cgah chiller iom

8/12/2019 Cgah Chiller Iom

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CGAH-SVX01A-EN

InstallationOperationMaintenance

CGAH Air Cooled Liquid ChillersSMM Configuration SMM Module forScroll Units, H Generation


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American Standard Inc. 2001 CGAH-SVX01A-EN2

CGAH Air Cooled Liquid ChillersContents

ForewordWarrantyAcceptance of deliveryGeneralRefrigerant

Product nomenclatureInstallation

Unit nameplateInstallation instructionsHandlingWater to evaporator connectionUnit dimensionsGeneral unit characteristicsElectrical connectionsWiring diagram-Customer electric power supply

General start-upPreparationStarting up the unitFinal checksPressure drops

OperationControl and unit operationWeekly start up and week-end shutdownStart up and seasonal shutdown

MaintenanceMaintenance instructionsTroubleshooting guideInstallation checklitSafety recommendationsMaintenance contractTraining

SMM ConfigurationHardwareOperation of the module

Function of the keys 0 and 1Function of the keys , , andHow to reset the SMM ?Content of the meun

A General informationB Customer configurationC Events log and resetD Customer configuration (rest)E Information on pressures and refr igerant temperatures and optional temperatures

Explanation of the fault codes

3

45

13

16

17

2223

26


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3 CGAH-SVX01A-EN

ForewordThe aim of this document is to set out therules for the installation, set-up. operationand maintenance of this type of Trane aircooled liquid chillers.The maintenance operations required toinsure that this machine operates reliabilythroughout its full service life are not

exhaustively described. Only the services ofa qualified technician employed by areputable service company can ensure thatthe machine operates durably and reliably.

WarrantyWarranty is based on the general terms andconditions of Societe Trane. The warranty isvoid if the equipment is modified without thewritten approval of Trane, if the operatinglimits are exceeded or if the control systemor the electrical wiring is modified.Damage due to misuse, lack of maintenanceor failure to comply with the manufacturersinstructions or recommendations is notcovered by the warranty obligation.

Acceptance on deliveryAll air-conditioning units are shipped to theirinstallation site on a wooden skid.All machines reach final destinationcompletely connected and assembled readyfor immediate start-up.

Please check that the unit has not in anyway been damaged during transport, assoon as it arr ives on site. If damage isobserved, or even on suspicion of damage:Carry out instructions for notification ofdamage in transport, and warn your TraneAgency.

Caution:

Failure to conform to the above rules will result in loss of insurance coverage.

GeneralAbout this manual:"Caution" and "Warning" messages appearat the appropriate place throughout thismanual. Your personal safety and the properoperation of this machine require that youfollow them carefully.Trane Taiwan assumes no liability forinstallation or servicing performed byunqualified personnel.

RefrigerantThe refrigerant provided by the constructormeets all the requirements of our units.When using recycled or reprocessedrefrigerant, it is advisable to ensure itsquality is equivalent to that of a newrefrigerant.For this, it is necessary to have a preciseanalysis made by a specialized laboratory. If

this condition is not respected, theconstructor warranty could be cancelled.

Contents


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DIGIT 1,2,3,4 Chiller Type

DIGIT 5,6,7 Model

DIGIT 8 Electrical Power

DIGIT 9 Design Sequence

DIGIT 10 Controls

020

5,6,7

2

8

B

9

U

10

N

11

M

12

R

13

N

14

A

15

CG

1,2

A

3

H

4

Product nomenclature


DIGIT 11 Built In Water Pump

DIGIT 12 Main Disconnect Switch

DIGIT 13 Operating Ambient Temperature

DIGIT 14 Options

DIGIT 15 Service Sequence

N=Without (standard)R=With (Option for model 020 & 025 Cooling-Only 60Hz unit)

M=Without (Standard)

G=With (Optional)

R=Normal (standard 3-43C)L=Low (below 3C)

N=No optionsB=Blue fin condenserJ=Compressor sound attenuatorK=Blue fin condenser & Compressor sound attenuator

A=First

CGAH=Air-cooled Chillers

020025030

040050060

2=220V/60Hz/33=380V/60Hz/34=460V/60Hz/35=380V/50Hz/36=400V/50Hz/37=415V/50Hz/3

B=Second

U=MicroprocessorM=Pneumatic control (For domestic only)


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5 CGAH-SVX01A-EN

Installation

CGAH(50Hz)A(mm)B(mm)

MAX. WEIGHT(kg)

02013002200750

02513002200850

03013002200975

040130022001450

050220022001550

060220022001750

Figure 2: Dimensions of recommended slings and swing-ber

Unit nameplateThe unit nameplate gives the completemodel reference numbers.The unit power rating is shown, and powersupplies should not deviate by more than10% from the rated power.The customers electrical installation mustbe able to withstand this current.(Figure 1)

Installation instructionsFoundationsNo special foundations are required,provided the supporting surface is flat andlevel, and can withstand the weight of theunit.

Anti-vibration rubber padsThey are supplied as standard with themachine, and should be placed between thesupporting floor and the unit to attenuate

vibrations.4 pads for the sizes 020-0306 pads for the sizes 040-060

ClearanceInsure there is sufficient clearance aroundthe unit to allow maintenance operations totake place without obstruction.For minimum clearance, please refer tofigure 5.

Handling (Figure 2)

Figure 1: Unit nameplate

Dimensions of recommended slings and swing-bar:


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Water to evaporator connectionInstall water circulation pump upstream ofthe evaporator, insuring that the evaporatoris under positive pressure.Tables for power supply connections andwater return are shown on the certifiedsubmittals.These drawings are available on request

from your Trane agency.The 1/4 coupling located on the outletconnections may be used as the drainingoutlet from the plate heat exchanger.

Note: Complete draining of all the installation is difficult. The use of antifreeze liquid is recommended to protect the heat exchanger.

The following recommendations refer toFigure 3.1. Pressure gauges: shows entering and

leaving water pressure. Stop valvesshould be provided on water inlets andoutlets.

2. Thermometers: indicate chilled waterentering and leaving temperatures.

3. Balancing valve: controls water flow.4. Stop valves: isolate chillers and water

circuting pump during maintenanceoperations.

5. Water strainer: avoid to get heatexchangers dirty. (Factory provided, fieldinstalled)

Caution: All installation must be equipped with strainer provided by factory in order that only clean water enters into exchangers.

Insure that all chilled water pipes are fullyinsulated, in order to prevent frost damage.Mount heating resistors on all water pipesexposed to negative temperatures.

Minimum water capacityMinimum volume of water is depending onthe type of application. Consult your TraneAgency. If necessary a buffer tank should befitted. Safety and control devices will onlyoperate correctly if there is sufficient water inthe system.

Water treatmentUntreated or insufficiently treated water, ifused in this unit, may cause scale, slime oralgae to accumulate or cause erosion andcorrosion. The services of a qualified watertreatment specialist are recommended todetermine what treatment, if any, isadvisable. Trane disclaims any liability withregard to damage arising from the use ofuntreated or improperly treated water, orfrom the use of saline or brackish water.

Figure 3: Water to evaporator connection


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7 CGAH-SVX01A-EN

Unit dimensionsCGAH-020/025/030

CGAH-040/050/060


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General Unit Characteristics50Hz

60Hz

Notes:(1)Maximun load amps to be used for sizing of cables, fuses and disconnect swith.(2)Staring amps with one compressor staring, the remaining compressor(s) running at full load.

HCFC-22

Model

CompressorsCircuitCapacity Steps

Max Load Amps(1)

C0mpressors Power input

C0mpressors Running Current

C0mpressors Starting Current(2)

Rated Water FlowEvaporator Head Loss(H 2 O)

Number Of Fan(s)Air Flow RateNominal Fan SpeedFan Motor Full Load Power input Each

Fan Motor Staring Amps Each

Fan Motor Full Load Amps Each

Operating WeightLenghtWidthHeight

Refrigerant

220V380V440V

220V380V440V220V380V440V

220V380V

440V220V380V440V

AAA

kWAAAAAA

L.P.M.m

TypekgEA

m 3 /sRPM

kWAA

AAAA

kgmmmmmm

CGAH020

10T+10T12

844842

21.9643732

2971731361753.5

9.62

7.76600.97.55.5

3.74.52.62.2750

206010201560

CGAH025

10T+15T12

1066153

26.3804640

4522531912214.0

12.22

7.26600.97.55.5

3.74.52.62.2900

206010201560

CGAH030

15T+15T12

1287464

30.7965548

4682631992634.4

14.52

7.56600.97.55.5

3.74.52.62.2

1050206010201860

CGAH040

2x (10T+10T)24

1709885

43.81287464

3612111683653.5

20.14

15.46600.97.55.5

3.74.52.62.2

1450225018901560

CGAH050

2x(10T+15T)24

21212210652.51609280

5323002314434.0

24.34

14.46600.97.55.5

3.74.52.62.2

1650225018901560

CGAH060

2x(15T+15T)24

25614812861.419211196

5643182475264.4

28.94

15.06600.97.55.5

3.74.52.62.2

1900225018901860

HCFC-22

ModelCompressorsCircuitCapacity Steps

Max Load Amps(1)

C0mpressors Power input

C0mpressors Running Current

C0mpressors Starting Current(2)

Rated Water FlowEvaporator Head Loss(H 2 O)

Number Of Fan(s)Air Flow RateNominal Fan SpeedFan Motor Full Load Power input EachFan Motor Staring Amps EachFan Motor Full Load Amps EachOperating WeightLenghtWidthHeight

Refrigerant

380V400V415V

380V400V415V380V

400V415V

400V400V

AAA

kWAAAA

AA

L.P.M.m

TypekgEA

m 3 /sRPM

kWAA

kgmmmmmm

CGAH02010T+10T

12

424039

16.9302827

126

1331381453.6

9.62

7.77001.04.52.8750

206010201560

CGAH02510T+15T

12

535048

21.2403837

181

1901971874.0

12.22

7.77001.04.52.8850

206010201560

CGAH03015T+15T

12

636058

25.0484644

188

1982052234.1

14.52

7.27001.04.52.8975

206010201560

CGAH0402x (10T+10T)

24

848077

33.8605654

154

1631673063.6

20.14

15.47001.04.52.8

1450225018901560

CGAH0502x(10T+15T)

24

10510096

42.4807673

217

2282373734.0

24.34

15.47001.04.52.8

1550225018901560

CGAH0602x(15T+15T)

24

12612011649.9

979289

232

2442534474.1

28.94

14.47001.04.52.8

1750225018901560


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Performance Data50Hz

60Hz

9 CGAH-SVX01A-EN

Notes:(1)Cap.-Cooling Capacity(2)In.P-Total Input Power

LWT(C)

57957957957957957

9

MODEL

CGAH020(60Hz)

CGAH025(60Hz)

CGAH030(60Hz)

CGAH040(60Hz)

CGAH050(60Hz)

CGAH060(60Hz)

Cap.kW(MBH)

64.7(220.8)68.0(232.0)71.1(242.6)81.5(278.1)85.6(292.1)89.6(305.8)96.9(330.7)

101.6(346.7)106.2(362.4)134.0(457.3)141.0(481.2)148.1(505.4)163.1(556.6)171.2(584.2)179.3(611.9)193.7(661.0)203.1(693.1)

212.5(725.2)

In.PkW

19.419.820.123.023.423.726.827.227.640.340.841.346.146.747.453.654.4

55.1

Cap.kW(MBH)

61.7(210.6)64.8(221.1)67.8(231.4)77.9(265.8)81.7(278.8)85.6(292.1)92.5(315.7)97.1(331.4)

101.6(346.7)128.1(437.1)134.8(460.0)141.6(483.2)155.7(531.3)163.6(558.3)171.3(584.6)185.0(631.3)194.1(662.4)

203.0(692.7)

In.PkW

21.321.622.025.225.625.929.329.730.143.644.244.750.451.251.958.659.4

60.2

Cap.kW(MBH)

60.5(206.5)63.5(216.7)66.4(226.6)76.3(260.4)80.2(273.7)84.0(286.6)90.8(309.9)95.2(324.9)99.8(340.6)

125.5(428.3)132.3(451.5)138.9(474.0)152.7(521.1)160.5(547.7)168.1(573.6)181.5(619.4)190.5(650.1)

199.3(680.1)

In.PkW

22.122.422.826.226.526.930.430.831.245.045.646.252.353.153.860.861.6

62.5

Cap.kW(MBH)

58.4(199.3)61.4(209.5)64.3(219.4)74.0(252.5)77.8(265.5)81.5(278.1)88.0(300.3)92.4(315.3)96.7(330.0)

121.9(416.0)128.3(437.8)134.9(460.3)148.0(505.0)155.6(531.0)163.0(556.2)176.1(600.9)184.8(630.6)

193.5(660.3)

In.PkW

23.423.724.127.728.128.432.132.633.047.347.948.555.356.156.964.265.1

66.0

Cap.kW(MBH)

55.0(187.7)57.8(197.2)60.0(206.8)70.0(238.9)73.6(251.2)77.1(263.1)83.4(284.6)87.7(299.3)91.8(313.3)

115.4(393.8)121.6(415.0)127.9(436.5)140.0(477.7)147.3(502.7)154.4(526.9)166.9(569.5)175.2(597.9)

183.4(625.8)

In.PkW

25.726.126.530.330.831.235.235.736.251.452.052.760.761.662.470.571.4

72.4

25 30 32 35 40Entering air temperature on condensing coil (C)

LWT(C)

579579

579579579579

MODEL

CGAH020(50Hz)

CGAH025(50Hz)

CGAH030(50Hz)

CGAH040(50Hz)

CGAH050(50Hz)

CGAH060(50Hz)

Cap.kW(MBH)

53.7(183.3)56.5(192.8)59.3(202.4)68.6(234.1)72.2(246.4)75.7(258.3)

82.1(280.2)86.2(294.2)90.3(308.1)

112.1(382.5)118.0(402.7)124.1(423.5)137.2(468.2)144.3(492.4)151.3(516.3)164.2(560.3)172.4(588.3)180.7(616.6)

In.PkW

15.215.415.719.119.419.6

22.322.622.829.429.730.138.338.839.344.545.145.7

Cap.kW(MBH)

51.1(174.4)53.8(183.6)56.5(192.8)65.5(223.5)68.9(235.1)72.3(246.7)

78.5(267.9)82.5(281.5)86.4(294.8)

107.1(365.5)112.9(385.3)118.7(405.1)131.1(447.4)138.0(470.9)144.7(493.8)157.0(535.8)164.9(562.7)172.9(590.0)

In.PkW

16.817.017.321.021.321.6

24.424.725.132.232.633.042.042.643.148.849.550.1

Cap.kW(MBH)

50.2(171.3)52.7(179.8)55.4(189.1)64.3(219.4)67.6(230.7)71.0(242.3)

77.0(262.8)80.9(276.1)84.8(289.4)

105.2(359.0)110.9(378.4)116.6(397.9)128.7(439.2)135.3(461.7)142.0(484.6)153.9(525.2)161.8(552.1)169.7(579.1)

In.PkW

17.517.818.021.822.122.4

25.425.726.033.433.834.243.644.244.850.751.452.0

Cap.kW(MBH)

48.5(165.5)51.0(174.0)53.6(182.9)62.4(212.9)65.7(224.2)68.8(234.8)

74.7(254.9)78.5(267.9)82.3(280.8)

102.1(348.4)107.6(367.2)113.2(386.3)124.7(425.5)131.2(447.7)137.7(469.9)149.3(509.5)157.1(536.1)164.6(561.7)

In.PkW

18.618.919.223.123.423.7

26.827.227.535.435.836.246.246.847.453.754.455.1

Cap.kW(MBH)

45.7(156.0)48.1(164.1)50.5(172.3)58.9(201.0)62.0(211.6)65.2(222.5)

70.6(240.9)74.3(253.5)77.9(265.8)96.5(329.3)

101.9(347.7)107.3(366.2)117.8(402.0)124.1(423.5)130.4(445.0)141.2(481.8)148.6(507.1)155.9(532.0)

In.PkW

20.721.021.325.525.826.1

29.529.930.338.939.439.951.051.652.259.159.860.6

25 30 32 35 40Entering air temperature on condensing coil (C)


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Typical wiring diagram(Wiring on actual unit need to refer to diagram attatched on control box)Electrical connections1. The greatest care should be taken

when cutting through passages and installing electric wiring. Under no circumstances should chips of metal or cuttings of copper or isolating material fall into the starter panel or electric 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 drawing. Adequate insulation should be chosen, ensuring no foreign bodies enter the electical housing or components.

Caution:

1. Cabling must comply with standards in force. The type and location of fuses must also comply with standards. As a safety measure, fuses should be visibly installed, close to the unit.

2. Only copper wiring should be used..Using aluminum wires can produce galvanic corrosion and possibly lead to superheat and failure of connection points.


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11 CGAH-SVX01A-EN


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13 CGAH-SVX01A-EN

General Start-Up

PreparationBefore starting up the system. carry out thefollowing checks and operations:1. Before making any electrical connection,

insure that the isolation resistance of allpower supply terminals to groundcomplies with standards and regulations inforce. Check the isolation of. all electric

motors using a 500 V DC megohmeterwhich meets manufacturers specifications.

Caution: Do not start up a motor whose Insulation resistance is less than 2 meghoms.

2. Check that all electrical connections areclean and sound.

3. Switch on mains power supply switch.

Caution: Phase imbalance should not be greater than 2%. The voltage supplied to motors should be within 10% of the rated voltage shown on the compressor nameplate.

4. Check that unit power supplies matchrated input power.

5. Insure all water and refrigerant valves arein service positions.

6. Reset all manually set control devices.7. Insure that sensors are properly installed

in their bulbwells and submerged in heatconducting product. Check fixing ofcapillary tubes (check protection from

vibration and from wear, and insure thatthey are not damaged).

Starting-up the unitBefore start up:Carry out all operations on check list andfollow the instructions below to ensure thatthe unit is correctly installed and ready tooperate. The installer must check all thefollowing points before calling in the Traneservicing Department to put the equipment

into service.1. Chilled water circuit ready to operate,

filled with water, pressure test carried outand purged.

2. Thermometers and pressure gaugesinstalled in chilled water circuit.

3. Chilled water pump interconnected tocontrol panel.( refer to wiring diagram)

4. Check that all electrical connections areclean and sound.

5. Check that mains power supply switch issound.

6. Check compressor oil level at rest. Thelever should reach at least halfway upindicator located on housing. See Fig. 4for correct level.

7.Check direction of rotation of fan isdischarging upwards. To ensurecompressor is rotating correctly.

8.On start up of each motor in the system,check the direction of rotation andoperation of all the components theydrive.

9. Check extent of pressure drops throughevaporator, so that the value matchesvalues shown on graphs A and B, page14.

10. Check that there is sufficient demand forcooling on the day of start-up (around50% of nominal load).

Caution: Excessive emulsion shows that refrigerant is present into oil and the result will be that compressor is not lubricated enough. Shut down motor and identify cause.Excess oil in compressor may have as

much an adverse effect as not enough oil. Before adding oil, consult Trane technician. Use only products recommended by Trane.

Warning: The water circuit to the evaporator may be under pressure. Please refer to appropriate instructions to bring down this pressure before opening up the system before rinsing or filling operations. Failure

to comply with this instruction may cause accidental injury to maintenance personnel.

Caution: The compressors must operate in a single direction of rotation. If refrigerant high pressure remains stable in the 30 seconds after compressor start up,immediately shut down unit and check the direction of rotation

Figure 4: Compressor oil level


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Figure 5: Service and Maintenance Clearance

Start up1. Start-up unit pushing button "1" of control

module. The green LED must be lighted.2. After unit star t-up. leave in operation for at

least 15 minutes. to insure pressures arestabilized.

Then check: Compressor and fan current consumption.

Suction pressure. Discharge pressure. Superheat. Subcooling. Pressure drops and temperatures of

evaporator.

SuperheatNormal superheat is 6 C to 8 C. Excessrefrigerant supplied to the evaporatorproduces high suction pressure, and a lowdegree of superheat can draw the refrigerantback to the compressor. Insufficientsuperheat is corrected by adjusting theexpansion valve reduction lever. If thisproduces no result, it shows that theexpansion valve is no longer operatingsatisfactorily. The expansion valve must bereplaced.

Sub-coolingIf the system is correctly filled, the sub-cooling value of the refrigerant valve on theliquid line should be 8 C to 10 C on astandard unit.

Condenser fan motorsAll fans are fixed directly to the motor shaft.The operating sequence of fans is controlledby the SMM module.

Low temperature operations (air intake tocondenser)If the unit is set to operate at low air intaketemperature, follow procedure below toinsure the chilled water circuit is properlyprotected.Insure that all pipes are perfectly protectedagainst freezing.Otherwise use antifreeze solution in chilledwater circuit. If for any reason. the heatingresistors in the chilled water circuit cannotbe energized, the solution must be able towithstand any ice formation in the circuit.When using the antifreeze solution,manufacturers instructions for filling of thechilled water circuit, the degree of protectionand test procedures must be strictlyfollowed.

Final checkWhen the unit is operating correctly, a finalcheck should be made for the followingpoints:1. Check that unit is clean, and clear of any

debris, tools, ect..2. All valves in operating position.3. Close control and starter panel doors, and

check panels fixation.4. After 2 hours of operation, clean the water

strainer.

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.. (See Figure 5.)


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15 CGAH-SVX01A-EN

Figure A: Evaporator water pressure drop (mH 2O)-50Hz

Figure B: Evaporator water pressure drop (mH 2O)-60Hz


16/28


Operation

Control SystemThe control is throgh the SMM controlmodule.

Unit operationsStart up unit pushing button "1" of the SMMcontrol module.The unit will operate correctly when there issufficient water flow at the evaporator. Thecompressors will start up if the evaporatorwater leaving temperature is above the SMMcontrol module setpoint.

Weekly start upPush button "1" of the module to allow chilleroperation.

Week end shutdownIf the unit needs to be shut down for a shortperiod of time, push button "O" of themodule. If the unit is shut down for a longerperiod, see under "Seasonal shutdown",below.

Seasonal shutdown1. Push button "O" of the module.2. If the water piping is not protected against

freeze up, drain the evaporator by openingthe 1/4 connection on the water outletpipe.

Seasonal start-up(requires qualifiedtechnician)

1. Ensure all the instructions in "Annualmaintenance", in the "maintenance"chapter, have been complied with.

2. Fill up and purge chilled water circuits.3. Insure liquid line stop-valve is open.4. Check the tightness of the refrigerant

circuit.5. Start-up the chiller (see Unit operations)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.


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17 CGAH-SVX01A-EN

The following maintenance instructions arepart of maintenance operations required forthis equipment. A qualified technician isneeded for regular maintenance as part of aregular maintenance as part of a regularmaintenance contract.Carry out all operations as required byschedule.This will insure long unit service life andreduce the possibility of serious and costlybreakdown. Keep service records up to date,showing weekly information on unitoperations. These records can be of greathelp to maintenance personnel diagnostics.Similarly, if machine operator keeps a log ofchanges in unit operating conditions,problems can be identified and solutionsfound before more serious problems arise.

Weekly maintenance

1. Check compressor oil level at rest. Oillevel should be halfway up sightglasslocated on the housing. (See Figure 4)

2. Excess oil in the compressor can be asdamaging as not enough oil. Beforetopping up, contact a qualified technician.Use only Trane-recommended oils.

Caution: Excessive emulsion indicates presence of refrigerant in oil, resulting in poor lubrication of compressor. Stop motor and check cause.

3. Inspect the entire system for undesirableeffects, such as noisy compressor, looseaccess panels, leaks in pipes, or vibratingcontactors.

4. Keep records of temperatures, pressures,dates and times, or other observations inlog book.

Maintenance

Recommended oilPlease refer to specific Trane documentationon oil, available from your nearest Traneagency.

Note: Oils recommended by Trane have been exhaustively tested in Trane laboratories to the specific requirements of Trane

compressors, and hence the users requirements. Any use of oils not meeting specifications recommended by Trane is the responsibility of the user only, who thereby is liable to loss warranty.

Annual maintenance1. Check chilled water circuit, valve, pipes,

and clean filters if necessary. Analyzewater quality. Cleaning may be required, inwhich case use professional assistance.

Caution: Chilled water circuit may be pressurized.Check instruction to reduce circuit pressure before opening chilled water circuit. Failure to comply with this instruction may result in accident or injury to maintenance personnel.

2. Clean corroded outer surfaces, andrepaint.Check electrical panel seal door.

3. Check the tightness of the chilled watercircuit.Check circulating pump operation andassociated devices.Check percentage of anti-freeze in chilledwater circuit, and top up as necessary.

4. Carry out all weekly maintenanceinspections.

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.9. Clean the water strainer.

Other interventions may be necessary,

depending on the age and service life ofunit.

Note: It is important for unit to be regularly maintained by a qualified technician, at least once a year or every 2,000 hours of operation. Contact Trane Service for information on maintenance contracts.

A maintenance inspection by a qualifiedtechnician is also recommended after thefirst 500 hours of operation from unit start-

up.

Caution: Switch off unit mains power supplies before any intervention. Failure to follow this safety instruction can lead to accident death of the maintenance personnel and may also destroy equipment.

Cleaning of condensersClean the condenser coils with a brush or jet

of water. Please spray water from inside theunit. If the batteries are too dirty. consult acleaning professional.

Caution: Never steam clean condenser coils because the resulting increase in pressure could cause some refrigerant to be lost through the safety valve.


18/28


Troubleshooting guideThese are simple diagnostic. If there is abreakdown, the Trane Service Agencyshould be contacted for confirmation andassistance.

A. The compressor will not start up

Problems symptoms Probable cause Action recommended

Compressor terminals are live but motordose not start.Contactor motor not operationalNo current ahead of motor contactor.

Current ahead of fuse, but not oncontactor side.Low voltage reading on voltmeter.Starter coil not excited.

Compressor does not run. Compressormotor "groans".

Motor burned out.

Coil burned out or broken contacts.a)Power cutb)Mains power supply switched off.

Fuse blown.

Voltage too low.Regulation circuit open.

Compressor sticking (damaged or stickingcomponents).

Replace compressor.

Repair or replace.Check fuses and connection.See why system tripped.If system is operational, switch on mainspower supply.Check motor insulation. Replace fuse.

Contact Power Supply Utility.Locate regulation device which has trippedout, and see why. See instructionsconcerning this device.Replace compressor.

B. Compressor stops


High pressure switch tripped.

Over current thermal relay tripped

Motor temperature thermostat tripped.Anti-freeze security tripped.

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

See instructions for "discharge pressure toohigh".a) Contact Power Supply Utility.b) See instruction "discharge pressure too

high".Repair leak. Add refrigerantCheck water flow rate, and pressure switchcontact in water.


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19 CGAH-SVX01A-EN

C. Compressor stops just after its start


Suction pressure too low.Filter drier iced up.

Filter drier clogged Replace filter drier.

D. The compressor keeps running without stopping

Problems symptoms Probable cause Action recommendedTemperature too high in areas requiring air-conditioning.Chilled water temperature output too high.

Excess load on cooling system.

Excess cooling demande on system.

Check thermal insulation and air-tightnessof areas requiring air-conditioning.Check thermal insulation and air-tightnessof areas requiring air-conditioning.

E. Loss of oil in compressor


Oil level too low in indicator.Gradual fall of oil level.

Suction line too cold.Compressor noisy.

Not enought oil.Filter drier clogged.

Liquid flows back to compressor.

Add oil.Replace filter drier.

Adjust superheat and check bulb fixing ofthe expansion valve.

F. Compressor noisy


Compressor knocks.suction duct abnormally cold.

Components broken in compressora) Uneven liquid flow.b) Expansion valve locked in open position.

Change compressor.a) Check superheat setting and fixing or

expansion valve bulb.b) Repair or replace.

G. Insufficient cooling capacity


Thermostatic expansion valve "whistles".

Excess pressure drops through filter drier.Excessive superheat.

Insufficient water flow.

Not enough refigerant.

Drier filter colgged.Superheat not properly adjusted.

Chilled water pipes obstructed.

Check refrigerant circuit tightness and addrefrigerant.Replace.Check adjustment of superheat and adjustthermostatic expansion valve.Clean pipes and strainer.


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H. Discharge pressure too high


Condenser abnormally hot.

Chilled water leaving temperature too high

Condenser air output too hot.

Presence of uncondensable liquids insystem, or excess of refrigerant.Overload on cooling system.

Reduced air flow. Air intake temperaturehigher than specified for unit.

Purge uncondensable fluids and drain offexcess refrigerant.Reduce load on system.Reduce water flow if necessary.Clean coil. Check operation of fan motor.

I. Suction pressure too high


Compressor operates continuously.Suction duct abnormaly cold.Refrigerant flows back to compressor.

Excess cooling demand on evaporator.a) Expansion valve too far open.b) Expansion valve looked in open position.

Check system.a) Check for superheat and check that

expansion valve bule is secure.b) Replace.

J. Suction pressure too low


Excessive pressure drop through filterdrier. Refrigerant does not flow throughthermostatic expansion valve.Loss of powerSuperheat too low.

Filter drier clogged.Expansion valve bulb has lost its refrigerant.

Expansion valve obstructed.Excessive pressure drops though evaporator.

Replace the filter drier.Replace the bulb of the expansion valve.

Replace.Check adjustment of superheat and adjustthermostatic expansion valve.

Caution: The above is not a comprehensive analysis of the Scroll compressor refigeration system. The aim is to give operators simpleinstruction on basic unit processes

K. Insufficient cooling capacity


Low pressure drops through evaporator Low water flow rate. Check water flow rate. Check state ofstrainer check for obstruction in chilledwater pipes. Check pressure switchcontact in water.

so that they have the technical knowledge to identify and bring defective operations to the notice of qualified technicians.


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21 CGAH-SVX01A-EN

Installation checklistCGAH Trane Air Cooled Liquid ChillerThis list must be checked off by the installer toensure correct installation before the unit startsup.

Unit acceptanceCheck for damage, if any, ontransportation.Check for equipment shipped againstdelivery slip.Check lifting system

Unit positioningRemove packaging

Check position of unitCheck unit is levelCheck clearance around condenserCheck clearance required formaintenance accessCheck position of rubber pads.

Chilled water circuitCheck presence of stainer ahead ofevaporatorCheck the tightness of the water circuitCheck thermometer positioningCheck manometer positioningCheck chilled water flow rate balancingsystemCheck rinsing and filling of chilled waterpipesCheck pump operation and water flow.

Electrical equipmentCheck direction of rotation of compressorand fan motorsCheck chilled water pump drive roationCheck installation and rating of mainspower switch/fuseCheck that electrical connections complywith specificationCheck that electrical connections matchinformation on manufacturersidentification plate.Check electrical connections andconnections to mains power switchWater pressure switch.

GeneralCheck available cooling charge (50% ofrated installation load)Check with other trades handlinginstallation works.


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Hardware

Figure 6: Base Module When the jumper is in position 1, theauxiliary module is used to control thecircuit 2.

When the jumper is in position 2, theauxiliary module is used to control the fans.

When the jumper is in position 3, theauxiliary module is used to control theleaving hot water temperature.

When the jumper is in position 4, theauxiliary module is used to allow to displaythe evaporator and condenser inlet watertemperatures.

Figure 7: Auxiliary Module


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23 CGAH-SVX01A-EN

Operation of the module

C

C 02 NO

C 02 CLEAR

A B

Function of keys 0 and 1The key 1 is used to allow the start of thecompressor.The key 0 is used to stop the chiller.When the operator press on key 0, thefollowing message appears:A operator stop

How to reset the SMM?Press 3 times on the keythe following message appears

Press 1 time on the keyPress 1 time on the keyThe following message appears

Press on the keyThe following message appears

Press 1 time on the key during 5 seconds.The hour and the leaving chilled watertemperatures are displayed.The orange LED is switched off.

NotesIf one of the following faults is displayed:M comp A1 faultM comp A2 faultM comp B1 fault

M comp B2 faultthe corresponding overload relays must bereset before to reset the SMM.

How to have access to themenu A?Press 1 time on the keyThe following message appears

Press 1 time on the keyChilled water set point is displayed.

To have access to the following information,press the keyTo exit the menu press the key during afew seconds.

Information contained in the menu AA01 Active water setpointA02 Evaporator water outlet mix

temperatureA03 Circuit 1 evaporator water outlet

temperatureA04 Circuit 2 evaporator water outlet

temperatureA05 Air temperatureA06 Number of compressor A1 operating

hoursA07 Number of compressor A1 startsA08 Number of compressor B1 operating

hoursA09 Number of compressor B1 startsA10 Number of compressor A2 operating

hours

A11 Number of compressor A2 startsA12 Number of compressor B2 operating

hoursA13 Number of compressor B2 starts

A01 Value C

How to have access to themenu B?Press twice on the keyThe following message appears

Press 1 time on the keyThe leaving chilled water temperature set

point value is displayed.To change the value, press on the keys orTo have access to the following parameters,press on the keyTo change the value of these parameters,press on the keys orTo exit this menu, press the key during afew seconds.

Parameters which can be modified in themenu BB01 Evaporator outlet temperature setpoint

Setting -26.0C to 30.0C by 0.1Cincrement. Default value 6.0.

B02 Hot water outlet temperature setpointSetting 20.0C to 60.0C by 0.1Cincrement. Default value 45.0.

B03 Auxiliary water outlet temperature setpointSetting -26.0C to 60.0C by 0.1Cincrement. Default value 6.0.

B04 Circuit 1 ON validationEnabled circuit: Enable. Disabled circuit:Disable. Default value: Enable

B05 Circuit 2 ON validationEnabled circuit: Enable. Disabled circuit:Disable. Default value: Enable

B06 Operating modeCooling mode: Cooling Heating mode:HeatingSerial link control: Extern Default value:Cooling


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C

D

D 01 None

B07 Remote control validationRemote control: RemoteLocal control: LocalDefault value: Local

B08 Auxiliary setpoint validationEnabled circuit: Enable. Disabled circuit:Disable.Default value: Disable

B09 Current date displayB091 day-setting 1 to 31B092 month-setting 1 to 12B093 year-setting 00 to 99.

B10 Current hour displayB101 hour-setting 00 to 23B102 Minutes-setting 00 to 59B103 Seconds-setting 00 to 59.

B11 Set this parameter at 0,0CB12 Set this parameter at 0,0CB13 Set this parameter at 0,0C

How to have access to themenu C ?Press 3 times on the keyThe following message appears

Press 1 time on the keyThe last fault is displayed.Press successively on the key to displaythe last 20 faultsPress successively on the key to displaythe last fault.To exit this menu, press during a fewseconds on the key .This menu is used also to reset theSMM(see parapragh How to reset theSMM?)

How to have access to themenu D?Press 4 times on the keyThe following message appears

Press 1 time on the keyThe following message appears

To change the value, press on the keys orTo have access to the following parameters,press on the keyTo change the values of these parameters,press on the keys or K

To exit this menu, press on the key duringa few seconds.

Parameters which can be modified in themenu D

D01 Cooling setpoint reset typeNone: None-On air: Air-On water: Ret.Wat.-Default value: None

D02 Cooling reset starting valueSetting 2C to 55C by 0.1C increment.Default value 20.0.

D03 Cooling reset value rangeSetting 2C to 20C by 0.1C increment.Default value 10.0.

D04 Cooling reset rangeSetting -15C to 15C by 0.1Cincrement. Default value 5.0.

D05 Heating setpoint reset typeNone: None-On air: Air-On water: Ret.Wat.-Default value: None

D06 Heating reset starting valueSetting 2C to 55C by 0.1Cincrement. Default value 20.0.

D07 Heating reset value rangeSetting 2C to 20C by 0.1Cincrement. Default value 10.0.

D08 Heating reset rangeSetting -15C to 15C by 0.1Cincrement. Default value 5.0.

Example of programmation of the chilledwater temperature set point in function ofthe air temperature

D09 Generic input type0..10 Volts 0..10V2..10 Volts 2..10V0.20mA 0..20mA4..20mA 4..20mADefault value 0..10V10V or 20 mA lead to a chilled watertemperature set point reset of 20C.

D10 Evaporator pump stop timerSetting 1 to 10 mn by 1 mn increment.Default value 1.

D11 Evaporator water pump automaticalcleaningNone None6 hours 6H12 hours 12H24 hours 24H48 hours 48HDefault value None

ParameterB01D01D02

D03D04

Value12,0Air

20,0

10,0-5,0

Expected operationSet point (C)

Outside temp.(C)3020

7

12

Values to be programmed


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25 CGAH-SVX01A-EN

E

D12 compressor lead-lagIncreasing fix 1-2Decreasing fix 2-1Start and hour balancing AutoAutomatic inversion at each star TRANEDefault value TRANEThe parameters D13 and D14 are usedto determine the conditions under whichthe fault relays switch on.

D13 Default 1 report type

Unit or circuit 1manual reset defaulbitUnit or circuit 2manual reset defaultUnit or circuit 1automatic reset defaultUnit or circuit 2automatic reset defaultCircuit 1 not available

or in limitCircuit 2 not availableor in limitInformational defaulton unitDefault value

Displayedvalue

1

2

4

8

16

32

64

bit 0

bit 1

bit 2

bit 3

bit 4

bit 5

bit 61

D14 Default 2 report type

Unit or circuit 1manual reset defaultUnit or circuit 2manual reset defaultUnit or circuit 1automatic reset defaultUnit or circuit 2automatic reset defaultCircuit 1 not availableor in limitCircuit 2 not availableor in limitInformational defaulton unitDefault value

Example:on a 2 circuit unit, we wish that the faultrelay 1 (D13) switches on if a manual or

an automatic reset fault occur. i.e.in thecases corresponding to the dits 0, 1, 2and 3. In this case, we have to displaythe value 15 (1+2+4+8)

D15 Serial link addresssetting 0 to 62. Default value 0.

UseFor comfort type application, increasing thereset point when the air temperaturedecreases allows to obtain better C.O.P. atpart load, so to decrease the energyconsumption.

E01 Value C

How to have access to themenu E?Press 5 times on the keyThe following message appears

Press 1 time on the keyThe saturated refrigerant temperature inside

circuit 1 evaporator is displayed.

To have access to the following information,press on the keyTo exit this menu, press on the key duringa few seconds.

information contained in the menu EE01 Circuit 1 evaporator saturated

temperatureE02 Circuit 1 evaporator saturated pressure

E03 Circuit 1 condenser saturatedtemperature

E04 Circuit 1 condenser saturated pressureE05 Circuit 2 evaporator saturated

temperatureE06 Circuit 2 evaporator saturated pressureE07 Circuit 2 condenser saturated

temperatureE08 Circuit 2 condenser saturated pressureE09 Evaporator water inlet temperatureE10 Condenser water outlet temperatureE11 Condenser water inlet temperature

Displayedvalue

1

2

4

8

16

32

64

bit 0

bit 1

bit 2

bit 3

bit 4

bit 5

bit 62


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Explanation of the fault codes

I Service demandI E2P par.chg

I XRAM par.chg

I E2P par.prog.

A User ckt1 stop

A User ckt2 stopA Ext. ckt1 stopA Ext. ckt2 stopA Rem. ckt1 stopA Rem. ckt2 stopA User unit stop

A Ext. unit stop

A Rem. unit stop

A Operator stopI E2prom fault

A Ckt1 limiting

A Ckt2 limiting

A Ckt1 HP limit.

A Ckt2 HP limit.

A Low ambienceA Ckt1 defrostA Ckt2 defrostA EVP water flow

A Sensor 4 main

A Sensor 1 I/O 2

Service request on the unit: one of the compressor configurated as presently has reached the value 1When powering-up the module, one or more of the operating parameters in E2PROM was incorrect andhas been corrected (default value). Check the configuration.When powering-up the module, one or more of the operating parameters in XRAM was incorrect and hasbeen corrected (default value). Check the configuration.When powering-up the module, all the operating parameters in EPROM were incorrect and have beemreplaced by their default value. Make the configuration.Circuit 1 is forced to stop due to the operator's configuration(menu B04)

Circuit 2 is forced to stop due to the operator's configuration(menu B05)Circuit 1 is forced to stop due to an external cause, by the O/l input Auto/Stop 1.Circuit 2 is forced to stop due to an external cause, by the O/l input Auto/Stop 2.Circuit 1 is forced to stop by the serial link.Circuit 2 is forced to stop by the serial link.Unit is forced to stop due to the operator's configuration. On single circuit units, this message is displayedif circuit 1 is devalidated (menu B04). On dual circuit this message is displayed if both circuits 1 and 2 aredevalidated (menu B04 and menu B05)Unit is forced to stop due to an external causes. On single circuit units, this message is displayed if circuit1 is devalidated (O/I input Auto-Stop 1)On dual circuit units, this message is displayed if both circuits 1and 2 are devalidated (O/l input Auto/Stop 1 and Auto/stop 2).Unit is forced to stop by the serial link. On single circuit units, this message is displayed if circuit 1 isdevalidated by the serial link. On dual circuit units, this message is displayed if both circuits 1 and 2 aredevalidated by the serial link.

The unit is stopped by the operator who has prshed key 0.A default occured when writing information in E2PROM.The value in memory may not be right and thuscorrected at next powering-up.One of the compressors of circuit 1 is prevented to start because one of the limitation is active(evaporator 1 outlet water temperature below the evaporator outlet water temperature low setpoint,evaporator 1 refrigerant temperature below the refrigerant temperature low setpoint, evaporator outlettemperature too high).One of the compressors of circuit 2 is prevented to start because one of the limitation is active(evaporator 2 outlet water temperature below the evaporator outlet water temperature low setpoint,evaporator 2 refrigerant temperature below the refrigerant temperature low setpoint, evaporator outletwater temperature too high). NB: this message can be displayed on 3 compressor units but without anyinfluence on the operation of circuit 2.The condenser side refrigerant pressure on circuit 1 is too high, and the system reduces the number ofcompressors in operation until its complete stop if necessary.

The condenser side refrigerant pressure on circuit 2 is too high, and the system reduces the number ofcompressors in operation until its complete stop if necessary.The outdoor air temperature is lower than the low ambient setpoint.Circuit 1 is de-icing and thus preventing the operation of circuit 2 (if present)Circuit 2 is de-icing and thus preventing the operation of circuit 1Loss of evaporator water flow during more than 2 sec. lf one of the compressor was operating, then thedefault LED is lit, if not, it is not lit.The customer analogical in put is configurated as 2..10V or 4..20 mA and the signal is lower than 1V or 2mA.Sensor 1 (air temperature) of module I/O 2 is out of range (short circuit40C, or circuit open 80C).

Contact Trane Service AgencyCheck the configuration

Check the configuration

Check the configuration

For info only. No necessary action

For info only. No necessary actionFor info only. No necessary actionFor info only. No necessary actionFor info only. No necessary actionFor info only. No necessary actionFor info only. No necessary action



For info only. No necessary actionSwitch off the SMM during 5 seconds



Check condenser cleaning and fan state.

Check condenser cleaning and fan state.

For info only. No necessary actionFor info only. No necessary actionFor info only. No necessary actionCheck chilled water pump state.

Check configuration of parameter D09 andanalogic inlet.Change the sensor.

Displayed messages Description Action


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27 CGAH-SVX01A-EN

NoteThe first letter of the displayed message indicates the type of default I for information A automatic reset defaultM manual reset defauit

A Sensor 1 I/O 3

A Sensor 1 I/O 4

A Sensor 1 main

A Sensor 2 main

A Sensor 3 main

A Sensor 1 I/O 1

A Sensor 2 I/O 1

A Sensor 3 I/O 1

A Com I/O 1

A Com I/O 2

A Com I/O 3

A Com I/O 4

M Low ref.ckt1M Low ref.ckt2M Low water ckt1M Low water ckt2M Pressure ckt1M Pressure ckt2M Discharge ckt1

M Discharge ckt2

M Comp. A1 faultM Comp. B1 fault

M Comp. A2 faultM Comp. B2 faultM ckt1 faultM ckt2 faultM Unit fault

Sensor 1 (condenser water outlet temperature) of module I/O 3 is out of range (short circuit40C, orcircuit open 80C).Sensor 1 (evaporator water inlet temperature) of module I/O 4 is out of range (short circuit40C, orcircuit open 80C).Sensor 1 (evaporator 1 water outlet temperature) of the main module is out of range (short circuit40C, or circuit open 80C).Sensor 2 (evaporator 1 refrigerant saturated temperature) of the main module is out of range (shortcircuit 40C, or circuit open 80C).

Sensor 3 (evaporator 1 refrigerant saturated temperature) of the main module is out of range (shortcircuit 40C, or circuit open 80C).Sensor 1 (evaporator 2 water outlet temperature) of module I/O 1 is out of range (short circuit40C, orcircuit open 80C).Sensor 2 (evaporator 2 refrigerant saturated temperature) of module I/O 1 is out of range (short circuit40C, or circuit open 80C).Sensor 3 (evaporator 2 refrigerant saturated temperature) of module I/O 1 is out of range (short circuit40C, or circuit open 80C).The main module does not communicate anymore with module I/O 1. Check the link wiring with thismodule as well as its address (circuit 2 board)The main module does not communicate anymore with module I/O 2. Check the link wiring with thismodule as well as its address (air-cooled unit board)The main module does not communicate anymore with module I/O 3. Check the link wiring with thismodule as well as its address (reversible unit board)

The main module does not communicate anymore with module I/O 4. Check the link wiring with thismodule as well as its address (option doard)Evaporator 1 refrigerant saturated temperature has overtaken the refrigerant low remperature setpoint.Evaporator 2 refrigerant saturated temperature has overtaken the refrigerant low remperature setpoint.Evaporator 1 water outlet temperature has overtaken the evaporator water low temperature setpoint.Evaporator 2 water outlet temperature has overtaken the evaporator water low temperature setpoint.Circuit 1 has been put in consecutive stand-by too near: thus it is stopped.Circuit 2 has been put in consecutive stand-by too near: thus it is stopped.One of the circuit 1 compressors has operated during a too long period with a high dischargetemperature: thus it is stopped.One of the circuit 2 compressors has operated during a too long period with a high dischargetemperature: thus it is stopped.The compressor A1 default I/O input shows a default.The compressor B1 default I/O input shows a default.

The compressor A2 default I/O input shows a default.The compressor B1 default I/O input shows a default.The compressor A1 and B1 default I/O inputs simultaneously show a default.The compressor A2 ( and B2 if present) default I/O inputs simultaneously show a default.All the present compressor default I/O inputs simultaneouslyshow a default.

Change the sensor.

Change the sensor.

Change the sensor.

Change the sensor.

Change the sensor.

Change the sensor.

Change the sensor.

Change the sensor.

Check the link wiring




Check expansion valve state and refrigerant loadCheck expansion valve state and refrigerant loadCheck chilled water flowCheck chilled water flowCheck condenser cleanlinessCheck condenser cleanlinessCheck refrigerant load

Check refrigerant load

Reset the overload relay of compressor A1Reset the overload relay of compressor B1

Reset the overload relay of compressor A2Reset the overload relay of compressor B2Reset pressostat HP, circuit 1Reset pressostat HP, circuit 2Reset pressostats and thermal relays

Displayed messages Description Action


28/28

Since The Trane Company has a policy of continuous product improvement, it reserves the right to change design and

Literature Order Number

File Number

Supersedes

Stocking location

CGAH-IOM-2

CGAH-SVX01A-EN-0200

CGAH-IOM-1

Taipei Taiwan

North American Group The Trane Company 3600 Pammel Creek Road La Crosse, Wl 54601-7599

http : // www.trane.com

ISO 9002 Qualified factoryFM 38631

cgah chiller iom

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