Trane CGA Series, CXA Series Installation Operation & Maintenance
Scroll chillers and heat pumps
Models CGA/CXA
May 2015 CG-SVX031A-GB
Original instructions
Installation
Operation
Maintenance
Contents
Overview 3
Reference and certifications 4
Installation 8
Electrical connections 9
Hydraulic diagrams 12
Tank mounting instructions 14
Start-up procedures 17
Start-up 20
Maintenance 23
Recommended spare parts 23
Overview
Warranty
A. 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.
B. Warranty is twelve (12) months as from the date of first start up at installation place or eighteen (18) months after
delivery at the project or other delivery location indicated by the customer. The date the unit is operated for the first time
means the date reported in the “1st start up form” contained into the “unit log book”. This form should be filled in and
sent, within 8 days from the start up, to Trane.
C. The warranty is valid if all the installation and start-up instructions have been adhered to (both those which may have
come from Trane and those coming from current practice), if the “1st start up form” has been filled in and sent to the
Trane after sales department.
D. The warranty is subject to any faults or defects being reported within eight days from their discovery. The warranty will
only be applied if and when the purchaser suspends use of the equipment as soon as a defect has been found.
E. The warranty is valid if the first running of the unit is carried out by a Trane authorized assistance center.
F. The warranty is subject to regular maintenance of the unit which is appropriately indicated in the “unit log book” locat-
ed inside the electrical panel.
G. Warranty automatically ends in case of payments not fulfilled, non-performance of the contract and even if the units
show tampering without TRANE written approvals.
Receiving the unit
On receiving the unit, it is up to the customer to check that there is no obvious damage or pieces missing. If this is so, an
immediate complaint must be made to the carrier for damage or for not-delivery and the Receiving Card to be found
inside the unit electrical panel must be filled in. Photographic evidence must be provided for macroscopic damage. The
card must be sent to Trane within 8 days of receiving the goods: if it is not sent back or delayed, the complaint will not be
accepted.
Factory inspection
Units are inspected in the factory, in appropriate areas, in accordance with internal procedures. Each performance test
carried out on the unit is possible only if the same conditions are reproduced and maintained (charge consistency,
constant temperature and evaporation - condensation and recovery capacity, quality and tolerance of the measuring
instruments etc.) in the test rooms.
The inspection conditions are those indicated by the customer in the ordering phase: if not otherwise specified, reference
should be made to the nominal performance indicated in the product catalog in force at the date of the Confirmation of
the Order.
Improper uses
The unit is projected and built up to grant the maximum safety in its proximity, as well as to resist to the aggressive
environmental conditions. The fans are protected by grilles. Residual risks are indicated with warning labels.
SAFETY SYMBOLS
DANGER: DANGER: DANGER: DANGER:
General danger Temperature Moving parts Cut off
voltage
Reference and certifications
Reference standards
PRESSURE EQUIPMENT DIRECTIVE (97/23/EC)
UNI EN ISO 3744 ACOUSTIC REGULATION
UNI-EN-ISO 9001:2008: QUALITY MANAGEMENT SYSTEMS
LOW VOLTAGE DIRECTIVE (LVD) 2006/95/EC
MACHINERY DIRECTIVE 2006/42/EC
DIRECTIVE FOR ELECTROMAGNETIC COMPATIBILITY 2004/108/CE
CEI-EN 60204-1 DIRECTIVE (CEI44-5; CEI EN 62061) MACHINERY SAFETY – ELECTRIC MACHINERY –
EQUIPMENTS
ERP DIRECTIVE (ENERGY-RELATED-PRODUCTS ECODESIGN 2009/125/CE)
UNI EN 14511-1-2-3-4 TESTING CONDITIONS
Certifications
PED RELEASED FROM IMQ SPA - NOTIFIED BODY FOR REGULATION 97/23/EC (NO. 0051) ACCORDING TO THE
FOLLOWING STATEMENTS:
• DECLARATION OF QUALITY SYSTEM APPROVAL - FORM H1 (QUALITY ASSURANCE WITH DESIGN CONTROL
AND MONITORING OF FINAL CHECK DETAIL): CERTIFICATE N. PEC-0051-1105003.
• CERTIFICATES OF EXAMINATION OF THE PROJECT N. 0051-PEC-1105004/05/06/07/08.
QUALITY CERTIFICATION ACCORDING TO THE STANDARD UNI EN ISO 9001:2008 ISSUED BY CSQ (ACCREDITED BY ACCREDIA).
PERFORMANCE CERTIFICATION OF THE UNIT WITH THE PRESENCE OF RINA SPA DURING THE TESTING
PROCESS (OPTIONAL).
GOST CERTIFICATION - (OPTIONAL) FOR PRESSURE RECIPIENTS OF THE RUSSIAN FEDERATION.
Definitions
Owner:
The legal representative of the company, body or natural person who owns the plant in which the Trane unit is installed:
he or she is responsible for the control and respect of all the safety regulations indicated in this manual as well as the
national ones in force.
Installer:
The legal representative of the company appointed by the owner to position and hydraulically, electrically etc. connect the
Trane unit to the plant: he or she is responsible for moving and the correct installation of the unit in accordance with the
indications in this manual and with the national regulations in force.
Operator:
A person authorised by the owner to carry out all the operations of regulation and control on the Trane unit which are
specifically mentioned in this manual. He or she should keep to actions described in the manual and limit his or her action
to what is explicitly allowed.
Technician:
A person who is directly authorised by Trane or, secondarily, for all EU countries except for Italy, by the distributor of the
Trane product, under their own responsibility, to carry out all ordinary or extraordinary maintenance operations, as well as
regulations, controls, repairs and parts replacement which may be necessary during the lifetime of the unit.
Access to dangerous areas
The access to the unit dangerous areas is usually obstructed through protection panels, which are removable, by using a
tool. Axial fans are protected with accident prevention grilles.
Finned coil, for units not equipped with coil protection grilles, is completely accessible with danger for cuts and
abrasions. In these cases technicians and operators must be aware about this risk.
For all the units which allow access to the cooling piping or to the packaged condensing coils with fins, without security
gratings (optional) or closing panelling, the following precautions must be taken
mark the areas with contact risks.
apply warning signs
The danger zone must be of a suitable size to avoid any contact, even accidental contact.
In the presence of safety valves without relevant remote controls, the operating area must be of a size which considers
a range of action of the discharge flow of 3 metres.
Trane declines any responsibility for damage to things and unauthorised personnel in case of absence of clear and
static limiting systems of the risk areas and of the relevant warning and danger signs.
General precautions
The operator must only intervene on the unit controls. He or she must not open any panels except for the one which gives
access to the control module.
The installer must only intervene on the connections between the plant and the machine. He or she must not open any
machine panels nor carry out any commands.
The following precautions should be made when approaching or working on the unit:
• do not wear jewellery, baggy clothes or any other accessory which can get caught up.
• Use appropriate protection (gloves, glasses etc.) when using an open flame (welding) or compressed air.
• If the unit is located in a closed environment, wear hearing protection.
• before disconnecting, removing tubes, filters, joints or other line parts intercept the connection tubes, empty them until
the pressure reaches that of the atmosphere.
• do not use your hands to check for possible pressure losses.
• always use tools which are in good condition; make sure the instructions have been fully understood before using them.
• make sure that any tools, electrical cables or other loose objects have been removed before closing the unit and starting
it up again.
Precautions against risks due to the refrigerant
Precautions against residual risks
Prevention from risks due to the command system
• make sure the instructions for use have been understood before carrying out any work on the control panel
• always keep the instruction manual close at hand when working on the control panel
• start up the unit only after having certified that it is correctly connected to the plant
• inform the technician promptly of any alarms which appear on the unit
• do not reset the alarms to manual restart without having first identified the cause and removed it
Prevention against residual mechanical risks
• install the unit in accordance with the provisions of the following manual
• carry out all the maintenance operations provided for by this manual regularly
Safety data R410a
Toxicity
Not important
Risks for skin touching
Splashes or sprinkles can cause chill burns. The risk of absorptions through the skin is not relevant.
Those refrigerants could take some lightly irritating effects and in liquid stage they have a strong skinning effect. In this case it
is necessary to rinse with fresh water the contaminated parts of the skin
The refrigerant in liquid stage in contact with wet clothes causes freezing and adherence to the skin. In this case it is necessary to take off the contaminated clothes to avoid freezing. Contact a doctor in case of irritation of the contaminated parts.
Risks for contact with the
eyes
Vapors don’t take any effect. Splashes or sprinklers can cause chill burns. In those cases it is necessary to rinse eyes with
water or with solution for ocular washings for 10 minutes. The intervention of a doctor is needed.
Risks for ingestion
Should it happen, it causes chill burns. It does not cause vomiting. The person must be kept awake. It is needed to rinse the
mouth with fresh water and to drink almost 0,25 liters. The intervention of a doctor is useful.
Risks for inhalation
High concentration of vapours in air can lead to anaesthetic effects up to a loss of conscience. Long exposures could give
rise to cardiac arrhythmia and sometimes even to death.
High concentrations can create a reduction of oxygen in air, with consequent possibility of suffocation. Should it happen the
person must be taken to the open air and let him to take a rest.
Administer oxygen if needed. In case the breathing has interrupted or become irregular, it is necessary to apply the artificial
breathing. In case of cardiac arrest a heart massage must be applied. Contact a doctor immediately.
Conditions to avoid
Use in presence of exposed flames, and of high levels of humidity.
Dangerous reactions
Possibility of violent reactions with the sodium, the potassium, the barium and with other alkaline substances, incompatible
materials and all the alloys containing more than 2% of magnesium.
Protection wearing - Behavior in case of losses or
leaks
Wear protection apparel and self respirators. Insulate the source of the loss, if this operation can be done in safety conditions. Small quantitative of refrigerant escaped at liquid state can be allowed to evaporate only if the room is well ventilated.
In case of great losses ventilate the room immediately. Plug the loss with sand, soil or other absorbent material; avoid that
the liquid refrigerant can enter in water-drainages or losing pools.
Disassembly
The best procedure is the recovery and the recycle. If this is not possible the refrigerant must be conferred to an accredited
system for its destruction in order to neutralize acid and toxic by-products.
• wear a protective helmet before entering inside the unit
• before opening a machine panel make sure that it is firmly connected by means of a hinge
• do not touch the air condensation coils without having first put on protective gloves
• do not remove the protections to the moving parts while the unit is running
• before restarting the unit make sure that the moving part protections are in the correct position
Prevention against residual electrical risks
• connect the unit to the mains in accordance with the provisions of this manual
• carry out all maintenance operations regularly
• before opening the control panel disconnect the unit from the mains by means of the external knife switch
• check that the unit has been earthen correctly before starting it up
• control all the electrical connections, the connection cables paying particular attention to the state of isolation; replace
the cables which are clearly worn or damaged
• carry out periodic checks of the wiring inside the panel
• do not use cables with an inappropriate section or flying connections not even for a limited period or in an emergency
Prevention against residual risks of a different nature
• Residual risks due to pressure are mainly coming from non-functioning of the safety devices. To prevent them it is
necessary to follow checks and replacements as following (§12.1 and 13)
• To protect from safety devices exhaust it is not allowed to remove the protections while the unit is in operation and to
approach the unit without wearing the right protections. In case of accidental contact with refrigerant due to the safety
valves exhaust it is necessary to follow the above (§2.5)
• carry out the plant connections to the unit by following the indications reported on the following manual and on the
panels of the unit itself
• if a part is disassembled, make sure that it is correctly reassembled before restarting the unit
• do not touch the discharge line of the compressor, the compressor itself or any other tube or component which is inside
the machine without putting on protective gloves
• keep a fire extinguisher which is able to put out fires on electrical equipment near the machine
• on units installed inside, connect the refrigerant circuit shut off valve to a network of tubes which are able to lead the
possible spillage of refrigerating fluid outside
• eliminate any fluid loss inside or outside the unit
• collect the discharge liquid and clean up any possible oil leakage
• periodically clean the compressor casing of the accumulated dirt deposits
• do not keep inflammable liquids near the unit
• do not dispose of the refrigerant fluid and the lubricating oil in the environment
• welding should only be carried out on empty tubes; do not approach the tubes containing refrigerant fluid with flames or
other sources of heat
• do not bend or strike tubes containing pressurised fluids
Precautions to be observed during maintenance operations
Authorised technicians may only carry out maintenance operations. Before carrying out any maintenance the following
must be performed:
• isolate the unit from the mains electricity by using the external knife switch
• place a notice on the external knife switch which says “do not use - maintenance in progress”
• make sure that any possible on-off commands are disabled
• use appropriate safety equipment (helmet, isolating gloves, protective glasses, safety shoes etc.)
If measurements or controls must be carried out which require the machine to be running the following observations must
be followed:
• operate with the electrical panel open for as short a time as is possible
• close the electrical panel as soon as the individual measurement or control has been carried out
• for units which are located outside, do not carry out interventions in dangerous atmospheric conditions such as rain,
snow, fog etc.
The following precautions should also be taken at all times:
• never dispose of fluids contained in the refrigerant circuit into the environment
• when replacing an EPROM or electronic card always use appropriate equipment (extractor, anti-static bracelet, etc.)
• if a compressor, the evaporator, the condensation coils or any other heavy part is to be replaced, make sure that the
lifting equipment matches the weight to be lifted
• in the air cooled units with an independent compressor compartment, do not open the ventilator compartment without
having first isolated the machine using the knife switch on the side of the panel and only after having placed a sign which
says “do not use - maintenance in progress”
• if modifications must be carried out to the cooling, hydraulic or electrical circuit of the unit, as well as to its command
logic, contact Trane
• if particularly complicated assembly or disassembly operations are to be carried out contact Trane
• always use original spare parts bought directly from Trane or from official dealers of the companies reported in the list of
recommended spare parts
• if the unit is to be moved after a year of being in the site or if it has to be dismantled contact Trane
Manual alarm reset
If there is an alarm the unit must not be manually reset before having located and eliminated the cause of the fault.
Repeated manual resets may cause the guarantee to be void
Operating range
The operating ranges are indicated on the plate placed on the unit
Installation
Moving and positioning the unit
The units have been designed to be lifted from above by means of eyebolts and holes in the base members. Use
retractor bars to keep the lifting wires or chains away from the unit. Lifting procedures provided with the unit have to be
respected.
CAUTION!
Do not use forklift trucks to lift the unit from below. If equipment for lifting from above is not available, use rollers to move
the unit.
The surface on which the unit is placed must be flat and strong enough to withstand the weight of the unit while running.
In order to reduce the transmission of vibrations to the supporting structures, fit shock absorbers in every fastening point.
Rubber shock absorbers are recommended for units installed on the ground, spring shock absorbers for units installed on
roofs. Open spaces around the unit must be provided for in order to allow for the passage of necessary airflow and in
order to allow normal maintenance to be carried out (as shown on general catalogues).
NOTE: if two units have to be installed side by side, the safety distance must be doubled.
After the unit has reached the final position, fix the ant-vibration bolts.
Precautions for dominant winds
Avoid obstacles on suction and discharge sides of the units. Respect the safety distances as shown on the units
dimensional drawings.
In case of presence of dominant winds in the installation area it is strictly necessary to avoid (for units with horizontal flow
fans) that such winds blow in front of the unit (fans discharge side). In case of unit with vertical flow fans it is strictly
necessary to avoid installations where the dominant winds could cause rejected hot air to come back to the condensing
coils.
Precautions against direct sunshine
Direct solar radiation can raise the temperature of condensation until it causes the unit shutdown or failure start-up of the
same by action of the high pressure switch.
Precautions against the presence of fireplaces and exhaust hot air
Avoid installation of the machines downwind of chimneys, smokestacks and different effluent discharges.
Precautions against the presence of foliage and foreign bodies
Avoid installing the unit in the immediate vicinity of plants that can prevent proper intake and discharge air.
Control of compressor fastening
The compressors are fitted on shock absorbers. For fixing through spring ant vibration mounts, it is necessary to remove
blockages put to fasten the compressors, as indicated on the label on compressors body.
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