CG-SVX15A-E4

Installation
Operation
Maintenance
LARGE COMMERCIAL
AIR COOLED CHILLER
CGAP 025-030-040-050-060 & CGAH 080
50 Hz
TRANE
R
64)-

i
General nformation
charge is not included in the standard
manufacturer Warranty Cover.
General Information
About this manual
Caution appears at appropriate places
in this instruction manual.
Your personal safety and the proper
operation of this machine require that
you follow them carefully. The con-
structor assumes no liability for instal-
lations or servicing performed by un-
qualified personnel.
About the unit
These chiller units are assembled,
pressure tested, dehydrated, charged
and run tested before shipment. The
information contained in this manual
applies to units designated CGAP
025 ~ 060 & CGAH 080.
Refrigerant
The refri gerant provi ded by the
manufacturer meets al l the
requi rements of our uni ts. When
usi ng recycl ed or reprocessed
refrigerant, it is advisable to ensure its
quality is equivalent to that of a new
refrigerant. For this, it is necessary to
have a precise analysis made by a
specialized laboratory. If this condition
is not respected, the manufacturer
warranty could be cancelled.
Foreword
These installation, operation and
maintenance instructions are given as
a gui de to good practi ce i n the
i nstal l ati on, putti ng i nto servi ce,
operation, and maintenance by the
user, of Trane chillers. They do not con-
tain full service procedures necessary
for the continued successful operation
of this equipment: The services of
a qualified technician should be em-
ployed through the medium of a main-
tenance contract with a reputable ser-
vice company.
Warranty
Warranty is based on the general terms
and conditions of the manufacturer.
The warranty is void if the equipment
is repaired or modified without the
written approval of the manufacturer, if
the operating limits are exceeded or if
the control system or the electrical
wiring is modified. Damage due to
mi suse, l ack of mai ntenance or
fai l ure to compl y wi th the
manufacturer' s i nstructi ons or
recommendations is not covered by the
warranty obligation. If the user does
not conform to the rules of chapter
"Maintenance", it may entail cancella-
tion of warranty and liabilities by
the manufacturer.
Reception
On arrival, inspect the unit before
signing the delivery note. Specify any
damage on the delivery note, and
send a registered letter of protest to
the last carrier of the goods within 72
hours of delivery. Notify the local Trane
Sales Office at the same time. The
unit should be totally inspected within
7 days of delivery. If any concealed
damage is discover, send a resgitered
letter of protest to the carrier within 7
days of delivery and notify the local
Trane Office.
Units are shipped with the refrigerent
operatri ng charge and shoul d be
exami ned wi th an el ectroni c l eak
detector to determine the hermetic
integrity of the unit. The refrigerant
64)-

Contents
General Information
Contents
Introduction
Model Nomenclature
General Data
Unit Installation
General start-up
Control System
Dimensional Data
Wiring Diagram
Installation Check List
Maintenance
Troubleshooting
ii
(i)
(ii)
1
2
4
5
11
13
14
17
23
24
26
64)-

ntroduction
NOTICE:
Warnings and Cautions appear at
appropriate sections throughout this
manual. Read these carefully.
WARNING - Indicates a
potentially hazardous situation which,
if not avoided, could result in death or
serious injury.
CAUTION - Indicates a
potentially hazardous situation which,
if not avoided, may result in minor or
moderate injury. It may also be used
to alert against unsafe practices.
CAUTION-Indi cates a si tuati on
property-damage-only accidents.
1
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.
Thi s bookl et descri bes proper
i nstal l ati on, operati on, and
maintenance procedures for air cooled
chiller systems. By carefully reviewing
the information within this manual and
following the instruction, the risk of
improper operation and/or component
damage will be minimized.
It i s i mportant that peri odi c
maintenance be performed to help
assure troubl e free operati on. A
maintenance schedule is provided at
the end of thi s manual . Shoul d
equipment failure occur, contact a
qualified service organization with
qual i fi ed, experi enced 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. Do Not release
refrigerant to the atmosphere! If
adding or removing refrigerant is
required, the service technician must
comply with all federal, state, and
local laws.
64)-

2
CGAP MODEL
NOMENCLATURE
DIGIT 1,2,3
DIGIT 4
DIGIT 5,6,7
DIGIT 8
DIGIT 9
DIGIT 10
DIGIT 11
DIGIT 12
DIGIT 13
DIGIT 14
DIGIT 15
Chiller / Cooling Only / Air-Cooled
Development Sequence
Nominal Cooling Capacity
025 = 250 MBH 040 = 400 MBH 060 = 600MBH
030 = 300 MBH 050 = 500 MBH
Electrical Rating / Utilization Range
D = 380-415V / 3 Phase / 50Hz
Factory Mounted Control
1 = DOL Starter with CAREL controller
2 = Soft Starter with CAREL controller
Minor Design Sequence
H = Introduction of Carel Controller and FUJI Starter
Factory Installed Options
X = None
1 = Corrosion Resistant Coated Fin
Refrigerant Type
A = R22
B = R407C
Future Use
Future Use
Service Indicator
C G A P 0 2 5 D 1 H X A 0 0 A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
C G A
P
0 2 5
D
1
H
X
A
0
0
A
64)-

3
CGAH MODEL
NOMENCLATURE
DIGIT 1,2,3
DIGIT 4
DIGIT 5,6,7
DIGIT 8
DIGIT 9
DIGIT 10
DIGIT 11
DIGIT 12
DIGIT 13
DIGIT 14
DIGIT 15
Chiller / Cooling Only / Air-Cooled
Development Sequence
Nominal Cooling Capacity
080 = 208kW
Electrical Rating / Utilization Range
D = 380-415V / 3 Phase / 50Hz
Minor Design Sequence
Factory Installed Options
X = None
J = Condenser Protecting Grille
L = Compressor Sound Attenuator
K = J & L
Factory Mounted Control
1 = DOL Starter with CAREL Controller
2 = Soft Starter with CAREL Controller
Operating Ambient Temperature
R = Normal, 3-43 C
Refrigerant Type
A = R22
B = R407C
Built In Water Pump
N = Without [Standard]
Service Indicator
C G A H 0 8 0 D E X 1 R A N A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
C G A
H
0 8 0
D
E
X
1
R
A
N
A
64)-

General Data 20-60 Ton

Air-Cooled Chiller
4
Notes
[1] Based on chilled water EWT & LWT of 54 deg. F & 44 deg F
and 95 deg F, ambient air temp.
[2] Per Motor @ 400V
[3] Minimum Circuit Ampacity (MCA) is 125% of the largest compressor
RLA plus 100% of the other compressor RLA plus the sum of the
condenser fan FLA.
Performances (1)
Gross Cooling Capacity [R22] (1)
Gross Cooling Capacity (R407C)
Unit Capacity Steps (%)
Total Compressor Power Input (1)
Main Power Supply
Utilization Range
Sound Power Level
Compressor
Number
Type
Model
Speeds Number
Motors Number
Unit MCA Amps(3)
RLA / LRA(2)
Motor RPM
Condenser Coil
Type
Tube Size
Tube Type
Height
Length
Quantity
Rows
Fins Per Foot (fpf)
Evaporator Data
Type
Water Flowrate
Nominal Flow, water PD
Minimum Flowrate
Maximum Flowrate
Water Strainer
Water Connection
Fan
Type
Number
Diameter
Drive Type
Speeds Number
Motors Quantity
Motors kW (2)
FLA (2)
Motor RPM
Dimensions
Height
Width
Length
Weight Uncrated
Weight Crated
System Data
Refri erant Circuit
Minimum Outdoor Air Temperature for Mechanical Cooling
Standard Ambient Operating Range
Hight Pressure [cut out-cut in]
Low Pressure [cut out-cut in]
CGAP - CGAH General Data
CGAP 030
77.7 / 265.2
73.8 / 252
100-50
26.8
400/3/50
89
2
Scroll
2 X 15T
1
1
57
24/175
2900
Plate Fin
9.52
Smooth
72
70
1
3
144
54
7.5
40.5
67.5
2 1/2
Propeller
2
711/28
Direct
1
2
0.6/0.75
1.5
900
1911
1002
2264
593
613
1
59-109F
15-43 C
(kW)/(MBH)
(kW)/(MBH)
(kW)
(dB(A)
(A)
(A)
(rpm)
(mm)
(in)
(in)
US GPM
ft H2O
US GPM
US GPM
BSPT
(mm)/(in)
kw/hp
(A)
(rpm)
(mm)
(mm)
(mm)
(kg)
(kg)
(F)
(C)
(psig)
(psig)
CGAP 040
100.1/341.8
95/324.7
100-75-50-25
36.2
400/3/50
89
4
Scroll
2x(10T+10T)
1
1
75
16.5/130
2900
Plate Fin
9.52
Smooth
72
70
2
2
144
70
8
52.5
87.5
2 1/2
Propeller
3
711/28
Direct
1
3
0.6/0.75
1.5
900
1911
1992
2264
990
1025
2
59-109F
15-43 C
CGAP 050
127.1/433.8
120.7/412
100-75-50-25
50.4
400/3/50
90
4
Scroll
2x(13T+13T)
1
1
75
20.5/135
2900
Plate Fin
9.52
Smooth
72
70
2
2+3
144
88
8.3
66
110
2 1/2
Propeller
4
711/28
Direct
1
4
0.6/0.75
1.5
900
1911
1992
2264
1153
1188
2
59-109F
15-43 C
CGAP 060
156.1/532.8
148.3/506.2
100-75-50-25
53.6
400/3/50
92
4
Scroll
2x(15T+15T)
1
1
108
24/175
2900
Plate Fin
9.52
Smooth
72
70
2
3
144
108.5
8.6
81.4
135.6
2 1/2
Propeller
4
711/28
Direct
1
4
0.6/0.75
1.5
900
1911
1992
2264
1177
1212
2
59-109F
15-43 C
CGAP 025
64.5 / 220.3
61.3 / 209.3
100-50
25.2
400/3/50
87
2
Scroll
2x13T
1
1
49
20.5/135
2900
Plate Fin
9.52
Smooth
72
70
1
2+3
144
45
7.4
33.8
56.3
2 1/2"
Propeller
2
711/28
Direct
1
2
0.6/0.75
1.5
900
1911
1002
2264
583
603
1
59-109 F
15-43 C
CGAH 080
208/710
197/674
100-75-50-25
75.2
400/3/50
92
4
Scroll
2x(20Tx2)
1
1
147
31/215
2900
Plate Fin
9.52
Smooth
62
108
2
3
144
142
12.4
106.5
177.5
2 1/2
Propeller
6
760/30
Direct
1
6
0.9/1.2
2.5
720
2002
1950
3160
2030
2080
2
59-109F
15-43 C
400+, -10%
415 +/- 10 psig, 250 +/- 15 psig
45 +/- 5 psig, 60 +/- psig
------ Brazed Plate Heat Exchanger ------
Standard, Accessory, Ship with but installed at site
64)-

Before preparing the unit for lifting, es-

timate the approximate centre of grav-
ity for lifting safety. Due to the place-
ment of internal components, the unit
weights may be unevenly distributed.
Unit shipping weights are provided in
the general data.
nstallation
5
WARNING: To prevent injury
or death and unit damage, observe
handling cautions and procedures
given in Figure 1 when lifting the
unit. Always test-lift the unit to
determine actual centre of gravity.
Figure 1 - Lifting of the unit
General
All Trane products are identified by a
model number that precisely identifies
the uni t. An expl anati on of the
alphanumeric identification codes for
CGAP uni ts i s provi ded on the
previous page. Its use will enable the
owner / operator installing contractors
and servi ce enabl e the owner /
operator installing contractors and
service engineers to define the opera-
tion, components and options for any
specific unit.
When ordering replacement parts or
requesting service, be sure to refer to
the serial number and specific model
number stamped on the uni t
nameplate.
Unit Nameplate
The uni t namepl ate speci fi es the
unit' s specific model number, serial
number, electrical characteristics, type
of refrigerant and other pertinent unit
data.
Compressor Nameplate
The namepl ate for the "Scrol l "
compressors are l ocated on the
compressor lower housing.
Unit Description
All air-cooled chillers are designed for
outdoor installation with vertical air dis-
charge. Each refrigerant circuit is
provided with and operating charge of
refrigerant and refrigerant oil, a filter
drier, sight glass/moisture indicator, Hi/
Low pressure switches, and Hi/Low
pressure ports (schraeder valves) and
external l y equal i zed thermostati c
expansion valve. All units are leak
tested, dehydrated, charged and tested
for proper control operation before
shipment.
An access panel(s) provides access
to the compressor section(s), and a
removable cover allows access to the
control box.
The brazed plate heat evaporators
used in these units are with integral
distributor. Each evaporator is fully
insulated.
Standard capacity and safety controls
are provi ded. Uni t operati on i s
governed by chilled water temperature
leaving the evaporator.
CAUTION: These units must
be lifted with utmost care. Avoid
shock load by lifting slowly and
evenly.
Special Lifting And Moving
Instruction
A specific lifting method is recom-
mended as follows:
1.Four lifting points are built into the
unit.
2.Sl i ngs and spreaded bar to be
provided by rigger and attached to
the four lifting points.
3.Mi ni mum rated l i fti ng capaci ty
(vertical) of each sling and spreader
bar shal l be no l ess than the
tabulated unit shipping weight as
above.
64)-

6
nstallation
Special Note on
Refrigeration Emissions
Based on the best currentl y
avai l abl e evi dence, worl d
environmental scientists have
concluded that the cause of ozone
depl eti on i n our upper
atmosphere is due to the release
of CFC ful l y hal ogenated
compounds.
The Trane Company urges all
HVAC servicing be done in a
responsible manner to conserve
refrigerants for continued use
(even when acceptable
alternatives are available). Always
make every effort to eliminate, if
possible, or vigorously reduce the
emission of CFC, HCFC and HFC
refrigerants to the atmosphere
resulting form installation,
operation, routine maintenance,
or major service on this
equipment
Isolating rubber pads
Place between the supporting floor and
the unit to isolate from the ground.
- 6 pads for the sizes 025-030
- 8 pads for the sizes 040-060/080
- Trane does not recommend to install
spring isolators.
Clearance
Respect recommended cl earance
arround the unit to allow maintenance
operati on to take pl ace wi thout
obstructi on and recommended
clearance around condenser.
In this case the standard operating
condi ti ons and performance are
modified.
Operation of the unit may be affected
by an increase in air temperature on
the condenser. When the units are
positioned in a windy area, avoid all
the risks of air recycling. Refer to cer-
tified drawings.
Caution
Unit operation is function of the air
temperature. Any recycling of the
air fed out by the fans will increase
the air intake temperature over the
condenser fins and can result in
high pressure cut-out.
General unit characteristics
For minimum clearance, consult the
certi fi ed submi ttal s, whi ch are
available on request from your Trane
Agency.
Unit nameplate
The unit nameplate gives the complete
model reference numbers. The unit
power rating is shown, and power
supplies should not deviate by more
than 5% from the rated power.
Compressor motor amperage i s
shown in electrical data table.
The customer's electrical installation
must be able to withstand this current.
Installation instructions
Foundations
No special foundations are required,
provided the supporting surface is flat
and level, and can withstand the weight
of the unit.
64)-

7
nstallation
Caution: If using an acidic
commerci al fl ushi ng sol uti on,
construct a temporary bypass
around the unit to prevent damage
to the evaporator i nternal
components.
8 Strainer : avoid to get heat
exchangers dirty. All installtion must
be equipped with efficient strainer in
order that only clean water enters into
exchanger.
The strainer used must be able to
stop all particles with a diameter
greater than 0.8 mm.
9 Draining: used as the draining the
plate heat exchanger.
Before making any connections,
make sure the labeling for entering
and leaving water corresponds to
the submittals.
Unit Water Piping
General Piping Recommendations
Thoroughl y fl ush al l water suppl y
piping before making the final piping
to the unit.
Evaporator water inlet and outlet types,
sizes and locations are shown in the
"Dimensional data" section Figure 2
on page 10 illustrates a typical water
piping components. Isolate the water
pump from the system to avoi d
vi brati on transmi ssi on. Al l water
piping are to be insulated to minimize
heat gain and prevent condensation.
Use a pipe sealant or Teflon tape on
all threaded connections.
Net Positive Suction Head
Evaporator water pumps should be
located in their piping systems such
that they operate with a net positive
suction head. This is to reduce the
possi bi ty of pump cavi tati on and
possibility differential aeration in the
water system which can rapidly result
in chiller internal corrosion.
Figure 2 - Typical water circuit
1 Pressure gauges: show entering
and leaving water pressure
2 Balancing valve: adjusts water flow.
3 Air purge allows to remove the air
from the water circuit during fill up.
4 Stop valves: isolate chillers and
water ci rcui ti ng pump duri ng
maintenance operations.
5 Thermometers: indicate chilled
water entering and leaving tempera-
tures.
6 Expansion compensators: avoid
mechanical stress between chiller
and piping installation.
7 Stop valve located on the outlet
connection: used to measure the
water pressure inlet or outlet of
evaporator.
64)-

8
nstallation
EVAPORATOR - Water Pressure Drop Data
Table 1
2.1
2.3
2.4
2.6
2.7
2.8
3.0
3.1
3.3
3.4
3.5
2.6
2.7
2.9
3.1
3.2
3.4
3.6
3.7
3.9
4.1
4.3
3.3
3.5
3.8
4.0
4.2
4.4
4.6
4.9
5.1
5.3
5.5
4.2
4.4
4.7
5.0
5.3
5.6
5.8
6.1
6.4
6.7
6.9
5.1
5.5
5.8
6.2
6.5
6.8
7.2
7.5
7.9
8.2
8.6
127.8
136.3
144.8
153.3
161.8
170.3
178.9
187.4
195.9
204.4
212.9
153.3
163.5
173.7
184.0
194.2
204.4
214.6
224.9
235.1
245.3
255.5
198.7
212.0
225.2
238.5
251.7
265.0
278.2
291.5
304.7
318.0
331.2
249.8
266.5
283.1
299.8
316.5
333.1
349.8
366.4
383.1
399.7
416.4
308.0
328.6
349.1
369.6
390.2
410.7
431.3
451.8
472.3
492.9
513.4
CGAP
025
CGAP
030
CGAP
040
CGAP
050
CGAP
060
lit/min m3/sec
Model
EVAP. Water Flowrate
33.8
36.0
38.3
40.5
42.8
45.0
47.3
49.5
51.8
54.0
56.3
40.5
43.2
45.9
48.6
51.3
54.0
56.7
59.4
62.1
64.8
67.5
52.5
56.0
59.5
63.0
66.5
70.0
73.5
77.0
80.5
84.0
87.5
66.0
70.4
74.8
79.2
83.6
88.0
92.4
96.8
101.2
105.6
110.0
81.4
86.8
92.2
97.7
103.1
108.5
113.9
119.4
124.8
130.2
135.6
gpm(us) kPa
4.3
4.9
5.5
6.1
6.8
7.4
8.0
8.6
9.2
9.8
10.6
4.4
5.0
5.6
6.2
6.8
7.5
8.1
8.7
9.3
9.9
10.7
4.8
4.4
6.1
6.7
7.3
8.0
8.6
9.3
9.9
10.8
11.7
5.0
5.6
6.3
6.9
7.6
8.3
8.9
9.6
10.3
11.2
12.2
5.2
5.9
6.5
7.2
7.9
8.6
9.3
9.9
10.9
11.8
12.8
ft H20
WPD
CGAH
080
Model
6.7
7.2
7.6
8.1
8.5
9.0
9.4
9.9
10.3
10.8
11.2
403.1
430.0
456.9
483.8
510.7
537.5
564.4
591.3
618.2
645.0
671.9
lit/min m3/sec
EVAP Water flowrate
106.5
113.6
120.7
127.8
134.9
142.0
149.1
156.2
163.3
170.4
177.5
gpm(us) kPa
7.5
8.3
9.2
10.0
11.2
12.4
13.6
14.8
16.0
17.2
18.5
ft H20
WPD
22.4
24.9
27.4
29.9
33.4
37.0
40.7
44.2
47.9
51.5
55.2
12.8
14.7
16.5
18.3
20.2
22.0
23.8
25.7
27.5
29.3
31.6
13.1
14.9
16.8
18.4
20.4
22.3
24.1
26.0
27.8
29.6
32.1
14.2
13.1
18.1
20.0
21.9
23.9
25.8
27.7
29.6
32.2
34.9
14.8
16.8
18.7
20.7
22.7
24.7
26.7
28.6
30.9
33.6
36.4
15.5
17.5
19.5
21.6
23.6
25.6
27.7
29.7
32.5
35.3
38.2
64)-

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P
0
5
0
C
G
A
H
0
8
0
C
G
A
P
0
4
0
C
G
A
P
0
6
0
C
G
A
P
0
3
0
9
nstallation
C
H
A
R
T

1
64)-

10
nstallation
Table 2 - CGAP / CGAH, Electrical Data (@ARI)
As per UL standard,
MCA = Minimum Circuit Ampacity,
MCA = 1.25 (LARGEST MOTOR AMP (RLA or FLA) + the SUM OF REMAINING MOTOR AMPS.
RLA (ARI) = Rated Load Amp at ARI Rating Point, (3.3C Evap / 54.4C Condensing)
WHEN, Compressor is Large Load:
MAX FUSE SIZE & MCA = (2.25 * LARGEST COMPR. RLA) + SUM OF REMAINING COMPRESSOR RLA + FAN MOTOR FLA.
Note: The standard fuse or circuit breaker size selected must be equal to or less than the calculated value.
Also, the selected device rating must be greater than the minimum circuit ampacity.
CGAP 025
CGAP 030
CGAP 040
CGAP 050
CGAP 060
CGAH 080
70
81
91
114
132
178
Compr. 1 UNIT
MCA
Model Power supply
Fan Motor @ 415V
49
57
75
93
108
147
Max Fuse
Size & MCB
Qty.
2
2
3
4
4
6
RLA(ARI)
20.5
24.0
16.5
20.5
24.0
31.0
LRA
135
175
130
135
175
215
Qty.
2
2
4
4
4
4
KW
0.6
0.6
0.6
0.6
0.6
0.9
FLA
1.5
1.5
1.5
1.5
1.5
2.5
380-415 V / 3Ph/50Hz
380-415 V / 3Ph/50Hz
380-415 V / 3Ph/50Hz
380-415 V / 3Ph/50Hz
380-415 V / 3Ph/50Hz
380-415 V / 3Ph/50Hz
One turn counterclockwise equals to -
1C to - 2C superheat decrease. It is
recommended to lower the superheat
by increasing the suction pressure by
making adjustments to the expansion
valve setting prior to attempting to lower
the LP setting parameter to avoid unit
tripping on low pressure. Make sure
there is enough subcooling.
HOW TO DETERMINE SU-
PERHEAT:
1. MEASURE the temperature of the
suction line at the compressor in-
let. NEARER to ACCESS VALVE.
(where suction pressure CAN BE
MEASURED).
2. OBTAIN the suction pressure that
exists in the suction line by reading
the gauge PRESSURE at the suc-
tion access VALVE.
3. Convert the pressure obtained above,
to saturated evaporator temperature
by using a temperature-pressure
chart.
4. Subtract the two temperatures ob-
tained in 1 & 3 - the difference is
SUPERHEAT. Recomended SU-
PERHEAT : 8 - 12F (4.4 - 6.7C)
Water treatment
Untreated or insufficiently treated
water, if used in this unit, may cause
scale, slime or algea to accumulate
or cause erosion and corrosion. As
Trane does not know the components
used in the hydraulic network and the
qual i ty of the water used, we
recommend the the servi ces of a
qualified water treatment specialist.
Trane will not accept any liability in
regards of damage due to the use of
untreated or improperly treated water
or from the use of saline or brackish
water. If required, contact your local
Trane sales office.
Electrical connections
Caution:
1. The greatest care should be taken
when cutting through passages and
installing electric wiring. Under no
ci rcumstances shoul d chi ps of
metal or cutti ngs of copper or
isolating material fall into the starter
panel or el ectri c components.
Relays, contactors, terminals and
control wiring should be covered
and protected before power
supplies are connected.
2. Install power supply cabling as
shown in wiring diagram. Adequate
cabl e gl and shoul d be chosen,
ensuring no foreign bodies enter
electrical housing or components.
Caution:
1. Cabling must comply with standards
in force. The type and location of
fuses also must comply with stan-
dards. As a safety measure, fuses
should be visibly installed, close
to the unit.
2. Only copper wiring should be used.
Using aluminium wires can produce
galvanic corrosion and possibly lead
to superheat and failure of connec-
tion points.
Expansion valves setting
In order to keep the compressor in the
operating envelope, it is mandatory to
control the superheat suction at
commissioning. It shall reduce the
compressor discharge gas temp and
increase the saturated suction
temperature, increasing by the way the
unit capacity. The rule to reduce the
suction superheat is to loosen the
expansion valve adjustment screw.
64)-

11
General start-up
- Check the isolation of the motors
using a 500V DC megohmeter which
meets manufacturer' s specifications
(minimum value 2 megohmeter)
- Check the direction of the rotation
using phasemeter.
Electrical power wiring:
- Check all the electrical terminals
tightening,
- Set-up compressors overload relays,
- Set-up fan-motors overload relays,
Electrical control wiring:
- Check all the electrical terminals
tightening,
- Check all the pressostats,
- Check and set-up the control module
- Test and start-up without the electri-
cal power, to compressors.
Condenser:
- Check direction of the rotation of fans,
- Check the isolation of the motors
using a 500V DC megohmeter which
meets manufacturer' s specification
(minimum value 500 megohmeter)
Operating parameters
statement:
- Start-up the unit following procedure
described in section control system
USER GUIDE.
- After unit start up, leave in operation
for at least 15 minutes, to ensure
pressures are stabilized.
Then check:
- voltage,
- compressors and fan - motors
currents,
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
1. Max. oil level
2. Min. oil level
- Check chilled water pressure drop
through evaporator
- On start-up of each motor in the
system, check the di recti on of
rotation and operation of all the
components they drive
- Check that there is sufficient demand
for cooling on the day of start-up
(around 50% of nominal load)
START-UP
Fol l ow the i nstructi ons bel ow to
correctly start-up the unit.
Installation and chiller inspection:
- Ensure that all the operations above
(start-up preparation), are followed.
- Ensure all water and refrigerant
valves are in service positions,
- Ensure that the unit is not damaged,
- Ensure that sensors are properly
installed in their bulb-wells and
submerged i n heat conducti ng
products,
- Reset all manually set control de-
vices,
- Check refrigerating circuits tightness
Checking and setting:
Compressors:
- Check oil level at rest. The level
should reach at least halfway up in-
dicator located on housing. See fig.
11 for correct level.
Figure 3 - Compressor oil level
- Check fixing of capillary tubes
(protection from vibration and from
wear) and ensure that they are not
damaged,
- Reset al l manual l y set control
devices,
- Check refrigerating circuits
tightness
- Check electrical terminals tightening
of the motors and in the control panel,
START UP PREPARATION
Installation Checklist
Complete this checklist once the unit
is installed to verify that all recom-
mended procedures have been ac-
complished before starting the system.
Do not operate the system until all
items covered by this checklist are
comnplete.
Unit
Inspect unit location for proper
required service clearances.
Check type and position of rubber
pads.
Inspect unit location for proper free
air clearances.
Inspect unit location for secure,
level mounting position.
Water System
Chi l l ed water ci rcui t ready to
operate, fi l l ed wi th water,
pressure test carried out and air
purged.
Chi l l ed water ci rcui t must be
rinsed
Chek the presence of water
strainer ahead of evaporator
The strainers must be cleaned
after 2 hours of pumps operation
Check the thermometers and
manometers position
System
Check chilled water pumps
interconnection to control panel
Ensure that the isolation
resistance of all power supply
terminals to ground complies with
standards and regulations in force
Check that unit voltage and
frequency supplied match rated
input voltage and frequency
- Check that all electrical
connections are clean and sound-
Check that main power supply switch
is sound
- Water flow control checking:
decrease the water flow and check
the electrical contact in the control
panel.
64)-

shut down uni t and check the

di recti on of ratati on usi ng
phasemeter.
Warning
- The chilled water circuit may be under
pressure. Bring down this pressure
before opening up the system to rise
out or fill up the water circuit. Failure
to comply with this instruction may
cause accidental injury to
maintenance personnel.
- If a cleaning solution is used in the
chilled water circuit, the chiller must
be isolated from the water circuit to
avoid all the damage risks of the
chiller and evaporator water pipes.
12
General start-up
- leaving and return chilled water
temperature,
- suction temperature and pressure,
- ambient air temperature,
- blowing air temperature,
- discharge pressure and temperature,
- liquid refrigerant temperature and
pressure,
- operating parameters:
- chilled water pressure drop through
evaporator unit available pressure.
- superheat : difference between
suction temperature and dew point
temperature. Normal superheat
should be within 4 and 7
o
C in cooling
mode,
- sub-cooling : difference between
liquid temperature and bubble point
temperature. Normal subcooling
shoul d be wi thi n 2 and 10
o
C i n
cooling mode,
Final check:
When the unit is operating correctly
- Check that the unit is clean and clear
of any debris, tools, etc...
- All valves are in operating position,
- Close control and starter panel doors
and check panels fixation.
Caution:
- For the warranty to apply, any start-up
carried out directly by the customer
must be recorded in a detailed report,
which must be sent as soon as
possible to the nearest Trane office.
- Do not start-up a motor whose
insulation resistance is less than 2
megaohms
- Phase i mbal ance shoul d not be
greater that 2%.
- The vol tage suppl i ed to motors
should be within 5% of the rated
vol tage on the compressor
nameplate.
- Excess oi l i n compressor can
damage the compressor. Before
adding oil, consult Trane technician.
Use onl y Trane products
recommended.
- The compressors must operate in a
si ngl e di recti on of rotati on. I
refrigerant high pressure remains
stabl e i n the 30 seconds after
compressor start-up, immediately
64)-

13
Control 8ystem
The control is through the CAREL
Controller, MCH3.
Refer to MCH3 - User Guide fr more
details.
Chilled Water Circulating
Pump
1 Once the system has been filled,
complete the following chilled water
system start-up procedure.
2 Ensure all power connection point
has been done propertly and switch
the MCB into ON position to power
the control circuitry and controller.
3 The controller will be running in
intialization mode and cheeking all
connecti on swi tches i s properl y
done. Once after the initialization
mode, the panel di spl ay wi l l
displayed the default screen with
chilled water IN temperature and
chilled water OUT temperature and
Chilled unit status.
4 Enable the unit operation by switching
the On/Off Unit mode from UNIT OFF
to UNIT ON.
5 The chilled water pump shall ON
before the unit operation start.
6 To balance the flow through the
evaporator, adjust the flow rates
between minimum and maximum
values given in Table-1.
7 Flow rates above or below these
values can cause equipment
damage or improper unit operation.
8 Measure the evaporator water
pressure drop at the system
pressure gauge(s). Compare the
readings to the pressure drop values
given in Table-1 / Chart 1.
Note: Evaporator pressure drop
approximation and is to be used as a
tool to estimate flow rate and as an
aid to waterside system piping
design. If an accurate measurement
of flow is required, a flow meter must
be installed in the system.
Unit operations
1 Ensure all controller output has
connected to entire contactor and
termination block.
2 Ensure the Error button has not
lighted up.
3 Enable the unit operation by switching
the On/Off Unit mode from UNIT OFF
to UNIT ON.
4 Chilled Water Pump motor shall start
before the unit operation start.
5 Compressor(s) shall ON/OFF in
sequence base on setting parameter.
6 Condenser Fan shall ON when
compressor is running.
WARNING
ROTATING PARTS!
UNIT STARTS AUTOMATICALLY
Make sure all personnel are
standing clear of the unit before
proceeding.
WARNING!
CONTACTOR IS POWER UP BY
240VAC VOLTAGE
Make sure all controller output
connection has been done properly
and tools are clear from the control
panel before proceeding.
64)-

Dimensional Data Air Cooled

Chiller Unit CGAP 025/030
14
64)-

Dimensional Data Air Cooled

Chiller Unit CGAP 040,050,060
15
NOTE:
CGAP 040-3 Nos FAN.
64)-

Dimensional Data Air Cooled

Chiller Unit CGAH 080
16
64)-

17
Wiring Diagam - Power
DOL 8tarter CGAP 025/030
64)-

18
Wiring Diagam - Control
DOL 8tarter CGAP 025/030
64)-

19
Wiring Diagam - Power
C/W 8tarter CGAP 040/050/060
64)-

20
Wiring Diagam Control
DOL 8tarter CGAP 040/050/060
64)-

21
Wiring Diagam - Power
DOL 8tarter CGAH 080
64)-

22
Wiring Diagam Control
DOL 8tarter CGAH 080
64)-

nstallation Check List

This list must be checked off by the installer to ensure correct installation before
the unit start up.
UNIT POSITION
Check clearance around condenser
Check clearance required for maintenance access
Check type and position of rubbers pads
Check unit is level
CHILLED WATER CIRCUIT
Check thermometers and manometers presence and position
Check water flow rate balancing valve presence and position
Check presence of strainer ahead of evaporator
Chek presence of air-purge valve
Check rinsing and filling of chilled water pipes
Check water pump(s) contactor interconnected to control panel
Check water flow
Check chilled water pressure drop
Check for leaks in chilled water pipes
ELECTRICAL EQUIPMENT
Check installation and rating of mains power switch/fuses
Check electrical connections complied with specification
Check that electrical connections are in accordance with information on
manufacturer's identification plate
Check direction of rotation using phasemeter
Comments
....................................................................................................................................................................................................
....................................................................................................................................................................................................
....................................................................................................................................................................................................
....................................................................................................................................................................................................
Unit model:
Work Size:
Contact:
Signature / Name:
Serial number:
Telephone:
Fax;
Please return this form to your local Trane Service Agency.
23
64)-

Maintenance
24
4. Check the tightness of the refrigerant
circuit.
5. Start-up the unit (see control section)
6. Check all interconnected devices
operate properly
7. Check oil level and service pressures
after the system has been in
operation for 15 to 20 minutes under
full load.
8. Check that high and low pressures
are correct.
9. Check refrigerant tubing is fixed.
Maintenances and services must be
completed by qualified technicians.
Please provide necessary
maintenance periodically for longer
using life and less failure.
Record operating states and save
service records. It will help technicians
to analyze failure.
Weekly maintenance
1. Check compressor oil level at rest.
Oil level should be halfway up of
sight glass located on the housing.
Don' t add excess oil. Excess oil in
the compressor can be as
damaging as not enough oil. Before
topping up, contact a qualified
technician. Use only Trane
recommended oils.
2. Inspect the entire system for
undesirable effects, such as noisy
compressor, loose access panels,
leaks in pipes, or vibrating
contactors.
3. Keep records of temperatures,
pressures, service dates and times
or other observations in log book.
Annual maintenance
1. Check water circuit, valve, pipes, and
clean filters if necessary. Analyze
water quality. Cleaning may be
required, in which case use
professional assistance.
2. Clean corroded outer surfaces and
repaint. Check electrical panel seal
door.
Then fol l owi ng mai ntenance
instructions are part of maintenance
operations required for this equipment.
A qualified technician is needed for
regul ar mai ntenance as part of a
regular maintenance contract. Carry
out al l operati ons as requi red by
schedule.
This will insure long unit service life
and reduce the possibility of serious
and costly breakdown.
Keep servi ce records up to date,
showing weekly information on unit
operations. These records can be of
great help to maintenance personnel
diagnostics. Similarly, if machine
operator keeps a log of changes in unit
operating conditions, problems can be
identified and solutions found before
more serious problems arise.
Shutdown
If the unit needs to be shut down for a
short period of time, push the "STOP"
button of the unit or "OFF" of the remote
switch. If the unit is shut down for a
longer period, make sure the main
power disconnected. If the water piping
is not protected. against freeze up, drain
the water circuit by the drainage valve.
Seasonal start up
If the unit starts up after shutdown for a
longer period of time, the following
points should be followed by qualified
technicians:
1. Carry out the instruction in "Annual
maintenance".
2. Fill up and purge the water circuit.
Insure the stop valve in the water
circuit is open.
3. Insure the liquid line stop valve is
open
3. Check the tightness of the chilled
water circuit. Check circulating pump
operation and associated devices.
4. Carry out all weekly maintenance
inspections.
5. Check contactors.
6. Check adjustment and operation of
each control device.
7. Check the tightness of the refrigerant
circuit.
8. Check insulation of motor windings.
Caution:
Water circuit may be pressurized,
check instruction to reduce circuit
pressure before opening water
circuit. Failure to comply with this
instruction may result in accident or
injury to maintenance personnel.
The unit should be regularly checked
by a qualified technician at least once
a year or every 2,000 operating hours
as a minimum.
Cleaning condense
Clean the condenser coils with a brush
or jet of water. Please jet water from
inside to outside of the unit. If the coils
are too dirty, consult a cleaning
professional.
Caution;
Never use steam of hot water above
60
o
C to clean condenser coils.
Caution:
Switch off unit main power supply
before any service. Failure to follow
this safety instruction can lead to
accident death of the maintenance
personnel and may also destroy
equipment.
64)-

25
Cleaning plate heat
exchanger
Trane Company suggests a chemical
cleaning for this. Cleaning solution
shoul d appl y hot phosphori c aci d
liquid with 15% concentration and 3-6
hours recycling cleaning time under
50-60C.
Caution:
Poisonous or corrosive cleaning liquid
must not be applied for this.
Maintenance
Fig. 4: Cleaning plate heat exchanger
water circulating pump
heating resolution container
check valve (off)
leaving
entering
check valve (off)
three way valve
three way valve
unit
unit
64)-

26
Troubleshooting
Troubleshooting guide
These are simple diagnostic . If there is a breakdown, the Trane Service Agency should be contacted for confirmation and
assistance.
Problems symptoms
A. The compressor will not start up
Compressor terminals are live but motor does not start.
Contactor motor not operational
No current ahead of motor contactor.
Low voltage reading on voltmeter.
Starter coil not excited.
Compressor does not run. Compressor motor "groans".
B. Compress stops
High pressure switch tripped.
Over current thermal relay tripped
Motor temperature thermostat tripped.
Anti-freeze security tripped.
C. Compressor stops just after its start
Suction pressure too low. Filter drier iced up.
D. The compressor keeps running without stopping
Temperature too high in areas requiring airconditioning.
Chilled water temperature output too high.
E. Loss of oil in compressor
Oil level too low in indicator.
Gradual fall of oil level.
Suction line too cold. Compressor noisy.
F. Compressor noisy
Compressor knocks.
suction duct abnormally cold.
G. Insufficient cooling capacity
Thermostatic expansion valve "whistles".
Excess pressure drops through filter drier.
Excessive superheat.
Insufficient water flow.
H. Discharge pressure too high
Condenser abnormally hot.
Chilled water leaving temperature too high
Condenser air output too hot.
Probable cause
Motor burned out.
Coil burned out or broken contacts.
a) Power cut
b) Mains power supply switched off.
Voltage too low.
Regulation circuit open.
Compressor sticking (damaged or sticking components).
Discharge pressure too high.
a) Voltage too low.
b) Cooling demand too high, or condensing temperature too high.
Not enough cooling fluid.
Water flow to evaporator too low
Filter drier clogged
Excess load on cooling system.
Excess cooling demanded on system.
Not enough oil.
Filter drier clogged.
Liquid flows back to compressor
Components broken in compressor
a) Uneven liquid flow.
b) Expansion valve locked in open position.
Not enough refigerant.
Drier filter colgged.
Superheat not properly adjusted.
Chilled water pipes obstructed.
Presence of uncondendable liquids in system, or excess of refrigerant.
Overload on cooling system.
Reduced air flow. Air intake temperature higher than specified for unit.
Action recommended
Replace compressor.
Repair or replace.
Check fuses and connection. See why system tripped.
If system is operational, switch on mains power supply.
Contact Power Supply Utility.
Replace compressor.
See instruction for "discharge pressure too high"
a) Contact Power Supply Utility.
b) See instruction "discharge pressure too high".
Repair leak. Add refrigerant
Check water flow rate, and pressure switch contact in water.
Replace filter drier.
Check thermal insulation and air-tightness of areas requiring air-conditioning.
Check thermal insulation and air-tightness of areas requiring air-conditioning.
Add oil.
Replace filter drier.
Adjust superheat and check bulb fixing of the expansion valve.
Change compressor.
a) Check superheat setting and fixing or expansion valve bulb.
b) Repair or replace.
Check refrigerant circuit tightness and add refrigerant
Replace.
Check adjustment of superheat and adjust thermostatic expansion valve.
Clean pipes and strainer.
Purge uncondensable fluids and drain off excess refrigerant.
Reduce load on system. Reduce water flow if necessary.
Clean coil. Check operation of fan motor.
64)-

Troubleshooting
27
Problems symptoms
1. Suction pressure too high
Compressor operates continuously.
Suction duct abnormaly cold.
Refrigerant flows back to compressor.
J. Suction pressure too low
Excessive pressure drop through filter drier.
Refrigerant does not flow through thermostatic expansion valve.
Loss of power
Superheat too low.
K. Insufficient cooling capacity
Low pressure drops through evaporator
Probable cause
Excess cooling demand on evaporator.
a) Expansion valve too far open.
b) Expansion valve looked in open position.
Filter drier clogged.
Expansion valve bulb has lost its refrigerant.
Expansion valve obstructed.
Excessive pressure drops though evaporator.
Low water flow rate.
Action recommended
Check system.
Check for superheat and check that expansion valve bule is secure.
a) Check for superheat and check that expansion valve bule is secure.
b) Replace.
Replace the filter drier.
Replace the bulb of the expansion valve.
Replace.
Check adjustment of superheat and adjust thermostatic expansion valve.
Check water flow rate. Check state of strainer check for obstruction
in chilled water pipes. Check pressure switch contact in water.
Caution:
The above is not a comprehensive analysis of the Scroll compressor refrigeration system. The aim is to give operators
simple instruction on basic unit processes so that they have the technical knowledge to identify and bring defective
operations to the notice of qualified technicians.
CG-SVX15A-E4 (October 2008)
CG-SVN03A-E4 (September 2003)
Malaysia
Literature Order Number
File Number
Supersedes
Stocking Location
Trane has a policy of continuous product and product data improvement and reserves the right to charge
design and specifications without notice. Only qualified technicians should perform the installation and
servicing of equipment referred to in this publication.
Trane
A business of American Standard Companies
www.trane.com
For more information, contact your local district
office
TRANE