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Trane Sintesis Advantage CGAF 100 SE, Installation Operation & Maintenance

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Trane Sintesis Advantage CGAF 100 SE Installation Operation & Maintenance Download Page 83

CG-SVX039C-GB

83

As a commitment to our customers, we have created a wide service network staffed with experienced factory-
authorized technicians. At Trane we offer all the benefits of after sales service direct from the manufacturer and we 
are committed to our mission statement to provide efficient customer care.
We would be delighted to discuss your individual requirement with you. For further information regarding Trane 
maintenance agreements please contact your local Trane sales office.

Year

Commis-

sioning

Inspec-

tion visit

Seasonal 

shut 

down

Seasonal 

start up

Oil 

analysis 

(2)

Vibration 

analysis 

(3)

Annual 

mainte-

nance

Preven-

tive 

mainte-

nance 

Tube 

analysis 

(1)

Com-

pressor 

R’newal 

(4)

1

x

x

x

x

x

xx

2

x

x

x 

x

xxx

3

x

x

x

x

xxx

4

x

x

x

x

xxx

5

x

x

x

x 

x

xxx

x

6

x

x

x

x

x

xxx

7

x

x

x

x

x

xxx

8

x

x

x

x

x

xxx

9

x

x

x

x

x

xxx

10

x

x

x

x

x

xxx

x

over 10

every 

year

every 

year

every 

year (2)

x

every 

year

3 every 

year

every 3 

years

40000 h

This timetable is applicable to units operating in normal conditions with an average of 4000 hours per year. 
If operating conditions are abnormally severe, an individual timetable must be made for that unit.

(1) 

Tube testing required if aggressive water conditions exist. Applies to condensers only on water cooled units.

(2) 

Schedule as per previous analysis result or at least once a year.

(3) 

 Year 1 to define equipment baseline. Subsequent year based on oil analysis results or schedule as per 
vibration analysis.

(4) 

 Recommended at 40 000 run hours or 100 000 equivalent operating hours whichever comes first. 
Schedule also depends on results from oil analysis / vibration analysis.

Seasonal start up and shutdown are mainly recommended for comfort air conditioning. Annual and preventive 
maintenance are mainly recommended for Process applications.

Recommended service routine frequencies

Summary of Contents for Sintesis Advantage CGAF 100 SE

Page 1: ... SVX039C GB June 2021 Confidential and proprietaryTrane information Original instructions CGAF Air Cooled Scroll Chillers CXAF Air to Water Scroll Heat Pumps 260 710 kW Installation Operation Maintenance ...

Page 2: ...8 Installer Supplied Components 50 Operating Principles 51 Operating Map 56 Total Heat Recovery 57 Table 9 General Data forTotal Heat recovery THR Option CGAF 080 190 57 Table 10 Operating Map THR CGAF 080 190 58 Table 11 Refrigerant Charge THR Option CGAF 080 190 59 Partial Heat Recovery Option 60 Table 12 13 14 General data for Partial Heat Recovery CGAF 080 190 SE HE XE 61 Optional Free Cooling...

Page 3: ... the pressures are within the specified limits by using appropriate devices 2 Disconnect all power supplies before the start of any service activity on the unit 3 Service work on the refrigeration system and the electrical system should be carried out only by the qualified and experienced personnel 4 To avoid any risk it is recommended to place the unit on an area with limited access The following...

Page 4: ...ommended that you sign a maintenance contract with your local Service Agency This contract provides regular maintenance of your installation by a specialist in our equipment Regular maintenance ensures that any malfunction is detected and corrected in good time and minimizes the possibility that serious damage will occur Finally regular maintenance ensures the maximum operating life of your equipm...

Page 5: ...oid the unit shut down and keep producing the chilled or hot water These units come with various options and can be customized depending on capacity efficiencies acoustic levels application requirements at the time of order placement The unit received and its options can be cross checked with the serial and model number provided in unit nameplate and description provided under unit model number de...

Page 6: ...pe welded coupling 2 Grooved pipe with coupling and flange adapter Digit 19 Evaporator Application N Standard cooling 4 C 20 C P Low temperature process 12 C 4 C C Ice making 7 C 20 C with hardwired interface Digit 20 Evaporator Configurations B Brazed plate heat exchanger T Shell Tube heat exchanger Digit 21 Thermal Insulation N Standard Digit 22 Condenser Coating N Aluminium Micro Channel C E Co...

Page 7: ...Pads Digit 43 Literature Language B Bulgarian C Spanish D German E English F French H Dutch I Italian K Finnish L Danish M Swedish N Norwegian P Polish R Russian T Czech U Greek V Portuguese Z Slovenian 2 Romanian 3 Serbian 4 Slovak 5 Croatian 6 Hungarian 8 Turkish Digit 44 Shipping Package X Standard protection A Containerization package Digit 45 Refrigerant X None A R410A Factory full Refrigeran...

Page 8: ...ass proper 15 Verify chilled water strainer is clean and free of debris and evaporator chilled water circuits are filled 16 A pressure switch device to detect lack of water is not included in the pump package Installation of this type of device is highly recommended to avoid sealing damage due to operation of pump without enough water 17 Close the fused disconnect switches that supplies power to t...

Page 9: ... Customer Supplied Electrical Disconnect Switch Unit mounted starter Wiring sizes per submittals and local codes and regulations Terminal lugs Ground connection s BAS Wiring optional Control voltage wiring Chilled water pump contactor and wiring including interlock Option relays and wiring Water piping Flow Switch Water Strainer Optional Taps for thermometers and gauges Thermometers Water flow pre...

Page 10: ...Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 25 30 25 30 30 30 30 30 30 40 30 40 40 40 40 40 25 30 30 25 30 30 30 30 30 30 30 30 30 30 40 30 30 40 30 40 40 30 40 40 40 40 40 40 40 40 Max Comp Power input Circuit 1 Circuit 2 kW 28 4 38 2 28 4 38 2 38 2 38 2 38 2 38 2 38 2 45 2 38 2 45 2 45 2 45 2 45 2 45 2 28 4 38 2 38 2 28 4 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 45 2...

Page 11: ...minium Micro channel heat exchanger Quantity of coil 6 6 6 6 8 8 8 10 10 Face area per circuit m 8 88 8 88 8 88 8 88 11 84 11 84 11 84 14 8 14 8 Condenser Fan Quantity 6 6 6 6 8 8 8 10 10 Diameter mm 800 Fan motor Type Propeller fan Fixed speed AC motor Variable speed EC motor Digit 56 1 Fan motor Type Fixed speed AC motor Airflow per fan m3 h 17118 17037 16935 16830 17005 16943 16865 16984 16921 ...

Page 12: ...um cooling load 6 23 25 21 25 15 17 15 14 17 Total number of capacity steps 8 4 8 4 14 6 14 14 6 Standard Partial Heat Recovery Unit R410A refrigerant charge Circuit 1 Circuit 2 kg 18 18 19 19 19 5 19 5 20 5 20 5 30 30 32 32 33 33 38 38 39 38 Oil charge Circuit 1 Circuit 2 l 14 2 14 2 14 2 14 2 14 2 14 2 14 2 14 2 22 1 22 1 22 3 22 3 22 3 22 3 22 3 22 3 22 3 22 3 Oil charge Circuit 1 Circuit 2 l 1...

Page 13: ...mpressor Compressor Number per Circuit 2 2 2 2 2 3 3 3 3 3 Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 25 25 25 25 25 30 25 30 30 30 30 30 30 40 30 40 40 40 40 40 25 30 30 25 30 30 30 30 30 30 30 30 30 30 40 30 30 40 30 40 40 30 40 40 40 40 40 40 40 40 Max Comp Power input Circuit 1 Circuit 2 kW 28 4 28 4 28 4 28 4 34 1 44 3 34 1 44 3 38 ...

Page 14: ... 420 520 520 640 640 640 640 640 Antifreeze Heater with pump package and without buffer tank Single Water Pump digit 24 2 or 4 Dual Water Pump digit 24 1 or 3 W 1060 1120 1060 1120 1060 1120 1160 1220 1160 1220 1340 1400 1340 1400 1340 1400 1340 1400 1340 1400 Antifreeze Heater with pump package and with buffer tank Single Water Pump digit 24 2 or 4 Dual Water Pump digit 24 1 or 3 W 1940 2000 1940...

Page 15: ... kg 250 250 250 250 250 330 330 330 330 330 System data Nb of refrigerant circuit 2 2 2 2 2 2 2 2 2 2 Minimum cooling load 6 25 23 25 21 25 15 17 15 14 17 Total number of capacity steps 4 8 4 8 4 14 6 14 14 6 Standard Partial Heat Recovery Unit R410A refrigerant charge Circuit 1 Circuit 2 kg 22 0 22 27 5 27 5 27 5 27 5 28 5 28 5 29 29 39 39 39 39 39 39 43 43 43 5 43 5 Oil charge Circuit 1 Circuit ...

Page 16: ...1 75 61 75 75 75 75 75 47 61 61 47 61 61 61 61 61 61 61 61 61 61 75 61 61 75 61 75 75 61 75 75 75 75 75 75 75 75 Locked Rotor Amps Circuit 1 Circuit 2 direct start Digit 54 A A 260 260 260 260 260 294 260 294 294 294 294 294 294 413 294 413 413 413 413 413 260 294 294 260 294 294 294 294 294 294 294 294 294 294 413 294 294 413 294 413 413 294 413 413 413 413 413 413 413 413 Locked Rotor Amps Circu...

Page 17: ...ater with pump package and with buffer tank Single Water Pump digit 24 2 or 4 Dual Water Pump digit 24 1 or 3 W 1940 2000 1940 2000 1940 2000 1940 2000 2040 2100 2040 2100 2790 2850 2790 2850 2790 2850 2790 2850 Condenser Type Full aluminium Micro channel heat exchanger Quantity of coil 6 8 8 8 8 10 10 10 12 12 Face area per circuit m 8 88 11 84 11 84 11 84 11 84 14 80 14 80 14 80 17 76 17 76 Cond...

Page 18: ...14 6 Standard Partial Heat Recovery Unit R410A refrigerant charge Circuit 1 Circuit 2 kg 22 0 22 0 27 4 27 4 27 6 27 6 28 4 28 4 29 4 29 4 39 0 39 0 39 0 39 0 39 0 39 0 43 0 43 0 43 5 43 5 Oil charge Circuit 1 Circuit 2 Digit 19 N C l 14 2 14 2 14 3 14 3 14 4 14 4 14 4 14 4 14 4 14 4 22 4 22 4 22 6 22 6 22 5 22 5 22 4 22 4 22 4 22 4 Oil charge Circuit 1 Circuit 2 Digit 19 P l 16 2 16 2 16 3 16 3 1...

Page 19: ...dpf 0 89 0 90 0 88 0 87 0 90 0 90 Compressor Compressor Number per Circuit 2 2 2 2 3 3 Type Scroll Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 25 30 25 30 30 30 30 30 30 40 30 40 40 40 40 40 25 30 30 25 30 30 30 30 30 30 30 30 Max Comp Power input Circuit 1 Circuit 2 kW 28 4 38 2 38 2 38 2 38 2 38 2 38 2 45 2 38 2 45 2 45 2 45 2 45 2 45 2 28 4 38 2 38 2 28 4 38 2 38 2 38 2 38 2...

Page 20: ...changer Quantity of coil 6 6 6 6 8 8 Face area per circuit m 8 88 8 88 8 88 8 88 11 84 11 84 Condenser Fan Quantity 6 6 6 6 8 8 Diameter mm 800 Fan motor Type Propeller fan Fixed speed AC motor Variable speed EC small motor Variable speed EC strong motor Digit 56 1 Fan motor Type Fixed speed AC motor Airflow per fan m3 h 17117 17043 16949 16229 17001 16947 Max Power Input per Motor Kw 1 4 1 4 1 4 ...

Page 21: ...l 15 5 15 5 15 6 15 6 15 5 15 5 15 4 15 4 23 3 23 3 23 4 23 4 POE Oil type OIL058E OIL057E 1 Indicative performance at Evaporator water temperature 12 C 7 C Condenser air temperature 35 C for detailed performances on a given unit consult Order Write Up 2 Under 400V 3 50Hz 3 Rated Condition without Pump Package 4 Electrical system data are indicative and subject to change without notice Please refe...

Page 22: ...essor Compressor Number per Circuit 2 2 2 2 2 2 2 Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 25 25 25 25 25 30 25 30 30 30 30 30 25 25 25 25 25 30 25 30 30 30 30 30 30 40 30 40 Max Comp Power input Circuit 1 Circuit 2 kW 28 4 28 4 28 4 28 4 28 4 38 2 28 4 38 2 38 2 38 2 38 2 38 2 28 4 28 4 28 4 28 4 28 4 38 2 28 4 38 2 38 2 38 2 38 2 38 2 38 2 45 2 38 2 45 2...

Page 23: ...ube heat exchanger Quantity of coil 6 6 6 8 8 8 8 Face area per circuit m 6 97 6 97 6 97 9 3 9 3 9 3 9 29 Condenser Fan Quantity 6 6 6 8 8 8 8 Diameter mm 800 Digit 56 1 Fan motor Type Fixed speed AC motor Airflow per fan m3 h 18082 18025 17963 16796 16751 16701 18035 Max Power Input per Motor Kw 1 4 1 4 1 4 1 13 1 13 1 13 1 4 Max Amps per Motor A 2 8 2 8 2 8 2 2 2 2 2 2 2 8 Motor RPM rpm 900 900 ...

Page 24: ...nit R410A refrigerant charge Circuit 1 Circuit 2 kg 36 36 36 36 36 36 42 42 42 42 42 42 43 43 Oil charge Circuit 1 Circuit 2 l 16 1 16 1 16 2 16 2 16 4 16 4 17 1 17 1 17 2 17 2 17 4 17 4 17 4 17 4 POE Oil type OIL058E OIL057E 1 Indicative performance at Evaporator water temperature 12 C 7 C Condenser air temperature 35 C for cooling Condenser water temperature 40 C 45 C Evaporator air temperature ...

Page 25: ...roll Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 40 40 40 40 25 30 30 25 30 30 30 30 30 30 30 30 30 30 40 30 30 40 30 40 40 30 40 40 40 40 40 40 40 40 Max Comp Power input Circuit 1 Circuit 2 kW 45 2 45 2 45 2 45 2 28 4 38 2 38 2 28 4 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 45 2 38 2 38 2 45 2 38 2 45 2 45 2 38 2 45 2 45 2 45 2 45 2 45 2 45 2 45 2 45 2 Rated Amps Circ...

Page 26: ...r mm 800 800 800 800 800 800 Digit 56 1 Fan motor Type Airflow per fan m3 h 17976 18047 18010 17966 18018 17980 Max Power Input per Motor Kw 1 4 1 4 1 4 1 4 1 4 1 4 Max Amps per Motor A 2 8 2 8 2 8 2 8 2 8 2 8 Motor RPM rpm 900 900 900 900 900 900 Digit 56 2 Fan motor Type Airflow per fan m3 h 18983 17562 18378 18974 17959 18987 Max Power Input per Motor Kw 1 55 1 55 1 55 1 55 1 55 1 55 Max Amps p...

Page 27: ...ndicative performance at Evaporator water temperature 12 C 7 C Condenser air temperature 35 C for cooling Condenser water temperature 40 C 45 C Evaporator air temperature 7 C 6 C for detailed performances on a given unit consult Order Write Up 2 Under 400V 3 50Hz 3 Rated Condition without Pump Package 4 Electrical system data are indicative and subject to change without notice Please refer to unit...

Page 28: ...89 0 90 0 88 Compressor Compressor Number per Circuit 2 2 2 2 2 2 2 Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 25 25 25 25 25 30 25 30 30 30 30 30 25 25 25 25 25 30 25 30 30 30 30 30 30 40 30 40 Max Comp Power input Circuit 1 Circuit 2 kW 28 4 28 4 28 4 28 4 28 4 38 2 28 4 38 2 38 2 38 2 38 2 38 2 28 4 28 4 28 4 28 4 28 4 38 2 28 4 38 2 38 2 38 2 38 2 38 2 3...

Page 29: ...0 1940 2000 1940 2000 2040 2100 Antifreeze Heater with pump package and with buffer tank Single Water Pump digit 24 2 or 4 Dual Water Pump digit 24 1 or 3 W 1940 2000 1940 2000 1940 2000 2040 2100 2040 2100 2790 2850 2790 2850 Condenser Type Fin tube heat exchanger Quantity of coil 6 6 6 8 8 8 8 Face area per circuit m 6 97 6 97 6 97 9 3 9 3 9 3 9 29 Condenser Fan Quantity 6 6 6 8 8 8 8 Diameter m...

Page 30: ... 8 Standard Partial Heat Recovery Unit R410A refrigerant charge Circuit 1 Circuit 2 kg 41 41 41 41 42 42 49 49 49 49 49 49 50 50 Oil charge Circuit 1 Circuit 2 l 16 1 16 1 16 2 16 2 16 4 16 4 17 1 17 1 17 2 17 2 17 4 17 4 17 4 17 4 POE Oil type OIL058E OIL057E 1 Indicative performance at Evaporator water temperature 12 C 7 C Condenser air temperature 35 C for cooling Condenser water temperature 40...

Page 31: ...oll Scroll Scroll Scroll Model Circuit 1 Circuit 2 kW 40 40 40 40 25 30 30 25 30 30 30 30 30 30 30 30 30 30 40 30 30 40 30 40 40 30 40 40 40 40 40 40 40 40 Max Comp Power input Circuit 1 Circuit 2 kW 45 2 45 2 45 2 45 2 28 4 38 2 38 2 28 4 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 38 2 45 2 38 2 38 2 45 2 38 2 45 2 45 2 38 2 45 2 45 2 45 2 45 2 45 2 45 2 45 2 45 2 Rated Amps Circuit 1 Circuit 2...

Page 32: ...e Heater with pump package and with buffer tank Single Water Pump digit 24 2 or 4 Dual Water Pump digit 24 1 or 3 W 1940 2000 1940 2000 1940 2000 2040 2100 2040 2100 2790 2850 Condenser Type Fin tube heat exchanger Quantity of coil 8 10 10 10 12 12 Face area per circuit m 9 29 11 61 11 61 11 61 13 93 13 93 Condenser Fan Quantity 8 10 10 10 12 12 Diameter mm 800 Digit 56 1 Fan motor Type Fixed spee...

Page 33: ...efrigerant charge Circuit 1 Circuit 2 kg 50 50 67 70 68 71 68 71 77 80 78 81 Oil charge Circuit 1 Circuit 2 l 17 4 17 4 25 4 25 4 25 6 25 6 25 5 25 5 26 3 26 3 26 3 26 3 POE Oil type OIL058E OIL057E 1 Indicative performance at Evaporator water temperature 12 C 7 C Condenser air temperature 35 C for cooling Condenser water temperature 40 C 45 C Evaporator air temperature 7 C 6 C for detailed perfor...

Page 34: ...34 CG SVX039C GB Top view Typical CGAF CXAF Components location ...

Page 35: ...CG SVX039C GB 35 Typical CGAF CXAF Components location ...

Page 36: ...36 CG SVX039C GB Typical CGAF CXAF Components location ...

Page 37: ...porator water box 6 Supply and install an air vent cock to the top of the evaporator or evaporator piping 7 Furnish and install strainers ahead of all pumps and automatic modulating valves 8 Provide and install field wiring according to schematics provided in the control panel 9 Install heat tape and insulate the chilled water lines and any other portion of the system as required to prevent sweati...

Page 38: ...are given in the Neoprene isolators installation drawing which is supplied with the chiller Wrong placement along the unit may result in excessive deflection 1 Secure the isolators to the mounting surface using the mounting slots in the isolator s base plate Do NOT fully tighten the isolators mounting bolts at this time See the isolators submittals for isolators location maximum weights and isolat...

Page 39: ...the heater the copper ring gaskets When the unit is supplied with hydraulic module the following additional materials are in contact with water Pump frame and connections are made of cast iron Water pipes are made of carbon steel Pipe sealings are made of EPDM rubber ethylene propylene diene monomer rubber Pump sealings are made of silicon carbide Strainer is made of stainless steel Dirt scale pro...

Page 40: ...ntering and leaving water temperatures Install a balancing valve in the leaving water line to control water flow balance Install shut off valves on both the entering and leaving water lines so that the evaporator can be isolated for service It is mandatory to place a flow switch device at the outlet of the unit and to link it with the control of the unit see wiring diagrams shipped with the unit C...

Page 41: ...ssors rotation Dead band adjusted on chiller controller Minimum time between 2 starts of a compressor Minimum Water Volume for a Comfort Application For comfort application we can allow water temperature fluctuation at part load The parameter to take into account is the minimum operating time of the compressor In order to avoid lubrication problem on a scroll compressor it must run at least 2 minu...

Page 42: ... 30 25 40 15 10 15 20 50 75 100 BPHE 1 to 9 DFX650 Number of plates Shell Tube 10 11 1 7 4 3 5 8 9 10 2 6 20 30 25 40 15 10 15 20 50 75 100 BPHE 1 to 9 DFX650 Number of plates Shell Tube 10 11 1 7 4 3 5 8 9 10 2 6 20 30 25 40 15 10 15 20 50 75 100 BPHE 1 to 9 DFX650 Number of plates Shell Tube 10 11 1 7 4 3 5 8 9 10 2 6 20 30 25 40 15 10 15 20 50 75 100 BPHE 1 to 9 DFX650 Number of plates Shell Tu...

Page 43: ...n module with expansion vessel and pressure relief valve sufficient to ensure the expansion of the water loop ability Thermal insulation for antifreeze protection Balancing valve optional for equilibrate the flow of water circuit Drain valve Temperature sensor Note A pressure switch device to detect lack of water is not included in the pump package Installation of this type of device is highly rec...

Page 44: ... 130 140SE 5 150SE 6 165SE 7 180SE 8 190SE 9 90 100 SE T 10 110 130 SE T 11 140 150 SE T Max Flow 80SE 6 7 8 9 10 11 Max Flow 80SE 6 7 8 9 10 11 1 2 3 4 5 1 to 8 BPHE Evaporator 9 to 11 Shell Tube Evaporator 50 100 150 200 250 300 350 5 10 15 20 25 30 35 40 45 50 Avaiable Pressure kPa Water Flow Rates L s High Head Standard Efficiency 1 80 090SE 2 100SE 3 110SE 4 130SE 5 140SE 6 150SE 7 165SE 8 18...

Page 45: ...ications CAUTION When using freeze inhibitor never fill the system with pure glycol Always fill the system with diluted solution Maximum concentration of glycol is 40 Higher glycol concentration will damage pump seal OR 3 Drain Water Circuit For ambient temperatures below 20 C and for those installation not including either option 1 or 2 above described a Shut off power supply to unit and to all h...

Page 46: ...g shall be 6 C Freeze Protection with Glycol It is mandatory to use a freeze inhibitor for leaving water setpoint less or equal to 5 C On the glycol recommended concentration figure you must select concentration on or above the curve For example for 4 C brine temperature a concentration of 25 ethylene glycol is not sufficient The concentration must be 28 ethylene glycol or 33 propylene glycol Usin...

Page 47: ... operating conditions this effect can be significant 2 If additional glycol is used then use the actual glycol to establish the low refrigerant cutout set point withTrane service advice 3 The minimum low refrigerant cutout set point allowed is 20 6 C This minimum is established by the solubility limits of the oil in the refrigerant 4 With glycol application ensure that there is no fluctuation of b...

Page 48: ...Drive AFD3 Capacitor Discharge and BAS SVX19B E4 Hazardous Voltage Pressurized Burning Fluid Before removing compressor terminal box cover for servicing or servicing power side of control panel CLOSE COMPRESSOR DISCHARGE SERVICE VALVE and disconnect all electric power including remote disconnects Discharge all motor start run capacitors Follow lockout tagout procedures to ensure the power cannot b...

Page 49: ...Maximum Power input kW Unit rated amps Max comp Fan Control Unit start up amps Starting Amps of the largest comp RLA of 2nd comp RLA of all fans control Compressor Power factor Disconnect switch size A Short Circuit Rating for all sizes 15 kA Wiring diagrams are shipped with unit and can be found in the unit control panel Note Rating is made for 400 V 3 phases 50 Hz power supply ...

Page 50: ...sion heaters combined with evaporator pumps activation through Tracer UC800 Whenever the ambient temperature drops below 0 C the thermostat energizes the heaters and theTracer UC800 activates the pumps If ambient temperatures below 20 C are expected contact your Trane local office CAUTION The control panel main processor does not check for loss of power to the heat tape nor does it verify thermost...

Page 51: ... electronic expansion valve to maximize chiller efficiency at full and part load operation The CGAF chiller CXAF Heat Pump is equipped with a unit mounted starter and control panel Microprocessor based unit control modules TraneTracer UC800 provide accurate chilled water control and providing monitoring protection and adaptive limit functions The adaptive nature of the controls intelligently preve...

Page 52: ...section describes the overall flow chart principle for CGAF CXAF Detailed information for a given order is supplied with order package documentation Figure 9 Example ofTypical Refrigerant System Schematic Oil Lube Circuit Schematic for CGAF BPHE ...

Page 53: ...CG SVX039C GB 53 Operating Principles Figure 10 Example ofTypical Refrigerant System Schematic Oil Lube Circuit Schematic for CGAF S T ...

Page 54: ...X039C GB Operating Principles Figure 11 Example ofTypical Refrigerant System Schematic Oil Lube Circuit Schematic for CXAF BPHE RELEASED 03 Dec 2020 12 32 13 GMT RELE E RELEASED 03 Dec 2020 12 32 13 GMT RELE E ...

Page 55: ...CG SVX039C GB 55 Figure 12 Example ofTypical Refrigerant System Schematic Oil Lube Circuit Schematic for CXAF HEat Operating Principles ...

Page 56: ...ing map Cooling N H R Notes Minimum start up operation at low ambient air temperature based on wind speed lower than 2m s Maximum ambient operation is for unit at 12 C 7 C operating conditions The curve of limit current may vary from one machine size to another but it will always be a parallel curve to that shown in the operating map ...

Page 57: ... are not reversed CAUTION A field installed safety or relief valve on the water side is required with the total heat recovery to prevent risks resulting from a failure of the unit control Piping Recommendations A 1 to 1 6 mm strainer must be installed close to the total heat recovery heat exchanger entering water line to protect the heat exchanger Insulate water lines and other portions of the hea...

Page 58: ...ry Operation Map 30 33 0 49 52 0 55 52 0 55 7 2 30 7 2 10 0 20 0 30 0 40 0 50 0 60 0 25 30 35 40 45 50 55 60 Amb Temperature C THR LWT C THR 3 Way Valve Description The 3 way valve is divided into 2 mains parts the actuator and the valve body Valve body 2 types of valve are used DN50 DN65 with a Kvs respectively of 40 Kvs value is showing the capacity of media flow of a valve it characterizes the ...

Page 59: ...E THR Curve 10 50 250 2 4 8 16 32 Pressure Drop kPa Water Flow Rates L s TOTAL HEAT RECOVERY THR BPHE THR CGAF SE HE XE 1 080 090 SE HE XE 2 100 110 130 SE HE XE 3 140 150 165 SE HE XE 4 180 190 SE HE XE 5 BPHE 080 090 100 110 130 140 1 50 165 180 190 SE HE XE 2 1 3 4 5 1 to 4 Total THR Pressure Drop 5 BPHE THR Pressure Drop Figure 19 Partial Total heat recovery pipe recommendations A Trane suppli...

Page 60: ...the thermostat A 1 to 1 6 mm strainer must be installed close to the partial heat recovery heat exchanger entering water line to protect the heat exchanger The partial heat recovery water temperature entering the unit should be at least 40 C Insulate water lines and other portions of the heat recovery water loop to prevent heat loss and potential injury due to exposure to a hot surface For recomme...

Page 61: ... 76 5 76 5 76 5 76 Digit 19 P Heat Exchanger Model B12MT D 48 B12MT D 48 B12MT D 48 B12MT D 48 B12MT D 60 B35TM4 D 48 B35TM4 D 48 B35TM4 D 48 B35TM4 D 64 B35TM4 D 64 Water connection size Thread connection in mm 1 1 2 48 3 1 1 2 48 3 1 1 2 48 3 1 1 2 48 3 2 60 3 2 60 3 2 60 3 2 60 3 2 1 2 76 1 2 1 2 76 1 Water content volume l 1 44 1 44 1 44 1 44 1 80 4 32 4 32 4 32 5 76 5 76 Antifreeze Heater Max...

Page 62: ... P A 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 15 0 3 0 15 0 3 0 15 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 Table 16 General Data for Partial Heat recovery CXAF 080 190 High Efficiency CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF CXAF 80 90 100 80 90 100 110 130 140 150 165 180 190 SHE SHE SHE HE HE HE HE HE HE HE HE HE HE Partial Heat recovery PHR option Heat Exchang...

Page 63: ... 214 8 337 2 337 3 337 5 464 0 489 7 Winter customer pressure drop kPa 88 0 85 1 87 3 66 7 75 2 68 1 62 3 60 7 55 6 Antifreeze Heater W 240 240 240 240 240 240 240 240 240 Additional shipping weight kg 325 325 325 325 455 455 455 565 565 Additional water content L 67 33 67 33 67 33 67 33 81 09 81 09 81 09 94 86 94 86 Digit 12 H or Digit 12 A Coils quantity 4 6 6 6 6 8 8 8 10 10 FC Pump Max Motor P...

Page 64: ...he free cooling coils will be able to deliver the requested chilled water temperature The regulation of the capacity is described in the next section In this mode only fans are running General Information The chiller integrated free cooling system fluid based consist in a set of Macro channels or Radiators coils fit in the same frame than the MCHE condenser coils of the chiller refrigeration circu...

Page 65: ... customer and installed at the unit inlet Unit is shipped without glycol content on the free cooling circuit Free cooling loop venting must be performed by using manual overload mode to run the free cooling pump and opening free cooling and closing bypass valve At 10 to 20 C ambient the expansion shall be pressurized at 250kPa It should be checked when glycol loop is not yet filled or glycol press...

Page 66: ... remaining to evaporator Refer the settings table for more details Table 18 Direct Free Cooling Setting DIRECT FC 80 90 100 110 130 140 150 165 180 190 Open 0 0 0 0 20 30 30 30 40 40 Position 1 2 1 2 1 2 1 2 3 4 4 4 5 5 Table 19 Glycol Free Free Cooling Setting DIRECT FC 80 90 100 110 130 140 150 165 180 190 Open 0 0 0 0 20 20 20 30 30 30 Position 1 2 1 2 1 2 1 2 3 3 4 4 4 4 Note for maintenance C...

Page 67: ...ydronic Group Schematic Pump Package Free Cooling for CGAF Note Glycol free free cooling chilled water set point should be in the range of 4 C 20 C Water Glycol mixing is filled on the free cooling coils on valve item 11 Operating Principles ...

Page 68: ...ssure drop The free cooling water pressure drops given in charts below coil valve should be added to evaporator pressure drop to get full unit pressure drop 5 10 20 40 80 160 320 4 8 16 32 64 Pressure Drop kPa Water Flow Rates L s Glycol Free Free Cooling CGAF SE HE XE 1 SE 90 100 110 130 HE XE 80 2 SE 140 150 165 HE XE 90 100 110 130 3 SE 180 190 HE XE 140 150 165 4 HE XE 180 190 1 2 3 4 5 10 20 ...

Page 69: ... information you need on a day to day basis like set points limits diagnostic information and reports Day to day operational information is presented at the display Logically organized groups of information chiller mode of operation active diagnostics settings and reports put information conveniently at your fingertips Tracer TU TheTD7 operator interface allows for daily operation tasks and set po...

Page 70: ...mp starter 7 Start the chilled water pump to begin circulation of the water Inspect all piping for leakage and make any necessary repairs 8 With water circulating through the system adjust the water flow and check the water pressure drop through the evaporator 9 Adjust the chilled water flow switch for proper operation 10 Apply power to complete the procedures 11 Prove all interlock and interconne...

Page 71: ...ed To ensure correct venting open the vent screw located on the pump housing on the suction side see next figure Figure 27 Pump Package CAUTION When using freeze inhibitor never fill the system with pure glycol this will damage the shaft seal Always fill the system with diluted solution Maximum concentration of glycol is 40 for unit with pump package CAUTION Failure to operate pump w o water or in...

Page 72: ...s in the refrigerant indicate either low refrigerant charge or excessive pressure drop in the liquid line or an expansion valve that is stuck open A restriction in the line can sometimes be identified by a noticeable temperature differential between the two sides of the restriction Frost will often form on the line at this point Proper refrigerant charges are shown in the General Information Secti...

Page 73: ...during the full shutdown period of the chiller if the chilled water loop does not contain glycol to prevent any risk of evaporator freeze up Extended Shutdown Procedure The following procedure is to be followed if the system is to be taken out of service for an extended period of time i e seasonal shutdown 1 Test the unit for refrigerant leaks and repair as necessary 2 Open the electrical disconne...

Page 74: ...ween the two sides of the restriction Frost may often form on the liquid line at this point Correct refrigerant charges is shown in nameplate NOTICE A clear sight glass alone does not mean that the system is properly charged Also check the system superheat sub cooling and unit operating pressures NOTICE Use only manifold gauge sets designed for use with R410A refrigerant Use only recovery units an...

Page 75: ...em is properly charged Also check the rest of the system operating conditions WARNING Position all electrical disconnects in the Open position and lock them to prevent injury or death due to electrical shock 8 Clean the condenser fans Check the fan assemblies for proper clearance in the fan shroud openings and for motor shaft misalignment or abnormal end play vibration and noise Refrigerant Emissi...

Page 76: ... valve Possible whistling sound coming from liquid line due to high vapour velocity High condenser Sub cooler pressure drop Some of the symptoms of a refrigerant over charged unit Condenser Pressure Limit High Pressure Cutout diagnostic More than normal number of fans running Erratic fan control Higher than normal compressor power Some of the symptoms of an oil over charged unit Larger than normal...

Page 77: ...be evident Minor problems can be detected and repaired before they become major problems Oil Equalizer Line DSH Compressors The oil equalizer line is equipped with a Rotolock fitting for easy removal Torque value for tightening these fitting is 145 N m Recover the system refrigerant charge and Drain the oil to a level below the oil equalizer tube fitting before removing the oil equalizer line This...

Page 78: ...sistance must be infinity NOTICE Maximum allowable voltage imbalance is 2 percent Compressor ElectricalTerminal Box Be sure to protect the terminal box when unbrazing or brazing compressor refrigerant piping connections Compressor Crankcase Heaters Compressor crankcase heaters must be energized at least eight hours before starting the CGAF CXAF chiller This is required to boil refrigerant out of t...

Page 79: ...servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury 1 Disconnect Power to the unit 2 Wear proper personal protection equipment such as a face shield gloves and waterproof clothing 3 Remove enough panels from the unit to gain safe access to the microchannel coil N...

Page 80: ...g period of frost the pump has to be drained to avoid damage Remove the filling and drain plugs Do not re fit the plugs until the pump is taken into operation again Lubrication The bearings of motors 5 5kW and 7 5kW are greased for life and require no lubrication Increasing bearing noise and undue vibration indicate a worn bearing The bearing or the complete motor then needs replacement The bearing ...

Page 81: ...nar flow potential evaporator freezing scaling and poor temperature control Maximum water flow is 6 m s Flow rates greater than this will cause excessive erosion The BPHE evaporator is difficult to clean should it become plugged with debris Indications of a plugged BPHE evaporator include wet suction due to lack of heat exchange loss of superheat control discharge superheat less than 35 C compressor...

Page 82: ...rant Temperature C Refrigerant Pressure psia Approach Temperature C Water flow Status EXV Open Condenser Outdoor Temperature Ckt 1 Air flow Saturated Refrigerant Temperature C Refrigerant Pressure kPa Sub cooling in C Ckt 2 Air flow Saturated Refrigerant Temperature C Refrigerant Pressure kPa Sub cooling in C Compressor 1A Running Status Starts Running Time Hr min Oil Pressure kPa Compressor 1B Ru...

Page 83: ...xxx 9 x x x x x xxx 10 x x x x x xxx x over 10 every year every year every year 2 x every year 3 every year every 3 years 40000 h This timetable is applicable to units operating in normal conditions with an average of 4000 hours per year If operating conditions are abnormally severe an individual timetable must be made for that unit 1 Tube testing required if aggressive water conditions exist Appl...

Page 84: ...ese reports will indicate any corrosion scaling and alga growth in the system Refrigerant Analysis This Service includes a thorough analysis for contamination and solution upgrade It is recommended that this analysis be performed every six months Annual CoolingTower Maintenance This Service includes the inspection and maintenance of the cooling tower at least once a year This involves checking the...

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Page 88: ...ation 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 2021Trane CG SVX039C GB Jun 2021 Supersedes CG SVX039B GB July 2019 Confidential and proprietaryTrane information ...

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