Trane CGA-SVX01A-EN Installation, Operation and Maintenance Manual

Brand: Trane

Model: CGA-SVX01A-EN

Type: Installation, Operation and Maintenance Manual

Trane CGA-SVX01A-EN Air-Cooled Cold Generator offers exceptional temperature control and energy efficiency in various applications. Its versatile design allows for cooling-only operation or integration with a heat pump for year-round heating and cooling. The unit boasts a compact footprint, making it ideal for space-constrained areas. Advanced features such as flow switch interlock, voltage utilization range, and adjustable water temperature control ensure reliable operation and optimal performance.

Trane CGA-SVX01A-EN Air-Cooled Cold Generator offers exceptional temperature control and energy efficiency in various applications. Its versatile design allows for cooling-only operation or integration with a heat pump for year-round heating and cooling. The unit boasts a compact footprint, making it ideal for space-constrained areas. Advanced features such as flow switch interlock, voltage utilization range, and adjustable water temperature control ensure reliable operation and optimal performance.

CGA-SVX01A-EN

Installation

Operation

Maintenance

Air-Cooled Cold Generator

Air-Cooled Cold Generator

With Heat Pump Option

®

®

© American Standard Inc. 2001 CGA-SVX01A-EN

2

MODEL NOMENCLATURE

INSTALLATION

RIGGING

MOUNTING

WATER PIPING

FIGURE 1: RECOMMENDED HOISTING ARRANGEMENT

FIGURE 2: DIMENSION FOR MOUNTING

FIGURE 3: SERVICE & MAINTENANCE CLEARANCE

ELECTRICAL WIRING

UNIT POWER SUPPLY

FIGURE 4: TYPICAL PIPING ARRANGEMENT

FIGURE 5: TYPICAL SYSTEM APPLICATION

ELECTRICAL DATA

FLOW SWITCH INTERLOCK

CIRCUIT DIAGRAM FOR CGAK 030 - 075

CIRCUIT DIAGRAM FOR CGAR 030 - 075

CIRCUIT DIAGRAM FOR CGAK 100 - 200

CIRCUIT DIAGRAM FOR CGAR 100 - 150

INSTALLATION CHECKLIST

PRE-START PROCEDURE

VOLTAGE UTILIZATION RANGE

VOLTAGE IMBALANCE

WATER FLOW RATE

UNIT WATER PRESSURE DROP

FIGURE 6: HYDRAULIC CHARACTERISTIC

PRE-START CHECKLIST

OPERATION

START-UP PROCEDURE

EXTENDED UNIT SHUT-DOWN/WINTERIZATION

STANDARD AMBIENT OPERATION

OPTIONAL LOW AMBIENT OPERATION (CGAK)

OPTIONAL HEAT PUMP OPERATION (CGAR)

ELECTRICAL CONTROL & PROTECTION SYSTEM

MAINTENANCE

TROUBLE ANALYSIS

TABLE OF CONTENTS

3

4

11

12

17

22

26

27

3

CGA

1,2,3

K

4

050

5,6,7

5

8

D

9

F

10

R

11

M

12

R

13

N

14

A

15

CGA-SVX01A-EN

MODEL NOMENCLATURE

DIGIT 1,2,3

CGA=Air-Cooled Cold Generator

®

DIGIT 4 - Model

K=Cooling Only (030~200)

R=Cooling With Heat Pump Option (030~150)

DIGIT 5,6,7 - Number

030

040

050

075

100

125

150

175

200

DIGIT 8 - Voltage

1=220V/60Hz/1Ph

(For model 030,040,050)

2=220V/60Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

3=380V/60Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

4=460V/60Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

5=380V/50Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

6=400V/50Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

7=415V/50Hz/3Ph

(For model 050,075,100,125,150, 175, 200)

DIGIT 9 - Development Sequence

D=Fourth Design

DIGIT 10 - Controls

F=Fixed Entering Water Temperature Control

(Standard Option)

A=Adjustable Entering Water Temperature

Control

(Microprocessor Controller)

(For CGAK Models as Optional)

(For CGAR Models as Standard Option)

DIGIT 11- Water Pump

N = No Pump

R = Standard Pump

(Standard Option)

DIGIT 12 - Refrigerant Pressure Gauges

M = No

(Standard Option)

G = With High/Low Pressure Gauges

DIGIT 13 - Temperature Kit

R = Standard Ambient Temperature Kit

(Standard Option)

L = Low Ambient Temperature Kit

(For CGAK Models Only)

DIGIT 14 - Other Options

M = Standard Fin + Standard Grille Cover

N = Standard Fin + Luxury Grille Cover

C = Blue Fin + Standard Grille Cover

B = Blue Fin + Luxury Grille Cover

DIGIT 15 - Service Sequence

A = First

© American Standard Inc. 2001

4

INSTALLATION

Table 1 - Unit Shipping Weights

Maximum Shipping Weight (Kg)

230

250

260

370

450

500

530

550

570

Model

030

040

050

075

100

125

150

175

200

CGA-SVX01A-EN

Complete the “Installation Checklist” during

installation to verify completion of all

recommended procedures before unit

start-up.

RIGGING

Each unit is bolted to a shipping skid for

shipment to the job site. Move the unit using

a forklift of suitable capacity. See Table 1 for

unit shipping weights.

Locate the unit near a large-capacity drain to

allow system drainage during unit shutdown

and repair. Rig the unit using canvas belt.

Fasten the belt to the unit over the unit’s

base as show in Figure 1.

MOUNTING

Mounting methods that will minimize sound

and vibration problems are:

1. Mount the unit directly on an isolated

concrete pad or on isolated concrete

footings at each unit mounting point.

2. Install the optional neoprene or spring

isolators at each mounting location.

Refer to Figure 2 for unit and base

dimensions and Figure 3 for recommended

service clearance.

WATER PIPING

Thoroughly flush all water system piping

before making the final piping connections to

the unit.

5

Figure - 1:

Recommended Hoisting Arrangement

(CGAK-075 As Shown)

CGA-SVX01A-EN

© American Standard Inc. 2001

6

Figure - 2:

Dimension for Mounting

(CGAK-075 As Shown)

Note: All Dimensions in Millimeter

CGA-SVX01A-EN

7

Figure - 3:

Service and Maintenance Clearance

(CGAK-075 As Shown)

CGA-SVX01A-EN

© American Standard Inc. 2001

8

CGA-SVX01A-EN

CAUTION: If using an acidic commercial

flushing solution, construct a temporary

bypass around the unit to prevent

damage to the evaporator.

CAUTION: To avoid possible equipment

damage, do not use untreated or

improperly treated water.

For unit’s water connection sizes and

locations, please refer to Figure 2.

CAUTION: To prevent unit damage, do

not reverse system piping connections to

the unit; water entering the unit must

enter at the designated “Water In” and

leaving water must exit the unit through

the designated “Water Out” connection.

Figure 4 illustrates typical unit piping

components. Components and layout will

vary slightly depending upon the locations

of the connections and water source.

Figure 5 gives a schematic of a typical

system application for this unit.

Provide vents at high points in the piping to

bleed air from the chilled water system.

Install pressures gage(s) to monitor entering

and leaving chilled water pressure.

CAUTION: To prevent damage to the

waterside components of unit, do not

allow evaporator pressure to exceed 100

psig (i.e. maximum working pressure).

Use an expansion tank to isolate this

pressure if water pressure exceeds this

value.

ELECTRICAL WIRING

WARNING: To prevent injury or death,

disconnect electrical power source

before completing wiring connections to

the unit.

CAUTION: Use only copper conductors

for terminal connections to avoid

corrosion or over heating.

Figure 2 shows the location of the unit

electrical access openings. Table 2 provides

minimum circuit ampacities, recommended

fuse sizes, and motor electrical data.

UNIT POWER SUPPLY

Refer to the unit wiring schematic fixed to

the control panel cover. The installer must

provide a power supply of proper voltage

and a fused disconnect switch to the unit.

Run properly sized power wirings through the

electrical access opening on the side of the

unit, and connect it to the Voltage Terminal

Block (1TB1) in the unit control panel. Install

a fused disconnect switch as required by

local codes. Provide proper equipment

grounds for the ground connections in the

unit control panel and at the fused disconnect

switch.

Refer to wiring diagrams from Page 13 to

Page 16 for reference of a typical unit installa-

tion. For actual wiring diagram, refer to the

one fixed to the control panel cover.

FLOW SWITCH INTERLOCK

To avoid possible evaporator freeze-up

resulting from reduced water flow, install a

flow switch ( or other flow sensing device) in

the evaporator outlet water line. This sensing

device must be adjusted to stop compressor

operation if water flow to the evaporator

drops below 70% of the system design full-

flow rate.

The installer must provide interconnecting

wiring between the unit control panel and the

water flow sensing switch in the evaporator

water line.

9

Figure - 4:

Typical Piping Arrangement

(CGAK-075 As Shown)

CGA-SVX01A-EN

© American Standard Inc. 2001

10

Figure - 5:

Typical System Application

(CGAK-075 And Fans As Shown)

CGA-SVX01A-EN

11

CGA-SVX01A-EN

ELECTRICAL DATA

Table 2 - Electrical Data

60Hz

Electrical

Power

(V/Hz/Ph)

220/60/1

220/60/1

220/60/1

220/60/1

220/60/3

380/60/3

220/60/3

380/60/3

220/60/3

380/60/3

220/60/3

380/60/3

220/60/3

380/60/3

220/60/3

380/60/3

220/60/3

380/60/3

Model

Water

Pump

FLA

4.4

4.4

4.4

6.5

2.7

1.6

4.2

2.4

4.2

2.4

5.4

3.1

5.4

3.1

6.0

3.5

9.1

5.3

Comp

1

RLA

14.4

19.4

24.4

24.4

15.3

8.8

23.0

13.3

15.3

8.8

17.4

10.1

23.0

13.2

26.0

15.0

32.4

18.7

Comp

2

RLA

-

-

-

24.4

-

-

-

-

15.3

8.8

17.4

10.1

23.0

13.2

26.0

15.0

32.4

18.7

Fan

1

FLA

2.8

2.8

2.8

4.3

3.0

1.7

3.0

1.7

4.5

2.6

4.5

2.6

3.0

1.7

4.5

2.6

4.5

2.6

Fan

2

FLA

-

-

-

-

-

-

-

-

-

-

-

-

3.0

1.7

4.5

2.6

4.5

2.6

Unit

MCA

25.2

31.5

37.7

65.7

24.8

14.3

36.0

20.7

43.1

24.8

49.1

28.4

63.2

36.2

73.5

42.5

91.0

52.6

Rec.

Fuse

Size

28.8

36.3

43.8

71.8

28.7

16.5

41.7

24.1

47.0

27.0

53.4

31.0

68.9

39.5

80.0

46.2

99.1

57.3

Max

Fuse

Size

39.6

50.9

62.1

90.1

40.1

23.1

59.0

34.0

58.4

33.6

66.5

38.5

86.2

49.4

99.5

57.5

123.4

71.3

030

040

050

100

050

050

075

075

100

100

125

125

150

150

175

175

200

200

50Hz

Electrical

Power

(V/Hz/Ph)

380-415/50/3

380-415/50/3

380-415/50/3

380-415/50/3

380-415/50/3

380-415/50/3

380-415/50/3

Model

Water

Pump

FLA

1.1

1.4

1.4

1.7

1.7

2.0

2.8

Comp

1

RLA

7.4

11.6

7.4

8.7

11.6

13.0

15.1

Comp

2

RLA

-

-

7.4

8.7

11.6

13.0

15.1

Fan

1

FLA

1.5

1.5

2.2

2.2

1.5

2.2

2.2

Fan

2

FLA

-

-

-

-

1.5

2.2

2.2

Unit

MCA

11.9

17.4

20.3

23.5

30.8

36.5

41.2

Rec.

Fuse

Size

13.7

20.3

22.1

25.7

33.7

39.8

45.0

Max

Fuse

Size

19.3

29.0

27.7

32.2

42.4

49.5

56.3

050

075

100

125

150

175

200

Note:

• All voltages supply must fall within the utilization range of ±10 %

• Minimum Circuit Ampacity (MCA) = Largest Load x 1.25 + Sum of additional Loads. (Used for sizing wire)

• Recommended Fuse Size (REC) = Largest Load x 1.5 + Sum of additional Loads. (Select closest fuse size)

• Maximum Fuse Size (MFS) = Largest Load x 2.25 + Sum of additional Loads. (Select equal or next lower fuse size)

© American Standard Inc. 2001

12

Circuit Diagram:

For CGAK 030 - 075

CGA-SVX01A-EN

FLOW SWITCH INTERLOCK

13

Circuit Diagram:

For CGAR 030 - 075

CGA-SVX01A-EN

© American Standard Inc. 2001

14

Circuit Diagram:

For CGAK 100 - 200

CGA-SVX01A-EN

15

Circuit Diagram:

For CGAR 100 - 150

CGA-SVX01A-EN

© American Standard Inc. 2001

16

CGA-SVX01A-EN

INSTALLATION CHECKLIST

RECEIVING

 Verify that unit nameplate data

corresponds with sales order information.

 Inspect unit for shipping damages and

material shortages; report any damages

or shortages found to the carrier.

UNIT LOCATION AND MOUNTING

 Inspect unit installation location for

adequate ventilation.

 Provide drainage facilities for water

accumulated from the base.

 Remove and discard any shipping

materials (e.g. cartons, crates, etc.)

 Inspect to determine that service access

clearances are adequate.

 Install optional unit neoprene-in-shear or

spring isolators.

Secure unit to mounting surface.

Level the unit.

EVAPORATOR PIPING

 Flush and clean all chilled water piping.

CAUTION: If using an acidic commercial

flushing solution, construct a temporary

bypass around the unit to prevent

damage to the evaporator.

CAUTION: To avoid possible equipment

damage, do not use untreated or

improperly treated water.

 Make evaporator water connections.

 Vent the air from chilled water system at

high points.

 Install pressure gauges, thermometers

and shutoff valves on water inlet and

outlet piping.

 Install water strainer in evaporator supply

line.

 Install balancing valve and flow switch on

water outlet piping.

ELECTRICAL WIRING

CAUTION: Use only copper conductors

to prevent galvanic corrosion and

overheating at terminal connections.

 Connect unit power supply wiring (with

fused disconnect) to appropriate

terminals on terminal block (TB) in power

section of unit control panel.

 In order to turn on/off the chiller from

indoors, connect wiring across reserved

terminals 2 & 3 in the unit control panel

from an indoor REMOTE OFF/ON switch.

 For heat pump options only, in addition to

an indoor REMOTE ON/OFF switch, an

indoor cooling mode and heating mode

switch should be connected. Please

connect another set of wiring to switch

between cooling mode and heating mode

indoors. For CGAR-030 to CGAR-075,

connect wiring across terminals 12 & 13

for cooling mode, terminals 12 & 17 for

heating mode. For CGAR-100, CGAR-

150, and CGAR-150, connect wiring

across terminals 17 & 18 for cooling

mode and terminals 17 & 27 for heating

mode.

 Properly ground the unit, the chilled water

pump motor, all disconnects, and other

devices which require grounds.

 Install wiring to connect flow switch to unit

control panel.

FOR NO-PUMP OPTION ONLY

 Connect chilled water pump power supply

wiring (with fused disconnect) to the

proper terminals of the chilled water

pump.

 Install wiring to connect chilled water

pump switch to chilled water pump

starter.

 Connect auxiliary contacts of chilled

water pump starter to flow switch and unit

control panel.

17

CGA-SVX01A-EN

PRE-START PROCEDURES

VOLTAGE UTILIZATION

RANGE

Electrical power to the unit must meet

stringent requirements for unit to operate

properly. Total voltage supply and voltage

imbalance between phases should be within

the following tolerances.

Measure each leg supply voltage at all line

voltage disconnect switches. Readings must

fall within the voltage utilization range shown

on the unit nameplate (±10%). If voltage on

any leg does not fall within the tolerance,

notify the power company to correct this

situation before operating the unit.

Inadequate voltage to the unit will cause

control components to malfunction and

shorten the life of electrical components and

compressor motors.

VOLTAGE IMBALANCE

Excessive voltage imbalance between

phases in all 3-phase system will cause

motors to overheat and eventually fail.

Maximum allowable imbalance is 2 %.

Voltage imbalance is defined as follows:

The 2.2% imbalance that exists in the

example above exceeds maximum

allowable imbalance by 0.2 %. This much

imbalance between phases can equal as

much as 20 % current imbalance with a

resulting increase in winding temperature

that will decrease compressor motor life.

WATER FLOW RATE

Establish a balanced water flow through the

unit. Flow rates should fall between the

minimum and maximum values indicated in

TABLE 3. Evaporator water flow rates below

the minimum acceptable values will result in

a stratified flow; this reduces heat transfer

and causes either loss of expansion valve

control or repeated nuisance low pressure

cutouts. Conversely, excessively high flow

rate may cause erosion in the water system.

% Voltage Imbalance =

Where

Va = (V1 + V2 +V3) / 3(Average Voltage)

V1, V2, V3 = Line Voltages

Vd = Maximum Line Voltage deviation from Va

Example:

If the three voltages measured at the line 221

Volts, 230 Volts, and 227 Volts, the average

(Va) would be:

Va = (221 + 230 + 227)/3 = 226 Volts

then Vd = 221 Volts

The percentage of imbalance is then:

100x Va-Vd

Va

100x 226-221

226

2.2%

© American Standard Inc. 2001

18

TABLE 3 - Unit Water Flow Rate - 60HZ

60Hz

Model

030

040

050

075

100

125

150

175

200

Minimum Flow

18.5

22.9

30.2

44.9

59.1

74.7

89.5

102.6

120.0

Rated Flow

27.7

34.3

45.3

67.3

88.7

112.0

134.3

154.0

180.0

Maximum Flow

38.8

48.0

63.4

94.2

124.2

150.0

150.0

175.0

240.0

Model

050

075

100

125

150

175

200

Minimum Flow

25.1

37.3

49.1

62.1

74.4

85.5

98.3

Rated Flow

37.7

56.0

73.7

93.3

111.7

128.3

149.0

Maximum Flow

56.6

84.0

110.6

140.0

150.0

160.0

190.0

CGA-SVX01A-EN

Units: LPM

50Hz Units: LPM

UNIT WATER PRESSURE

DROP

Measure the water pressure rise across the

standard unit (with built-in pump). The

Externally Available Head (E.A.H) should

approximate those indicated by the E.A.H.

curves, with the corresponding flow rates.

For units (without built-in pump) with field-

installed pump outside the unit, water

pressure drop across the unit should

approximate those indicated by the Internal

Pressure Loss (I.P.L.) curves, with the

corresponding flow rates.

For standard unit with built-in pump, refer to

the E.A.H. curve for the system hydraulic

design. For optional unit without a built-in

pump, refer to the I.P.L. curves. (Refer to

Figure 6 for hydraulic characteristics of all

models.)

19

CGA-SVX01A-EN

Figure - 6:

Hydraulic Characteristics - 60Hz

© American Standard Inc. 2001

20

CGA-SVX01A-EN

Figure - 6:

Hydraulic Characteristics - 50Hz

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Trane CGA-SVX01A-EN Installation, Operation and Maintenance Manual

Brand: Trane

Model: CGA-SVX01A-EN

Type: Installation, Operation and Maintenance Manual

Trane CGA-SVX01A-EN Air-Cooled Cold Generator offers exceptional temperature control and energy efficiency in various applications. Its versatile design allows for cooling-only operation or integration with a heat pump for year-round heating and cooling. The unit boasts a compact footprint, making it ideal for space-constrained areas. Advanced features such as flow switch interlock, voltage utilization range, and adjustable water temperature control ensure reliable operation and optimal performance.

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