 463.8 463.9 558.3 558.5

Winter customer pressure drop kPa 48.9 60.1 55.5 56.6 45.2 40.8 40.4 45.8 54.6 56.2

Antifreeze Heater** W

Additional shipping weight kg 325 415 415 415 415 565 565 565 660 660

Additional water content L 67.33 81.09 81.09 81.09 81.09 94.86 94.86 94.86 108.62 108.62

Glycol Free Option

Total Free Cooling type Total Free Cooling (Digit 25 = H)

Digit 12=N

Coils quantity - 4 4 4 4 6 6 6 8 8

Summer nominal water ow L/s - 14.8 16.3 18.0 19.8 21.9 23.9 25.6 28.7 30.5

Summer & winter unit pressure drop kPa - 118.5 125.7 139.1 97.0 89.3 90.1 91.3 85.4 87.6

Glycol Free - Free Cooling Capacity kW - 175.5 176.6 177.6 174.6 265.6 268.3 270.2 374.0 380.1

Glycol Pump Motor Power kW - 2.3 2.3 2.3 2.3 2.56 2.56 2.56 3 3

Glycol Pump Rated Amps A - 4.3 4.3 4.3 4.3 5.8 5.8 5.8 6.15 6.15

FC BPHE Model -

Antifreeze Heater** W - 480 480 480 480 480 480 480 640 640

Additional shipping weight kg - 405 405 405 405 555 555 555 720 720

Additional water content L - 23.895 23.895 23.895 23.895 30.78 30.78 30.78 52.65 52.65

Glycol content L - 51.42 51.42 51.42 51.42 72.07 72.07 72.07 107.71 107.71

(in) (mm)

4" -

114.3

240 240 240 240 240 240 240 240 240 240

4" -

114.3

B427M2+

M1x118

4" -

114.3

B427M2+

M1x118

4" -

114.3

B427M2+

M1x118

4" -

114.3

B427M2+

M1x118

5" -

139.7

B427M2+

M1x152

5" -

139.7

B427M2+

M1x152

5" -

139.7

B427M2+

M1x152

5" -

139.7

B427H+ M2x260

139.7

B427H+

M2x260

5" -

CG-SVX039B-GB

Optional Free-Cooling

Table 13 – General data for free cooling option sizes 080-190 (continued)

CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF CGAF

080 090 100 110 130 140 150 165 180 190

Digit 12=H or Digit 12=A

Coils quantity 4 6 6 6 6 8 8 8 10 10

Summer nominal water ow L/s 13.7 15.7 17.4 19.4 21.3 23.2 25.4 27.2 29.8 31.6

Summer & winter unit pressure drop kPa 83.3 90.7 96.0 107.6 76.0 57.6 62.6 70.8 78.3 83.6

Glycol Free - Free Cooling Capacity kW 174.4 261.9 264.6 267.1 260.4 363.7 368.5 371.6 445.7 449.2

Glycol Pump Motor Power kW 2.3 2.56 2.56 2.56 2.56 3 3 3 3 3

Glycol Pump Rated Amps A 4.3 5.8 5.8 5.8 5.8 6.15 6.15 6.15 6.15 6.15

FC BPHE Model

Antifreeze Heater** W 480 480 480 480 480 640 640 640 640 640

Additional shipping weight kg 405 520 520 520 520 720 720 720 835 835

Additional water content L 23.895 30.78 30.78 30.78 30.78 52.65 52.65 52.65 59.535 59.535

Glycol content L 51.42 72.07 72.07 72.07 72.07 107.71 107.71 107.71 128.36 128.36

B427M2+

M1x118

(1) FC winter mode condition: EWT=20C, Amb T=0C

(2) 30% EG is used in glycol loop for GFFC

(3) ** = No heater on BPHE water inlet, Antifreeze Heater (W) minus 60W for 080 to140 Units & 120W from 150 to 190 Units.

B427M2+

M1x152

B427M2+

M1x152

B427M2+

M1x152

B427M2+

M1x152

B427H+ M2x260

B427H+

M2x260

B427H+ M2x294

CG-SVX039B-GB

Optional Free-Cooling

Chiller integrated free-cooling operation mode

The power of chiller integrated free-cooling relies on the chiller control to maximize the use of free-cooling when outdoor temperatures are favorable. The choice between compressor refrigeration and Free-Cooling refrigeration will be made and activated depending on three temperature measurements:

• The ambient air temperature

• The evaporator entering and leaving temperature

• The chilled water set point

Free-cooling coils are ﬁt in series with the evaporator, and a set of water regulation valves allows the coils to be by-passed when they are no longer needed due to outdoor temperatures which are favorable for freecooling.

Three operating modes can be differentiated:

1. Summer operation or Compressor refrigeration mode

In this operation mode, ambient temperature is higher than the temperature of the ﬂuid entering the evaporator. Free-cooling is not activated, compressors are running, and control is done in function of the fan/compressor logic of operation.

2. Mid-season operation or combined refrigeration +

Free-cooling mode

In this operation mode, free-cooling will be

Figure 18 – Total Free Cooling option

enabled whenever the outdoor temperature is below the evaporator entering water temperature. The operating logic is described below. The free-cooling system operates combined with the mechanical compressor refrigeration. Most of the time, free-cooling will only partially cover the required cooling duty. In other words, mechanical refrigeration will complete what has already been delivered by free-cooling.

3. Winter operation or full free-cooling mode

Below a certain ambient temperature, and depending on the chilled water set point requested, the entire cooling duty is delivered by the freecooling system. Compressors do not operate, since the free-cooling coils will be able to deliver the requested chilled water temperature. The regulation of the capacity is described in the next section. In this mode, only fans are running.

General information

The chiller integrated free-cooling system ﬂuid based consist in a set of “Macro-channels” or “Radiators” coils, ﬁt in the same frame than the MCHE condenser coils of the chiller refrigeration circuit. Free-cooling coils will be full aluminum, ﬂat radiator design type, with low air pressure drop to avoid fan performance degradation.

Free-cooling coils are ﬁt in series with the evaporator, and a set of water regulation valves ensures the system to reach the required free-cooling capacity.

If there is a need to get a deﬁnition for partial heat recovery coil distribution, please contact the TRANE sales ofﬁce.

CG-SVX039B-GB

Optional Free-Cooling

Free-Cooling Enabling Conditions:

To get the free cooling active, condition is to have unit in active cooling mode and that Outdoor temperature low enough according to ﬁgure below.

The free cooling function is enabled when outdoor air temperature is below Active chilled water cooling set point minus FC offset.

A hysteresis should also apply to avoid short cycling of Free Cooling enabling logic. The Free Cooling offset is an adjustable parameter to make free cooling active.

If free cooling function is enabled, free cooling becomes the 1st stage of cooling. Free cooling is the ﬁrst stage to engage for cooling capacity loading and the last stage to consider in capacity unloading.

Figure 19 – Free-Cooling enabling conditions

In Order to maximize tandem operation of free cooling with compressor the following logic is applied:

When unit is conﬁgured in “Partial free cooling”, when free cooling reached its full capacity and there is a call for compressor start, the ﬁrst circuit to start shall be circuit2 (if available). This also means compressor balancing function is disabled in these conditions.

Note: UC800 will not lockout compressor below free cooling change over point, but the compressor is locked out when outdoor air is below “low ambient limit” set at -10°C. So FC will be the only source of cooling below

-10°C. Note for installation: All Submittal, lifting diagram,

neoprene pads positioning, and wiring diagrams have been supplied with chiller order.

The maximum pressure for unit with Glycol free and Direct free cooling is 400kPa. Refer to unit nameplate for rated value.

Pump Operating with Glycol Free: It is requested to have a minimum water side pressure of 250kPa to avoid cavitation.

Glycol free Option: To avoid component damage, a ﬁlter (1mm mesh) must be supplied by the customer and installed at the unit inlet.

Unit is shipped without glycol content on the free cooling circuit.

Free cooling loop venting must be performed by using manual overload mode to run the free cooling pump and opening free cooling and closing bypass valve.

At 10 to 20°C ambient, the expansion shall be pressurized at 250kPa. It should be checked when glycol loop is not yet ﬁlled or glycol pressure is near zero.

All Free-cooling units must be freeze-protected with at least 30% Ethylene Glycol and to minimum ambient temperature in the cooling loop circuit in order to protect the unit against freezing. Upon receipt, make sure that there is no remaining test water in the free cooling circuit as it may freeze during winter periods.

Water can be trapped in BPHE and speciﬁc care must be taken to remove it completely from BPHE during off mode if drainage is the winter protection chosen.

The free cooling option circuit consists of copper, carbon steel, cast iron, zinc, synthetic rubber, brass, and Aluminum AA3102, AA3003, AA4045 in addition to other materials that may be in the building loop connected to the chiller. The inhibited glycol solution should be selected at desired concentration to ensure adequate inhibitor content. It is not advised to dilute a stronger concentrate due to inhibitor dilution. Glycol ﬂuid should be free from foreign solid particles. A maintenance schedule should be selected per the glycol manufacturer’s requirements to insure adequate protection during product usage.

Note: Equipment Damage! Failure to follow instructions below could cause equipment damage.

DO NOT USE UNTREATED WATER. Glycol solution must be utilized with Free Cooling option. Glycol percentage should be based on freeze avoidance requirements. The glycol solution requires an inhibitor package to be carefully chosen with the aid of a qualiﬁed water treatment specialist to abate corrosion in a mixed metal system.

The building glycol loop should not be vented to atmosphere. A closed system is required to limit oxidation potential within the loop.

Make-up water should be avoided.

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Figure 20 – Schematic – Free cooling option

Optional Free-Cooling

Free Cooling bypass valve Settings

Position 1: 0% - Closed – Free Cooling Position 2: 10% Position 3: 20% ….. Position 10: 100% - Fully Open – No Free Cooling Open position: Water ﬂow is directed to evaporator and

there will not be any free cooling. Closed position: All the water ﬂow is directed to free

cooling exchanger or decoupling bottle. In Free cooling mode water ﬂow will see highest pressure drop.

Slightly open: 0% to 30% will direct the some portion of water through free cooling exchanger and the remaining to evaporator.

Refer the settings table for more details.

Table 14 – Direct Free Cooling Setting

DIRECT FC 80 90 100 110 130 140 150 165 180 190

% open 0% 0% 0% 0% 20% 30% 30% 30% 40% 40%

Position 1/2* 1/2 1/2 1/2 3 4 4 4 5 5

Table 15 – Glycol Free Free Cooling Setting

DIRECT FC 80 90 100 110 130 140 150 165 180 190

% open 0% 0% 0% 0% 20% 20% 20% 30% 30% 30%

Position 1/2 1/2 1/2 1/2 3 3 4 4 4 4

Note for maintenance: Check glycol circuit pressure before free cooling operation season starts. Run glycol pump few minutes in manual override during monthly maintenance operation when free cooling is continuously OFF to avoid possible glycol crystallization. Pump Override function is located in TD7 via Button Settings -> Manual Control Settings -> Free cooling Pump Override.

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Operating Principles

Figure 21 – Example of Hydronic Group Schematic Pump Package / Free Cooling for CGAF

Note: Glycol free - free cooling chilled water set point should be in the range of (4°C-20°C). Water Glycol mixing is ﬁlled on the free cooling coils on valve item 11.

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Option Free Cooling

-25

-20

-15

-10

-5

-15 - 10 -5 0 5 10 15 20 25 30

Ambient Temperature/C

Customer EnteringTemperature / C

Glycol Free Free Cooling Operation Map

EC FAN

AC FAN

-25

-20

-15

-10

-5

-15 - 10 -5 0 5 10 15 20 25 30

Ambient Temperature/C

Customer EnteringTemperature / C

Direct Free Cooling Operation Map

EC FAN

AC FAN

160

320

4 8 16 32 64

Pressure Drop (kPa)

Water Flow Rates (L/s)

Glycol Free - Free Cooling (CGAF SE/HE/XE)

1- SE-90/100/110/130 HE/XE-80

2- SE-140/150/165 HE/XE-90/100/ 110/130

3- SE-180/190 HE/ XE-140/150/165

4- HE/XE-180/190

160

4 8 16 32 64

Pressure Drop (kPa)

Water Flow Rates (L/s)

Direct Free Cooling - CGAF SE/HE/XE

1 - SE-90/100/110/130 HE/XE-80

2 - HE-90/100/110/130

3- SE-140/150/165

4 - SE-180/190 HE/XE-140/ 150/165

5 - HE/XE-180/190

Figure 22 – Free Cooling Operating Maps

Figure 23 – Free Cooling Water pressure drop

The free cooling water pressure drops given in charts below (coil + valve) should be added to evaporator pressure drop to get full unit pressure drop.

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Controls/Tracer TD7 Operator Interface

Controls Overview

Sintesis CGAF / CXAF units use the following control/interface components:

• Tracer™ UC800 Controller

• Tracer TD7 Operator Interface

Communication Interfaces

There are four connections on the UC800 that support the communication interface. See CGAF / CXAF User Guide to locate the following ports: “Wiring and Ports Description” section.

• BACnet MS/TP

• MODBUS Slave

• LonTalk using LCI-C (from the IPC3 bus)

See User Guide for information on communication interface.

Tracer TD7 Operator Interface

Operator Interface

Information is tailored to operators, service technicians and owners. When operating a chiller, there is speciﬁc information you need on a day-to-day basis, like setpoints, limits, diagnostic information, and reports.

Day-to-day operational information is presented at the display. Logically organized groups of information-chiller mode of operation, active diagnostics, settings and reports put information conveniently at your ﬁngertips.

Tracer™ TU

The TD7 operator interface allows for daily operation tasks and set point changes. However to adequately service Sintesis CGAF chillers / CXAF Heat Pump, Tracer™TU service tool is required (Non-Trane personnel, contact your local Trane ofﬁce for software purchase information). Tracer TU adds a level of sophistication that improves service technician effectiveness and minimizes chiller downtime. This portable PC-based service-tool software supports service and maintenance tasks.

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Pre-Start Checkout

Installation Checklist

Complete this checklist as the unit is installed, and verify that all recommended procedures are accomplished before the unit is started. This checklist does not replace the detailed instructions given in the “Installation Mechanical” and “Installation Electrical” sections of this manual. Read both sections completely, to become familiar with the installation procedures, prior beginning the work.

General

When installation is complete, before starting the unit, the following prestart procedures must be reviewed and veriﬁed:

Caution : Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury

WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualiﬁed licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks.Failure to follow all electrical safety precautions when exposed to live electrical components could result indeath or serious injury.

1. Inspect all wiring connections in the compressor power circuits (disconnects, terminal block, contactors, compressor junction box terminals and so forth) to ensure they are clean and tight.

2. Verify that all refrigerant valves in the discharge, liquid, and oil return lines are “OPEN”.

3. Check the power-supply voltage to the unit at the main-power fused-disconnect switch. Voltage must be within the voltage use range and also stamped on the unit nameplate. Voltage ﬂuctuation must not exceed 10%.Voltage imbalance must not exceed 2%

4. Check the unit power phasing L1-L2-L3 in the starter to ensure that it has been installed in a “A-B-C” phase sequence.

5. Fill the evaporator chilled-water circuit. Vent the system while it is being ﬁlled. Open the vents on the top of the evaporator during ﬁlling and close when ﬁlling is completed.

6. Close the fused-disconnect switch(es) that supplies power to the chilled-water pump starter.

7. Start the chilled-water pump to begin circulation of the water. Inspect all piping for leakage and make any necessary repairs.

8. With water circulating through the system, adjust the water ﬂow and check the water pressure drop through the evaporator.

9. Adjust the chilled-water ﬂow switch for proper operation.

10. Reapply power to complete the procedures

11. Prove all Interlock and Interconnecting Wiring Interlock and External as described in the Electrical Installation section.

12. Check and set, as required, all UC800 TD7 menu items.

13. Stop the chilled-water pump.

14. Energize the compressor and oil separator heaters 24 hours, prior to unit start up.

Unit Voltage Power Supply

Unit voltage must meet the criteria given in the installation Electrical Section. Measure each lead of the supply voltage at the main power fused-disconnect switch for the unit. If the measured voltage on any lead is not within the speciﬁed range, notify the supplier of the power and correct the situation before operating the unit.

Unit Voltage Imbalance

Excessive voltage imbalance between the phases of a three-phase system can cause motors to overheat and eventually fail. The maximum allowable unbalance is 2%. Voltage imbalance is determined using the following calculations:

% Imbalance = [(Vx – Vave) x 100/Vave]

Vave = (V1 + V2 + V3)/3

Vx = phase with greatest difference from Vave (without regard to the sign)

Unit Voltage Phasing

It is important that proper rotation of the compressors be established before the unit is started. Proper motor rotation requires conﬁrmation of the electrical phase sequence of the power supply. The motor is internally connected for clockwise rotation with the incoming power supply phases A-B-C.

When rotation is clockwise, the phase sequence is usually called “ABC”, when counterclockwise “CBA”

This direction may be reversed by interchanging any two of the line wires.

1. Stop the unit from TD7/UC800.

2. Open the electrical disconnect or circuit protection switch that provides line power to the line power terminal block(s) in the starter panel (or to the unit mounted disconnect).

3. Connect the phase-sequence indicator leads to the line power terminal block (L1-L2-L3).

4. Turn power on by closing the unit supply-power fused-disconnect switch.

5. Read the phase sequence on the indicator. The ABC LED of the phase indicator will glow.

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Pre-Start Checkout

WARNING! It is imperative that L1, L2, and L3 in the

starter be connected in the A-BC phase sequence to prevent equipment damage due to reverse rotation.

WARNING!To prevent injury or death due to electrocution, take extreme care when performing service procedures with electrical power energized.

CAUTION! Do not interchange any load leads that are from the unit contactors or the motor terminals. Doing so may damage the equipment.

Water System Flow Rates

Establish a balanced chilled-water ﬂow through the evaporator. The ﬂow rates should be between the minimum and maximum values given on the pressure drop curves.

Water System Pressure Drop

Measure the water-pressure drop through the evaporator on the ﬁeld installed pressure taps on the system water piping. Use the same gauge for each measurement. Do not include valves, strainers, or ﬁttings in the pressure drop readings.

Integrated Pump Package (Optional)

Before starting up the pump, the pipe system must be thoroughly cleaned, ﬂushed and ﬁlled with clean water. Do not start the pump until it has been vented. To ensure correct venting, open the vent screw located on the pump housing on the suction side (see next ﬁgure).

If the chiller is installed in a humid environment or a location with high air humidity, the bottom drain hole on the pump motor should be opened. The enclosure class of the motor is then changed from IP55 to IP44. The function of the drain holes is to drain off water which has entered the stator housing with air humidity.

Tracer UC800 Set-Up

Using Tracer TU service tool, adjust the settings. Refer to Tracer TU manual and UC800 user guide for instruction on settings.

CAUTION! To prevent compressor damage, do not operate the unit until all refrigerant valves and oil-line service valves are opened.

IMPORTANT! A clear sight glass alone does not mean that the system is properly charged. Also check system discharge superheat, approach temperature and unit operating pressures.

Figure 24 – Pump Package

CAUTION! When using freeze inhibitor, never ﬁll the system with pure glycol; this will damage the shaft seal. Always ﬁll the system with diluted solution. Maximum concentration of glycol is 40% for unit with pump package.

CAUTION! Failure to operate pump w/o water or insert high glycol concentration will lead to premature seal damage and void the warranty.

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Unit Start Up Procedures

Daily Unit Start Up

The timeline for the sequence of operation begins with a power-up of the main power to the chiller. The sequence assumes 2 circuits, 2 compressors, Sintesis air cooled CGAF chiller with no diagnostics or malfunctioning components. External events such as the operator placing the chiller in AUTO or STOP, chilled water ﬂow through the evaporator, and application of load to the chilled-water loop causing loop water-temperature increases, are depicted and the chiller responses to those events are shown, with appropriate delays noted. The effects of diagnostics, and other external interlocks other than evaporator water-ﬂow proving, are not considered.

Note: unless the UC800 TD7 and building automation system are controlling the chilled-water pump, the manual unit start sequence is as follows. Operator actions are noted.

General

If the present checkout, as discussed above, has been completed, the unit is ready to start.

1. Press the STOP key on the TD7 display.

2. As necessary, adjust the set point values on the TD7 menus using Tracer TU.

3. Close the fused-disconnect switch for the chilledwater pump. Energize the pump(s) to start water circulation

4. Check the service valves on the discharge line, suction line, oil line, and liquid line for each circuit. These valves must be open (back seated) before starting the compressors.

5. Verify that chilled-water pump runs for at least one minute after the chiller is commanded to stop (for normal chilled-water systems).

6. Press the AUTO key. If the chiller control calls for cooling, and all safety interlocks are closed, the unit will start. The compressor(s) will load and unload in response to the leaving chilled – water temperature.

After the system has been operating for approximately 30 minutes and has become stabilized, complete the remaining start up procedures, as follows:

1. Check the evaporator refrigerant pressure and the condenser refrigerant pressure under Refrigerant Report on the TD7.

2. Check the EXV sight glasses after enough time has elapsed to stabilize the chiller. The refrigerant ﬂow through the sight glasses should be clear. Bubbles in the refrigerant indicate either low refrigerant charge or excessive pressure drop in the liquid line, or an expansion valve that is stuck open. A restriction in the line can sometimes be identiﬁed by a noticeable temperature differential between the two sides of the restriction. Frost will often form on the line at this point. Proper refrigerant charges are shown in the General Information Section.

Seasonal Unit Startup Procedure

1. Close all valves and reinstall the drain plugs in the evaporator.

2. Service the auxiliary equipment according to the startup and maintenance instructions provided by the respective equipment manufacturers.

3. Close the vents in the evaporator chilled-water circuits.

4. Open all the valves in the evaporator chilled-water circuits.

5. Open all refrigerant valves.

6. If the evaporator was previously drained, vent and ﬁll the evaporator and chilled-water circuit. When all air is removed from the system (including each pass), install the vent plugs in the evaporator water boxes.

7. Check the adjustment and operation of each safety and operating control.

8. Close all disconnect switches.

9. Refer to the sequence for daily unit start up for the remainder of the seasonal start up.

CAUTION! Ensure that the compressor and heaters have been operating for a minimum of 24 hours before starting. Failure to do so may result in equipment damage.

System Restart after Extended Shutdown

1. Verify that the liquid-line service valves, compressor discharge service valves, and optional suction service valves are open (back seated).

2. Check the oil level (see Maintenance procedures section).

3. Fill the evaporator water circuit. Vent the system while it is being ﬁlled. Open the vent on the top of the evaporator while ﬁlling, and close it when ﬁlling is completed.

4. Close the fused-disconnect switches that provide power to the chilled-water pump.

5. Start the evaporator water pump and, while water is circulating, inspect all piping for leakage. Make any necessary repairs before starting the unit.

6. While the water is circulating, adjust the water ﬂow and check the water pressure drops through the evaporator. Refer to “water-system ﬂow rates” and “water-system pressure drop”.

7. Adjust the ﬂow switch on the evaporator piping for proper operation.

8. Stop the water pump. The unit is now ready for startup as described “Startup procedures”.

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Unit Start Up Procedures

CAUTION! To prevent damage to the compressor, ensure

that all refrigerant valves are open before starting the unit. Do not use untreated or improperly treated water. Equipment damage may occur.

Temporary Shutdown and Restart

Temporary Shutdown is used for control operation, maintenance or to repair the unit typically less than one week.

To shut the unit down for a short time, use the following procedure:

1. Press the STOP key on the TD7. The compressors will stop when the compressor contactors de-energize.

2. Stop the water circulation by turning off the chilled water pump at least one minute after the stop of the compressors.

To restart the unit after a temporary shutdown, enable the chilled-water pump and press the AUTO key.

The unit will start normally, provided the following conditions exist:

• The UC800 receives a call for cooling and the differential-to-start is above the set point.

• All system operating interlocks and safety circuits are satisﬁed.

During an extended shutdown period, especially over the winter season, the evaporator must be drained of water, if the chilled water loop does not contain glycol, to prevent any risk of evaporator freeze-up.

CAUTION! Under freezing conditions, the chilled water pump must remain in operation during the full shutdown period of the chiller if the chilled water loop does not contain glycol, to prevent any risk of evaporator freeze-up.

Extended Shutdown Procedure

The following procedure is to be followed if the system is to be taken out of service for an extended period of time (i.e. seasonal shutdown):

1. Test the unit for refrigerant leaks and repair as necessary.

2. Open the electrical disconnect switches for the chilled-water pump. Lock the switches in the “OPEN” position.

3. Close all chilled-water supply valves. Drain the water from the evaporator.

4. Open the unit main electrical disconnect and unitmounted disconnect (if installed) and lock in the “OPEN” position.

5. At least every three months (quarterly), check the refrigerant pressure in the unit to verify the refrigerant charge integrity.

CAUTION! Lock the chilled-water pump disconnects open to prevent pump damage. Lock the disconnect switch in the “OPEN” position to prevent accidental startup and damage to the system when it has been set up for extended shutdown.

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Periodic Maintenance

General

Perform all maintenance procedures and inspections at the recommended intervals. This will increase the life of the chiller and minimize the possibility of serious and costly breakdown. Use an “Operator’s Log” to record the unit’s operating history. The log serves as a valuable diagnostic tool for service personnel. By observing trends in operating conditions, an operator can anticipate and prevent problem situations before they occur. If the unit is not operating properly during maintenance inspections, consult the “Diagnostic and Troubleshooting” section of this manual. Proper servicing of the service valves is required. Use a backup wrench as shown in Figure when loosening or tightening the service valve cap.

Figure 25 – Servicing of service valves

Weekly Maintenance

After the unit has been operating for approximately 30 minutes and the system has stabilized, check the operating conditions and complete the procedures below:

1. Check on the TD7 pressure for evaporator, condenser, and intermediate oil. Note: Pressures are referenced at sea level.

2. Inspect the entire system for unusual conditions and inspect the condenser coils for dirt and debris. If the coils are dirty, refer to coil cleaning.

Check the electronic expansion valve sight glasses. Note: The electronic expansion valve is commanded

closed at unit shutdown and if the unit is off, there will be no refrigerant ﬂow through the sight glasses. Only when a circuit is running will refrigerant ﬂow be present.

The refrigerant ﬂow through the sight glasses should be clear. Bubbles in the refrigerant indicate either low refrigerant charge or excessive pressure drop in the liquid line. A restriction in the line can sometimes be identiﬁed by a noticeable temperature differential between the two sides of the restriction. Frost may often form on the liquid line at this point. Correct refrigerant charges is shown in nameplate.

NOTICE: A clear sight glass alone does not mean that the system is properly charged. Also check the system superheat, subcooling and unit operating pressures.

NOTICE: Use only manifold gauge sets designed for use with R410A refrigerant.

Use only recovery units and cylinders designed for the higher pressure of R410A refrigerant and POE oil.

NOTICE: R410A must be charged in a liquid state.

Check the system superheat, subcooling, evaporator temperature drop (Delta-T), evaporator water ﬂow, evaporator approach temperature, compressor discharge superheat, and compressor RLA.

Normal operating conditions at ISO conditions are:

Evaporator pressure: 8 bars

Evaporator Approach: 3-5°C

Evaporator Superheat: 6-7°C

Note: In Case of Optional Service valve with CXAF, ensure the re-opening of the oil return valve (Item 13 in Refrigerant system schematic & Oil lube circuit schematic for CXAF – BPHE) after refrigerant transfer.

Note: If the superheat is unstable, check the suction temperature sensor. The suction temperature sensor should be well inserted into the well and thermal grease should be used to ensure a good contact between the sensor and the well.

Electronic Expansion Valve: 30-50 percent open

Evaporator Temperature Drop (Delta-T): 5°C

Condensing Pressure: 28-32 bars

Condensing Approach Temperature: 14-18°C

System Subcooling: 8-12°C

If operating pressures and sight glass conditions seem to indicate a refrigerant shortage, measure the system superheat and subcooling.

Refer to “System Superheat” and “System Subcooling.”

If operating conditions indicate a refrigerant overcharge, remove refrigerant at the liquid line service valve.

Allow refrigerant to escape slowly to minimize oil loss. Use a refrigerant recovery cylinder and do not discharge refrigerant into the atmosphere.

WARNING! Do no allow refrigerant to directly contact skin as injury from frostbite may result.

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Periodic Maintenance

Monthly Maintenance

1. Perform all weekly maintenance procedures.

2. Manually rotate the condenser fans to ensure that there is proper clearance on the fan shroud openings.

3. Check water pump (option): Manually rotate the pump. Remove plastic plug located at the bottom of the motor frame to drain any condensation which can occur in the motor.

4. Check and clean air ﬁlter of the control panel (option).

5. In case of Twin-pump, make sure there is no pump motor fault. Note: pump operation will be alternated at each new request of water ﬂow or when a pump fault is detected. WARNING! Position all electrical disconnects in the “OPEN” position and lock them to prevent injury of death due to electrical shock or moving parts. When electrical panels are ventilated, you need to change the fan ﬁlter.

6. Make any repairs necessary.

Annual Maintenance

1. Perform all weekly and monthly procedures.

2. Check the oil sump oil level and refrigerant charge while the unit is off.

Note: Routine changing of the oil is not required. Make an oil analysis to determine the condition of the oil.

1. Have TRANE or another qualiﬁed laboratory perform a compressor oil analysis to determine system moisture content and acid level. This analysis is a valuable diagnostic tool.

2. Contact a qualiﬁed service organization to leaktest the chiller, to check operating and safety controls, and to inspect electrical components for deﬁciencies.

3. Inspect all piping components for leakage and damage.

4. Clean all water strainers. NOTICE: If the CGAF chiller / CXAF Heat pump evaporator is drained of water, the freeze protection heater must be de-energized. Failure to de-energize the heater might cause it to burn out.

5. Clean and repaint any areas that show signs of corrosion.

6. Clean the condenser coils.

7. Check and tighten all electrical connections as necessary.

8. Clean the condenser fans. Check the fan assemblies for proper clearance in the fan shroud openings and for motor shaft misalignment or abnormal end-play, vibration and noise.

Refrigerant Emission Control

Conservation and emission reduction can be accomplished by following recommended Trane operation, maintenance, and service procedures, with speciﬁc attention to the following:

1. Refrigerant used in any type of air-conditioning or refrigerating equipment should be recovered and/or recycled for reuse, reprocessed (reclaimed). Never release refrigerant into the atmosphere.

2. Always determine possible recycle or reclaim requirements of the recovered refrigerant before beginning recovery by any method.

3. Use approved containment vessels and safety standards. Comply with all applicable transportation standards when shipping refrigerant containers.

4. To minimize emissions while recovering refrigerant, use recycling equipment. Always attempt to use methods that will pull the lowest possible vacuum while recovering and condensing refrigerant into containment.

5. Refrigerant-system cleanup methods that use ﬁlters and dryers are preferred. Do not use solvents that have ozone depletion factors. Properly dispose of used materials.

6. Take extra care to properly maintain all service equipment that directly supports refrigeration service work, such as gauges, hoses, vacuum pumps, and recycling equipment.

7. Stay aware of unit enhancements, conversion refrigerants, compatible parts, and manufacturer’s recommendations that will reduce refrigerant emissions and increase equipment operating efﬁciencies. Follow the manufacturer’s speciﬁc guidelines for conversion of existing system.

8. In order to assist in reducing power-generation emissions, always attempt to improve equipment performances with improved maintenance and operations that will help conserve energy resources.

CAUTION! A clear sight glass alone does not mean that the system is properly charged. Also check the rest of the system operating conditions. WARNING! Position all electrical disconnects in the “Open” position and lock them to prevent injury or death due to electrical shock.

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Refrigerant and Oil-charge Management

Proper oil and refrigerant charge is essential for proper unit operation, unit performances, and environmental protection. Only trained and licensed service personnel should service the chiller.

Some of the symptoms of a refrigerant under-charged unit:

• Larger-than-normal evaporator approach temperatures (leaving water temperature – saturated evaporator temperature). If the refrigerant charge is correct the approch temperature is 5°C.These values are given for units running at full load and with water without antifreeze

• Low Evaporator-refrigerant temperature limit

• Low Refrigerant-Temperature cutout diagnostic

• Fully-open expansion valve

• Possible whistling sound coming from liquid line (due to high vapor velocity)

• High condenser + Subcooler pressure drop

Periodic Maintenance

Some of the symptoms of a refrigerant over-charged unit

• Condenser Pressure Limit

• High –Pressure Cutout diagnostic

• More-than-normal number of fans running

• Erratic fan control

• Higher-than-normal compressor power

Some of the symptoms of an oil over-charged unit

• Larger-than-normal evaporator approach temperatures (Leaving-water-temperature – Saturated Evaporator Temperature)

• Low Evaporator-refrigerant Temperature limit

• Low Refrigerant – Temperature Cutout diagnostic

• Low unit capacity

• High oil-sump level after normal shutdown

Some of the symptoms of an oil under-charged unit

• Seized or Welded compressors

• Low oil-sump level after normal shutdown

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Compressor Service Information

Compressor Electrical Connections

It is very important that DSH compressors used in Trane Model CGAF chillers and CXAF Heat Pumps are wired correctly for proper rotation. These compressors will not tolerate reverse rotation. Verify correct rotation/phasing using a rotation meter.

Proper phasing is clockwise, A-B-C. If wired incorrectly a DSH compressor will make excessive noise, will not pump and will draw about half the normal current. It will also become very hot if allowed to run for an extended period.

Notice: Do not “bump” the compressor to check rotation as incorrect rotation could cause compressor motor failure in as little as 4 to 5 seconds!

Oil Level

To check compressor oil level, refer to the label near the compressor sight glass. The compressor(s) must be off. Wait three minutes. With tandem or triple compressors the oil level will equalize after shutdown. Compressor oil level should be no lower than the bottom of the sight glass and no more than a full sight glass. When operating, each compressor in a tandem or trio set may have a different oil level. The oil level may not be in the sight glass, but it must be visible through the sight glass.

Oil Fill, Removal and Capacity

The Model DSH compressors have an oil charging valve with a dip tube that goes to the bottom of the compressor. This can be used to add or remove oil from the compressor.

Care must be taken to prevent moisture from entering the systems when adding oil. Note that the POE oil used in this product is very hygroscopic and easily absorbs and retains moisture. Moisture is very difﬁcult to remove from oil using vacuum. Also note that once the seal on a container of POE oil is opened, the oil must be used.

Use only Trane OIL0057 (3.8 l) or OIL00058E (18.9 l). These are the same oil but different container size. Do not use any other POE oil.

NOTE: Never reuse oil.

Oil Testing

We recommend performing a complete oil analysis at least once a year with the Trane laboratory speciﬁcally dedicated to oil analysis for Trane equipment. It provides an in-depth view of both compressor and refrigerant circuit conditions including presence of water, wear particles, viscosity, acidity or dielectric data. If unacceptable wear conditions develop, a change in the characteristics of the oil will be evident. Minor problems can be detected and repaired before they become major problems.

Oil Equalizer Line

DSH Compressors

The oil equalizer line is equipped with a Rotolock ﬁtting for easy removal. Torque value for tightening these ﬁtting is 145 N.m. Recover the system refrigerant charge and Drain the oil to a level below the oil equalizer tube ﬁtting before removing the oil equalizer line. This must be done on both compressors. Use the oil drain valve on the compressor. If the oil is drained below the level of the oil level sight glass, it will be below the oil equalizer line level. Pressurize the low side of the compressor using nitrogen to help drain the oil. No more than 70 kPa of pressure will be needed.

Tandem and Triple Compressor Suction Restrictors

Since most tandem and triple compressor sets use unequal size compressors, these combinations require the use of a restrictor in the suction line of one or more compressors in order to provide correct oil level balance between compressors when they are operating.

Compressor Replacement

If the CGAF chiller / CXAF Heat Pump suffers a failed compressor, use these steps for replacement:

Each compressor has lifting eyes. Both lifting eyes must be used to lift the failed compressor. DO NOT LIFT A COMPRESSOR USING A SINGLE LIFTING EYE. Use proper lifting techniques, a spreader bar and rigging as for lifting both compressors simultaneously.

After a mechanical failure of a compressor, it is necessary to change the oil in the remaining compressor and also replace the liquid line ﬁlter drier. After an electrical failure of a compressor, it will also be necessary to change the oil in the remaining compressor, replace the liquid line ﬁlter drier and add a suction ﬁlter drier with clean-up cores.

Note: Do not alter the refrigerant piping in any way as this can affect compressor lubrication.

Refrigerant System Open Time

Model CGAF chillers / CXAF Heat Pump use POE oil and therefore refrigerant system open time must be kept to a minimum. The following procedure is recommended:

• Leave a new compressor sealed until it is

ready to be installed in the unit. Maximum system open time is dependent upon ambient conditions, but do not exceed one hour open time.

• Plug the open refrigerant line to minimize moisture absorption. Always change the liquid line ﬁlter drier.

• Evacuate the system to 500 microns or below.

• Do not leave POE oil containers open to the atmosphere. Always keep them sealed.

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Mechanical Compressor Failure

Replace the failed compressor(s) and change the oil in the remaining compressor(s) along with the refrigerant system liquid line ﬁlter drier.

Electrical Compressor Failure

Replace the failed compressor and change the oil in the other compressor(s). Also add a suction ﬁlter with cleanup cores and change the liquid line ﬁlter drier. Change ﬁlters and oil until the oil no longer test acidic. See “Oil Testing.”

Compressor Motor Megging

Motor megging determines the electrical integrity of the compressor motor winding insulation. Use a 500 volt megger. A less than 1 meg-ohm reading is acceptable and 1000 ohms per nameplate volts is required to safely start the compressor.

Compressor Current Imbalance

Normal current imbalance could be 4 to 15 percent with balanced voltage due to motor design. Each phase should register 0.3 to 1.0 ohms and each phase should be within 7 percent of the other two phases. Phase to ground resistance must be inﬁnity.

NOTICE: Maximum allowable voltage imbalance is 2 percent.

Compressor Service Information

Compressor Electrical Terminal Box

Be sure to protect the terminal box when unbrazing or brazing compressor refrigerant piping connections.

Compressor Crankcase Heaters

Compressor crankcase heaters must be energized at least eight hours before starting the CGAF / CXAF chiller. This is required to boil refrigerant out of the oil before startup. Ambient temperature (except 20°C and above) is not a factor and the crankcase heaters must always be energized prior to startup.

Refrigerant Piping

The compressor suction and discharge connections and piping are copper clad steel for easy brazing. In most instances, piping may be reused. If piping is not reusable, order the correct service parts. Cut all tubing with a tubing cutter to prevent copper ﬁlings from entering the system. Cut the tubing in a straight length of pipe after the compressor connection has been unsweated. The line can then be reinstalled using a slip coupling and brazing.

NOTICE: The compressor suction line conﬁguration must not be changed in any way. Changing compressor suction line conﬁguration will compromise proper oil return to the compressor(s).

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Condenser Coils MCHE Maintenance

Cleaning Procedures

It is mandatory to clean regularly the coils for a proper unit operation. Eliminate pollution and other residual material help to extend the life of the coils and the unit

CAUTION! Equipment Damage! Do not use coil cleaning agents to clean uncoated CGAF / CXAF coils. Use clean water only. Use of coil cleaning agents on uncoated CGAF / CXAF coils could cause damage to coils.

Regular coil maintenance, including frequent cleaningenhances the unit’s operating efﬁciency by minimizing compressor head pressure and amperage draw. The condenser coil (non-coated and e-coated) should be cleaned at least once each quarter or more if the unit is located in a “dirty” or corrosive environment. Cleaning with cleansers or detergents is strongly discouraged due to the all-aluminum construction; straight water should prove sufﬁcient. Any breach in the tubes can result in refrigerant leaks.

Important: Only in extreme cases should any type of chemical cleaner or detergent be used on micro channel coils. If it becomes absolutely necessary because water alone did not clean the coil, specify a cleaner that is:

• A is pH neutral cleaner.

• An alkaline cleaner that is no higher than 8 on the pH scale.

• An acidic cleaner that is no lower than 6 on the pH scale.

• Does not contain any hydroﬂuoric acids.

Be sure to follow the instructions provided with any cleaner chosen. Keep in mind that it is still MANDATORY that the coils are thoroughly rinsed with water after the application of the cleaner even if the instructions specify a “No Rinse” cleaner. Cleaners or detergents that are left on the coil due to improper rinsing will signiﬁcantly increase the possibility of corrosion damage on the micro channel coil.

Note: Quarterly cleaning (or more for harsh environment) is essential to extend the life of a MCHE coil and is required to maintain warranty coverage. Failure to clean a MCHE coil will void the warranty and may result in reduced efﬁciency and durability in the environment.

WARNING! Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

1. Disconnect Power to the unit.

2. Wear proper personal protection equipment such as a face shield, gloves and waterproof clothing.

3. Remove enough panels from the unit to gain safe access to the microchannel coil.

Note: It is better to clean the coil from the opposite direction of normal air ﬂow (inside of unit out) because this allows the debris to be pushed out rather than forced further into the coil.

1. Use a soft brush or vacuum to remove base debris or surface loaded ﬁbers from both sides of the coil.

Note: Remove solid residue is essential to preserve performance of the coil and avoid corrosion over the length of the product life.

2. Using a sprayer and water ONLY, clean the coil following the guidelines below. a. Sprayer nozzle pressure should not exceed

40 bars.

b. The maximum source angle should not exceed

25 degrees (Figure 22) to the face of the coil. For best results spray the micro channel perpendicular to face of the coil.

c. Spray nozzle should be approximately 5 to

10 cm from the coil surface.

d. Use at least a 15º fan type of spray nozzle.

Figure 26 – Sprayer source angle

To avoid damage from the spray wand contacting the coil, make sure the 90º attachment does not come in contact with the tube and ﬁn as abrasion to the coil could result.

Maintenance of Flanges Connection

It is mandatory to apply marine grease all around the coil ﬂange connections to the piping on a regular basis (for instance twice a year) to avoid traps of moisture and dirt in the gasket recess.

Repair / Replacement of Microchannel Coil

Microchannel coils are considerably more robust in design than tube and ﬁn condenser coils, however they are not indestructible. When damage or a leak occurs in the ﬁeld, it is possible to temporarily repair the coil until another coil can be ordered.

If the leak is found to be within the tube area of the coil, a ﬁeld repair kit (KIT16112) is available through your local Trane parts center. Because of the all-aluminum construction and aluminum’s high thermal expansion rate, a leak located at or on the header assembly cannot be repaired.

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Integrated Pump Maintenance

Water Pump Maintenance

WARNING! Before starting work on the pump, make sure

that the power supply has been switched off and that it cannot be accidentally switched on.

CAUTION! The lifting eyebolts of the motor are suitable for the weight of the motor only. It is not allowed to carry the complete pump on the lifting eyebolts of the motor.

It is important to keep the motor clean in order to ensure adequate cooling of the motor. If the pump is installed in dusty environments, it must be cleaned and checked regularly. Take the enclosure class of the motor into account when cleaning.

If the water loop must be emptied during period of frost, the pump has to be drained to avoid damage. Remove the ﬁlling and drain plugs. Do not reﬁt the plugs until the pump is taken into operation again.

Lubrication

The bearings of motors 5.5kW and 7.5kW are greased for life and require no lubrication. Increasing bearing noise and undue vibration indicate a worn bearing. The bearing or the complete motor then needs replacement.

The bearing of motors 11kW and up must be greased every 4000 hours or at yearly service. The required grease quantity is 10g per bearing. The motor must run during lubrication. Use lithium-based grease.

The pump shaft seal does not require any special maintenance. Visual leakage check are however required. Distinctly visible leakage will require an exchange of the seal.

For further details about pump maintenance please consult the pump supplier website.

Figure 27 – Motor bearings

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BPHE Evaporator Maintenance

The Trane Model CGAF / CXAF chiller and Heat Pump uses a brazed plate heat exchanger (BPHE) (or) a Shell & tube evaporator with factory installed ﬂow switch that is positioned in the evaporator water pipe. The evaporator inlet also includes a water strainer that must be kept in place to keep debris out of the evaporator.

Note: Strainer maintenance is critical to proper operation and reliability. Any particles larger than 1.6 mm entering the BPHE evaporator may cause the evaporator to fail, requiring replacement.

Acceptable BPHE evaporator water ﬂow rate is 1.4 to

4.2 l/ min per nominal unit kW capacity. To maintain 12-7°C in/out chilled water temperatures, the nominal water ﬂow rate is 2.8 l/min per cooling kW.

Minimum water ﬂow rate must be maintained to avoid laminar ﬂow, potential evaporator freezing, scaling and poor temperature control.

Maximum water ﬂow is 6 m/s. Flow rates greater than this will cause excessive erosion.

The BPHE evaporator is difﬁcult to clean should it become plugged with debris. Indications of a plugged BPHE evaporator include “wet” suction due to lack of heat exchange, loss of superheat control, discharge superheat less than 35°C, compressor oil dilution and/or starvation and premature compressor failure.

BPHE Evaporator replacement

If the CGAF / CXAF BPHE evaporator requires replacement, it is very important that the new evaporator be replaced correctly and with the correct refrigerant and water piping connections. The refrigerant inlet/ liquid connection is at the bottom of the evaporator and the refrigerant outlet/ suction connection is at the top of the evaporator and both are on the same side. Pay particular attention to evaporators with dual circuits. Avoid crosscircuiting when installing the new evaporator.

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Log Check Sheet

The operator log sheet are included for use as appropriate, for installation completion veriﬁcation before Trane Start-up is scheduled, and for reference during the Trane Start-up.

Operator Log

Sintesis CGAF chiller with UC800 Controller - Tracer AdaptiView Reports - Log Sheet

Start 15 minutes 30 minutes 1 hour

Active Chilled Water Setpoint Entering Water Temperature Leaving Water Temperature

Saturated Refrigerant Temperature (°C) Refrigerant Pressure (kPa) Approach Temperature (°C)

Water ow Status

EXV % Open

Saturated Refrigerant Temperature (°C) Refrigerant Pressure (psia) Approach Temperature (°C)

Water ow Status

EXV % Open

Outdoor Temperature

Air ow (%)

Saturated Refrigerant Temperature (°C) Refrigerant Pressure (kPa) Subcooling in °C

Air ow (%)

Saturated Refrigerant Temperature (°C) Refrigerant Pressure (kPa) Subcooling in °C

Running Status Starts Running Time (Hr:min) Oil Pressure (kPa)

Running Status Starts Running Time (Hr:min) Oil Pressure (psia)

Date: Technician: Owner:

Ckt 1

Ckt 2

Ckt 1

Ckt 2

Evaporator

Condenser

Compressor 1A

Compressor 1B

Compressor 2A

Compressor 2B

Compressor 3A

Compressor 3B

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Recommended service routine frequencies

As a commitment to our customers, we have created a wide service network staffed with experienced factoryauthorized technicians. At Trane we offer all the beneﬁts of after sales service direct from the manufacturer and we are committed to our mission statement to provide efﬁcient customer care.

We would be delighted to discuss your individual requirement with you. For further information regarding Trane maintenance agreements please contact your local TRANE sales ofﬁce.

Year

10 x x x x x xxx x

over 10

Commis-

sioning

1 x x x x x xx

2 x x x x xxx

3 x x x x xxx

4 x x x x xxx

5 x x x x x xxx x

6 x x x x x xxx

7 x x x x x xxx

8 x x x x x xxx

9 x x x x x xxx

Inspec-

tion visit

Seasonal

shut

down

every

year

Seasonal

start up

every

year

Oil

analysis

(2)

every

year (2)

Vibration

analysis

(3)

Annual

mainte-

nance

every

year

Preven-

tive

mainte-

nance

3 every

year

Tube

analysis

(1)

every 3

years

This timetable is applicable to units operating in normal conditions with an average of 4000 hours per year. If operating conditions are abnormally severe, an individual timetable must be made for that unit.

Com-

pressor

R’newal

(4)

40000 h

(1) Tube testing required if aggressive water conditions exist. Applies to condensers only on water cooled units.

(2) Schedule as per previous analysis result or at least once a year.

(3) Year 1 to deﬁne equipment baseline. Subsequent year based on oil analysis results or schedule as per

vibration analysis.

(4) Recommended at 40 000 run hours or 100 000 equivalent operating hours whichever comes ﬁrst.

Schedule also depends on results from oil analysis / vibration analysis.

Seasonal start up and shutdown are mainly recommended for comfort air conditioning. Annual and preventive maintenance are mainly recommended for Process applications.

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Additional services

Oil analysis

Trane Oil Analysis is a predictive tool used to detect minor issues before they become major problems. It also reduces failure detection time and allows planning for appropriate maintenance. Oil changes can be reduced by half resulting in lower operating costs and a lower impact on the environment.

Vibration analysis

Vibration analysis is required when oil analysis reveals the presence of wear indicating the start of possible bearing or motor failure. Trane oil analysis has the ability to identify the type of metallic particles in the oil which, when combined with the vibration analysis, will clearly point out the failing components.

Vibration analysis should be performed on a regular basis to build a vibration trend of the equipment and avoid unplanned downtime and costs.

System upgrade

This Service provides a consulting service. Upgrading your equipment will increase the unit reliability and can reduce the operating costs by optimizing the controls. A list of solutions / recommendations to the system will be explained to the customer Actual upgrade for the system will be costed separately.

Water treatment

This Service provides all of the necessary chemicals to properly treat each water system for the period designated.

The inspections will be conducted at agreed upon intervals and Trane Service First will submit a written report to the customer after each inspection.

These reports will indicate any corrosion, scaling, and alga growth in the system.

Refrigerant analysis

This Service includes a thorough analysis for contamination and solution upgrade.

It is recommended that this analysis be performed every six months.

Annual cooling tower maintenance

This Service includes the inspection and maintenance of the cooling tower at least once a year.

This involves checking the motor.

24 hours duty

This service includes emergency calls outside of the ofﬁce normal working hours.

This Service is only available with a Maintenance Contract, where available.

Trane Select Agreements

Trane Select Agreements are programs tailored to your needs, your business and your application. They offer four different levels of coverage. From preventive maintenance plans to fully comprehensive solutions, you have the option of selecting the coverage that best suits your requirements.

5 years motor-compressor warranty

This Service will provide a 5 years part and labor warranty for the motor compressor only.

This Service is only available for units covered by a 5 years Maintenance Contract.

Tube analysis (Shell & Tube)

- Eddy Current Tube Testing for prediction of tube failure/ wear

- Frequency - every 5 years for ﬁrst 10 years (depending on the water quality), then every 3 years thereafter.

Energy enhancement

With Trane Building Advantage you can now explore cost effective ways to optimize the energy efﬁciency of your existing system and generate immediate savings. Energy management solutions are not only for new systems or buildings. Trane Building Advantage offers solutions designed to unlock energy savings in your existing system.

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Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in creating and sustaining safe, comfortable and energy efﬁcient environments, Trane offers a broad portfolio of advanced controls and HVAC systems, comprehensive building services and parts. For more information visit www.Trane.com

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Trane CGAF 100 SE, CGAF 90 SE, CGAF 130 SE, CGAF 150 SE, CGAF 140 SE Installation Operation & Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual