Installation Operation Maintenance

Air-Cooled Water Chiller Air-Cooled Water Chiller with Heat Pump Option 3~30 Tons

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TABLE OF CONTENTS

MODEL NOMENCLATURE INSTALLATION

RIGGING MOUNTING WATER PIPING FIGURE 1 : RECOMMENDED HOISTING ARRANGEMENT FIGURE 2 : DIMENSION FOR MOUNTING FIGURE 3 : SERVICE & MAINTENANCE CLEARANCE ELECTRICAL WIRING UNIT POWER SUPPLY FIGURE 4 : TYPICAL PIPING ARRANGEMENT FIGURE 5 : TYPICAL SYSTEM APPLICATION

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ELECTRICAL DATA FLOW SWITCH INTERLOCK

CIRCUIT DIAGRAM 1 : FOR CGAK 030~075 CIRCUIT DIAGRAM 2 : FOR CGAR 030~075 CIRCUIT DIAGRAM 3 : FOR CGAK 100~200 CIRCUIT DIAGRAM 4 : FOR CGAR 100~200 CIRCUIT DIAGRAM 5 : FOR CGAK 250~300 INSTALLATION CHECKLIST

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PRE-START PROCEDURE
VOLTAGE UTILIZATION RANGE VOLTAGE IMBALANCE WATER FLOW RATE UNIT WATER PRESSURE DROP FIGURE 6 : HYDRAULIC CHARACTERISTIC PRE-START CHECKLIST

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OPERATION
START-UP PROCEDURE EXTENDED UNIT SHUT-DOWN/WINTERIZATION STANDARD AMBIENT OPERATION OPTIONAL LOW AMBIENT OPERATION (CGAK) OPTIONAL HEAT PUMP OPERATION (CGAR) ELECTRICAL CONTROL & PROTECTION SYSTEM

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MAINTENANCE TROUBLE ANALYSIS

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MODEL NOMENCLATURE

CGA 1,2,3

K 4

050 5,6,7

5 8

D 9

F R M R N A 10 11 12 13 14 15
DIGIT 9 - Development Sequence D=Fourth Design DIGIT 10 - Controls F=Fixed Entering Water Temperature Control (Standard Option) A=Microprocessor Controller (Adjustable Entering Water Temperature) (For CGAK Models as Optional) (For CGAR Models as Standard Option) DIGIT 11- Water Pump N = No Pump R = Standard Pump (Standard Option) DIGIT 12 - Refrigerant Pressure Gauges M = No (Standard Option) G = With High/Low Pressure Gauges

DIGIT 1,2,3 CGA=Air-Cooled Water Chiller DIGIT 4 - Model K=Cooling Only R=Cooling With Heat Pump Option DIGIT 5,6,7 - Nominal Capacity (tons) 030 040 050 075 100 125 150 175 200 250 300 DIGIT 8 - Voltage 1=220V/60Hz/1Ph (For model 030,040,050) 2=220V/60Hz/3Ph (For model 050,075,100,125,150,175,200,250,300) 3=380V/60Hz/3Ph (For model 050,075,100,125,150,175,200,250,300) 4=460V/60Hz/3Ph (For model 050,075,100,125,150,175,200,250,300) 5=380V/50Hz/3Ph (For model 050,075,100,125,150,175,200,250,300) 6=400V/50Hz/3Ph (For model 050,075,100,125,150,175,200,250,300) 7=415V/50Hz/3Ph (For model 050,075,100,125,150,175,200,250,300)

DIGIT 13 - Temperature Kit R = Standard Ambient Temperature Kit (Standard Option) L = Low Ambient Temperature Kit (For CGAK Models Only) DIGIT 14 - Other Options M = Standard Fin + Standard Grille Cover C = Blue Fin + Standard Grille Cover DIGIT 15 - Service Sequence A = First

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INSTALLATION

Complete the Installation Checklist during installation to verify completion of all recommended procedures before unit start-up.

MOUNTING
Mounting methods that will minimize sound and vibration problems are: 1. Mount the unit directly on an isolated concrete pad or on isolated concrete footings at each unit mounting point. 2. Install the optional neoprene or spring isolators at each mounting location. Refer to Figure 2 for unit and base dimensions and Figure 3 for recommended service clearance.

Table 1 : Unit Shipping Weights Model 030 040 050 075 100 125 150 175 200 250 300 Maximum Shipping Weight (Kg) 230 250 260 320 370 450 530 550 570 750 800

RIGGING
Each unit is bolted to a shipping skid for shipment to the job site. Move the unit using a forklift of suitable capacity. See Table 1 for unit shipping weights. Locate the unit near a large-capacity drain to allow system drainage during unit shutdown and repair. Rig the unit using canvas belt. Fasten the belt to the unit over the units base as show in Figure 1.

WATER PIPING
Thoroughly flush all water system piping before making the final piping connections to the unit.

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Figure 1 : Recommended Hoisting Arrangement (CGAK-075 As Shown)

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Figure 2 : Dimension for Mounting (CGAK-075 As Shown) Note: All Dimensions in Millimeter

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Figure 3 : Service and Maintenance Clearance (CGAK-075 As Shown)

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CAUTION: If using an acidic commercial flushing solution, construct a temporary bypass around the unit to prevent damage to the evaporator. CAUTION: To avoid possible equipment damage, do not use untreated or improperly treated water.
For units water connection sizes and locations, please refer to Figure 2.

ELECTRICAL WIRING
WARNING: To prevent injury or death, disconnect electrical power source before completing wiring connections to the unit. CAUTION: Use only copper conductors for terminal connections to avoid corrosion or over heating.
Figure 2 shows the location of the unit

FLOW SWITCH INTERLOCK

To avoid possible evaporator freeze-up resulting from reduced water flow, install a flow switch ( or other flow sensing device) in the evaporator outlet water line. This sensing device must be adjusted to stop compressor operation if water flow to the evaporator drops below 70% of the system design full-flow rate. The installer must provide interconnecting wiring between the unit control panel and the water flow sensing switch in the evaporator water line.

CAUTION: To prevent unit damage, do not reverse system piping connections to the unit; water entering the unit must enter at the designated Water In and leaving water must exit the unit through the designated Water Out connection.
Figure 4 illustrates typical unit piping components. Components and layout will vary slightly depending upon the locations of the connections and water source. Figure 5 gives a schematic of a typical system application for this unit. Provide vents at high points in the piping to bleed air from the chilled water system. Install pressures gage(s) to monitor entering and leaving chilled water pressure.

electrical access openings. Table 2 provides minimum circuit ampacities, recommended fuse sizes, and motor electrical data.

UNIT POWER SUPPLY

Refer to the unit wiring schematic fixed to the control panel cover. The installer must provide a power supply of proper voltage and a fused disconnect switch to the unit. Run properly sized power wirings through the electrical access opening on the side of the unit, and connect it to the Voltage Terminal Block (1TB1) in the unit control panel. Install a fused disconnect switch as required by local codes. Provide proper equipment grounds for the ground connections in the unit control panel and at the fused disconnect switch. Refer to wiring diagrams from Page 12 to Page 16 for reference of a typical unit installation. For actual wiring diagram, refer to the one fixed to the control panel cover.

CAUTION: To prevent damage to the waterside components of unit, do not allow evaporator pressure to exceed 100 psig (i.e. maximum working pressure). Use an expansion tank to isolate this pressure if water pressure exceeds this value.

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Figure 4 : Typical Piping Arrangement (CGAK-075 As Shown)

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Figure 5 : Typical System Application (CGAK-075 And Fans As Shown)

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ELECTRICAL DATA

Table 2 : Electrical Data 60Hz Model 030 040 050 100 050 050 075 075 100 100 125 125 150 150 175 175 200 200 250 250 300 300 50Hz Model Electrical Power (V/Hz/Ph) 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 380-415/50/3 Water Pump FLA 1.1 1.4 1.4 1.7 1.7 2.0 2.8 2.8 5.9 Comp 1 RLA 7.4 11.6 7.4 8.7 11.6 13.0 15.1 15.0 25.0 Comp 2 RLA 7.4 8.7 11.6 13.0 15.1 25.0 25.0 Fan 1 FLA 1.5 1.5 2.2 2.2 1.5 2.2 2.2 2.2 2.2 Fan 2 FLA 1.5 2.2 2.2 2.2 2.2 Unit MCA 11.9 17.4 20.3 23.5 30.8 36.5 41.2 53.5 66.6 Rec. Fuse Size 13.7 20.3 22.1 25.7 33.7 39.8 45.0 59.7 72.8 Max Fuse Size 19.3 29.0 27.7 32.2 42.4 49.5 56.3 78.5 91.6 Electrical Power (V/Hz/Ph) 220/60/1 220/60/1 220/60/1 220/60/1 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 220/60/3 380/60/3 Water Pump FLA 4.4 4.4 4.4 6.5 2.7 1.6 4.2 2.4 4.2 2.4 5.4 3.1 5.4 3.1 6.0 3.5 9.1 5.3 9.1 5.3 11.3 6.5 Comp 1 RLA 14.4 19.4 24.4 24.4 15.3 8.8 23.0 13.3 15.3 8.8 17.4 10.1 23.0 13.2 26.0 15.0 32.4 18.7 35.0 20.0 51.0 29.0 Comp 2 RLA 24.4 15.3 8.8 17.4 10.1 23.0 13.2 26.0 15.0 32.4 18.7 51.0 29.0 51.0 29.0 Fan 1 FLA 2.8 2.8 2.8 4.3 3.0 1.7 3.0 1.7 4.5 2.6 4.5 2.6 3.0 1.7 4.5 2.6 4.5 2.6 4.5 2.6 4.5 2.6 Fan 2 FLA 3.0 1.7 4.5 2.6 4.5 2.6 4.5 2.6 4.5 2.6 Unit MCA 25.2 31.5 37.7 65.7 24.8 14.3 36.0 20.7 43.1 24.8 49.1 28.4 63.2 36.2 73.5 42.5 91.0 52.6 116.9 66.8 135.1 77.0 Rec. Fuse Size 28.8 36.3 43.8 71.8 28.7 16.5 41.7 24.1 47.0 27.0 53.4 31.0 68.9 39.5 80.0 46.2 99.1 57.3 129.6 74.0 147.8 84.2 Max Fuse Size 39.6 50.9 62.1 90.1 40.1 23.1 59.0 34.0 58.4 33.6 66.5 38.5 86.2 49.4 99.5 57.5 123.4 71.3 167.9 95.8 186.1 106.0

050 075 100 125 150 175 200 250 300

Note: All voltages supply must fall within the utilization range of 10 % Minimum Circuit Ampacity (MCA) = Largest Load x 1.25 + Sum of additional Loads. (Used for sizing wire) Recommended Fuse Size (REC) = Largest Load x 1.5 + Sum of additional Loads. (Select closest fuse size) Maximum Fuse Size (MFS) = Largest Load x 2.25 + Sum of additional Loads. (Select equal or next lower fuse size)

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FLOW SWITCH INTERLOCK

Circuit Diagram 1 : For CGAK 030~075

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Circuit Diagram 2 : For CGAR 030~075

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Circuit Diagram 3 : For CGAK 100~200

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Circuit Diagram 4 : For CGAR 100~200

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Circuit Diagram 5 : For CGAK 250~300

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INSTALLATION CHECKLIST
RECEIVING Verify that unit nameplate data corresponds with sales order information. Inspect unit for shipping damages and material shortages; report any damages or shortages found to the carrier. UNIT LOCATION AND MOUNTING Inspect unit installation location for adequate ventilation. Provide drainage facilities for water accumulated from the base. Remove and discard any shipping materials (e.g. cartons, crates, etc.) Inspect to determine that service access clearances are adequate. Install optional unit neoprene-in-shear or spring isolators. Secure unit to mounting surface. Level the unit.

EVAPORATOR PIPING Flush and clean all chilled water piping.

ELECTRICAL WIRING

CAUTION: If using an acidic commercial flushing solution, construct a temporary bypass around the unit to prevent damage to the evaporator. CAUTION: To avoid possible equipment damage, do not use untreated or improperly treated water.
Make evaporator water connections. Vent the air from chilled water system at high points. Install pressure gauges, thermometers and shutoff valves on water inlet and outlet piping. Install water strainer in evaporator supply line. Install balancing valve and flow switch on water outlet piping.

CAUTION: Use only copper conductors to prevent galvanic corrosion and overheating at terminal connections.
Connect unit power supply wiring (with fused disconnect) to appropriate terminals on terminal block (TB) in power section of unit control panel. In order to turn on/off the chiller from indoors, connect wiring across reserved terminals 2 & 3 in the unit control panel from an indoor REMOTE OFF/ON switch. Properly ground the unit, the chilled water pump motor, all disconnects, and other devices which require grounds. Install wiring to connect flow switch to unit control panel. FOR NO-PUMP OPTION ONLY Connect chilled water pump power supply wiring (with fused disconnect) to the proper terminals of the chilled water pump. Install wiring to connect chilled water pump switch to chilled water pump starter. Connect auxiliary contacts of chilled water pump starter to flow switch and unit control panel.

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PRE-START PROCEDURES

VOLTAGE UTILIZATION RANGE

Electrical power to the unit must meet stringent requirements for unit to operate properly. Total voltage supply and voltage imbalance between phases should be within the following tolerances.

VOLTAGE IMBALANCE
Excessive voltage imbalance between phases in all 3-phase system will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2 %. Voltage imbalance is defined as follows: % Voltage Imbalance = 100x Va-Vd Va

The 2.2% imbalance that exists in the example above exceeds maximum allowable imbalance by 0.2 %. This much imbalance between phases can equal as much as 20 % current imbalance with a resulting increase in winding temperature that will decrease compressor motor life.

Measure each leg supply voltage at all line voltage disconnect switches. Readings must fall within the voltage utilization range shown on the unit nameplate (10%). If voltage on any leg does not fall within the tolerance, notify the power company to correct this situation before operating the unit. Inadequate voltage to the unit will cause control components to malfunction and shorten the life of electrical components and compressor motors. Where

WATER FLOW RATE

Establish a balanced water flow through the unit. Flow rates should fall between the minimum and maximum values indicated in TABLE 3. Evaporator water flow rates below the minimum acceptable values will result in a stratified flow; this reduces heat transfer and causes either loss of expansion valve control or repeated nuisance low pressure cutouts. Conversely, excessively high flow rate may cause erosion in the water system.

Va = (V1 + V2 +V3) / 3(Average Voltage) V1, V2, V3 = Line Voltages Vd = Maximum Line Voltage deviation from Va Example: If the three voltages measured at the line 221 Volts, 230 Volts, and 227 Volts, the average (Va) would be: Va = (221 + 230 + 227)/3 = 226 Volts then Vd = 221 Volts The percentage of imbalance is then: 100x 226-221 226 2.2%

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Table 3 : Unit Water Flow Rate 60Hz Model 030 040 050 075 100 125 150 175 200 250 300 50Hz Model 050 075 100 125 150 175 200 250 300 Minimum Flow 25.1 37.3 49.1 62.1 74.4 85.5 98.3 124.6 148.6 Rated Flow 37.7 56.0 73.7 93.3 111.7 128.3 149.0 187.0 223.0 Minimum Flow 18.5 22.9 30.2 44.9 59.1 74.7 89.5 102.6 120.0 147.3 175.3 Rated Flow 27.7 34.3 45.3 67.3 88.7 112.0 134.3 154.0 180.0 221.0 263.0

Units: LPM

Maximum Flow 38.8 48.0 63.4 94.2 124.2 150.0 150.0 175.0 240.0 290.0 350.0
Units: LPM

UNIT WATER PRESSURE DROP

Measure the water pressure rise across the standard unit (with built-in pump). The Externally Available Head (E.A.H) should approximate those indicated by the E.A.H. curves, with the corresponding flow rates. For units (without built-in pump) with fieldinstalled pump outside the unit, water pressure drop across the unit should approximate those indicated by the Internal Pressure Loss (I.P.L.) curves, with the corresponding flow rates. For standard unit with built-in pump, refer to the E.A.H. curve for the system hydraulic design. For optional unit without a built-in pump, refer to the I.P.L. curves. (Refer to Figure 6 for hydraulic characteristics of all models.)

Maximum Flow 56.6 84.0 110.6 140.0 150.0 160.0 190.0 240.0 300.0

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Figure 6 : Hydraulic Characteristics - 60Hz

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50Hz

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PRE-START CHECKLIST
Inspect all wiring connections; electrical connections should be clean and tight. Check power supply voltage to the unit at the main power fused disconnect switch. Fill the chilled water circuit, leaving the system air vents open. Close vents after all air is out, and the system is completely filled. Remove jumper wire across terminals 1 and 5 (in the control panel) for water system testing. Close the fused disconnect switch and start the unit by turning the REMOTE/ OFF/ON switch to ON position. Pump should start and with water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs. Adjust the water flow rate through the chilled water circuit, and check the external available water pressure of the unit (for standard unit) or the evaporator water pressure drop for the no-pump option unit.

NOTE: With the water pump operating, throttle the water flow to approximately 50% of the full flow rate. Following the manufacturers instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to verify opening and closure of the flow switch contacts.
Stop the chilled water pump. Open all fused disconnect switches. Make electrical connection of flow switch to terminals 1 & 5 in the control panel.

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OPERATION

START-UP PROCEDURE
Close the fused disconnect switch and turn REMOTE/OFF/ON switch to ON. Pump will start immediately. After 2 minutes, compressors 1 will start. 1 minute later, compressor 2 will start (only in units with two refrigerant circuits). For CGAR models, turn REMOTE/OFF/ ON switch to ON as described above, turn the already installed indoors cooling and heating mode switch to cooling mode, then the operation of the chiller would be similar to what is described above. As for start-up with heating mode, first turn REMOTE/OFF/ON switch to OFF. Then, turn the cooling and heating mode switch to heating. Finally, turn the REMOTE/OFF/ON switch to ON (see section on electrical wiring of the installation checklist). Once the unit has operated for at least 30 minutes and the system has stabilized, complete the following checklist to ensure proper unit operation. Re-check unit water flow and pressure rise (for no built-in pump unit with fieldinstalled pump system). These readings should be stable at proper levels. Measure unit suction and discharge pressures by installing pressure gauges on the discharge and suction line access ports. Normal operation should render suction pressure in the range of 50-85 psig and discharge pressure 200-310 psig.

Check compressor amp draw. Check electrical power supply. Check the liquid line sight glasses.

Measure system subcooling. Normal subcooling for each circuit is 6.7C to 12.2C ARI conditions (12.2C entering water, 6.7C leaving water, and 35C ambient temperature). If subcooling for either circuit is normal but subcooling is not in this range, check superheat for the circuit and adjust, if required. If superheat is normal but subcooling is not, contact a qualified service technician. If operating pressure, sight glass, superheat and subcooling readings indicate refrigerant shortage, find and repair leaks and, gas-charge refrigerant into each circuit. Refrigerant shortage is indicated if operating pressures are low and subcooling is also low.

NOTE: Bubbles in the liquid line may indicate either a low refrigerant charge, or excessive pressure drop in the liquid line. Such a restriction can often be identified by a noticeable difference in line temperature on either side of the restricted area. (Frost often forms on the outside of the liquid line at the point of restriction, as well). Bubbles are not necessarily a symptom of improper system operation. CAUTION: A clear sight glass does not necessarily mean that the system is sufficiently charged; be sure to consider system superheat, subcooling, and unit operating pressures and ambient temperatures.
Proper unit refrigerant charge-per circuit-is indicated on the unit nameplate. Measure system superheat. Normal system superheat is 6.7C to 8.3C for each circuit at ARI conditions (12.2C entering water, 6.7C leaving water, and 35C ambient temperature). If the superheat measured for either circuit does not fall within this range, alter the setting of the superheat adjustment on the thermal expansion valve to obtain the desired reading. Allow 15 to 30 minutes between adjustments for the expansion valve to stabilize at each new setting.

CAUTION: If suction and discharge pressures are low, but subcooling is normal, no refrigerant shortage exists. Adding refrigerant will result in overcharging.
Add refrigerant vapor with the unit running by charging through the access port on the suction line until operating pressures are normal. If operating pressures indicate an overcharge, slowly (to minimize oil loss) recover refrigerant at the liquid line service valve. Be sure that all remote sensing bulbs are properly installed in bulb wells with heat transfer grease. Remote bulb capillary tubes must be secured (i.e. protected from vibration and abrasion) and undamaged. Inspect the unit. Remove any debris, tools and hardware. Secure all exterior panels, including the control and compressor access panels. Replace and tighten all retaining screws.
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EXTENDED UNIT SHUT-DOWN/ WINTERIZATION

If the system is taken out of operation for long periods of time for any reasons (e.g., seasonal shutdown), use this procedure to prepare the system for shutdown. 1. Check the refrigerant piping for leaks, fixing any that exist. 2. Service the chilled water pump and any air handling equipment according to the manufacturer s recommendtions. 3. Open both electrical disconnect switches for the unit and chilled water pump; lock both disconnects in the open position.

3. Remove compressor delay on timer(s) (TR1, TR2). Record down the original socket for the respective timer so that the correct timer(s) are replaced correctly later. 4. Close the unit disconnect switch for power supply. 5. Turn the REMOTE/OFF/ON switch to ON position. With water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs. 6. Adjust the water flow rate, using the balancing valve, through the chilled water circuit, and check the water pressure rise (or drop) through the unit. 7. Adjust the flow switch (installed on the unit outlet piping) to provide proper operation.

STANDARD AMBIENT OPERATION

Standard unit will operate in outdoor ambient temperature down to 15C.

OPTIONAL LOW AMBIENT OPERATION (CGAK)

A factory installed Low Ambient Unit (LAU) option will enable units to operate at outdoor low ambient temperature (see Table 4).

OPTIONAL HEAT PUMP OPERATION (CGAR)

A factory installed heat pump unit (CGAR) option will enable units to get either cooling and heating performance (not simultaneous). When the unit is switched to heating mode, the four-valve is activated. Evaporator becomes the condenser while the condenser becomes the evaporator. There are two liquid lines in a CGAR unit. One is for cooling mode while another is for heating mode. To carefully measure the high pressure, there are two access ports in these two liquid lines. If you operate this unit in cooling mode, connect high pressure gauge to the access port of the cooling liquid line. While operating this unit in heating mode, must change the connection to the access port of the heating liquid line. A timer override low pressure switch delays for 2 minutes to prevent nuisance trip-outs.

WINTERIZATION: Close all evaporator water supply valves and drain the evaporator by removing the drain plug and opening the vent on the entering water line just outside the unit. Re-install the drain plug. Since the evaporator does not drain completely, add ethylene glycol antifreeze to the remaining water through the vent or evaporator drain hole, to keep the water from freezing. Protect system to 5.5C below the expected ambient temperature.
SYSTEM RESTART AFTER EXTENDED SHUTDOWN 1. Remove winterization antifreeze as it can reduce system capacity. 2. Fill the chilled water circuit by opening the gate valves at the returning and supply water piping. Be sure to vent the system while filling it, and close the vents when system is full.

NOTE: With the unit operating, throttle the water flow to approximately 50% of the full flow rate. Following the manufacturers instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to check for contact opening and closure.
8. Stop the unit by turning the REMOTE/ OFF/ON switch to OFF position. 9. Replace compressor delay on timer (TR1, TR2) back to their original sockets. This unit now is ready for normal operation.

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ELECTRICAL CONTROL & PROTECTION SYSTEM

Low Pressure Cutouts (LP1, LP2) These units are protected by low pressure cutouts that open and stop compressor operation if the operating pressure drops below 25 4 psig . The cutout automatically resets when the pressure reaches 50 4 psig. The LP is a SPDT device and if it opens at low ambient start-up, there will be a 2 minute override to prevent nuisance trip-outs ( for LAU only). High Pressure Cutouts (HP1, HP2) These units have high pressure cutouts that open and stop compressor operation if the discharge pressure reaches 400 7 psig. The cutout automatically resets when pressure drops to 300 20 psig. Reset Relays (CR1,CR2) If the unit is shut down by safety devices (LP, HP, FS, FU, KF etc.) the reset relay locks out the compressor contactor (MC1, MC2). This prevents the system from recycling until the condition that caused the safety devices to trip is determined and corrected.

during normal unit operation, the leaving chilled water temperature falls to the trip point, the FU will open to interrupt compressor operation. When leaving chilled water temperature falls down, the suction temperature also falls down. For further protection to avoid freeze damage, another freezestat ( FS1 , FS2 ) in contact with the suction line. If suction temperature falls to the trip point , the FS1 (FS2) will open to interrupt compressor operation. Motor Overloads These units have internal compressor and condenser fan motor overloads to protect the motors from overcurrent and overheating conditions and automatically reset as soon as they cool sufficiently. Pump motor has thermal overload installed at the load contactor. Pump overload needs manual reset. Cooling Mode Water Temperature Thermostat Operation (TS1, TS2) for cooling mode For Double Refrigeration Circuit Operation At Start-up, the pump will come on immediately. Two minutes after the pump is on and EWT(entering water temperature)is above 14.0 C, compressor 1 will start. One minute later, if the EWT is above 13. 5C, compressor 2 will start. When cooling demand is met and EWT drops to 10.0 C. Compressor 1 will stop,if EWT continues to fall to 9.5 C,compressor 2 will stop. Subsequently,when load builds up and EWT rises to 13.5 C compressor 2 comes on, and if EWT rises further to 14.0C, compressor 1 comes on. Pump remains on unless the unit is turned off.

For Single Refrigeration Circuit Operation For units with only one refrigerant circuit, the operation of water pump, fan and compressor is exactly the same. The only difference is the unit will operate the single compressor from any temperature over 14.0 C and 10. 0C when the compressor will stop. Heating Mode Water Temperature Thermostat Operation (TS3, TS4) for cooling mode For Double Refrigeration Circuit Operation At start-up, pump will come on immediately. Two minutes after the pump is on and EWT (entering water temperature)is below 38. 0C, compressor 1 will start. One minute later, if EWT is below 39.0 C, compressor 2 will start. When heating demand is met and EWT rises to 42.0 C, compressor 1 will stop, if EWT continues to rise to 43.0 C,compressor 2 will stop. Subsequently,when load builds up and EWT drops to 39.0 C, compressor 2 comes on, and if EWT drops further to 38.0 C, compressor 1 comes on. Pump remains on unless the unit is turned off. For Single Refrigeration Circuit Operation For units with only one refrigerant circuit, the operation of water pump, fan and compressor is exactly the same. The only difference is the unit will operate the single compressor from any temperature below 38.0 C and 42. 0 C when the compressor will stop.

CAUTION: To prevent unit damage, do not reset the control circuit until the cause of the safety lockout is identified and corrected.
To reset CR1 and CR2, open and reclose the unit REMOTE/OFF/ON switch. Anti-freeze Cutout (FS1, FS2, FU) The FS and FU are designed to protect the evaporator from freeze damage in the event of a water temperature thermostat (WTT) malfunction or restricted water flow. The FUs remote sensing bulb is mounted at the outlet end of the evaporator, where it monitors leaving water temperature. If

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Table 4 : Range of Operating Ambient Model All Models Cooling Mode All Models Heating Mode Standard Unit 15C-46C Above 10C Low Ambient Unit (If LAU option is added) 7C-46C Above -4C

Table 5 : Control Settings and Time Delays Control Description High Pressure Cutoff Low Pressure Cutoff Antifreeze Cutout (Refrigerant Side) Antifreeze Cutout (Water Side) 1st compressor On Delay 2nd compressor On Delay Low Suction Pressure Override Delay (CGAR) Electrical Designation HP1, HP2 LP1, LP2 FS1, FS2 FU TR1 TR2 TR3, TR4 Contacts Open 400 7 psig 25 4 psig -3C 2.0C 1.8C 1.5C Normally Open, Time Closed Normally Open, Time Closed Normally Closed, Time Open Contacts Close (Reset) 300 20 psig 50 4 psig 3C 2.0C 7C 1.5C 2 Minutes 3 Minutes 2 Minutes

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Maintenance

Once the unit has been operating for about 30 minutes and the system has stabilized, check operating conditions and complete the checkout procedure described below:

Monthly Check suction and discharge pressures for normal operating pressures. Check the liquid line sight glass indicator for normal operating conditions. If operating pressures and sight glass conditions indicate a refrigerant shortage, measure system superheat and subcooling. If operating conditions indicate an overcharge, slowly (to minimize oil loss) recover refrigerant from the schraeder valve. Open the unit disconnect switch; then manually rotate the condenser fan(s) to ensure proper orifice clearance. Inspect the fan mounting bolts for tightness. Check fan set screws for tightness. Please clean up internal and pipes strainer once the unit first starts running and monthly after use.

Annually Perform all monthly maintenance procedure. Have a qualified service technician check the setting and function of each control and inspect the condition of all contactors and replace as necessary. Drain water from unit. Inspect piping for damage. Clean out the built-in water strainer and any other in-line water strainer. Clean and repaint any corroded surfaces. Clean condenser coil with soft brush and water spray. Inspect the expansion valve(s) sensing bulbs for cleanliness; clean if required. These bulbs must make good contact with the suction lines and must be properly insulated. Clean condenser fan.

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TROUBLE ANALYSIS

A. Compressor Neither Starts Nor Hums Probable Cause (1) No power to unit Recommended Action Check for followings: a. Disconnect switch open b. Fuse(s) blown Check for followings: a. Defective thermostat b. Broken or improper control wiring (3) Compressor start delay (TR1,TR2) timer has not timed out time out (4) Unit locked out by reset relay (CR) c. Blown control power fuse Wait at least 2 minutes for the timer to time out Check for the followings: a. Excessive discharge pressure b. Defective high pressure control c. Low charge; Low pressure cut-out d. Gate/water valve not open causing flow switch or anti-freeze cutoff to trip e. Fan motor internal temperature switch open f . Defective reset relay contact (5) Compressor contactor will not close Check for the followings: a. Defective compressor contactor b. Improper wiring c. Reset relay (CR) open (6) Compressor winding stat open B. Compressor Hums, But Will Not Start Probable Cause (1) Low voltage at compressor Recommended Action Check for the followings: a. Single blown fuse b. Low line voltage c. Defective compressor contactor (2) Defective compressor d. Loose wiring connections Check for the followings: a. Open motor winding b. Excessive amp draw on all phases (3) Insufficient starting voltage (Single-Phase Units Only) Check for the followings: a. Defective start capacitor b. Defective start relay d. Low pressure cut-out open Check compressor amp draw

(2) No call for cooling

American Standard Inc. 2004

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CGA-SVX01B-EN

C. 2nd Stage Compressor Fails To Start Probable Cause (1) Time delay contacts fail to close (2) No call for cooling Recommended Action Replace time delay relay Check for the followings: a. Defective thermostat b. Broken or improper control winding (3) Unit locked out by reset relay (CR) (4) Compressor contactor will not close D. Compressor Short Cycles Probable Cause (1) Intermittent contact in control circuit Recommended Action Check for the followings: a. Defective relay contacts b. Loose wiring connections E. Compressor Runs Continuously Probable Cause (1) Unit undersized for load (cannot maintain water temperature) (2) Thermostat setpoint too low (3) Defective thermostat or control wiring (4) Welded contacts on compressor contactor (5) Leaky valves in compressor (indicated by abnormally low discharge and high suction pressures) (6) Shortage of refrigerant (indicated by reduced capacity, high superheat, low subcooling, and low suction pressure) F. Compressor Motor Winding Stat Open Probable Cause (1) Excessive load on evaporator (indicated by high supply water temperature) (2) Lack of motor cooling (indicated by excessive superheat) Recommended Action Check for the followings: a. Excessive water flow b. High return water temperature Check for the followings: a. Improper expansion valve setting b. Faulty expansion valve (3) Improper voltage at compressor c. Restriction in liquid line Check for the followings: a. Low or imbalanced line voltage b. Loose power wiring (4) Internal parts of compressor damaged c. Defective compressor contactor Replace compressor Recommended Action Check for cause of excessive load Readjust thermostat Replace thermostat Replace or repair control wiring Repair or replace contactor Replace compressor Find and repair refrigerant leak Recharge system See (A) item (4) See (A) item (5)

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G. Compressor is Noisy Probable Cause (1) Internal parts of compressor damaged or broken (compressor knocks) (2) Liquid floodback (indicated by abnormally cold suction line and low superheat) (3) Liquid refrigerant in compressor at start-up (indicated by abnormally cold compressor shell) H. System Short of Capacity Probable Cause (1) Low refrigerant charge (indicated by high superheat and low subcooling) (2) Clogged filter drier (indicated by temperature change in refrigerant line through drier) (3) Incorrect expansion valve setting (4) Expansion valve stuck or obstructed(i.e., high superheat and high water temperature) (5) Low evaporator water flow (6) Noncondensibles in system (7) Leaky valves in compressor (i.e., operation at abnormally high suction and low discharge pressures) I. Suction Pressure Too Low Probable Cause (1) Shortage of refrigerant (i.e., high superheat, low subcooling) (2) Thermostat set too low (i.e., low discharge pressure, low leaving water temperature) (3) Low water flow (4) Clogged filter drier (5) Expansion valve power assembly has lost charge (6) Obstructed expansion valve (i.e., high superheat) J. Suction Pressure Too High Probable Cause (1) Excessive cooling load (i.e., high supply water temperatures) (2) Expansion valve overfeeding (i.e.,superheat too low, liquid flooding to compressor) (3) Suction valves broken (i.e. noisy compressor) Recommended Action See (E) above Adjust superheat setting; verify that remote bulb is properly attached to suction line Replace compressor Recommended Action Find and repair leak; recharge system Readjust thermostat Check for clogged strainers and ncorrect balancing valve settings Check for frost on filter drier. Replace if needed Repair or replace expansion valve power head assembly Clean or replace valve Add refrigerant Replace filter drier or filter drier core Readjust expansion valve Repair or replace expansion valve Check strainers. Adjust water flow Evacuate and recharge system Replace compressor Recommended Action Replace compressor Check and adjust superheat Check for refrigerant overcharge Recommended Action

American Standard Inc. 2004

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CGA-SVX01B-EN

K. Discharge Pressure Too Low Probable Cause (1) Shortage of refrigerant (i.e., low subcooling, high superheat, bubbles in sight glass) (2) Broken or leaky compressor discharge valves (3) Defective low pressure switch (4) Unit running below minimum operating ambient Recommended Action Find and repair leak; recharge system Replace compressor Replace defective control Provide adequate head pressure controls, or an ambient lockout switch

L. Discharge Pressure Too High Probable Cause (1) Too little or too warm condenser air; airflow restricted (2) Air or non-condensable gas in system (i.e., exceptionally hot condenser) (3) Refrigerant overcharge (i.e., high subcooling, low superheat, high suction pressure) (4) Excessive system load (5) Defective condenser fan or fan pressure control (i.e., 1 fan off, high condenser pressure) M. System Cannot Heating Mode (CGAR Model Only) Probable Cause (1) Broken or improper control wiring (2) Defective four-way valve N. Suction Pressure Too Low - Heating Mode (CGAR Model Only) Probable Cause (1) Low refrigerant charge (2) Too little or too cold evaporator air; airflow restricted (3) Unit running below minimum operating ambient (4) Expansion valve power assembly has lost charge Recommended Action Add refrigerant Clean coil; Check fans and motors for proper function Provide an ambient lockout switch Repair or replace expansion valve power head assembly Recommended Action Check control wiring Replace four-way valve Recommended Action Clean coil; Check fans and motors for proper function Evacuate and recharge system Recover excess refrigerant Reduced load Repair or replace switch

O. Discharge Pressure Too High - Heating Mode (CGAR Model Only) Probable Cause (1) Low water flow (2) Defective heating thermostat switch Recommended Action Check for clogged strainers and incorrect balancing valve settings a. Verify that sense bulb is properly inserted bulbwell of heat-exchanger b. Replace heating thermostat switch

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FM 38631 ISO 9001 Qualified factory - Trane Taiwan

North American Group The Trane Company 3600 Pammel Creek Road La Crosse, Wl 54601-7599 http : // www.trane.com

Literature Order Number File Number Supersedes Stocking location

CGA-SVX01B-EN-0404 CGA-IOM-7 CGA-SVX01A-EN-0701 Taipei, Taiwan

An American-Standard Company

Since The Trane Company has a policy of continuous product improvement, it reserves the right to change design and specifications without notice.