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8

Compressor Motor Winding Thermostats (Standard)

A thermostat is embedded in the motor windings of each
Scroll compressor. Each thermostat is designed to open if
the motor windings exceeds approximately 221

o

F. The ther-

mostat will reset automatically when the winding tempera-
ture decreases to approximately 181

o

F. Rapid cycling, loss

of charge, abnormally high suction temperatures, or the
compressor running backwards could cause the thermostat
to open. During a request for compressor operation, if the
Compressor Module detects a problem outside of it’s nor-
mal parameters, it turns any operating compressor(s) on
that circuit “Off”, locks out all compressor operation for that
circuit, and initiates a manual reset diagnostic.

Low Ambient Compressor Lockout (Standard)

When low ambient compressor lockout is enabled, the com-
pressors are not allowed to operate if the temperature of
the outside air falls below the lockout setpoint. Compressor
operation is enabled when the temperature rises 5

o

F above

the lockout setpoint. The setpoints and enable/disable op-
tion is programmable at the Human Interface inside the unit
control panel. The default setting is 30

o

F.

Short Cycle Protection (Standard)

If compressor operation is interrupted by a loss of power or
by a manual reset diagnostic, a minimum of one minute
must elapse before the affected compressor(s) will be al-
lowed to restart for “Process” applications. A minimum of
three minutes must elapse before the affected
compressor(s) will be allowed to restart for “Comfort Cool-
ing” applications.

Hot Start (Load Limit) Control (Standard)

Each time the system is started and the control of the CGM
transitions from “Loop Stabilization” to either “Process” or
“Comfort Cooling”, if the Leaving Solution Temperature
(LST) is higher than the programmable Hot Start Load Limit
Setpoint (HSLLS), the lag compressor on each circuit will
be prevented from operating until the leaving solution tem-
perature is lowered by 5

o

F below the HSLLS.

If the Hot Start Limit time interval elapses before the LST is
5

o

F below the HSLLS, the control will transition immediately

into the Hot Operation mode.

Hot Operation mode is programmable to:

1. Do not limit capacity, initiate an informational diagnostic

until the LST falls 5

o

F below the HSLLS.

2. Limit the capacity to 50 percent (one compressor per cir-

cuit), initiate an auto reset diagnostic until the LST falls
5

o

 F below the HSLLS.

3. Turn “Off” and lockout all of the compressors and initiate

a manual reset diagnostic.

Loss-of-Flow (Solution) Protection (Standard)

All units:
Compressors are allowed to operate once the pump is run-
ning and the flow switch input is closed.  If the flow switch
input opens during normal operation for longer than 6 sec-
onds, the compressors and fans will stop. If the switch input
is still open after 5 minutes, a auto-reset 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
fails open or is not connected when the chiller starts up,

General Information

only the solution pump output will be energized.  5 minutes
later, an auto-reset diagnostic (Evap Solution Flow Proving
Switch) will be generated.  Once the flow switch input
closes, the chiller will operate normally.

If the chiller controls the pump (Chiller solution pump
mode = AUTO):

If the pump is cycled off by the CGM or a power failure oc-
curs, and the unit is re-started, the flow switch input must
open and then close for proper operation.  If the switch is
stuck closed or shorted, the pump will start but compres-
sors will not operate.  Also, a manual resettable diagnostic
(Evaporator Solution Flow Loss) will be generated.  To reset
the diagnostic, stop the pump and allow the flow switch to
open, then reset at the Human Interface (see Programming
Guide).

Note:  There is a minimum "off" time of 60 seconds for the
pump output.  This "off" time is overridden if the flow switch
opens.

If the chiller does not control the pump (Chiller solution
pump mode = ON):

Do not bypass the flow switch input!  If the flow switch input
is bypassed, the unit will not have flow loss protection and
equipment damage may result.

WARNING
Equipment Damage!

Do not bypass the flow switch input!  If the flow switch
input is bypassed, the unit will not have flow loss pro-
tection and equipment damage may result.

The flow switch input must be closed for compressor opera-
tion.  If the flow switch input is open and a request for cool-
ing is given, compressors will not start and a auto-reset di-
agnostic (Evap Solution Flow Proving Switch) will be gener-
ated after 5 minutes.  Once this input is closed, the diag-
nostic will clear and the compressors will be allowed to op-
erate.

Low Ambient Start (Standard)

Before first start of a compressor on a refrigerant circuit, the
CGM Low Ambient LPC Bypass output is closed which by-
passes the Freeze Protection Cutout (FPC) switch in the
MCM Low Pressure Cutout (LPC) input circuit for a period
of time that varies based on the prevailing ambient tem-
perature. The relationship between this variable time period
and the ambient temperature is linear from a maximum of 5
minutes at 0°F to a minimum of two minutes at 65°F. A fixed
three minute bypass time is initiated each time a subse-
quent compressor is started on a refrigerant circuit. No ad-
ditional compressors will be allowed to start within that cir-
cuit until the bypass time has expired.

Chiller Solution Pump Output Relay (Standard)

A Solution Pump binary output (Form C) relay is located on
the CGM which may be used to control the chiller solution
pump.

If the Chiller Solution Pump Mode, at the Human Interface
Module, is set to “On”, the Solution Pump will run continu-
ously.

If the Chiller Solution Pump Mode, at the Human Interface
Module, is set to Auto, the Solution Pump will be turned
“Off”:

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...

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