Trane AquaStream 2 CCUN 205 HE Installation Operation & Maintenance Download

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Contents

CG-SVX06D-E4

General start-up

Preparation

Start-up

Operation

Installation checklist

Control and unit operation

Weekly start up

Weekend shutdown

Seasonal shutdown

Seasonal start-up

Maintenance

Maintenance instructions

Troubleshooting guide

Safety recommendations

Maintenance contract

Training

Summary of Contents for AquaStream 2 CCUN 205 HE

Page 1: ...chiller with integrated hydraulic module Water cooled CGWN 205 206 207 208 209 210 211 212 213 214 215 Condenserless CCUN 205 206 207 208 209 210 211 212 213 214 215 Installation Operation Maintenance...

Page 2: ...refrigerant implemented in Trane Air Conditioning and Refrigeration Equipment The operator contractor or end user must check local environmental regulations impacting installation operation and dispos...

Page 3: ...he site representative must notify Trane Epinal Operations Claims team and send a copy of the delivery note The customer or the site representative should send a registered letter to the last carrier...

Page 4: ...nty 3 Reception 3 About this manual 3 About the unit 3 Refrigerant 3 General data 6 Installation 13 Unit nameplate 13 Installation instructions 13 Handling 14 Minimal installation water content 17 Wat...

Page 5: ...ation 53 Installation checklist 53 Control and unit operation 54 Weekly start up 54 Weekend shutdown 54 Seasonal shutdown 54 Seasonal start up 55 Maintenance 56 Maintenance instructions 56 Troubleshoo...

Page 6: ...Heater compA CompB W 160 160 Evaporator Number 1 Type Brazed plate Model DP400 74 DP400 90 DP400 114 DP400 162 DP400 186 DP400 186 DP400 206 Water volume total L 15 6 18 9 24 0 34 1 39 2 39 2 43 4 An...

Page 7: ...porator Water Connections Grooved pipe connections Diameter 4 Max water side operating pressure without hydraulic module kPa 1000 1000 1000 1000 with hydraulic module kPa 400 400 400 400 Condenser Num...

Page 8: ...B W 160 160 160 160 160 160 Evaporator Number 1 Type Brazed plate Model DV58 138 DV58 154 DV58 170 Water volume total l 32 4 32 4 34 1 Antifreeze Heater W Evaporator Water Connections Grooved pipe con...

Page 9: ...m 2900 Power factor compA CompB 0 82 0 82 0 82 0 87 0 87 0 87 0 87 0 84 0 84 0 84 0 84 0 88 0 88 0 88 Sump Heater compA CompB W 160 160 Evaporator Number 1 Type Brazed plate Model DP400 74 DP400 90 DP...

Page 10: ...Brazed plate Model AC350 190DQ AC350 190DQ AC350 210DQ AC350 230DQ Water volume total l 38 38 42 46 Antifreeze Heater W no no no no Evaporator Water Connections Grooved pipe connections Diameter 4 Ma...

Page 11: ...215 215 Motor RPM rpm 2900 2900 2900 Power factor compA CompB 0 82 0 82 0 82 0 87 0 87 0 87 Sump Heater compA CompB W 160 160 160 160 160 160 Evaporator Number 1 Type Brazed plate Model DP400 154 DP4...

Page 12: ...ser volume expansion capacity 3 l 3600 3600 3600 3600 3600 3600 3600 5100 5100 5100 5100 Water strainer diameter 3 3 4 4 4 4 4 4 4 4 4 Piping Steel Table 8 Condenser hydraulic module 205 206 207 208 2...

Page 13: ...face is flat and level and can withstand the weight or the unit Isolating rubber pads 6 pads are supplied as standard with the machine 55x150mm They should be placed between the supporting floor and t...

Page 14: ...fting points 3 Minimum rated lifting capacity vertical of each sling and spreader bar shall be no less than the tabulated unit shipping weight Refer to Figures 1 and 2 CAUTION This unit must be lifted...

Page 15: ...Installation 15 CG SVX06D E4 Figure 2 Rigging the unit CGWN CCUN 212 215 C B A D C B A D...

Page 16: ...2400 CGWN 206 CGWN 207 CGWN 208 CGWN 209 CGWN 210 CGWN 211 CGWN 212 CGWN 213 CGWN 214 CGWN 215 CGWN 205 HE CGWN 206 HE CGWN 207 HE CCUN 205 CCUN 206 CCUN 207 CCUN 208 CCUN 209 CCUN 210 CCUN 211 CCUN...

Page 17: ...improperly treated water or from the use of saline or brackish water If water treatment is required contact your local Trane sales office Table 10 Minimal water content Notes 1 Minimum water loop vol...

Page 18: ...mp integrated hydraulic module single or dual pump low or high pressure head 2 Condenser side options No hydraulic control With pump contactors to control a remote pump single or dual With pump integr...

Page 19: ...le 212 215 CW HW 3 3 2 1 3 3 4 4 5 1 Insulated evaporator 2 Valve for air vent 3 SAE Male pressure tab 4 SAE Male drain tab 5 Condenser CW Chilled water loop HW Condensation water loop TT Temperature...

Page 20: ...1 Figure 6 CCUN hydraulic flow chart without hydraulic module 212 215 CW 1 2 3 4 3 1 Insulated evaporator 2 Valve for air vent 3 SAE Male pressure tab 4 SAE Male drain tab CW Chilled water loop TT Tem...

Page 21: ...d evaporator 2 Valve for air vent 3 SAE Male pressure tab 4 SAE Male drain tab 5 Condenser 6 Water strainer 7 Expansion Tank 8 Pressure relief valve 9 Single or double evaporator pump 10 Drain pan 11...

Page 22: ...e tab 4 SAE Male drain tab 5 Single condenser 6 Water strainer 7 Expansion Tank 8 Pressure relief valve 9 Single or double evaporator pump 10 Drain pan 11 Double condenser pump 12 1 4 NPT drain tab 13...

Page 23: ...porator 2 Valve for air vent 3 SAE Male pressure tab 4 SAE Male drain tab 5 Condenser 6 Water strainer 7 Expansion Tank 8 Pressure relief valve 9 Single or double evaporator pump 10 Drain pan CW Chill...

Page 24: ...e 9 Single or double evaporator pump 10 Drain pan 11 Condenser pump CW Chilled water loop TT Temperature sensor Pi Pressure gauge FT Water flow switch For sizes 205 to 207 standard head 3 For sizes 20...

Page 25: ...water entering and leaving temperatures not mandatory 6 Expansion compensators avoid mechanical stress between chiller and piping installation 7 Stop valve located on the outlet connection used to me...

Page 26: ...ed water temperature and subcooling Tables 12 14 provide the maximum acceptable height according to subcooling available and recommended diameters for discharge liquid lines when CCUN condenserless ch...

Page 27: ...n 27 CG SVX06D E4 Figure 14 Installation configuration CCUN below remote condenser 1 Discharge line 2 Liquid line Figure 15 Installation configuration CCUN above remote condenser 1 Discharge line 2 Li...

Page 28: ...amount of subcooling more refrigerant charge is required Table 11 Maximum elevation H of CCUN above remote condenser For recommended discharge line diameters refer to the following tables For vertical...

Page 29: ...1 8 1 3 8 1 5 8 CCUN 209 1 1 8 1 3 8 1 5 8 CCUN 210 1 1 8 1 3 8 1 5 8 CCUN 211 1 1 8 1 3 8 1 5 8 CCUN 212 1 3 8 1 5 8 2 1 8 CCUN 213 1 5 8 2 1 8 CCUN 214 1 5 8 2 1 8 CCUN 215 1 5 8 2 1 8 2 5 8 Require...

Page 30: ...08 7 8 1 1 8 1 3 8 CCUN 209 7 8 1 1 8 1 3 8 CCUN 210 7 8 1 1 8 1 3 8 CCUN 211 7 8 1 1 8 1 3 8 CCUN 212 1 1 8 1 3 8 CCUN 213 1 1 8 1 3 8 1 5 8 CCUN 214 1 1 8 1 3 8 1 5 8 CCUN 215 1 1 8 1 3 8 1 5 8 Requ...

Page 31: ...ated pressure Refrigerant charge CCUN 205 211 units are delivered with a 3kg refrigerant charge per circuit and isolating valves CCUN 212 215 units are delivered with a nitrogen holding charge and iso...

Page 32: ...6 1 3 8 45 1 1 8 70 211 Standard 1 2 79 1 3 8 44 1 1 8 69 212 Standard 1 109 1 3 8 76 1 5 8 54 Standard 2 77 1 3 8 43 1 5 8 30 213 Standard 1 109 1 3 8 76 1 5 8 54 Standard 2 109 1 3 8 76 1 5 8 54 214...

Page 33: ...rature 3 Add ethylene glycol in the chilled water 4 Drain water circuit however be aware of corrosion process when drained Note If machinery room can be exposed to temperature below 0 C systems 2 3 an...

Page 34: ...covered and protected before power supplies are connected 2 Install power supply cabling as shown in wiring diagram Adequate cable gland should be chosen ensuring no foreign bodies enter the electric...

Page 35: ...Installation 35 CG SVX06D E4 Figure 21 CGWN and CCUN main power supply connection 1 212 215 1 Power cable inlet 2 Disconnect switch 1 shown here CGWN Components in same location on CCUN 1 2...

Page 36: ...ired also The sensing bulb is extended on the sensor side outside the unit These wires can be spliced with two 0 75mm type or similar wires with a maximum of 305 meters Splice at sensor end must be wa...

Page 37: ...Installation 37 CG SVX06D E4 Note Make sure phase order is correct Should the compressor be noisy reverse 2 phases Figure 24 Outdoor ambient air sensor connection...

Page 38: ...0 1 1 75 00 7 3 5 1 0 1 1 87 50 8 4 0 1 1 1 100 00 Stage Number of Fans 1 2 3 4 Capacity 0 0 0 0 0 0 0 00 1 1 1 0 0 0 25 00 2 2 1 0 1 0 50 00 3 3 0 0 1 1 75 00 4 4 1 0 1 1 100 00 Output relay Fan 1 F...

Page 39: ...ture to minimize compressor discharge temperature For very high leaving condensing water temperature above 55 C the refrigerant charge can be minimized by 20 Figure 25 CGWN operating limits 180 kW 350...

Page 40: ...the thermometers and manometers position Check chilled water pumps interconnection to control panel Ensure that the isolation resistance of all power supply terminals to ground complies with standards...

Page 41: ...s Checking and setting Compressors Check oil level at rest The level should reach at least the minimum oil level on the indicator located on oil equalization line see figure 30 when the compressors ha...

Page 42: ...value 2 megohms Operating parameters statement Switch on main power supply switch Start the water pump s and check there is no cavitation Start up the unit following procedure described in the CGWN C...

Page 43: ...ort which must be sent as soon as possible to your local Trane office Do not start up a motor whose insulation resistance is less than 2 megohms Phase imbalance should not be greater than 2 The voltag...

Page 44: ...Standard and High Efficiency units evaporator pressure drop EWFR Evaporator Waterflow Rate EWPD Evaporator Water Pressure Drop Figure 31 Standard units condenser pressure drop CWFR Condenser Waterflo...

Page 45: ...igh Efficiency units Low head pressure Single pump EWFR Evaporator Waterflow Rate EWPD Evaporator Water Pressure Drop Figure 33 Evaporator available pressure Standard and High Efficiency units Low hea...

Page 46: ...gh Efficiency units High head pressure Single pump EWFR Evaporator Waterflow Rate EWPD Evaporator Water Pressure Drop Figure 35 Evaporator available pressure Standard and High Efficiency units High he...

Page 47: ...low Rate CWPD Condenser Water Pressure Drop Note Pumps remain the same when variable speed drive option is selected Figure 37 Condenser available pressure Standard and High Efficiency units High head...

Page 48: ...6D E4 48 Figure 38 Condenser available pressure Standard units Variable speed pump 212 215 CWFR Condenser Waterflow Rate CWPD Condenser Water Pressure Drop 0 50 100 150 200 0 5 10 15 20 25 30 35 CWFR...

Page 49: ...added in the chilled water circuit the following adjustment factors have to be taken in account Figure 39 Ethylene Glycol recommended concentration LWT Lowest water temperature 0 5 10 15 20 25 30 35...

Page 50: ...General Start up CG SVX06D E4 50 Figure 40 Propylene Glycol recommended concentration LWT Lowest water temperature 0 5 10 15 20 25 30 35 40 45 10 8 6 4 2 0 2 4 LWT C Concentration Concentration...

Page 51: ...1 00 1 00 Ethylene Glycol 10 0 0 99 1 00 1 02 1 02 1 00 1 00 20 0 0 98 1 00 1 05 1 06 1 00 1 00 30 0 0 97 1 00 1 10 1 10 1 00 1 00 0 10 1 00 1 00 1 00 1 00 1 02 1 05 0 20 1 00 1 01 1 00 1 00 1 04 1 09...

Page 52: ...nd in the table above can be applied as follows 1 Cooling capacity with glycol kW F CC x Cooling capacity water kW found in the General data section 2 Power Input with glycol kW F PI x Power Input wat...

Page 53: ...evaporator Check 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...

Page 54: ...cautions are taken to prevent frost damages during negative ambient temperature Do not put the general disconnect switches to off except if the unit is drained Trane does not recommend draining the un...

Page 55: ...eak test Check configuration of unit control module Change the oil as required based upon results of the oil analysis made during seasonal shutdown Get the 8 condition measurements at the same time on...

Page 56: ...is Carry out leak test Inspect contacts and tighten terminals Record operating pressures temperatures amperages and voltage Check operation of machines compare conditions of operation against original...

Page 57: ...exhaustively tested in Trane laboratories to the specific requirement of Trane chiller and hence the user s requirements Any use of oils not meeting specifications recommended by Trane is the respons...

Page 58: ...ripped 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 dischar...

Page 59: ...ystem Reduce water flow if necessary Condenser air output too hot Reduced air flow Air intake temperature higher than specified for unit Clean or replace air filters Clean coil Check operation of fan...

Page 60: ...should be observed during maintenance and service visits 1 The maximum allowable pressures for system leak testing on low and high pressure side are given in the chapter Installation Always provide a...

Page 61: ...Notes 61 CG SVX06D E4...

Page 62: ...Notes CG SVX06D E4 62...

Page 63: ...Notes 63 CG SVX06D E4...

Page 64: ...t to change design and specifications without notice Only qualified technicians should perform the installation and servicing of equipment referred to in this publication www trane com For more inform...

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