Trane CGAF-C50, CGAF-C20, CGAF-C30, CGAF-C60, CGAF-C40 Installation & Operation Manual
...
Installation CG-SVX02B-EN
Operation
Maintenance
Library Service Literature
Product Section Refrigeration
Product Hermetic Scroll Liquid Chillers, Air Cooled
Model CG
Literature Type Installation, Operation & Maintenance
Sequence 02B
Date January 2005
File No. SV-RF-CG-SVX02B-EN 105
Supersedes CG-SVX02A-EN 403
IntelliPak
TM
Air-Cooled Cold Generator
Models
"K" and Later Design Sequence
CGAF-C20 CGAF-C40
CGAF-C25 CGAF-C50
CGAF-C30 CGAF-C60
With 3-DTM Scroll Compressors
Ó 2005 American Standard Inc. All rights reserved
http://www.trane.com
Note: The installation of this equipment must
comply with all National, State and Local
Codes.
Trane has a policy of continuous product and product
data improvement and reserves the right to change design and specifications without notice. Only qualified
technicians should perform the installation and servicing of equipment referred to in this publication.
About the Manual
Literature Change History
CG-SVX02B-EN (November 2004)
First issue of manual; provides Installation, Operation, and
Maintenance instructions for “K” and later design sequence
on CGAF 20 through 60 Ton air cooled Cold Generators.
Overview of Manual
Note: One copy of this document ships inside the
control panel of each unit and is customer
property. It must be retained by the unit’s
maintenance personnel.
This booklet describes proper installation, operation, and
maintenance procedures for air cooled systems. By carefully reviewing the information within this manual and follow-
ing the instructions, the risk of improper operation and/or
component damage will be minimized.
It is important that periodic maintenance be performed to
help assure trouble free operation. A maintenance schedule
is provided at the end of this manual. Should equipment
failure occur, contact a qualified service organization with
qualified, experienced HVAC technicians to properly diagnose and repair this equipment.
Note: The procedures discussed in this manual
should only be performed by qualified, experienced
HVAC technicians.
atmosphere! If adding or removing refrigerant is
required, the service technician must comply with
all federal, state, and local laws.
Do Not release refrigerant to the
2
Table of Contents
About the Manual
Literature Change History ................................................. 2
Overview of Manual .......................................................... 2
General Information
Model Number Description ...............................................4
Unit Nameplate .................................................................. 4
Evaporator Barrel Nameplate ........................................... 4
Compressor Nameplate .................................................... 4
Hazard Identification .........................................................4
Unit Description .................................................................5
Input Devices & System Functions ................................... 5
Unit Component “Layout” and “Shipwith” Locations ........ 8
Module Mounting Locations .......................................... 9
Installation
Unit Inspection ................................................................ 10
Unit Clearances .............................................................. 10
Unit Dimensions & Weight Information ......................... 10
Foundation ...................................................................... 10
Rigging ............................................................................ 19
Unit Isolation ................................................................... 19
Leveling the Unit ............................................................. 19
Shipping Fasteners ........................................................ 22
General Unit Requirements ........................................... 23
Chilled Water Piping Requirements ........................... 23
Main Electrical Power Requirements ......................... 23
Field Installed Control Wiring Requirements ............. 23
Low Voltage Wiring (AC & DC) .................................. 23
Chilled Water Piping ....................................................... 23
Chilled Water Access Holes ........................................... 24
Final Water Piping Connections .................................... 26
Freeze Protection from Ambient Contitions .................. 26
Field Installed Power Wiring .......................................... 28
Disconnect Switch External Handle .............................. 28
Main Unit Power Wiring ................................................. 28
Power Wire Sizing and Protection Device Equations ... 30
Field Installed Control Wiring ......................................... 32
Controls Using 115 VAC ............................................. 32
Controls using 24 VAC ............................................... 32
Controls using DC Analog Input/Outputs................... 32
Controls using DC Communication Links .................. 33
Ice Building Control Option ............................................ 33
System Pre-Start Procedures
Voltage Imbalance.......................................................... 38
Electrical Phasing ........................................................... 39
System Start-Up
Sequence of Operation .................................................. 40
Chilled Water Circulating Pump ..................................... 44
Ethylene Glycol Adjustment Factor ............................... 44
Verifying Proper Fan Rotation ....................................... 47
Compressor Start-Up ..................................................... 47
Compressor Crankcase Heaters ................................... 51
Low Ambient Damper Adjustment ................................. 51
Final System Setup ........................................................ 51
Service & Maintenance
Compressor Operational Sounds .................................. 53
Scroll Compressor Replacement ................................... 53
Fuse Replacement Data ................................................ 54
Monthly Maintenance ..................................................... 55
Coil Cleaning .................................................................. 56
Annual Maintenance ...................................................... 57
Final Process .................................................................. 57
Index ................................................................................... 59
3
General Information
G = Superheat / Subcooling
P
* = Field Installed Options
Model Number Description
All Trane products are identified by a multiple-character
model number that precisely identifies a particular type of
unit. An explanation of the alphanumeric identification code
is provided below. Its use will enable the owner/operator, installing contractors, and service engineers to define the op-
Sample Model Number: CGAF - C30 4 A A B 0 D etc.
Digit Number: 1,2,3,4 5,6,7 8 9 10 11 12 13 +
Digit 1,2 - Unit Function Digit 9 - Heating Capacity Digit 13, etc. Miscellaneous
CG = Cold Generator A = Standard A = Communications Interface (TCI)
Digit 3 - Unit Type Digit 10 - Design Sequence
A = Air-Cooled Condenser H = Brazed Plate Chiller D = Non-Fused Unit-Mounted Disconnect
Digit 4 - Development Sequence Digit 11 - Leaving Water Setpoint
F = Sixth A = 40 - 50 F w/o Ice Machine
B = 30 - 39 F w/o Ice Machine H = Hot Gas Bypass
Digit 5,6,7 - Nominal Capacity
C20 = 20 Tons E = 20 - 29 F w/o Ice Machine L = LonTalk© Communication Interface Module
C25 = 25 Tons 1 = 40 - 50 F w Ice Machine K = Stock Unit
C30 = 30 Tons 2 = 30 - 39 F w Ice Machine L = LonTalk© Communication Interface Module
C40 = 40 Tons 3 = 51 - 65 F w Ice Machine M = *Remote Human Interface
C50 = 50 Tons 4 = 20 - 29 F w Ice Machine N = Generic BAS Module 0-10 VDC Analog Output
C60 = 60 Tons S = Special P = Remote Setpoint Potentiometer P/S
Digit 8 - Power Supply
E = 200/60/3 P/S*** V = Copper Fin Condenser Coil
F = 230/60/3 W = **Electronic Low Ambient Dampers P/S
4 = 460/60/3 P/S*** Y = *Inter-Processor Comm Bridge (IPCB)
5 = 575/50/3
9 = 380/50/3 0 = None
D = 415/50/3 1 = UL/CSA ** = Factory or Field Installed Option
S = Special *** Available on Pack Stock Units
D = 51 - 65 F w/o Ice Machine J = Generic BAS Module 0-5 VDC Input, Binary O.
Digit 12 - Agency Approval
eration, specific components, and other options for any specific unit.
When ordering replacement parts or requesting service, be
sure to refer to the specific model number, serial number,
and DL number (if applicable) stamped on the unit nameplate.
B = No Unit Heat Tape (50 Hz Units Only)
C = Compressor Current Sensing (CSM)
E = *Unit Isolators - Neoprene P/S
F = *Unit Isolators - Spring P/S
Q = *Zone Sensor (Chilled Solution Reset) P/S
S = Special
9 = Packed Stock Unit
Unit Nameplate
Compressor Nameplate
One Mylar unit nameplate is located on the outside upper
right corner of the control panel door. It includes the unit
model number, serial number, electrical characteristics,
weight, refrigerant charge, as well as other pertinent unit
data. A small metal nameplate with the Model Number, Serial Number, and Unit Weight is located just above the Mylar
nameplate, and a third nameplate is located on the inside of
the control panel door.
When ordering replacement parts or requesting service, be
sure to refer to the specific model number, serial number,
and DL number (if applicable) stamped on the unit nameplate.
Evaporator Nameplate
The nameplate is located on the opposite side of the water
connections. The word “Nameplate” is stenciled on the insulation above the nameplate. To view the nameplate, remove the tape over the area and spread the insulation.
Retape the insulation after viewing.
Echelon, LON, LONWORKS, LonBuilder, NodeBuilder, LonManager, LonTalk, LonUsers, Neuron, 3120, 3150, the Echelon logo, and the LonUsers logo are
trademarks of Echelon Corporation registered in the United States and other countries. LonLink, LonResponse, LonSupport, LonMaker, and LonPoint are
trademarks of Echelon Corporation.
The nameplate for the “Scroll” compressors are located on
the compressor lower housing.
Hazard Identification
WARNING– Indicates a
situation which, if not avoided, could result in death or
serious injury.
potentially hazardous
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.
CAUTION – Indicates a situation that may result in
equipment or property-damage-only accidents.
4
General Information
Unit Description
Before shipment, each unit is leak tested, dehydrated,
charged with refrigerant and compressor oil, and run tested
for proper control operation.
Each unit is equipped with manifolded scroll compressors.
Each manifolded set of compressors is piped in parallel and
utilizes a passive oil management system to maintain
proper compressor oil level.
The condenser coils are aluminum fin, mechanically bonded
to copper tubing. Copper-fin coils are optional. Louvered
condenser grilles for coil protection are standard.
Direct-drive, vertical discharge condenser fans are provided
with built-in thermal overload protection.
For “Ship with” items, refer to the Unit Component “Layout”
and “Ship with” Locations illustration.
If low ambient operation is required, low ambient dampers
are available as a field or factory installed option.
The evaporators used in each air-cooled cold generator are
of brazed plate construction. Each evaporator is fully insulated. Entering and leaving temperatures of the chilled solution are measured by sensors located on the evaporator.
A liquid line solenoid valve, filter drier, sight glass, thermostatic expansion valve, and service valves (liquid and discharge) are provided on each circuit.
Standard controls for these units is a microelectronics control system that consists of a network of modules referred to
collectively as Unit Control Modules (UCM). The acronym
UCM is used extensively throughout this document when
referring to the control system network.
These modules, through Proportional/Integral control algorithms, perform specific unit functions that governs unit operation in response to chilled water temperature leaving the
evaporator. The stages of capacity control for these units is
achieved by starting and stopping the compressors.
The modules are mounted in the control panel and are factory wired to their respective internal components. They receive and interpret information from other unit modules,
sensors, remote panels, and customer binary contacts to
satisfy the applicable request for cooling. Refer to the following discussion for an explanation of each module function.
Human Interface Module (HI - Standard)
(1U65 = Local, 6U66 = Remote)
The Human Interface module enables the operator to adjust
the operating parameters for the unit using it’s 16 key keypad. The 2 line, 40 character LCD screen provides status
information for the various unit functions as well as menus
for the operator to set or modify the operating parameters.
Cold Generator Module (1U48) (CGM - Standard)
The Cold Generator Module (CGM) responds to cooling requests by energizing the proper unit components based on
information received from other unit modules, sensors, remote panels, and customer supplied binary inputs. It initiates unit operation based on that information.
Compressor Module (1U44) (MCM)
The Compressor module, upon receiving a request for mechanical cooling, energizes the appropriate compressors
and condenser fans. It monitors the compressor operation
through feedback information it receives from various protection devices. It also provides heat tape output control for
heat exchanger protection.
Interprocessor Communications Board (1U55) (IPCB Optional - used with Optional Remote Human Interface)
The Interprocessor Communication Board expands communications from the unit’s UCM network to a Remote Human Interface Panel. DIP switch settings on the IPCB module for this application should be; Switches 1 and 2 “Off”, Switch 3 “On”.
Trane Communications Interface Module (1U54) (TCI Optional - used with Trane ICS
TM
Systems)
The Trane Communication Interface module expands
communications from the unit’s UCM network to a Trane Tracer
100™ or a Tracer Summit™ system and allows external setpoint
adjustment and monitoring of status and diagnostics.
DIP Switch settings on the TCI module for these applications should be: Switches 1, 2, and 3 are “Off”
Generic Building Automation System Module
(1U51 = GBAS 0-5V, 1U98 = GBAS 0-10V)
Optional - used with Non-Trane Building Control System)
The Generic Building Automation System (GBAS) module
allows a non-Trane building control system to communicate
with the unit and accepts external setpoints in form of analog inputs (0 - 5 DCV or 0 - 10 DCV depending on the module selected) and a binary Input for demand limit. Five (5)
binary outputs are available on 0 - 5 DCV modules. One (1)
binary output and four (4) analog outputs are available on
the 0 - 10 DCV modules. Refer to the “Field Installed Control Wiring” section for the control wiring to the GBAS module and the various desired setpoints with the corresponding DC voltage inputs.
Lontalk Communication Interface Module (1U54)
(LCI Optional - used on units with Trane ICS
™
or 3rd
party Building Automation Systems)
The LonTalk Communication Interface module expands communications from the unit’s UCM network to a Trane Tracer
™
Summit
or a 3rd party building automation system, that utilizes LonTalk, and allows external setpoint and configuration
adjustment and monitoring of status and diagnostics.
Current Sensing Module (1U90) (CSM - Optional)
Current transformers located around two (2) of the main
power leads for each compressor monitors the running current during compressor operation. The information is sent to
the CGM and can be accessed through the “Compressor
Status” submenu displayed at the Human Interface Module.
Superheat & Subcooling Module (1U91) (SSM Optional)
Monitors the system operating superheat and subcooling
through the use of pressure transducers, liquid line, and
suction line temperature sensors. The information is sent to
the SSM and can be accessed through the “Compressor
Status” submenu displayed at the Human Interface Module.
Input Devices & System Functions
The descriptions of the following basic Input Devices used
within the UCM network are to acquaint the operator with
their function as they interface with the various modules.
Refer to the unit’s electrical schematic for the specific module connections.
5
Lead/Lag (Standard)
When Lead-Lag is enabled, for each capacity add request,
the CGM will begin sequencing the compressors “On” that
have:
a. the least number of starts; or,
b. the least run time (if number of starts are equal)
At each capacity subtract request, the CGM will begin sequencing the compressors “Off” that have:
a. the most run time; or,
b. the least number of starts (if more than one
compressor has the same run time)
If a compressor is locked out for any reason when a capacity add request occurs, the next available compressor which
meets the specified criteria will be started.
If a compressor can not be turned “Off” due to the minimum
“On Time”, the next compressor which meets the specified
criteria will be turned “Off”.
On dual circuit units, as the first two capacity add requests
are initiated, one compressor on each circuit will start before any additional compressors on any circuit is started.
When staging down from three compressor stages to two
compressor stages, the CGM will turn the compressors
“Off” on the circuit that has the most compressors operating.
With Lead/Lag enabled, HGBP operation (if applicable) will
be bypassed and the system will go directly into pumpdown
when the last subtract command is initiated.
When the UCM is powered up (after a power loss), or any
time the compressor’s start time and run time are equal, the
lead compressor for single circuit units (20 through 30
Tons), will be the first “On” and the lag compressor will be
the first “Off”. For dual circuit units (40 through 60 Tons), the
“On” sequence will be A-C-B-D and the “Off” sequence will
be D-B-C-A.
Loss of Charge/Flow (Refrigerant) Control
Is accomplished by Loss of Charge Cutout (LCC)
switch(es), located on the suction line(s) near the scroll
compressor(s). The LCC are connected to the SCM or
MCM Low Pressure Cutout (LPC) binary input.
The LCC contacts are designed to open if the suction pressure approaches 7 ± 4 psig. If the LCC opens after a compressor has started, all compressors operating on that circuit will be turned off immediately and will remain off for a
minimum of three minutes.
The LCC contacts are designed to close when the suction
pressure exceeds 22 ± 4 psig. If the LCC is open when a
compressor is requested to start, none of the compressors
on that circuit will be allowed to operate. They are locked
out and a manual reset diagnostic is initiated. If the LCC
opens four consecutive times, during the initial three minutes of compressor operation on a circuit, the compressors
General Information
on that circuit will be locked out and a manual reset diagnostic is initiated.
Evaporator Freeze Protection
Is accomplished by Freeze Protection Cutout (FPC)
switch(es), located on the suction line(s) near the scroll
compressor(s).
The FPC are connected to the SCM or MCM Low Pressure
Cutout (LPC) binary input, in series with the LCC
switch(es.) The FPC switch is used to prevent the refrigerant from becoming cold enough to cause the chilled solution in the Evaporator to freeze. This pressure switch is typically set to trip at a higher refrigerant pressure, typically 20
to 45 PSIG depending on the selected leaving water
setpoint range of the unit.
If the FPC opens after a compressor has started, all compressors operating on that circuit will be turned off immediately and will remain off for a minimum of three minutes.
If the FPC is open when a compressor is requested to start,
none of the compressors on that circuit will be allowed to
operate. They are locked out and a manual reset diagnostic
is initiated.
If the FPC opens four consecutive times, during the initial
three minutes of compressor operation on a circuit, the
compressors on that circuit will be locked out and a manual
reset diagnostic is initiated.
Saturated Condenser Temperature Sensors (Standard)
Are analog input devices mounted inside a temperature well
located on a condenser tube bend. They monitor the saturated refrigerant temperature inside the condenser coil and
are connected to the compressor module (MCM). As the
saturated refrigerant temperature varies due to operating
conditions, the condenser fans are cycled “On” or “Off” as
required to maintain acceptable operating pressures.
Head Pressure Control (Standard)
Is generally achieved by staging condenser fans on on if
the Saturated Condensing Temperature (SCT) rises above
the Saturated Condensing Temperature Control Band Upper Limit (SCTUL) and staged off if the SCT falls below the
Saturated Condensing Temperature Control Band Low Limit
(SCTLL), in an effort to maintain the SCT within this fixed
temperature range.
For 20 and 40 ton units, two outputs (A and C) per circuit
are controlled. For 25, 30, 50 and 60 ton units, three outputs (A, B and C) per circuit are controlled. Each output
controls a condenser fan motor contactor. Output C will energize on initial call for fan staging, and will remain energized as long as a compressor on that circuit is on. The
third condenser fan motor associated with Output C will be
located under the low ambient damper, if that option is installed.
Condenser Fan Output Control (MCM relays and fan motor contactors)
Output A Output B Output C*
Unit MCM Fan MCM Fan MCM Fan No. of
Tonnage Circuit Relay Contactor Relay Contactor Relay Contactor Stages
20 1 K1 1K8 na na K7 1K7 2
25 1 K1 1K8 K2 1K12 K7 1K7 3
30 1 K1 1K8 K2 1K12 K7 1K7 4
40 1 K1 1K8 na na K7 1K7 2
2 K5 1K10 na na K8 1K9 2
50 1 K1 1K8 K2 1K12 K7 1K7 3
2 K5 1K10 K6 1K13 K8 1K9 3
60 1 K1 1K8 K2 1K12 K7 1K7 3
2 K5 1K10 K6 1K13 K8 1K9 3
* Output under the Low Ambient Damper, if installed.
6
For 25, 30, 50 and 60 ton units, the Saturated Condenser
OA Temp Suppression Setpoint (SCTOATSS) is a Human
Interface settable parameter (default: 40°F, range: 30 50°F, Disabled: above 50°F) which determines how many
condenser fan outputs will turn on.
Upon first compressor start on a circuit, all condenser fans
remain off until the SCT rises above the control band lower
limit. On 25, 30, 50 and 60 ton units, if the Outdoor Air
Temperature (OAT) is greater than or equal to the
SCTOATSS, or the SCTOATSS Function is disabled, all
condenser fan outputs will be energized. If the OAT is less
than the SCTOATSS, only Outputs B and C are energized.
On 20 and 40 ton units, all condenser fan outputs will be
energized.
When one or more condenser fan outputs are energized:
If the SCT rises above the SCTUL, for 20 and 40 ton units,
all condenser fan outputs are energized. For 25, 30, 50
and 60 ton units, if the OAT is less than the SCTOATSS
only one condenser fan stage will be added. If the OAT is
greater than or equal to SCTOATSS, or the SCTOATSS
Function is disabled, all condenser fan stages will be energized.
If the SCT falls below the SCTLL, for 20 and 40 ton units, if
both Outputs A and C are on, then Output A is de-energized. If only Output C was on, it remains on. For 25, 50
and 60 ton units, if both Outputs A and B are on, Output A is
de-energized.
energized.
are on, Output A is de-energized.
is on, Output B is de-energized and Output A is energized.
(see Note 4)
Note 2)
(See Note 1)
(See Note 2)
If only Output B is on, Output B is de-
For 30 ton units, if both Outputs A and B
(see Note 3)
If only Output B
If only Output A is on, Output A is de-energized.
(see
If the SCT rises above the Saturated Condensing Temperature Efficiency Check Point (SCTECP), for 20 and 40 ton
units, no outputs are changed. For 25, 50 and 60 ton units,
if the OAT is less than the SCTOATSS, no outputs are
changed. If the OAT is greater than the SCTOATSS, or disabled, if Output A and Output B are off, then Output B is energized. If Output B is on and Output A is off, no outputs
are changed. For 30 ton units, if the OAT is less than the
SCTOATSS, no outputs are changed. If the OAT is greater
than the SCTOATSS, or disabled, if Output A and Output B
are off, Output A is de-energized. If Output A is on and Output B is off, Output B is energized and Output A is de-energized. If Output B is on and Output A is off, no outputs are
changed.
Notes:
1. If the SCT remains below the SCTLL for 30 seconds after
the stage change, then Output B will be de-energized. At
this time, only the fan (under the low ambient damper)
controlled by Output C will be on.
2. At this time, only the fan (under the low ambient damper)
controlled by Output C will be on.
3. If the SCT remains below the SCTLL for 30 seconds after
the stage change, then Output A will be energized and
Output B will be de-energized. If the SCT remains below
the SCTLL for an additional 30 seconds after the stage
change, then Output A will be de-energized. At this time,
only the fan (under the low ambient damper) controlled
by Output C will be on.
4. If the Sat Cond. Temp. remains below the SCTLL for an
additional 30 seconds after the stage change, then Output A will be de-energized. At this time, only the fan (under the low ambient damper) controlled by Output C will
be on.
To prevent rapid fan cycling, minimum condenser fan
stage on and off time is 5.2 seconds, except when all
compressor stages on a circuit are de-energized for
any reason, the condenser fan stages on that circuit
General Information
are de-energized immediately without regard to the
condenser fan minimum on time. Also, if four fan
stage changes occur within a ten minute period, then
SCT is controlled to SCTLL minus “Saturated Condenser Temp Control Band Temporary Low Limit Suppression” for a period of one hour.
In a low ambient condition, adding or subtracting a full fan
stage provides excess capacity. To provide head pressure
control in low ambient conditions, the UCM controls SCT to
the “Saturated Condensing Temperature Low Ambient Control Point” by modulating the capacity of a dedicated condenser fan stage between 0 and 100% via the Low Ambient
Fan Control Actuator output
Normally, the head pressure control allows unit operation
down to 30°F. With the addition of a low ambient damper,
This feature allows for low ambient compressor operation
down to 0°F.
The low ambient control algorithm is active on all units, regardless of whether the unit is configured as having low
ambient damper option.
High Pressure Controls (Standard)
High Pressure controls are located on the discharge lines
near the scroll compressors. They are designed to open
when the discharge pressure approaches the unit specific
pressure setting. The controls reset automatically when the
discharge pressure decreases to the unit specific pressure
setting. However, the compressors on that circuit are locked
out and a manual reset diagnostic is initiated.
Low Ambient Control (Optional)
The low ambient modulating output on the compressor
module is functional on all units with or without the low ambient option.
Anytime the unit is powered-on, this output is operational,
regardless if the compressors are ON or OFF. Once the
condenser fan operation is started, the condenser fan located under this damper will remain ON until all compressors on that circuit are turned OFF. These dampers will
modulate to maintain the saturated condensing temperature
to the "Saturated Condensing Temperature Control Point"
and the "Low Ambient Control Deadband" which are located
under the Human Interface setup screens for Head Pressure Control.
Status/Alarm Output (Standard)
Is an internal function within the CGM control module that
provides;
a. diagnostic signals to the Human Interface Alarm
LED.
b. control of the binary Alarm output.
c. control of the binary outputs on the GBAS module to
inform the customer of the operational status and/or
diagnostic conditions.
Compressor Circuit Breakers (Standard)
The Scroll Compressors are protected by circuit breakers
which interrupt the power supply to the compressors if the
current exceeds the breakers “must trip” value and opens a
set of auxiliary contacts in the control circuit.
When the Compressor Module (MCM) detects the open
auxiliary compressor contacts, it turns any operating
compressor(s) on that circuit “Off”, locks out all compressor
operation for that circuit, and initiates a manual reset diagnostic.
7
General Information
Compressor Motor Winding Thermostats (Standard)
A thermostat is embedded in the motor windings of each
Scroll compressor. Each thermostat is designed to open if
the motor windings exceeds approximately 221oF. The thermostat will reset automatically when the winding temperature decreases to approximately 181
o
F. Rapid cycling, loss
of charge, abnormally high suction temperatures, or the
compressor running backwards could cause the thermostat
to open. During a request for compressor operation, if the
Compressor Module detects a problem outside of it’s normal parameters, it turns any operating compressor(s) on
that circuit “Off”, locks out all compressor operation for that
circuit, and initiates a manual reset diagnostic.
Low Ambient Compressor Lockout (Standard)
When low ambient compressor lockout is enabled, the compressors are not allowed to operate if the temperature of
the outside air falls below the lockout setpoint. Compressor
operation is enabled when the temperature rises 5
o
F above
the lockout setpoint. The setpoints and enable/disable option is programmable at the Human Interface inside the unit
control panel. The default setting is 30
o
F.
Short Cycle Protection (Standard)
If compressor operation is interrupted by a loss of power or
by a manual reset diagnostic, a minimum of one minute
must elapse before the affected compressor(s) will be allowed to restart for “Process” applications. A minimum of
three minutes must elapse before the affected
compressor(s) will be allowed to restart for “Comfort Cooling” applications.
Hot Start (Load Limit) Control (Standard)
Each time the system is started and the control of the CGM
transitions from “Loop Stabilization” to either “Process” or
“Comfort Cooling”, if the Leaving Solution Temperature
(LST) is higher than the programmable Hot Start Load Limit
Setpoint (HSLLS), the lag compressor on each circuit will
be prevented from operating until the leaving solution temperature is lowered by 5
If the Hot Start Limit time interval elapses before the LST is
o
F below the HSLLS, the control will transition immediately
5
o
F below the HSLLS.
into the Hot Operation mode.
Hot Operation mode is programmable to:
1. Do not limit capacity, initiate an informational diagnostic
until the LST falls 5
o
F below the HSLLS.
2. Limit the capacity to 50 percent (one compressor per cir-
cuit), initiate an auto reset diagnostic until the LST falls
5o F below the HSLLS.
3. Turn “Off” and lockout all of the compressors and initiate
a manual reset diagnostic.
Loss-of-Flow (Solution) Protection (Standard)
All units:
Compressors are allowed to operate once the pump is running and the flow switch input is closed. If the flow switch
input opens during normal operation for longer than 6 seconds, the compressors and fans will stop. If the switch input
is still open after 5 minutes, a auto-reset diagnostic (Evap
Solution Flow Proving Switch) will be generated. Once this
input is closed, the diagnostic will clear and the compressors will be allowed to resume operation. If the flow switch
fails open or is not connected when the chiller starts up,
only the solution pump output will be energized. 5 minutes
later, an auto-reset diagnostic (Evap Solution Flow Proving
Switch) will be generated. Once the flow switch input
closes, the chiller will operate normally.
If the chiller controls the pump (Chiller solution pump
mode = AUTO):
If the pump is cycled off by the CGM or a power failure occurs, and the unit is re-started, the flow switch input must
open and then close for proper operation. If the switch is
stuck closed or shorted, the pump will start but compressors will not operate. Also, a manual resettable diagnostic
(Evaporator Solution Flow Loss) will be generated. To reset
the diagnostic, stop the pump and allow the flow switch to
open, then reset at the Human Interface (see Programming
Guide).
Note: There is a minimum "off" time of 60 seconds for the
pump output. This "off" time is overridden if the flow switch
opens.
If the chiller does not control the pump (Chiller solution
pump mode = ON):
Do not bypass the flow switch input! If the flow switch input
is bypassed, the unit will not have flow loss protection and
equipment damage may result.
WARNING
Equipment Damage!
Do not bypass the flow switch input! If the flow switch
input is bypassed, the unit will not have flow loss protection and equipment damage may result.
The flow switch input must be closed for compressor operation. If the flow switch input is open and a request for cooling is given, compressors will not start and a auto-reset diagnostic (Evap Solution Flow Proving Switch) will be generated after 5 minutes. Once this input is closed, the diagnostic will clear and the compressors will be allowed to operate.
Low Ambient Start (Standard)
Before first start of a compressor on a refrigerant circuit, the
CGM Low Ambient LPC Bypass output is closed which bypasses the Freeze Protection Cutout (FPC) switch in the
MCM Low Pressure Cutout (LPC) input circuit for a period
of time that varies based on the prevailing ambient temperature. The relationship between this variable time period
and the ambient temperature is linear from a maximum of 5
minutes at 0°F to a minimum of two minutes at 65°F. A fixed
three minute bypass time is initiated each time a subsequent compressor is started on a refrigerant circuit. No additional compressors will be allowed to start within that circuit until the bypass time has expired.
Chiller Solution Pump Output Relay (Standard)
A Solution Pump binary output (Form C) relay is located on
the CGM which may be used to control the chiller solution
pump.
If the Chiller Solution Pump Mode, at the Human Interface
Module, is set to “On”, the Solution Pump will run continuously.
If the Chiller Solution Pump Mode, at the Human Interface
Module, is set to Auto, the Solution Pump will be turned
“Off”:
8
1. when the unit is stopped (Unit Stop or External Auto/
Stop)
2. during the unit’s Power On Delay Time
3. when the primary control states are:
Ice Rebuild Delay
Ice Building Complete
A Solution Pump “Off Delay” Time may be programmed to
allow the Solution Pump to remain “On”, for an adjustable
period of time between 0.5 minutes and 10 minutes, at the
time an “Off” state is requested. The Solution Pump will always run for this delay time when turning off except during
an Emergency Stop condition. If an Emergency Stop is initiated, the Solution Pump is immediately turned “Off” (relay
de-energized).
On units configured with pump mode 'Auto', a solution pump
'On Delay' of 60 seconds will be enforced after the pump
turns off to allow the solution flow proving switch to open
before the pump is allowed to start. If the flow switch opens,
this delay will be over-riden and the pump will be allowed to
start.
Low Ambient Pump Control (Standard)
A Low Ambient Pump “On” Control function (LAPC) allows
the pump to run continuously if either the entering or leaving
solution temperature falls below a programmable Low Ambient Pump Override Temperature (LAPT) Setpoint or if either
the entering or leaving Solution temperature input failure
occurs. An Auto Reset Diagnostic will be issued and remain
as long as the condition exists.
If both entering and leaving solution temperatures rise
above the Low Ambient Pump Override Temp Setpoint plus
three degrees and either temperature has risen above the
Active Leaving Solution Setpoint, the Auto Reset diagnostic
is cleared and the pump is turned off.
This function will be disabled when an Emergency Stop
request is initiated.
During service test operation, if a low ambient condition exists when the operator attempts to turn the pump “Off”, a
message will be displayed on the Human Interface Module
advising that the pump cannot be turned off due to the low
ambient condition.
General Information
External Auto/Stop (Optional)
The unit can be Stopped and Started by a remote customer
provided field installed binary input device (such as a time
clock) connected to the CGM. When the input is opened
(Stop), the unit will stage the compressors and the solution
pump “Off” in a normal manner and display “Off due to external stop” at the unit Human Interface. When the input is
closed (Start), the unit will start and run normally.
The External Auto/Stop input operates in the same manner
as the STOP/AUTO keys on the unit mounted Human Inter
face or the Remote Human Interface (RHI). However, the
Stop key at the unit mounted Human Interface has priority
over both the remote External Auto/Stop and the Remote
Human Interface Auto/Stop.
Note: If the STOP key is pressed at the unit
mounted Human Interface, no remote AUTO (Start)
key will start the unit until the AUTO key is pressed
at the unit mounted Human Interface.
A start (AUTO) command is allowed only if no overriding diagnostics or higher priority function is present.
Flow Switch Interlock (Standard)
While the factory provided field installed flow switch is wired
to the CGM, if it opens for more than 6 continuous seconds
when the pump is requested to be "On", compressor operation will be inhibited and if compressors are operating, they
will be turned off. If the flow switch remains open for 5 continuous minutes an auto reset diagnostic will occur.
Chiller Heat Tape Control Output
Heat tape control for the chiller heat exchanger will be provided by the unit. If either the entering or leaving solution
temperatures fall below the heat tape temperature setpoint,
the heat tape relay on the MCM module will de-energize,
turning the heat tape on. If either of these two sensors fail,
the heat tape relay will de-energize, turning the heat tape
on. The heat tape relay will energize, turning the heat tape
off when 1) compressor operation is required, or 2) both
EST and LST rise 3
Unit Component “Layout” and “Ship with”
Locations
(60 Ton Unit Illustrated)
o
F above the heat tape temperature.
Emergency Stop (Optional)
Is accomplished when a customer provided, field installed
binary input device is connected to the CGM. The unit will
immediately shut down when the contacts are opened.
Emergency Stop is a top priority command that will override
all other commands received by the UCM. A manual reset
diagnostic will occur and an indication showing that the unit
is shut down due to Emergency Stop will be displayed at the
Human Interface Module.
9
Module Mounting Locations & Screw Hole
General Information
10
Installation
Unit Inspection
As soon as the unit arrives at the job site
[ ] Verify that the nameplate data matches the data on the
sales order and bill of lading (including electrical data).
[ ] Verify that the power supply complies with the unit name-
plate specifications.
[ ] Visually inspect the exterior of the unit, including the roof,
for signs of shipping damage.
[ ] Check for material shortages. Refer to the Component
Layout and Shipwith Location illustration.
If the job site inspection of the unit reveals damage or material shortages,
Specify the type and extent of the damage on the “bill of
lading” before signing.
[ ] Visually inspect the internal components for shipping
damage as soon as possible after delivery and before it
is stored. Do
file a claim with the carrier immediately.
not walk on the sheet metal base pans.
WARNING
No Step Surface!
Do not walk on the sheet metal drain pan. Walking on
the drain pan could cause the supporting metal to collapse. Failure of the drain pan could result in death or
serious injury.
Unit Clearances
Figure 1 illustrates the minimum operating and service
clearances for either a single, multiple, or pit application.
These clearances are the minimum distances necessary to
assure adequate serviceability, cataloged unit capacity, and
peak operating efficiency.
Providing less than the recommended clearances may result in condenser coil starvation or recirculation of hot condenser air.
Locate the unit as close to the applicable system support
equipment as possible to minimize refrigerant piping
lengths.
Unit Dimensions & Weight Information
Overall unit dimensional data for each unit is illustrated in
Figure 2.
A Center-of-Gravity illustration and the dimensional data is
shown in Figure 3.
Table 1 lists the typical unit operating and point loading
weights.
Foundation
If the unit is installed at ground level, elevate it above the
snow line. Provide concrete footings at each support location or a slab foundation for support. Refer to Table 1 for the
unit operating and point loading weights when constructing
the footing foundation.
Bridging between the unit's main supports may consist
of multiple 2 by 12 boards or sheet metal grating.
[ ] If concealed damage is discovered, notify the carrier’s
terminal of damage immediately by phone and by mail.
Concealed damage must be reported within 15 days.
Request an immediate joint inspection of the damage by
the carrier and the consignee. Do not remove damaged material from the receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery.
[ ] Notify the appropriate Trane office before installing or re-
pairing a damaged unit.
Anchor the unit to the footings or slab using hold down bolts
or isolators. Isolators should be installed to minimize the
transmission of vibrations into the building. Refer to the
“Unit Isolation” section for spring or rubber isolator installation instructions.
For rooftop applications, ensure the roof is strong enough to
support the unit. Refer to Table 1 for the unit operating
weights.
Anchor the unit to the roof with hold-down bolts or isolators.
Follow the instructions under “Unit Isolation” for proper isolator placement and installation.
Check with a roofing contractor for proper waterproofing
procedures.
11
Figure 1
Typical Installation Clearances for Single, Multiple or Pit Applications
12
Figure 2
C20 Ton Unit Dimensional Data & Recommended Clearances
13
Figure 2
C25 Ton Unit Dimensional Data & Recommended Clearances
14
Figure 2
C30 Ton Unit Dimensional Data & Recommended Clearances
15
Figure 2
C40 Ton Unit Dimensional Data & Recommended Clearances
16
Figure 2
C50 Ton Unit Dimensional Data & Recommended Clearances
17
Figure 2
C60 Ton Unit Dimensional Data & Recommended Clearances
18
Installation
Copper
Copper
Copper
Copper
Copper
Copper
Shipping
Center of Gravity
Unit
Weight
C20
39" 991
C25
C30
37" 940
C40
42" 1067
C50
52" 1321
C60
54" 1372
Table 1
Typical Unit Weights & Point Loading Data
Unit Condenser Operating Operating Weight Distribution @ Unit Mounting Points
SizeFin Mat’l.Weight123456
C20 Alum. 1870 595 470 470 335 — —
2085 690 475 490 430 — —
C25 Alum. 2085 700 470 490 425 — —
2370 760 540 580 490 — —
C30 Alum. 3060 865 430 725 340 430 270
3450 875 525 830 385 555 280
C40 Alum. 3290 560 580 580 595 480 495
3680 570 755 605 540 640 570
C50 Alum. 3900 685 715 720 750 505 525
4435 840 870 660 680 680 705
C60 Alum. 4885 885 820 855 985 620 720
5820 935 1220 875 920 1010 860
Notes:
1. Mounting locations correlate w ith those shown in point loading illustration.
2. Operating weight includes refrigerant, oil and water.
3. Shipping weight includes refrigerant and oil charges.
XZ
Size (Max. Lbs.) Inches mm Inches mm
1875
2085 40" 1016 26" 660
3065
3290
3900
4865
26" 660
30" 762
45" 1143
45" 1143
46" 1168
Figure 3
Rigging and Center-of-Gravity Data
WARNING
Heavy Objects!
Do not use cables (chains or slings) except as shown.
Each of the cables (chains or slings) used to lift the
unit must be capable of supporting the entire weight of
the unit. Lifting cables (chains or slings) may not be of
the same length. Adjust as necessary for even unit lift.
Other lifting arrangements may cause equipment or
property-only damage. Failure to properly lift unit could
result in death or serious injury. See details below.
Note: Use spreader bars as shown in the diagram.
Refer to the Installation manual or nameplate for
unit weight. Refer to the Installation instructions
located inside the control panel for further rigging
information.
19
Rigging
A Rigging illustration and Center-of-Gravity dimensional
data table is shown in Figure 3. Refer to the typical unit operating weights table before proceeding.
1. Rig the condensing unit as shown in Figure 3. Attach adequate strength lifting slings to all four lifting brackets in
the unit base rail. Do not use cables, chains, or slings except as shown.
2. Install spreader bars, as shown in Figure 3, to protect the
unit and to facilitate a uniform lift. The minimum distance
between the lifting hook and the top of the unit should be
7 feet.
3. Test-lift the unit to ensure it is properly rigged and balanced, make any necessary rigging adjustments.
4. Lift the unit and position it into place.
Unit Isolation
Installation
6. Level the unit carefully. Refer to the “Leveling the Unit”
section.
7. After the unit is level, tighten the isolator base mounting
bolts to secure them to the mounting surface.
Spring Isolators
Install the spring isolators at each unit mounting (load) point
using the following procedure:
1. Elevate the unit (one side at a time) to allow access to
the base rail mounting holes.
WARNING
Isolator Installation!
Use solid type blocks, i.e. 4" X 4" wood blocks or similar
material to prevent collapsing. Keep hands and other body
limbs clear of elevated base rail while installing isolators to
prevent personal injury.
To minimize unit sound and vibration transmission, one of
the following installation methods should be used:
1. Install the unit directly on an isolated (detached) concrete
pad or on isolated concrete footings located at each unit
load point.
2. Install the optional neoprene or spring isolators at each
mounting location. Refer to the following “Neoprene isolators” or “Spring Isolator” section.
Neoprene Isolators
Install the neoprene isolators at each unit mounting (load)
point, using the following procedure:
1. Elevate the unit (one side at a time) to allow access to
the base rail mounting holes.
WARNING
Isolator Installation!
Use solid type blocks, i.e. 4" X 4" wood blocks or similar
material to prevent collapsing. Keep hands and other body
limbs clear of elevated base rail while installing isolators to
prevent personal injury.
2. Align the mounting holes in the base rail of the unit with
the holes in the top of the appropriate isolator. Refer to
Figure 4 for the appropriate isolator for each load point.
3. Install a 1/2" NC bolt (field supplied) through the base rail
of the unit into the threaded bolt hole of the isolator. Position the isolator to allow access to the mounting holes
in the base of the isolator, then tighten securely.
4. Lower the unit and isolator onto the mounting surface.
The maximum isolator deflection should be approxi-
mately 1/4 inch.
5. Secure the isolator to the mounting surface using the
base holes in the isolator.
2. Align the mounting holes in the base rail of the unit with
the positioning pin in the top of the appropriate isolator.
Refer to Figure 5 for the appropriate isolator for each
load point.
3. Position the isolator to allow access to the mounting
holes in the base of the isolator.
4. Lower the unit onto the isolator. The positioning pin on
the isolator must engage into the hole of the base rail.
The clearance between the upper and lower isolator
housings should be approximately 1/4 to 1/2 inch. Refer
to Figure 5. A clearance greater than 1/2 inch indicates
that shims are required to level the unit. Refer to the
“Leveling the Unit” section.
5. Make minor clearance adjustments by turning the isolator
leveling bolt (Figure 5) clockwise to increase the clear-
ance and counterclockwise to decrease the clearance. If
proper isolator clearance cannot be obtained by turning
the leveling bolt, level the isolators themselves. A 1/4
inch variance in elevation is acceptable.
6. Secure the isolator to the mounting surface using the
base holes in the isolator.
7. After the unit is level, tighten the isolator base mounting
bolts to secure them to the mounting surface.
Leveling the Unit
Before tightening the mounting bolts, level the unit carefully.
Use the unit base rail as a reference. Level the unit to within
1/4 inch over its entire length. Use shims if non-adjustable
isolators (neoprene) are used.
If adjustable isolators (spring) are used, ensure that the
proper isolator housing clearance is maintained while leveling the unit. Isolators are identified by color and/or an isolator part number. Shims under the isolators may be required
if the unit can not be leveled using the isolator leveling bolt.
20
Loading...