Installation Operation Maintenance - Heating and …

1 2003 American Standard Inc. All rights Liquid ChillersModels CGWF/CCAF20-60 TonsJanuary 20042 CGWF-SVX01A-ENImportant Environmental Concerns!Scientific research has shown that certain man-made chemicals can affect the earth s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants including industry replacements for CFCs such as HCFCs and HFCs. Responsible Refrigerant Practices!Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified.

2 The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them. WARNING Contains Refrigerant!System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment : Warnings and Cautions appear at appropriate sections through-out this literature. Read these carefully.

3 WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe : Indicates a situation that may result in equipment or property-damage only of ContentsGeneral Information .. 7 Literature Change 7 Unit Identification .. 7 Nameplates .. 7 Unit 7 Compressor Nameplate .. 7 Evaporator Nameplate .. 7 Condenser 8 Unit Inspection .. 8 Inspection Checklist .. 8 Loose Parts Inventory .. 8 Unit 8 Unit Model 8 Installation Overview .. 12 Installation Mechanical .. 17 Unit Storage .. 17 Location Requirement .. 17 Noise Consideration .. 17 Drainage .. 17 Rigging .. 17 Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF 18 Lifting Procedure for 60 Ton Units .. 20 Alternate Moving 21 Access Restrictions.

4 21 Recommended Clearances .. 22 Unit Isolation .. 22 Direct Mounting .. 22 Neoprene Isolator Mounting .. 22 Neoprene Isolator Data .. 22 Unit Leveling .. 23 Unit Piping .. 29 General Water Piping Recommendations .. 29 Water System .. 29 Water Flow 29 Pressure Drop Measurement .. 29 Evaporator Water 32 Evaporator Water 32 Evaporator Piping Components .. 32 Flow Sensing Devices .. 32 Evaporator Drain.. 33 Condenser Water Piping .. 33 Condenser Water Connections.. 33 Condenser Piping 33 Condenser Drains.. 34 Water Regulating Valve .. 35 Water pressure Relief Valves .. 37 Low Temperature Operation .. 37 Pressure Relief Valve Venting .. 38 Refrigerant Piping (CCAF only) .. 404 CGWF-SVX01A-ENTable of ContentsLiquid Line Components and Connections .. 40 Liquid Line Sizing .. 40 Discharge (hot gas) Lines .. 40 Leak Test .. 42 System Evacuation .. 42 Refrigerant 42 Installation Electrical.

5 43 General Recommendations .. 43 Power Supply Wiring .. 43 Unit Power Supply .. 43 Equipment 43 Terminal Lugs, Circuit Breakers and Non-Fused Disconnect 43 Scroll Compressor Electrical Phasing .. 47 Correcting Improper Electrical Phase Sequence .. 47 Unit Voltage .. 48 Voltage Imbalance .. 48 Control Power Supply .. 48 Modules Connections for Interconnecting Wiring .. 48 Chilled Water Flow Switch .. 49 Chilled Water Pump Control .. 49 Condenser Water Loss of Flow Protection .. 49 Condenser Water Pump Starter .. 49 Programmable 49 External 50 Compressor Inhibit/ High Ambient Operation .. 50 Condenser Water Temperature Sensor 50 Chilled Water 50 External Chilled Water Setpoint Option .. 51 Ice Machine Control 51 Communications Interface 51 Optional Tracer Communications Interface .. 51 LonTalk Communications Interface for Chillers (LCI-C) Option .. 52 CCAF - Fan Control .. 54 Outdoor Air Temperature Control.

6 54 Operating System .. 55 Controls Interface .. 57CH530 Communications Overview .. 57 Controls Interface .. 57 DynaView .. 57 TechView .. 57 DynaView Interface .. 58 Key Functions .. 58 Radio Buttons .. 58 Spin Value Buttons .. 58 Action Buttons .. 59 File Folder Tabs .. 59 Display Screens .. 59 Basic Screen Format .. 59 Keypad/Display Lockout Feature .. 60 CGWF-SVX01A-EN5 Table of ContentsMain Screens .. 61 Reports 65 Settings Screen .. 67 Diagnostics 69 TechView Interface .. 69 Software 70 Instructions for First Time TechView Users .. 70 Diagnostics .. 73 Unit Start-up .. 77 Pre-Start Checklist .. 77 Unit Power Up .. 79 Checking Operating Conditions .. 79 System Superheat .. 80 System 80 Unit Shutdown .. 81 Normal Unit Shutdown .. 81 Extended Shutdown Procedure .. 81 System Restart After Extended Shutdown .. 82 Unit Maintenance .. 83 Periodic Maintenance .. 83 Weekly 83 Monthly Maintenance .

7 83 Annual 83 Maintenance Procedures .. 84 Mechanical Cleaning .. 84 Chemical Cleaning .. 84 Cleaning the Evaporator (Chiller) .. 84 Water Treatment .. 85 Wiring Schematics .. 89 Schematics Page 1&2 .. 90 Component Location .. 94 Field Wiring Diagram .. 95 Field Layout 966 CGWF-SVX01A-ENTable of ContentsCGWF-SVX01A-EN7 General InformationLiterature Change HistoryNew manual describes the Installation , Operation and Maintenance of CGWF/CCAF IdentificationWhen the unit arrives, compare all nameplate data with ordering, submittal, and shipping information. A typical unit nameplate is shown in Figure NameplatesThe CGWF/CCAF unit nameplate is mounted on the control panel door. The Unit nameplate provides the following information: Unit model number. Unit serial number. Identifies unit electrical requirements. Lists correct Operation charge of R-22 and refrigerant oil. Lists unit test pressures and maximum operating pressures.

8 Identifies Installation , Operation and Maintenance literature. Lists the drawing numbers for the unit wiring NameplateThe nameplate for the Scroll compressor is mounted on the compressor housing near the motor terminal NameplateThe evaporator ASME nameplate is mounted on the top of the evaporator supply-end tube sheet. The word nameplate is applied to the insulation just above the nameplate. To view the evaporator nameplate, remove the tape over the area and spread the 1 Unit Nameplate8 CGWF-SVX01A-ENGeneral InformationCondenser NameplateThe condenser ASME nameplate (30 and 60 ton condensers only) is mounted on the top of the condenser near the water outlet on 60 ton units and on the side of the condenser near the water outlet on 30 ton InspectionCarefully inspect chiller while still on shipping conveyance. If unit is damaged or has broken free from anchorage, require inspection by transportation inspectors. File damage claims with the carrier and notify a Trane sales representative.

9 The manufacturer is not responsible for damage occurring during transit. Do not install a damaged unit without sales office ChecklistTo protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit: Inspect individual pieces of the shipment before accepting the unit. Check for obvious damage to the unit or packing material. Check the unit for concealed damage before it is stored and as soon as possible after delivery. Concealed damage must be reported within 15 days. If concealed damage is discovered, stop unpacking the shipment. Do not remove damaged material from receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery. Notify the carrier s terminal of damage immediately by phone and by mail. Request an immediate joint inspection of the damage by the carrier and the con-signee.

10 Notify a Trane sales representative and arrange for repair. Do not repair the unit until damage is inspected by the carrier s Parts InventoryCheck all items against shipping list. Water vessel drain plugs, rigging and electrical diagrams, service literature and optional water temperature sensors are placed inside the UCP (unit control panel) for shipment before it is shrinkwrapped with waterproof plastic. When ordered, the optional neoprene isolators are secured in place on the shipping DescriptionTrane Model CGWF/CCAF 20 - 60 ton Scroll Liquid Chillers, utilizing multiple Trane scroll compressors, are designed for Installation indoors. Each unit is completely assembled hermetic package that is factory-piped, wired, leak-tested, dehydrated, charged and tested for proper control Operation before inlet and outlet openings are covered before shipment. The units contain an operating refrigerant compressors are factory charged with the proper amount of refrigerant Model NumberTable 1 Unit Model NumberFCATFCODEM/N digit M/N value DescriptionMODL1-4 Chiller modelCGWFCGWFW ater cooled scroll chillerCCAFCCAFS croll compressor-chiller (condenserless)CGWF-SVX01A-EN9 General InformationNTON5-7 Unit nominal tonnage2002020 nominal tons2502525 nominal tons3003030 nominal tons4004040 nominal tons5005050 nominal tons6006060 nominal tonsVOLT8 Unit VoltageDULAG208-230/60/3 power supply380AD380/60/3 power supply460A4460/60/3 power supply575A5575/60/3 power supply400BN400/50/3 power supplySHIPCYC9 Ship cycleMTO(C)Made to orderSTK(C)Packed stock (contact BU)