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About the Manual

Literature Change History

CG-SVX02B-EN (November 2004)

First issue of manual; provides Installation, Operation, and
Maintenance instructions for “K” and later design sequence
on CGAF 20 through 60 Ton air cooled Cold Generators.

Overview of Manual

Note: One copy of this document ships inside the
control panel of each unit and is customer
property. It must be retained by the unit’s
maintenance personnel.

This booklet describes proper installation, operation, and
maintenance procedures for air cooled systems. By care-
fully reviewing the information within this manual and follow-

ing the instructions, the risk of improper operation and/or
component damage will be minimized.

It is important that periodic maintenance be performed to
help assure trouble free operation. A maintenance schedule
is provided at the end of this manual. Should equipment
failure occur, contact a qualified service organization with
qualified, experienced HVAC technicians to properly diag-
nose and repair this equipment.

Note: The procedures discussed in this manual
should only be performed by qualified, experienced
HVAC technicians. Do Not release refrigerant to the
atmosphere! If adding or removing refrigerant is
required, the service technician must comply with
all federal, state, and local laws.

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Содержание IntelliPak CG-SVX02B-EN

Страница 1: ...uct Section Refrigeration Product Hermetic Scroll Liquid Chillers Air Cooled Model CG Literature Type Installation Operation Maintenance Sequence 02B Date January 2005 File No SV RF CG SVX02B EN 105 S...

Страница 2: ...ing the information within this manual and follow ing the instructions the risk of improper operation and or component damage will be minimized It is important that periodic maintenance be performed t...

Страница 3: ...es 24 Final Water Piping Connections 26 Freeze Protection from Ambient Contitions 26 Field Installed Power Wiring 28 Disconnect Switch External Handle 28 Main Unit Power Wiring 28 Power Wire Sizing an...

Страница 4: ...ary O P C20 20 Tons E 20 29 F w o Ice Machine L LonTalk Communication Interface Module C25 25 Tons 1 40 50 F w Ice Machine K Stock Unit C30 30 Tons 2 30 39 F w Ice Machine L LonTalk Communication Inte...

Страница 5: ...iving a request for me chanical cooling energizes the appropriate compressors and condenser fans It monitors the compressor operation through feedback information it receives from various pro tection...

Страница 6: ...the suction line s near the scroll compressor s The FPC are connected to the SCM or MCM Low Pressure Cutout LPC binary input in series with the LCC switch es The FPC switch is used to prevent the refr...

Страница 7: ...additional 30 seconds after the stage change then Out put A will be de energized At this time only the fan un der the low ambient damper controlled by Output C will be on To prevent rapid fan cycling...

Страница 8: ...eset diagnostic Evap Solution Flow Proving Switch will be generated Once this input is closed the diagnostic will clear and the compres sors will be allowed to resume operation If the flow switch fail...

Страница 9: ...ncy Stop is a top priority command that will override all other commands received by the UCM A manual reset diagnostic will occur and an indication showing that the unit is shut down due to Emergency...

Страница 10: ...10 General Information Module Mounting Locations Screw Hole...

Страница 11: ...ery Notify the appropriate Trane office before installing or re pairing a damaged unit Unit Clearances Figure 1 illustrates the minimum operating and service clearances for either a single multiple or...

Страница 12: ...12 Figure 1 Typical Installation Clearances for Single Multiple or Pit Applications...

Страница 13: ...13 Figure 2 C20 Ton Unit Dimensional Data Recommended Clearances...

Страница 14: ...14 Figure 2 C25 Ton Unit Dimensional Data Recommended Clearances...

Страница 15: ...15 Figure 2 C30 Ton Unit Dimensional Data Recommended Clearances...

Страница 16: ...16 Figure 2 C40 Ton Unit Dimensional Data Recommended Clearances...

Страница 17: ...17 Figure 2 C50 Ton Unit Dimensional Data Recommended Clearances...

Страница 18: ...18 Figure 2 C60 Ton Unit Dimensional Data Recommended Clearances...

Страница 19: ...frigerant and oil charges Figure 3 Rigging and Center of Gravity Data WARNING Heavy Objects Do not use cables chains or slings except as shown Each of the cables chains or slings used to lift the unit...

Страница 20: ...e holes in the isolator 6 Level the unit carefully Refer to the Leveling the Unit section 7 After the unit is level tighten the isolator base mounting bolts to secure them to the mounting surface Spri...

Страница 21: ...DP 4 BLK RDP 3 GRN RDP 3 GRY RDP 3 RED RDP 3 GRN RDP 3 RED Cu RDP 4 BLK RDP 3 GRN RDP 3 GRY RDP 3 GRN RDP 3 GRY RDP 3 RED C40 Al RDP 3 GRY RDP 3 GRY RDP 3 GRY RDP 3 GRY RDP 3 GRN RDP 3 GRN Cu RDP 3 GR...

Страница 22: ...28 CP 1 28 CP 1 31 CP 1 28 CP 1 28 CP 1 28 CP 1 28 CP 1 27 CP 1 28 CP 1 27 CP 1 28 C50 CP 1 31 CP 1 32 CP 1 31 CP 1 32 CP 1 31 CP 1 31 CP 1 31 CP 1 31 CP 1 28 CP 1 31 CP 1 28 CP 1 31 C60 CP 1 32 CP 2...

Страница 23: ...ace by two ship ping braces that secure each compressor assembly rail to the unit s base rail To remove the shipping hardware follow the procedures below 1 Remove the four anchor bolts 2 front and 2 r...

Страница 24: ...with over current protection to the main power terminal block 1TB1 or to an optional factory mounted nonfused disconnect switch 1S1 in the control panel Install and connect properly sized power supply...

Страница 25: ...the filling pro cess Water Pressure Gauges Install pressure gauge s at the chiller barrel to monitor the entering and leaving solution pressure Note To prevent evaporator damage do not exceed 150 psi...

Страница 26: ...26 Figure 7A Typical Water Access Holes for 20 through 60 Ton Units Figure 7B Edge Protector Installation Figure 7C Clearance Requirements Around Water Pipe...

Страница 27: ...ainst ice formation at the lowest expected operating temperatures by adding a non freezing low temperature heat transfer fluid to the chilled water Ice making units with a termination setpoint of 27o...

Страница 28: ...t both ends Be sure to install the ther mostat on the most exposed i e coldest portion of the pipe 4 Wrap the pipe with an insulation material and cover it with a weatherproof tape if additional prote...

Страница 29: ...be closed with the handle in any one of the three positions outlined above provided it matches the disconnect switch position The handle can be locked in the OFF position While hold ing the handle in...

Страница 30: ...30 Installation Figure 11 Typical Field Installed Power Wiring Refer to the Wiring Diagram Notes at the end of this Section Table 3 Customer Connection Wire Range...

Страница 31: ...P OR MORE Calculation 1 MCA MOP and RDE MCA 1 25 x LOAD 1 LOAD 2 LOAD 4 MOP 2 25 x LOAD 1 LOAD 2 LOAD 4 Select a fuse rating equal to the MOP value If the MOP value does not equal a standard fuse size...

Страница 32: ...223 250 4 35 5 55 5 251 376 6 4 1 0 9 CGAF 460 60 3 98 110 4 16 5 24 2 117 178 6 1 8 0 9 50 575 60 3 77 90 4 12 4 19 4 94 143 6 1 4 0 9 380 50 3 97 110 4 15 5 24 2 110 174 6 1 7 0 75 415 50 3 97 110 4...

Страница 33: ...y output devices and the system components utilizing a DC analog input output signal to the unit Field Installed Control Wiring Before installing any connecting wiring refer to Figure 2 for the electr...

Страница 34: ...t the Tracer 100 3 Connect the shielded twisted pair leads from the Tracer to the proper terminals on the UCM There is no polarity requirement for this connection 4 At the UCM the shield should be cut...

Страница 35: ...35...

Страница 36: ...36 Figure 12B Typical GBAS 0 5 Volt Connections Diagram...

Страница 37: ...37...

Страница 38: ...38...

Страница 39: ...damage do not use untreated or improperly treated system water WARNING Live Electrical Components During installation testing servicing and troubleshoot ing of this product it may be necessary to wor...

Страница 40: ...oper phasing of the electri cal supply to the unit is critical for proper operation and reli ability The compressor motor is internally connected for clockwise rotation with the incoming power supply...

Страница 41: ...ELCI HGBP operation will be initi ated before the last compressor is turned Off Once HGBP has been initiated all subtract commands sent by the ELCI will be ignored If the Leaving Solution Temperature...

Страница 42: ...compressor stages are locked On and the fractional part represents the duty cycle required for the next higher compressor stage For a 4 compressor unit the Load Value will range from 0 0 to 4 0 For a...

Страница 43: ...culated reset amount is equal to selected Max Amount If Outside Air Temperature is between the Start Temp and the End Temp Max Amount calculated reset amount OA Start Temp Outside Air Temp OA Start Te...

Страница 44: ...5 Start Temperature Range 66 81 Factory Preset 78 Zone Temperature Zone Reset Cooling Factory Preset 5 Table 8B Chilled Solution Reset Schedule based on Outside Air Temperature Active Leaving Solution...

Страница 45: ...rcuit that has the most compressors operating The Lead Lag function is ignored treated as disabled when the Hot Gas Bypass option is installed and enabled When the UCM is powered up after a power loss...

Страница 46: ...service test will begin after the TEST START key is pressed and the delay desig nated in this step has elapsed Press the ENTER key to confirm this choice WARNING Rotating Components During installati...

Страница 47: ...47 System Start Up Figure 13 Evaporator Water Pressure Drop for CGAF C20 Through C60 Units English Note 1 Factor to convert Feet of Water to Lbs per Sq Inch PSI 2 3 Feet of Water 1 PSI...

Страница 48: ...48 System Start Up Figure 14 Performance Adjustments and Solution Freezing Points Use Only When Leaving Brine Temperature is Between 40o F 50o F...

Страница 49: ...ower including remote discon nects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvert ently energized Failure to disconnect power before ser vicing could...

Страница 50: ...ressor 2A Off Compressor 2B Off Condenser Fans On Solution Pump On Note Pump operation is dependent upon proper solution flow proving switch operation Please see section titled Loss Of Flow Protection...

Страница 51: ...key until the LCD displays the Start test in __Sec screen Press the key to designate the de lay before the test is to start This service test will begin after the TEST START key is pressed and the de...

Страница 52: ...pressure at the suction line gauge access port located near the compressor b Using a Refrigerant Temperature chart convert the pressure reading to a corresponding saturated vapor temperature c Measur...

Страница 53: ...ndition could damage com pressor bearings dur to reduced lubrication and could cause compressor mechanical failures When power has been Off for an extended period allow the crankcase heater to operate...

Страница 54: ...n switch and Zone Temperature settings for comfort systems are correct Inspect the unit for misplaced tools hardware and de bris Turn the solution pump control circuit disconnect switch to the On posi...

Страница 55: ...Compressor Replacement Table 12 lists the specific compressor electrical data and the circuit breaker operating ranges The compressor manifold system was purposely designed to provide proper oil retu...

Страница 56: ...56 9 409 67 6 77 7 230 56 9 376 67 6 77 7 C30 2 15 380 415 25 2 174 29 5 33 9 460 25 1 178 29 5 33 9 575 19 9 143 23 6 27 2 200 39 4 269 43 2 49 7 230 39 4 251 43 2 49 7 C40 4 9 380 415 17 2 110 18 9...

Страница 57: ...ese bearings add grease until a light bead appears all around the seal Do not over lubricate After greasing the bearings check the setscrews to en sure that the shaft is held securely to the bearings...

Страница 58: ...erials Care must be taken to protect the roof from oil leaks or spills 5 Pour the cleaning solution into the sprayer If a high pres sure sprayer is used a do not allow sprayer pressure to exceed 600 p...

Страница 59: ...end play or vibration and noise WARNING Rotating Components During installation testing servicing and troubleshoot ing of this product it may be necessary to measure the speed of rotating components H...

Страница 60: ...t be obligated to pay for the cost of lost refrigerant No liability whatever shall at tach to the Company until said products have been paid for and then said liability shall be limited to the purchas...

Страница 61: ...rol for Ice Building 40 Control for Process Applications 41 Current Sensing Module 5 D DC Conductors 33 See Table 6 discharge pressure approaches 405 7 psig 6 discharge pressure decreases to approxima...

Страница 62: ...8 19 See Figure 3 S Saturated Condenser Temperature Sensors 6 saturated condensing temperature falls 6 scroll compressor design 53 Secure the isolator 19 shell and tube type evaporator 5 Shipwith item...

Страница 63: ...63...

Страница 64: ......

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