Trane Flex II 170, Flex II, Flex II 175, Flex II 180, Flex II 177 Original Instructions Manual
...
Installation
Operation
Maintenance
Flex II
Air-to-water heat pumps with fixed
speed scroll compressors
CG-SVX048A-GB
Original instructions
Contents
1 OVERVIEW ..................................................................................................................................... 4
2 SAFETY REGULATIONS ................................................................................................................... 4
3 OPERATING LIMITS ........................................................................................................................ 7
4 INSTALLATION ............................................................................................................................. 10
5 ACOUSTIC PROTECTION .............................................................................................................. 12
6 ELECTRICAL POWER SUPPLY ....................................................................................................... 12
7 WATER CONNECTIONS ................................................................................................................. 13
8 ELECTRICAL PANEL ..................................................................................................................... 24
9 OPERATOR RESPONSABILITIES ..................................................................................................... 27
10 START-UP PRELIMINARY PROCEDURES ....................................................................................... 27
12 CHECK LIST – MANDATORY OPERATION CONTROL BEFORE START-UP ........................................ 28
13 START-UP ................................................................................................................................... 33
14 MAINTENANCE ............................................................................................................................ 35
15 RECOMMENDED SPARE PARTS ..................................................................................................... 39
16 TROUBLESHOOTING .................................................................................................................... 40
17 IMPROPER USES ......................................................................................................................... 43
1 OVERVIEW
1.1
WARRANTY
A. Warranty is based on th e general terms and conditions of the manufactu r e r . The warranty is void if t he 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 m isu se , lack of maintenance or f ail u r e to comply
with the manufact urer’s instructions or re c omm e n dations is not cove r e d b y t h e warran ty obligation. If the user does
not conform to the ru l e s o f t his manu al, it may entail cance l l at io n of warranty and liabilities by the manufacturer.
B. Warranty is twelve (12) months as from the dat e of first start up at installat io n place or eighteen ( 18) mo n ths
after delivery at the project or other delivery location indicated by the customer. The date the unit is operated for
the first time mean s the date reported in the “1st start up form” contained into the “unit log book ” . This form should
be filled in and sen t, within 8 days from the start up, to Trane.
C. The warranty is valid if all the installat ion and start-up instructions have been adhered to (both those which may
have come from Trane an d those coming from current practice), if the “ 1st start up form” has been f il led in and sent
to the Trane after sal e s 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 p u rc h aser suspends use of the equipment as soon as a defect has been
found.
E. The warrant y is v al id if the first running of the unit is carried out b y a T ran e authorized assistance center.
F. The warrant y is su bject to regular maintenan c e of the unit which is appropriately indicat e d in the “unit log book”
located inside the electrical panel.
G. Warranty automat ical l y e n ds in case of payment s n ot fulfilled, non-performance of the contract and even if the
units show tampering without TRANE written approvals.
1.2
RECEIVING THE UNIT
On receiving the unit, it is up to the customer to check that there is no obviou s damage or pie ces 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 with in 8 days of receiving the goods: if it is not se n t b ack or de lay ed, the complaint will not
be accepted.
1.3
FACTORY INSPECTION
Trane units are inspected into the factory, in appropriate areas, in accordance with internal procedures. Each performance
test carried out on t he unit is possible only if the same condit ions 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 technical bulletin in force at the date of the Confirmation of
the Order.
2 SAFETY REGULATIONS
2.1
ACCESS TO DANGEROUS AREA
The access to the u n it d an gerous areas is usually obstru c t ed through protection panels, which are rem ovable, by using a
tool. Axial fans are p ro tected with accident p r e vention grilles.
For all the units which al l ow access to the cooling piping without security gratings (optional) o r c l osin g panelling, the
following precaut ion s mu st be taken:
-mark the areas with c ontact risks.
-apply warning sign s.
The danger zone mu st be of a suitable size to avoid an y c on tact, even accidental c on tact.
Trane declines any r e sponsibility for damage to things and unauthoriz ed personnel in case of absence of clear and
static limiting systems of the risk areas and of the relevant warning an d danger signs.
2.2
GENERAL PRECAUTIONS
The operator must only intervene on the unit commands; he or she must not open any panels except for the one which
gives access to the c omm an d 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:
• Use appropriate protection (glove s, glasses etc.) when u sin g an open flame (welding) or c om p r e sse d air.
• If the unit is loc ated in a closed environm e n t, wear hearing protection.
• Before disconnecting, rem oving tubes, filt e rs, joints or other line parts in tercept the connect ion tubes, empty them
until the pressure reaches that of the atmosphere.
• Do not use your h an ds to check for possible pressure losses.
• Always use tools w h ic h ar e in good condition; make sure the instructions h av e b een fu lly understood before using them.
• Make sure that any tools, e le ctrical cables or other loose objects have been removed before closing the unit and
starting it up again.
2.3
PRECAUTIONS AGAINST RISKS DUE TO THE REFRIGERANT
Refer to Safety Data Sheet. Refrigerant shall be always recovered before ope n ing any part of refrigeratin g circuit.
2.4
PRECAUTIONS AGAINST RESIDUAL RISKS
Prevention from risk s d u e to the command system
• make sure the instructions for use have been understood before carrying out any work on the control panel.
• always keep t h e 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 t he al ar ms to manual restart wit h ou t having first identified the cause and removed it.
2.5
PREVENTION AGAINST RESIDUAL MECHANICAL RISKS
• install the un it in accordance with the provisions of the f o llowin g manual.
• carry out all the maintenance op e r at io n s provided for by this manual regularly.
• wear a protective helmet before entering inside the unit.
• before open in g a machine panel make sure that it is firmly conne c ted by means of a hinge.
• do not touch t he air condensation batter ie s without having first put on protective gloves.
• do not remove the protections to the moving parts while the unit is running.
• before rest arting the unit make sure that the moving part prot e c tions are in the correct position.
2.6
PREVENTION AGAINST RESIDUAL ELECTRICAL RISKS
• connect the unit to the mains in accordance with the provisions of this manual.
• carry out all maint e nance 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 connect ions and the connection cable s paying particular attention to the state of iso lation;
replace the cables which are clearly worn or damaged.
• carry out periodic checks of the w irin g inside the panel.
• do not use cabl e s with an inappropriate se c tion or flying connect ions not even for a limite d p e r iod or in an emergency.
2.7
PREVENTION AGAINST RESIDUAL RISKS OF A DIFFERENT NATURE
• the r e sidual risks due to pressur e ar e m ain ly coming from a failure of the safety devices. To prev e nt them it is
necessary to check and replace them when required
• 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 t h at it is correctly reassembl e d before restarting t h e unit.
• do not tou ch t h e discharg e l ine 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 ex t inguisher which is able t o p u t ou t fires on electrical equip m e n t near the machine.
• on units install e d inside, connect the refrigerant circuit sh ut off valve to a network o f tube s which are able to lead
the possible spillag e of refrigerating fl u id outside.
• eliminate any f l u id l oss inside or outside th e unit.
• collect the d isc h ar ge liquid and clean up an y possible oil leakage.
• periodically clean the compressor casing of t h e accumu late d d irt deposits.
• do not keep inflammable liquids near the unit.
• do not dispose o f 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 pressurized fluids.
2.8
PRECAUTIONS TO BE OBSERVED DURING MAINTENANCE OPERATIONS
Only authorised technic ian s may carry out maintenanc e op erations. Before carr ying out any mainten an c e the
following must be performed:
• isolate the unit from the mains electric ity by using the extern al k n ife switch.
• place a notice on t h e external knife swit ch w h ic h say s “do not use - maintenance in progress”.
WARNING! DO NOT REMOVE THE HIGH PRESSURE SWITCHES HP IF THE UNIT IS NOT COMPLETELY
SERIOUS INJURY!
• make sure that any possible on-off commands are disabled.
• use appropriate safety equipmen t (helmet, isolating g l oves, protective glasse s, safety shoes etc.).
If measurements or con trols must be carried ou t which require the mach in e to be running the followin g observations
must be followed:
• operate with the electrical pan e l open for as short a time as is possible.
• close the ele c t r ic al panel as soon as the individual measurement or co n trol has been carried out.
• for un its which are located outside, do not carry out interventions in dangerou s atmospheric conditions such as rain,
snow, fog etc.
The following pr e c au tions should also be taken at al l times:
• never dispose of fluids contained in the refrigerant circuit in to the environment.
• when replacing the el e ctr on ic car d always use appropriate equipment (extractor, anti-static brace l e t, etc.).
• if a compressor, the evaporator, th e c on densation batteries or an y other heavy part is to be re placed, make sure that
the lifting equipment matches the weight to be lifted.
• if the unit has an indepe nden t compre ssor compartment, do not open the ventilator compartment without having
first isolated the mac h in e using the main switch on the side of the pan el and only after having plac e d a sign which says
“do not use - maintenance in progress”.
• if modifications must be carried o u t to the cooling, hydraulic or electrical circuit of the unit, or to its command
logic, contact Trane.
• if particularly co mplicated assembly o r disassembly operations are to be carried out c ontact Trane.
• always use orig inal spare parts bought directly from Trane or from official dealers of the companies reporte d in the
list of recommended spare parts.
• if the unit is t o be m oved after a year of being in the site or if it has to be dismantled contact Trane.
VERY IMPORTANT
No high pressure safety valve is installed on the unit.
The unit fail safe is assured by cut-out of the electrical power sup p l y to the coils of the compressor contactors. T he cu t out action is carried ou t by the electrical cont ac t of the unit high pre ssu r e switch.
No Schrader valve is instal l e d in the port the unit h igh pressure switch is plugged into.
This implies that fol lo w in g instruction must be observed:
VOID OF REFRIG ERANT. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DEATH OR
2.9
MANUAL ALARM RESET
If there is an alarm the u n it must not be manually r e set before having located an d e l imin ated the cause of the f au l t.
Repeated manual r e se ts may cause unit damage an d the warranty to be annulled.
CHILLER MODE
kit -10°C
3 OPERATING LIMITS
3.1
STORAGE
The units can be st o red within the following environmental cond it io n s:
Min ambient temper ature : -10°C
Max ambient tempe r ature : 53°C
Max relative humidity : 95% not condensable
CAUTION: The storage in a very hig h h u midity space (condensation ) can damage electron ic components.
3.2
OPERATING LIMITS
Unit operation is perm itted within the lim its indicated in the d iag r am provided in 3.3.
CAUTION: The operation outside the limits specified may c au se the activation of t h e protections and disrupt
the operation of t h e un it and, in extreme cases, damage the unit.
In case of doubt, con tact Trane.
These operating lim it s apply to unit operating at full load.
3.3
OPERATING RANGE
OAT
= Outdoor Air Temperature [°C]
LWT
= Leaving Water Temperature [°C]
Low ambient kit down to -10°C:
• EC fans
Glycol
HEAT PUMP MODE
kit
-15°C
OAT
= Outdoor Air Temperature [°C]
LWT
= Leaving Water Temperature [°C]
Low ambient kit down to -15°C:
• Heater in control box
Pressure drop coefficient
Flow rate coefficient
1,02
1,033
1,05
1,072
1,095
1,124
ETHYLENE GLYCOL CORRECTION TABLE
% Ethylene glycol weight
Freezing temperature
Suggested security limit Cooling
capacity coefficient
Power input coefficient
Flow rate coefficient
In order to calculate performance with glycoled solutions multipl y main sizes by respect i ve co ef fici ent s.
°C -2 -3,9 -6,5 -8,9 -11,8 -15,6 -19 -23,4
°C 3 1 -1 -4 -6 -10 -14 -19
- 0,995 0,99 0,985 0,981 0,977 0,974 0,971 0,968
- 0,997 0,993 0,99 0,988 0,986 0,984 0,982 0,981
- 1,003 1,01 1,02 1,033 1,05 1,072 1,095 1,124
- 1,029 1,06 1,09 1,118 1,149 1,182 1,211 1,243
GLYCOL PERCENTAGE DEPENDING ON FREEZINGTEMPERATURE
% glycol according to the freezing temperature
Freezing temperature 0°C -5°C -10°C -15°C -20°C -25°C
% Ethylene glycol
5% 10% 15% 20% 25% 30% 35% 40%
5% 12% 20% 28% 35% 40%
In order to calculate performance with glycoled solutions multipl y main sizes by respect i ve co ef fici ent s.
IMPORTANT: Ove r sized water pump as on board un it pump is required for operation with glycol > 25%. If any doubt please contact
your local sales office.
IMPORTANT:
Correct lifting procedure
Figure 1
4 INSTALLATION
4.1
MOVING AND POSITIONING THE UNIT
The units have bee n d esigned to be lifted from above by means of eyebolts and h o les in the base members.
Use retractor bars t o keep the lifting wires or c h ain s 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 avail ab l e , using rollers may 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 su p porting structures, f it sh oc k absorbers in every
fastening point. Rubber shock absorbers are recommended for units installed on the ground , spring shock absorber s f o r
units installed on roof s. Open spaces around th e unit must be provided for in order to allow for t h e passage of necessary
airflow and in order to allow normal maintenance to be carried out (as shown on general catalogues).
For example horizont al positioning of the u n it can l e ad to irreversible damage to the compressors.
Damage arising from incorrect transport will not be under warranty by the manufact ure r.
Immediately report an incorrect receipt of goods.
An arrow positioned up ward indicates the vertical position of the unit.
Make sure that dur in g transport the unit ALWAY S remains in the correct p osition!
minimum space requirements [mm]
Figure 2
4.2
MINIMUM SPACE REQUIREMENTS
Dimensional drawing sh al l be respected to avoid:
• Noise
• Incorrect heat exchange and ventilat ion
• Difficult mainten an ce or inaccessibility to components
It is fundamental to respect minimum distan c e s on all u n its, in order to en su re optimum ventilation for
the condenser coils. Limited installati on space could reduce th e normal air flow, thus signif ic an tly reducing
the unit performance and considerably increasing consumption of e le ct rical ene rg y .
CAUTION: in case two stand-alone units have to be inst all e d side by side, the distance of respect must
be doubled.
** As far as modular units are concerned no side space is required between any of the units and the
adjacent one. The minimum side space of 500 mm featured in Figure 2 is required only for the units
placed at the far sides of the modular system.
After the unit has re ach ed the final position, f ix the antivibration bolts.
4.3
PRECAUTIONS FOR DOMINANT WINDS
Avoid obstacles on suction and discharge sid es of the units. Respect the safety distances as sho w n on the units
dimensional drawings.
In case of presence of dominant winds in the installation area it is strict l y n e c e ssar y to avoid (for unit s with horizontal
flow fans) that such winds blow in front of the u n it (fans discharge side). In case of unit with vertical flow fans it is
strictly necessary to av o id installations w h e r e the dominant winds cou ld cause rejected hot air to co me back to the
condensing coils.
4.4
PRECAUTIONS AGAINST DIRECT SUNSHINE
Direct solar radiation c an raise the temperat u r e of condensation until it cau se s the unit shutdown or failure start-up of
the same by action of the high pressure switch.
4.5
PRECAUTIONS AGAINST THE PRESENCE OF FIREPLACES AND EXHAUST HOT AIR
Avoid installation of the machines downwind of chimneys, smokestacks and different e ffluent discharges.
4.6
PRECAUTIONS AGAINST THE PRESENCE OF FOLIAGE AND FOREIGN BODIES
Avoid installing the unit in the immediate v icin ity of plants that can p r e vent proper intake and discharge air.
4.7
CONTROL OF COMPRESSOR FASTENING
The compressors are fitted on shock absorber s. For fixing through spr in g anti-vibration moun ts, it is necessary to remove
blockages put to fast e n the compressors, as indicat e d on the label on compr e ssor s b o d y .
5 ACOUSTIC PROTECTION
When the sound level must be checked in particular, it is necessary to pay maximum WARNING in isolation from
the base of the unit properly applying the anti-vibration mounts (provided optionally). A lso, install flexible
joints on water connections.
6 ELECTRICAL POWER SUPPLY
The mains power supply characteristics have to match the unit’s absor p tion. The mains power su p ply tension must
correspond to the nominal value ± 10%, with a maximum difference between the phases of 2%.
All power supply w irin g must be sized and sele cted accordingly by the p roject engineer in accordance with standard IEC
60364. All wiring must comply with local code.
6.1
POWER CONNECTIONS
Protect the unit electric box power supply circuit with p rotection d evices (not included in the supplied
equipment). Connect the line terminals with a three-core cable of a section wh ich is ap propriate to the
machine absorption. The switch and the fu se s l ik e all the power connect ion s m u st co mp ly with the regulations
in force.
6.2
IMBALANCE BETWEEN THE SUPPLY TENSION PHASES
Do not run the electrical motors when the voltage unbalance between the phases is more than 2%.
Use the following formula to check:
% Imbalance = [(Vx – Vave) x 100/Vave]
Vave = (V1 + V2 + V3)/3
Vx = phase with greatest d i f ferenc e from Vave (without
regard to the sign)
IMPORTANT: If the mains voltage has an imbalance of above 2%, con t act the company, which distributes the electrical
energy. If the unit functions with a unit voltage imbalance between the phases of above 2% the warranty is invalid.
6.3
UNIT VOLTAGE PHASING
It is important that proper rotation of the compressors be establish ed before the unit is started. Proper mot or
rotation requires confirmation of the el e c t r ic al phase sequence of th e p ower supply. The motor is internally
connected for cloc k wise rotation with the in c om in g power supply phases A-B-C.
7 WATER CONNECTIONS
7.1
EVAPORATOR
The connection tubes have to be supported adequately in order that their weight does not damage the plant. The
following parts hav e to be installed on the w ater circuit of the evaporato r:
• Two pressure gaug e s o f adequate scale (in and out of the unit)
• Two shock-absorbing joints (in and out of the unit)
• One shut off valve (normal one in input)
• One setting valve (in output)
• Two thermomet e r s ( in and out)
• One circulation pump
• One safety valve on the water buffer
• One aut om at ic air vent valve
• One expansion tank
• An inlet filter placed as near as possible to the evaporator
• One flo w switch
The above-mention ed installation indications represent nece ssar y c on ditions for the warranty to be valid.
Trane is at your dispo sal t o e xamine any different requirements, which have to be approved before starting up the un it.
It is necessary that t he wat er flow rate to the un it is compat ible wit h the ev aporator on e. It is also n ecessar y that t he
water flow rate is ke pt un iform while th e un it is runnin g: it is sugg est ed t o use alw ays a pu mp syst em d edic ated to the
unit and independent from the remaining part of the plant.
Before stalling unit s with temperature ar ou n d 0°C please evacuate the exchanger with compr e sse d air in order to avoid
breakings due to ic e .
If the unit is installed in order to replace another, the entire hydraulic system must be emptied and cleaned before
the new unit is installed. Regular tests and proper chemical treatment of water are recommended before starting
up the new unit.
In the event that glycol is added to the hydraulic system as anti-freeze protection, pay attention to the fact that
intake pressure will be lower, the unit’s performance will be lower and water pressure drops will be greater. All
unit-protection methods, such as anti-freeze, and low-pressure protection will need to be reset. Before insulating
water piping, check that there are no leaks.
CAUTION: Install a mechanical water filter at the water inlet of each heat exchange r. Fail u re to install the filt e r al lo w s
access of solid partic les and / or welding sl ag inside the heat exch an ger. We recommend the in stallation of a filter
having a filtering n et with holes not exceed in g 0.5 mm in diameter.
Trane cannot be held responsible for any damage to he at exchangers due to the lack of good quality water fil ters.
** In case the unit is a modular one the water filter and the flow switch are on board the unit so the installation of
water filter and flow switch in the customer plant is not needed
Cold water heat production
Hot water heat production
150
155
157
160
165
170
180
190
1100
1110
1115
7.1.1
The machine needs a minimum water content according to the following values:
Calculation of total minimum water content and flow rates
FLEX II
V K Q min Q max V K Q min Q max
[m3] [m3/h] [m3/h] [m3] [m3/h] [m3/h]
- 202,5 5,3 14,1 200,4 6,0 16,1 0,48
- 199,1 5,8 15,6 197,0 6,7 17,9 0,54
- 196,4 6,1 16,4 194,2 7,0 18,8 0,56
- 195,6 6,5 17,3 193,3 7,5 20,0 0,60
- 84,8 7,0 18,7 84,2 7,9 21,1 0,63
- 84,1 7,3 19,6 83,5 8,3 22,2 0,67
- 81,9 8,2 21,8 81,3 9,2 24,5 0,74
- 80,2 9,3 24,8 79,5 10,5 28,0 0,84
- 43,0 10,6 28,2 42,7 11,7 31,3 0,94
- 42,5 11,5 30,6 42,2 12,7 33,9 1,02
- 41,8 12,3 32,8 41,5 14,1 37,6 1,13
LEGEND:
V
: minimum water content of the plant
Q min
Q max
: minimum water flow to the heat exchanger
: maximum water flow to the heat exchanger
∆Tmax chiller = 8 °C
∆Tmax heat pump = 8 °C
dpw = K·Q² / 1000 Q = 0,86 P/∆T
IMPORTANT: If pumps driven by inverters (either unit onboard pump or external pump) in every working condition the variation of
the water flow rate mu st be as low as possible. Vari ation must be less th an 10% o f the nominal flow rate per minu t e
7.2
WATER CIRCUIT REGULATION EQUIPMENT
Centrifugal motor pump block
Assures the discharge an d the prevalence n e c e ssar y to supply tube nest e v aporator, the tank and th e u tility.
Automatic filling unit
Assures the water p r e ssu r e in the plant is maintained at least 1.5 bar, automatically resetting it when necessary.
Safety valve
Takes care of openin g the plant in atmospher e if the pressure exceeds the value of 6 bar.
Expansion tank
Takes care of compen sating small water hammering and variations of volume for different temperatures.
Check valves
Take care of interc e pting the pump for possibl e m ain tenance.
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