Trane Koolman R410A Installation, Operation And Maintenance Manual Download

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Contents

Model Number Descriptions ....................................................................................................................5
Dimensions .................................................................................................................................................6

Mini casing ............................................................................................................................................6
Standard casing ...................................................................................................................................7

Installation ...................................................................................................................................................9

Electrical ...................................................................................................................................................16

Wiring Diagram ........................................................................................................................................18
Pre-Start-up ...............................................................................................................................................23

Start-up and Operation ...........................................................................................................................28

Summary of Contents for Koolman R410A

Page 1: ...the equipment The installation starting up and servicing of heating ventilating and air conditioning equipment can be hazardous and requires specific knowledge and training Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and on the tags stickers and labels tha...

Page 2: ...can operate properly and reliably The installation of the air conditioner must be completed by the professional personnel appointed byTrane This manual does not aim to summarize the differences of all the water chillers or any possible problem in the installation If the buyer needs further information or has any special problem please contact the local sales offices ofTrane CAUTION This machine wo...

Page 3: ...ata 50Hz 17 A Mini type 17 B Standard type 17 Wiring Diagram 18 Pre Start up 23 Voltage range 23 Voltage unbalance 23 Water flow 23 Water pressure drop 23 Check the following items before start 24 Unit settings 26 Jumper settings 26 Dial switch settings 26 System position setup 27 Operating parameter setting 27 Start up and Operation 28 Starting procedures 28 Long term shutdown 29 Restarting the s...

Page 4: ...changer 30 Overload protection of motor 30 Flow protection 30 Running operation 30 Thermo probe TH1 30 Cooling mode 31 Heating mode 31 Ambient temperature operation limit 31 Controller 32 Wired controller 32 Operation and display panel 33 Control panel 33 Display panel 33 Operation instructions 33 Troubleshooting and Diagnostics 34 Troubleshooting checklist 34 ...

Page 5: ...croprocessor based adjustable water temperature controller Digit 11 Water Side Electric Heater N None Digit 12 Service Sequence A The first time For Model 1505 2005 B The second time For Model 0305 0306 0505 0605 0755 CGAK1205 C The third time For Model 0606 1005 CGAR1205 Digit 13 Water Pump for Unit R With Pump inside standard N Without Pump Digit 14 ApplicableAmbientTemperature R Standard ambine...

Page 6: ...N Dimensions Mini casing CGAK R 0305R 0306R 0505R 0605R Unit mm CGAK R 0705 R Unit mm 90 740 950 660 1285 402 393 203 690 Ø1 Water outlet Ø1 Water inlet 86 402 393 1590 660 950 824 856 183 Inlet PT RP 1 Outlet PT RP 1 ...

Page 7: ...R 1005R Unit mm CGAK 1205R Unit mm 500 1900 850 580 245 335 490 Ø40 connect wire hole Inlet RC 1 385 Drain Hole Outlet RC 1 1290 50 500 1990 580 1000 900 1900 490 120 155 99 75 Outlet PT RC 1 1 4 Drain Hole 1 2 Ø40 connect wire hole Inlet PT RC 1 1 4 TM TM ...

Page 8: ...nit mm 500 580 1900 Ø40 connect wire hole Inlet Outlet Drain hole 1 2 1990 335 245 490 1550 75 TM TM CGAR 1205R Unit mm 1990 580 1900 500 1736 1550 30 85 245 370 490 50 Drain Hole 1 2 Ø40 connect wire hole Ø40 connect wire hole Inlet RC 1 Outlet RC 1 ...

Page 9: ...own or repair Please use the forklift with proper capacity tonnage to move this water chiller to its installation position During lifting work please use canvas sling which shall be wrapped across the water chiller pedestal and tied tightly as shown in Figure 1 Installation Model The maximum net weight kg 0305R 130 0306R 131 0505R 141 0605R 149 0606R 320 0755R 202 1005R 449 1205R 530 1505R 530 200...

Page 10: ...it springs or rubber shockproof gaskets Fix the unit in its installation position Adjust the levelness of the water chiller Adoption of the following water chiller fixing methods can minimize the noise of the water chiller Install the unit on an independent concrete foundation Fit spring or rubber shockproof gasket at each fixing foot For overall dimension of the water chiller and the dimension of...

Page 11: ...Installation Figure 3 Service and Maintenance Space Requirement 500 300 300 500 300 300 500 500 Mini Koolman Air Flow Air Flow Air Flow Air Flow Air Flow Air Flow no obstacle in front of unit no obstacle in front of unit ...

Page 12: ...s at the cold water side of the water chiller The return water temperature of heating shall not be set more than 40 otherwise the compressor will not be exchanged as per theThree Guarantees Before the final piping connection of the water chiller all external water supply piping systems shall be washed thoroughly Any impurity mixed in the piping system is strictly forbidden otherwise we will assume...

Page 13: ...ssories the model of this diagram is CGAR100 Make up water Water intake Oil return inlet Automatic air vent Manual gate valve Balancing valve ball valve Thermometer Flow switch Shockproof hose Filter Expansion tank Manual gate valve Manometer Water intake Water outlet Shockproof gasket ...

Page 14: ...diagram for typical system piping the model of this diagram is CGAR100 c r Z N c r Z O c r Z P c r Z Q c r Z R c r Z S Make up water Water drainage Direct return Manual gate valve Thermometer Flow switch Shockproof hose Manometer Reversed return Tee valve ...

Page 15: ...en the pressure is lower than 0 6bar the makeup water valve will open to make up water automatically and the drainage valve will open to drain water automatically while the pressure is more than 5bar P P Makeup water valve DrainValve Shut off Electric heater Fan coil X4 Tap water Water drainage Direct return Reversed return Shockpro of hose Thermometer Automatic air vent Primary Unit pressurised w...

Page 16: ...king point dry contact to the point between the control terminals 12 and U Connect the flow switch to the point between connecting terminals U or L and 15 of the water chiller control box Power supply Please refer to the wiring diagram on the cover plate of the water chiller control box the installation unit shall supply power with proper voltage and provide a suitable breaker to the water chiller...

Page 17: ...f the power supply copper core wire diameter mm2 0305R 380 415 50 3 1 45 6 01 0 4 2 12 85 16 16 2 5 0306R 220 50 1 3 65 18 78 0 4 2 35 4 50 50 6 0505R 380 415 50 3 1 45 7 97 0 7 2 14 1 20 20 2 5 0605R 380 415 50 3 1 45 10 02 0 7 2 18 85 25 25 4 0755R 380 415 50 3 1 45 13 77 0 7 3 20 4 25 25 4 B Standard type Model Power supply V Hz Ph Full load current of the water pump FLA A Rated current of the ...

Page 18: ...n Contactor Crankcase Heater Compressor Alarm Output Input Low pressure switch Reversing Valve Flow Switch N COM Common Neutral Line Factory wiring On site wiring EN SAVE Energy Saving 2 Way FAN Fan Motor Cfr TB HEAT A HT Fan capacitance Terminal Blocks Water Circuit Based Plate Heat Exchanger Heater PUMP Water Pump OV PUMP Pump Overload Control panel Indoor installation C H C H Outer Cool Heat Pu...

Page 19: ...OM Common Neutral Line Factory wiring On site wiring EN SAVE Energy Saving 2 Way FAN Fan Motor Cfr TB HEAT A HT Fan capacitance Terminal Blocks Water Circuit Based Plate Heat Exchanger Heater PUMP Water Pump OV PUMP Pump Overload C H Outer Cool Heat Pump Setting OV COMP Compressor Overload HP High pressure switch PS Medium pressure switch HF Fan high speed LF Fan low speed Name Name Electrical Hea...

Page 20: ...et sensor water outlet sensor Discharge sensor 1 Defrost sensor 1 Defrost sensor 2 Discharge sensor 2 Heat pump only 21 19 20 18 LP1 OVF1 17 14 13 15 N 25 LP2 FS 4WV1 MC2 MP AL RUN 4WV2 MF MC1 EG SAVE 12 C H 16 OL2 OL1 22 HP1 HP2 0V PUMP FL0W 0V C0MP1 FREZ LP2 VHT HP2 N COM EN SAVE C H HP1 LP1 0V C0MP2 0V FAN YE YE YE YE 3 PS1 PS2 TO Controller Alarm indicator Running indicator Wiring Diagram powe...

Page 21: ...Valve Flow Switch N COM Common Neutral Line Factory wiring On site wiring EN SAVE Energy Saving 2 Way FAN Fan Motor Cfr TB HEAT A HT Fan capacitance Terminal Blocks Water Circuit Based Plate Heat Exchanger Heater PUMP Water Pump OV PUMP Pump Overload C H Outer Cool Heat Pump Setting OV COMP Compressor Overload HP High pressure switch PS Medium pressure switch HF Fan high speed LF Fan low speed Nam...

Page 22: ...V1 4WV1 COMP1 COMP2 H FAN1 M FAN2 RUN OUT PUMP 4WV2 A HAT RUN IN AL OUT AL IN RD WH CN4 Technical requirement 1 For all fault inputs the unit is normal when power on and gives an alarm when power off 2 The flow switch is installed on site and connected between terminals U and 15 3 Single unit the pump is optional if customer provide pump each unit can use digital output 7 to control it while remov...

Page 23: ...ween phases with maximum difference to Va Water flow The flow rate of the cold water passing through the water chiller must be between the upper limit and the lower limit listed in table 4 If the flow rate of the cold water coming into the evaporator is below the lower limit it will result in discontinuous water flow and reduce the heat transfer effect and then lead to out of control expansion val...

Page 24: ...s circularly in the cold water system please check if there is any leakage at all piping connection points Adjust the water flow in the cold water loop to inspect the external water pressure of the water chiller for the standard model or pressure drop of the evaporator for the model without water pump Stop operation of the water pump Shut off all power supply Connect the flow switch to the connect...

Page 25: ...0 5 10 15 20 25 30 1 344 1 568 1 792 2 016 2 24 2 464 2 688 2 912 3 136 CGAR0605 0 5 10 15 20 25 30 1 68 1 96 2 24 2 52 2 8 3 08 3 36 3 64 CGAR0606 0 5 10 15 20 25 30 2 292 2 674 3 056 3 438 3 82 4 202 4 584 4 966 5 348 CGAR0755 0 5 10 15 20 25 30 2 31 2 70 3 08 3 47 3 85 4 24 4 62 5 01 5 39 CGAR1005 0 5 10 15 20 25 30 2 74 3 19 3 65 4 10 4 56 5 02 5 47 5 93 CGAR1205 0 5 10 15 20 25 30 35 4 03 4 7...

Page 26: ... only valid for the water chiller with double compressors Mode 00 Normal operation mode 01 Computer supervision mode 10 System self checking and configuration mode 11 On site commissioning mode C H 0 external refrigeration heating switch invalid 1 external refrigeration heating switch valid Fan 0 single fan 1 double fans Type 00 heat pump electric heating 01 single refrigeration method electric he...

Page 27: ... Maximum value Minimum value Regulation precision Factory setting Refrigerating return water temperature 25 10 1 12 Heating return water temperature 50 25 1 40 Winter antifreezing temperature 5 1 1 3 Defrost interval 90min 30min 1min 45min Minimum running time of defrost 8min 1min 1min 1min NOTICE a It is recommended that refrigerating return water temperature be kept as factory setting otherwise ...

Page 28: ...superheat but abnormal supercooling please contact professional maintenance personnel 8 In the case of inadequate cooling agent exhibited through running pressure sight glass superheat degree and supercooling degree leak points shall be identified and gaseous cooling agent shall be charged to the circuit During the water chiller operation cooling agent is filled from low pressure line till normal ...

Page 29: ...check the water pressure of the water chiller 6 Regulate the flow switch arranged in the water discharge pipe of the water chiller so as to ensure normal running 7 Press ON OFF button on the control panel to stop the water chiller 8 Restore connection of the flow switch In this way the water chiller can run normally at once System protection Low voltage protection LP1 LP2 A low voltage switch is p...

Page 30: ...r In the case of heating by a single compressor system when cooling agent pressure at plate side is over a certain value the fan or both the fan and compressor shall be closed displaying E Overload protection of motor Compressor motor overload and superheat protection Water pump motor overload protection Fan motor superheat protection Thermo probe protection In case the thermo probe fails an alarm...

Page 31: ...ased and return water temperature is raised to No 1 compressor will be started again The water pump will not stop unless the water chiller is shut down Heating mode Dual system When the system is started the water pump shall run at once 2min later the water pump remains in operation if return water temperature is below No 1 compressor will be started 1MIN later if return water temperature is below...

Page 32: ...32 PKGP SVX03D EN Controller Wired controller ...

Page 33: ...n and heating must be set in a shutdown state 3 Parameter browse Parameters to be browsed cover refrigerating return water temperature heating return water temperature winter antifreezing temperature defrost interval and running time of defrost By double control of the key the five parameters can be browsed 4 Outlet water temperature display When the system is on upon pressure of the mode key the ...

Page 34: ...load B H2 65 The electric heater is to be closed 6 FLOW Inadequate water flow D FL 6D All peripherals are to be closed 7 OV PUMP Water pump overloaded B OP 6A All peripherals are to be closed 8 OV FAN Compressor 1 middlum pressure alarming B 78 78 All peripherals are to be closed 9 OV COMP1 Compressor 1 overloaded C C1 68 Only compressor 1 is to be shut down 10 HP1 Compressor 1 high voltage pressu...

Page 35: ... Water pump overloaded B OP 6A All peripherals are to be closed 10 OV FAN Fan overloaded B OF 6B All peripherals are to be closed 11 OV COMP1 Compressor 1 overloaded Compressor 1 middlum pressure alarming C 78 78 Only compressor 1 is to be shut down 12 OV COMP2 Compressor 2 overloaded Compressor 2 middlum pressure alarming E 78 78 Only compressor 2 is to be shut down 13 HP1 Compressor 1 high volta...

Page 36: ...s not switched on e Internal protection contact of fan trips f Microcomputer controller goes wrong Electromagnetic switch of compressor fails in exciting Check the following items a Poor function of compressor contact b Poor wiring c Open circuit of low voltage switch Internal protection contact of compressor trips Check the following items a Check compressor current b Await restoration of interna...

Page 37: ... low superheating degree and low low pressure pressure Identify leak points of coolant repair and fill with coolant Possible cause Solution Too high evaporator load high return water temperature Check the following items a Excessive water flow b Tool high return water temperature Inadequate motor cooling too high superheat degree Check the following items a Improper setting of expansion valve b Fa...

Page 38: ...f temperature switch too low low pressure pressure and too low outlet water temperature Regulate the temperature switch again Too low cold water flow Check whether the filter screen is blocked and whether the balance valve is correctly set Blocked dry filter Check whether the dry filter is frosted and if necessary change it Blocked expansion valve high superheat degree Clean or change the expansio...

Page 39: ... fan a certain fan fails and too high pressure of condenser Repair or change the switch Possible cause Solution Wrong or poor control line Check the control line Four way valve failure Change the four way valve Possible cause Solution Insufficient coolant Replenish coolant Too low or too cold of air entering the coiler Clean the coiler and check whether fan and motor are normal The water chiller i...

Page 40: ...nvironments for commercial and residential applications For more information please visit trane com or tranetechnologies com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice We are committed to using environmentally conscious print practices Confidential and proprietaryTrane information ...

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