Installation Operation Maintenance...

Installation Operation Maintenance

KOOLMANAir-Cooled Water ChillerWith Heat Pump Option

CG-SVX10A-EN3000-9384-01

Contents

1

1

2

Contents

Pre-start Procedures

Operation

Lcd Microcomputer Control

Function Inlustration

Trouble Analyses

Important Note: installation procedures should be performed in the sequence that they appear in this manual. This manual is customer's property. Do not destroy or remove the manual from the unit. The manual should remain weather protected with the unit until all installation procedures are completed.

Warning: Open and lock the disconnect switch before attempting any installation or maintenance. Failure to do so will cause severe injury even to death for electrical shock or contact with moving parts.

Note: It is not the intention of this manual

to cover all possible variations in systems that may occur or to provide comprehensive information concerning every possible contingency that may be encountered during an installation. If additional information is required or if specific problems arise that are not fully discussed in this manual, contact your local Sales office.

Note: Warning and Cautions appear at appropriate places in this manual. Your personal safety and the proper operation of this machine require that you follow them carefully. The Company assumes no liability for installation or servicing performed by unqualified personnel.

Model Number Description

Dimensional Data

Installation Instruction

Electrical data

Wiring Diagram

3

5

12

13

31

34

37

39

41

2

Model Number Description(Unitary Unit)

C G A R 0 7 5 7 D B R N F N D1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Digit 1,2,3 CGA=Air-cooled Water ChillerDigit 4 K=Cooling Only R=Heat PumpDigit 5,6,7 Model 030 (mini casing) 050 (mini casing) 060 (mini casing) 075 100 150Digit 8 Power Supply 5=380V/50Hz/3PH 6=220V/50Hz/1PH(for 030 only) 7=415V/50Hz/3PH(for 075,100,150 only)Digit 9 Manufacturing Code (defaulted by factory) A=030, 060 (mini casing) D=075 ; 150 double compressors F=050 (mini casing); 100; 150 single compressorDigit 10 Controller B=Microprocessor-based adjustable water temperature controllerDigit 11 Chilled water pump R=Internal pumpDigit 12 Supplement water electric heater N= None Digit 13 Applicable ambient temperature / Fin options F=Standard ambient temperature / Al-fin (standard) E=Standard ambient temperature / Blue fin.Digit 14 Fitting options N = None (standard) B = 5 liters pressurized water tank (WTANK-5) C = 12 liters pressurized water tank (WTANK-12)

Note: Digit 14 is indicated as "N" prior to shipment. When the pressurized water tank is required, it shall be packed individually and the model number in the bracket shall be used.

Digit 15 Service sequence D = R407c refrigerant

3

Dimensional Data

A. Mini Type Model: 0305A / 0306A / 0505F / 0605A

Water In (Ø1"FTP)

Water Out (Ø1"FTP)

950

190

648

740

402

393

640

90

1285

15

37

4

Dimension Data

B. Standard Type

Model

DimW

1290

1990

H

1900

1900

D

500

500

075 /100

1501

1/4'

' F

PT

Wat

er In

75

W

D

H

44.2

100120187

100

40

Wat

er O

ut

Bas

e

5


RiggingMove the unit using a forklift or crane 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 over the units base as show in Figure 1.

Installation Checklist1). Reception• Verify that unit nameplate data corresponds with ordering information.• Inspect unit for shipping damages and material shortages; report any damages or shortages found to the carrier.

2). 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, crate, etc.)

• Inspect to determine that service access clearances are adequate.

• Install the optional neoprene or spring isolators at each mounting location.

• Secure unit to mounting surface.

• Level the unit.

Mounting methods that will minimize sound and vibration problems are:• Mount the unit directly on an isolated concrete pad or on isolated concrete footings at each unit mounting point.

• 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 pipingEvaporator Piping • Thoroughly flush all water system piping before making the final piping connections to the unit.• Connect the evaporator piping.

• Vent the air from chilled water system at the highest point.

• Install pressure gauges, thermometers and valves on water inlet and outlet piping.

• Install water strainer in evaporator supply line.

• Install balancing valve and flow switch on water outlet piping.

Caution:• If using an acidic commercial flushing solution, construct a temporary bypass around the unit to prevent damage to the evaporator.

• To avoid possible equipment damage, do not use untreated or improperly treated water.

Figure 4 illustrates typical unit piping components. Components and layout will vary slightly depending upon the locations of the connections and water source.

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.

• Provide vent valve at highest point in the piping to bleed air from the chilled water system.

• To prevent damage to the waterside components of unit , do not al low evaporator pressure to exceed 0.5MPa (i.e. maximum working pressure).

• Before the final connection, flush carefully of all the external piping system . We have no any warranty for the case that impurities are combined in the piping.

Figure 1:Recommended hoisting arrangement(CGAK-075 As shown)

Tape

Tape

Hoisting belt

Hoisting belt

Wooden skid

Protectivecard board




Hook

Model

0305A

0306A

0505F

0605A

0755D

Maximal Shipping Weight (kg)

161

165

185

185

320

320

434

530

496

Table 1

1507D

1507F

0757D

1005F

1007F

1505D

1505F

530

496

434

6


Figure 2:Dimension for MountingNote: All Dimensions in Millimeter

640

950

402 393

A

FE

D 350 100

CB

4030

740

640

496

50

A. Mini Type: 0305A/0306A/0505F/ 0605A

B. Standard Type: 075/100/150

F

365

365

640

E

0

0

150

C

0

0

775

D

365

365

640

B

850

850

1550

A

1630

1630

2330

Model

075

100

150

7


Figure 3:Service and Maintenance Clearance

300

500

1500

300

500

Air Direction

8


Figure4: Typical Piping Arrangement (CGAK-075 As Shown)

WATER MAKEUP

EXPANSION TANK

RETURN CHILLED WATER

SUPPLY CHILLED WATER

AIR VENT

GATE VALVE

GATE VALVE

BALANGING VALVE(GLOBE)

THERMOMETERS

WATER FLOW SWITCH

STRAINER

PRESSURE GAUGE

ISOLATOR

WATER IN

WATER OUT

VIBRATION ELEMINATOR

9


Wat

er M

akeu

p

3-w

ay V

alve

3-w

ay V

alve

Gat

e Va

lve

Ther

mom

eter

s

Wat

er F

low

Sw

itch

Vibe

ratio

n E

lem

inat

or

Pre

ssur

e G

auge

FCU

=3

FCU

=2

FCU

=1FC

U=6

FCU

=5

FCU

=4

Dra

inag

e

Figure5: Typical System Application (CGAK-075 And Fans As Shown)


10

Pressurized Expansion Water TankThe system is used to adjust the pressure and quantity. Install a handle stop valve at each side of the system, which is convenient to maintenance. Installation Principle Figure shows the installation method in detail.

Principle description of the pressurized expansion water tank:

1. In order to avoid the pipe cracking due to the system overpressure resulting from the change of ambient temperature and also to avoid the steam hammer in the pipes, a pressure-type water tank shall be added in the pipeline system.

2. In order to avoid the excessively high or low pressure in the pipe, an automatic makeup water valve and an automatic drain valve are added in the pressurized water tank. When pressure is under 0.6bar, the makeup water valve works automatically to replenish water, while over 5bar, the drain valve works.

3. The makeup water and drain pressure can be varied with the jobsite situation.

AB

DC E

HG

F

Water Out Drainage port Water In

Dim

Model

WTANK-5

WTANK-12

A

470

620

B

263

400

C

230

324

D

132

162

E

254

356

F

435

569

G

415

440

H

455

475


11

Unit

Figure6: Option Installation Principle Figure

Pressurized Water Tank Makeup Water Valve

Tap Water

DrainageDrainage Valve

Auto Relief ValveReverse Return

Note: Mount auto vent Valve at the peak point of pipe line.

Direct Return

FCU X 4

Strainer

ViberationEleminator

Flow SwitchThermometer

How pressurized expansion water tank work:1. Pressurized expansion water tank used in the system to avoid pipe line

crack due to system overpressure resulting from the change of ambient temperature and also to avoid steam hammer formation in the pipe line.

2. Ultra high or low pressure is avoided by adding a makeup water valve and a drainage valve, when pressure is under 0.6bar, the makeup water valve works to replenish water, while over 5bar, the drainage valve works.

field condition.3. The makeup water and drain pressure can be reset according to

12

Electrical data

Electrical wiring• Connect unit power supply wiring to appropriate terminals block on distribution box.• Connect control panel (installed indoor) wiring to main control board.• For no-pump option only, connect chilled water pump power supply wiring to the proper terminals of the chilled water pump.• Properly ground the unit, the chilled water pump motor, and other devices which require grounding.• If with electric heater option, connect the power supply and control wiring to its terminal Tb2, which is shown on page 13.• If the interlocked controlling of the two-way valve of fan coil unit is available, disconnect the jumper JP6 on the control panel on spot, and connect the interlocked points to control terminal 12 and U.• Connect flow switch to the corresponding terminal U( or L) and 15.

Caution: To prevent injury or death, disconnect electrical power supply before completing wiring connections to the unit.

Note: Use only copper conductors for terminal connections to avoid corrosion or over heating.

Table 2 provides minimum circuit ampacities, recommended fuse sizes, and motor electrical data.

Unit Power SupplyRefer to the unit wiring diagram pasted on the control box cover. The installer must provide a power supply of proper voltage and a fused disconnect switch to the unit.

Refer to wiring diagram from page 15 to 24 for reference of a typical unit installation.

For actual wiring diagram, refer to the one fixed to the inside of control panel cover.

Note: The variation of input power voltage should be limited at ±10%.

Caution: For the 380V unit adopts the scroll compressor, the phase reversing and loss protection controller is installed which should be checked with electricity connection before start-up.If the green light of phase sequence in the control box is on, it means the phase sequence is right. Red light being on means the optional phases of power wiring should be exchanged, and the yellow means lacking phase which need check with electricity disconnection.In any case that the phases are reversed or lacked, the unit will shut down its operation and start-up automatically.

B:Standard Type

Model Power(V/Hz/Ph)

Pump FLA(A)

Comp#1 RLA(A)

Comp#2 RLA(A)

Blower motor#1 FLA(A)

Blower motor#2 FLA(A)

Minimum circuit ampacity

MCA

RecommendFuse Spec.

REC(A)

Maximum Fuse Spec.

MFS(A)

Min cross section area ofpower coppercable(mm2)

0755D 380-415/50/3 1.4 13.3 ― 1.6 ― 19.6 23.0 32.9 61005F 380-415/50/3 1.4 9.1 9.1 1.6 ― 25.8 30.3 44.0 61505D 380-415/50/3 2.6 14 14 1.6 1.6 40.8 47.8 68.8 101505F 380-415/50/3 2.6 27.3 ― 1.6 1.6 39.9 46.8 67.2 10

Table2: Electrical DataA:Mini Type

Model Power(V/Hz/Ph)

WaterPump FLA(A)

Comp#1 RLA(A)

Blower motor#1

FLA

Blower motor#2

FLA

Minimumcircuit ampacity

MCA

RecommendFuse Spec.

REC(A)

MaximumFuse Spec.

MFS(A)

Min crosssection area ofpower copper cable(mm2)

0305A 380-415/50/3 1.1 6.6 0.5 0.5 10.4 12.0 17.0 2.50306A 220/50/1 2.4 17 0.5 0.5 24.7 28.9 41.7 60505F 380-415/50/3 1.1 8.7 0.5 0.5 13.0 15.2 21.7 40605A 380-415/50/3 1.1 11.7 0.5 0.5 16.7 19.7 28.4 4

13

Wiring Diagram

146

13

42

614

313

51

42

13

5

Main Unit

LN

23

Main Unit

VWN

U

32

Breaker

Breaker

220V~ Power Supply

380V~ Power Supply

TB1

Cooling Only/Heating Pump

WRControl Panel

Control Panel

Control Panel

220V~/50H

z/1Ph

TB1

220/380V~/50H

z/3 -N

TB1

R

14

Wiring Diagram

TMC

1

Mic

ropr

oces

sor C

ontro

ller

(With

One

Com

pres

sor)

EG

-SA

VE

NU

VW

220V

~

TB1

MC

MP

OL

MFA

NM

OTO

R

1~MFA

N

MC

(L3)

R

380V

~/50

Hz/

3 -

N

PU

MP

CO

MP

(L2)

(L1)

ST

3 ~MM 3 ~

MF C

CH

MO

TOR

1~

RFS

RFS

Red

Whi

te

Yel

low

Red

Whi

te

Yel

low

Red

Red

Red

Red

Blu

e

Blu

e

Bla

ckB

lack

TO M

icro

proc

esso

r Con

trolle

r

Red

Bla

ckTr

ansf

orm

er

CG

AR

0605

AB

CG

AR

0505

FBC

GA

R03

05A

B

1#2#

C AB

(11)

(14)

NU

MV

MC

MF

MP

1

N

34

67

8N

11

36

AL

12 15 16 20 21

MP

MC

MF

CC

H

HE

AT

CO

MP

AL-

OU

T/IN

FAN

PU

MP

A-H

T

FLO

WO

V-P

UM

P

LP

N-C

OM

EN

-SA

VE

HC

HS

TB

TRA

NE

P/N

101

0-93

82-0

1

4WV

U U

Cfr

U

LAux

iliar

y E

lect

rical

Hea

ter

Pla

te H

eat E

xcha

nger

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dica

tion

Con

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(Inst

all I

ndoo

r)

The

Jum

p JP

6 M

ust B

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hut O

ff B

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put t

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arm

Not

e:

2.1.

Chi

ller W

ater

Pum

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ctor

Com

pres

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tart

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pres

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t

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TH1

TH3

TH4

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AL-IN

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A-HEAT

HEATER

4WV

L

FAN

OV

-FA

N

OV

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HP

1

LP1

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W

LP1

OV

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OV

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MP

N-C

OM

EN

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VE

OV

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AT

N

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CN

1

JP6

Inlet Sensor

Outlet Sensor

Defrosting Sensor

Inner Coil Sensor ofPlate Heat Exchanger

CGAR0605AB / CGAR0505FB / CGAR0305AB

15

Wiring Diagram

CGAK0305AB / CGAK0605AB / CGAK0505FB

380V

~/50

Hz/

3 -

N

TMC

1

Mic

ropr

oces

sor C

ontro

ller

(With

One

Com

pres

sor)

EG

-SA

VE

NV

UW

S(L

2)M

MC C

CH

MO

TOR

3 ~

MF

1~MFA

N

(L3)

RC

OM

P

MO

TOR

FA

NM 1~

TB1

M

MC

T(L

1)

3 ~

MP

OL

PU

MP

220V

~

RFS

RFS

TO M

icro

proc

esso

r Con

trolle

r

Tran

sfor

mer

1#2#

CG

AK

0305

AB

CG

AK

0605

AB

CG

AK

0505

FB

Red

Yel

low

Whi

te

Red

Whi

te

Yel

low

Red Red

Blu

e

Blu

eB

lack

Red

Red

Bla

ck

Bla

ckB AC

(14)

(11)

LPLo

w P

ress

ure

SW

Fan

Mot

or C

apac

itanc

eC

fr

Fan

Mot

or

N-C

OM

EN

-SA

VE

AL-

OU

T/IN

Com

mon

Nat

ure

Line

Ener

gy S

aving

/2-W

ay V

alve

Inte

rlock

Ale

rt O

utpu

t/Inp

ut

A-H

T

PU

MP

FAN

Pla

te H

eat E

xcha

nger

Hea

ting

Wat

er P

ump

TBP

ower

Ter

m B

lock

TRA

NE

P/N

101

0-93

82-0

3

118

16

7N

OV

-PU

MP

FLO

W

MC

CO

MP

CC

HM

F

MP

Flow

SW

Wat

er P

ump

Mot

or O

verlo

ad

V N

15 16 U 212012N UU

NU

AL

MC

MP

MF

6

L

Pla

te H

eat E

xcha

nger

Hea

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Ale

rt In

dica

tion

Inlet Sensor

Outlet Sensor

Con

trol P

anel

(Inst

all I

ndoo

r)

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rwis

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put t

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ust B

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ater

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tart

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r

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1TH

3TH

2TH

4

FLO

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CO

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CO

N-S

OV

-PU

MP

FLO

W

OV

-PU

MP

OV

-FA

N

LP1

HP

1

LP1

AL-OUT

JP6

FAN

A-HEAT

COMP

HEATER

4WV

PUMP

L

AL-IN

EN

-SA

VE

N-C

OM

OV

-HE

AT

OV

-CO

MP

16

Wiring Diagram

CGAR0306AB

NL

TMC

1(W

ith O

ne C

ompr

esso

r)

Mic

ropr

oces

sor C

ontro

ller

NL

MP

MO

TOR

M

M

CC

H

Cfr1

1~

MC

MO

TOR

FA

NC

fr21~

FAN

MF

Cr1

RSC

OM

P1~M

MC

T

PU

MP

1~M

TB1

220V

~/50

Hz

220V

~

TO M

icro

proc

esso

r Con

trolle

r

Red

Yel

low

Red Y

ello

wY

ello

w

Whi

te

Red

Red

Blu

e

Blu

e

Bla

ck

Blu

e

Blu

e

Bla

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Red

Tran

sfor

mer

Bla

ck

1#2#

CG

AR

0306

AB

Ele

ctric

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r

Aux

iliar

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ter

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Exc

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T

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AT

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HC

HS

TB

TRA

NE

P/N

101

0-93

82-0

2

118

31

46

7N

FLO

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C

CO

MP

CC

HM

F

MP

15 L 212012N LL

NL

AL

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MF

MV

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L

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(Inst

all I

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r)

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Whi

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al c

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tion,

The

Jum

p JP

6 M

ust B

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ff B

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terlo

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Tw

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Not

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ater

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Com

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Run

Con

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r

Com

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wat

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late

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hang

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Fan

Mot

or

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rt O

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Com

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Nat

ure

Line

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gy S

aving

/2-W

ay V

alve

Inte

rl ock

Flow

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Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

4-W

ay R

ever

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Val

ve

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ting

Con

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Pro

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Man

ufat

ure

Con

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Jobs

ite C

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n

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iptio

nN

ame

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crip

tion

CN

1TH

1TH

3TH

2TH

4

FLO

WN

CO

N-P

CO

N-S

FLO

W

OV

-PU

MP

OV

-FA

N

LP1

HP

1

LP1

AL-OUT

JP6

FAN

A-HEAT

COMP

HEATE

4WV

PUMP

L

AL-IN

EG

-SA

VE

EN

-SA

VE

N-C

OM

OV

-HE

AT

OV

-CO

MP

Inlet Sensor

Outlet Sensor

Defrosting Sensor


17

Wiring Diagram

CGAK0306AB

L NTM

C1

(With

One

Com

pres

sor)

Mic

ropr

oces

sor C

ontro

ller

EG

-SA

VE

LN

1~C

OM

P

MC C

CH

FAN

MO

TOR

1~

Cfr1

R M

MF

MO

TOR

1~M

FAN

Cfr2

1~

TM

C

Cr1

SW

hite

MP

M

PU

MP

M

TB1

220V

~

220V

~/50

Hz

TO M

icro

proc

esso

r Con

trolle

r

Tran

sfor

mer

Red

Yel

low

Red

Yel

low

Yel

low

Red Red

Blu

e

Blu

e Bla

ck

Blu

e

Blu

e Bla

ck

2#1#

CG

AK

0306

AB

Bla

ck

Red

LPC

fr

AL-

OU

T/IN

N-C

OM

EN

-SA

VE

A-H

TP

UM

PFA

N

TB

TRA

NE

P/N

101

0-93

82-0

4

118

16

7N

MC

CO

MP

CC

HM

F

MP

FLO

W

15 20 21LLLL12N

L

MC

MP

MF

AL

6

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

ot

herw

ise,

the

syst

em is

on

troub

le c

ondi

tion

and

alar

m2.1.

Not

e:

(Inst

all I

ndoo

r)

Con

trol P

anel

Inlet Sensor

Outlet Sensor

Pla

te H

eat E

xcha

nger

Hea

ter

Ale

rt In

dica

tion

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

Fan

Mot

or C

apac

itanc

e

Pla

te H

eat E

xcha

nger

Hea

ting

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

ut

Ener

gy S

aving

/2-W

ay V

alve

Inte

rlock

Flow

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n

N-C

OM

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

CN

1TH

1TH

3TH

2TH

4

FLO

WN

CO

N-P

CO

N-S

FLO

W

OV

-PU

MP

OV

-FA

N

LP1

HP

1

LP1

AL-OUT

FAN

A-HEAT

COMP

HEATER

4WV

PUMP

L

AL-IN

OV

-CO

MP

EN

-SA

VE

N-C

OM

OV

-HE

AT

JP6

18

Wiring Diagram

CGAR0755DB

V N30

SM

T06

NV

UW

PU

MP

CO

MP

MO

TOR

RFS

MC C

CH

MC

MF

3 ~M

FAN

(L2)

(L3)

(L1)

R3

~MST

TB1

OL

MP

3 ~M

RFS

380V

ac/5

0Hz/

3

220V

ac

TO M

icro

proc

esso

r Con

trolle

r

Tran

sfor

mer

Mic

ropr

oces

sor C

ontro

ller

CG

AR

0755

DB

Red

Whi

teB

lack

Red

Whi

te

Bla

ck

Red

Whi

teB

lack

Bla

ck

Whi

te

Red

Red

Whi

teB

lack

Bla

ck

Whi

te

Red

Red

Bla

ck

(With

One

Com

pres

sor)

Bla

ck

Yel

low

Bla

ck

Yel

low

B AC

(11)

(14)

U

LPC

OM

P

RFS

TB HC

HS

4WV

EN

-SA

VE

OV

-HE

AT

OV

-CO

MP

FAN

AL-

OU

T/IN

N-C

OM

A-H

TH

EA

T

PU

MP

FS OV

P

HP

OV

F

MC

CC

HM

F

MP

1010

-933

1-01

212017

31

64

N

4WV

MC

87

11N

1615UU12N

MF

MP

AL

Aux

iliar

y E

lect

rical

Hea

ter

Pla

te H

eat E

xcha

nger

Hea

ter

36

Inlet Sensor

Outlet SensorInner Coil Sensor of

Defrosting Sensor

Con

trol P

anel

(Inst

all I

ndoo

r)

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

ot

herw

ise,

the

syst

em is

on

troub

l e c

ondi

tion

and

alar

m

1.N

ote:

2.

Ale

rt In

dica

tion

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

Ele

ctric

al h

eatin

g co

ntro

l In

wat

er c

ircui

tPl

ate

Hea

t Exc

hang

e H

eatin

g

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

utN

-CO

M

Ener

gy S

aving

/2-W

ay V

alve I

nterl o

ck

Hea

ting

Ove

rload

Com

pres

sor O

verlo

ad/O

verh

eat

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

tFa

n M

otor

Ove

rhea

t

Hig

h P

ress

ure

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Phas

e R

ever

sing

Con

trolle

r4-

Way

Rev

ersi

ng V

alve

Hea

ting

Con

tact

or

Hea

ting

Pro

tect

ion

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n

Plate Heat Exchanger

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

OV

-PU

MP

TH1

TH3

TH2

TH4

CO

N-S

CO

N-P

CN

1

HP

1

LP1

OV

-FA

N

A-HEAT

NL

HEAT

COMP

4WV

AL-IN

FAN

PUMP

AL-OUT

EN

-SA

VE

JP6

OV

-CO

MP

FLO

W

OV

-HE

AT

N-C

OM

LP1

HP

1

OV

F

OV

P

FSEG

-SA

VE

19

Wiring Diagram

CGAK0755DB

(With

One

Com

pres

sor)

Mic

ropr

oces

sor C

ontro

ller

30V N

SM

T06

WV

UN

220V

ac

380V

ac/5

0Hz/

3

M 3 ~

OL

MP

PU

MP

MS

(L2)

T(L

1)M

C

MF

R(L

3)3

~C

OM

P

3 ~

CC

H

MC

FAN

MO

TOR

M

Tran

sfor

mer

To M

icro

proc

esso

r Con

trolle

rRFS

RFS

Whi

te

Bla

ck

Red

Red

CG

AK

0755

DB

Bla

ckY

ello

w

Bla

ck

Bla

ck

Whi

te

Red

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Yel

low

Bla

ck

AC B

(11)

(14)

6

MF

AL Ale

rt In

dica

tion

MP

MC

U N

N 12

11N

86

17

15 16 2017

Pla

te H

eat E

xcha

nger

Hea

ter

21

Con

trol P

anel

(Inst

all I

ndoo

r)

Outlet Sensor

Inlet Sensor

1.N

ote:

2.W

hile

the

inpu

t ter

min

als

is o

f ele

ctric

, the

sys

tem

is o

n no

rmal

con

ditio

n,

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

1010

-933

1-02

Chi

ller W

ater

Pum

p C

onta

ctor

Fan

Run

Con

tact

or

Com

pres

sor S

tart

Con

tact

orM

PM

CM

FC

rank

case

Hea

ter

Com

pres

sor

Ele

ctric

al h

eatin

g co

ntro

l

CC

HC

OM

PH

EA

T

Man

ufat

ure

Con

nect

ion

N-C

OM

OV

-HE

AT

EN

-SA

VE

N-C

OM

Hea

ting

Ove

rload

Ener

gy S

aving

/2-W

ay V

alve I

nterlo

ck

TBFS OV

P

OV

F

HP

LP

Plat

e He

at E

xcha

nger

Hea

ting

A-H

T

AL-

OU

T/IN

FAN

PU

MP

Fan

Mot

or

Ale

rt O

utpu

t/Inp

ut

Wat

er P

ump

Pow

er T

erm

Blo

ck

Low

Pre

ssur

e S

W

Fan

Mot

or O

verh

eat

Hig

h P

ress

ure

SW

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

t

RFS

Phas

e R

ever

sing

Con

trolle

r

Jobs

ite C

onne

ctio

nO

V-C

OM

PCo

mpr

esso

r Ove

rload

/Ove

rhea

t

U U

In w

ater

circ

uit

othe

rwis

e, th

e sy

stem

is o

n tro

uble

con

ditio

n an

d al

arm

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

EN

-SA

VE

N-C

OM

FAN

PUMP

AL-IN

4WV

COMP

HEAT

A-HEAT

AL-OUT

OV

-HE

AT

OV

-CO

MP

JP6

OV

-PU

MP

OV

-FA

N

FLO

W

CO

N-P

CO

N-S

NL

OV

F

EG

-SA

VE

OV

P

HP

1

FS

LP1

HP

1

CN

1TH

4TH

3TH

1TH

2

LP1

20

Wiring Diagram

CGAR1005FB / CGAR1505DB

MC

H03

3130N

V

Mic

ropr

oces

sor C

ontro

ller

(With

Tw

o C

ompr

esso

r)

WN

UV

220V

ac

TO M

icro

proc

esso

r Con

trolle

rC

CH

2

CC

H1

MC

2

FOR

CG

AK

/R 1

505D

175

5D O

NLY

MC

1

3 ~M

FAN

MO

TOR

MF

MFA

NM

OTO

R3

~

(L2)

(L1)

MC

2

ST

(L3)

RC

OM

P2

3 ~M

(L3)

(L2)

(L1)

MC

1

S RT

CO

MP

13

~M

TB1

MP

OL

3 ~M

PU

MP

380V

ac/5

0Hz/

3

RFS

RFS

CG

AR

1005

FBC

GA

R15

05D

B

2

1

Bla

ck

Yel

low

Red

Whi

teB

lack

Red

Whi

te

Bla

ck

Red

Whi

teB

lack

Bla

ck

Whi

te

Red

Red

Whi

teB

lack

Bla

ck

Whi

teR

ed

Red

Whi

teB

lack

Bla

ck

Whi

teR

ed

Red

Whi

teB

lack

Bla

ck

Yel

low

Bla

ck

Yel

low

Bla

ck

Yel

low

B AC

(11)

(14)

CG

AR

1505

/175

5DB

CG

AR

1505

/175

5DB

CG

AR

1505

/175

5DB

EN

-SA

VE

SE

T/S

F

CC

H

PU

MP

AL-

OU

T/IN

N-C

OM

H/F

AN

HT/

EV

1A

-HA

T

CO

MP

MC

MF

MP

OV

F

4WV

HS

HC

LP TBHP

FS OV

P

1010

-933

1-03

MC

1

31

26

711

45

U N

36

Aux

iliar

y E

lect

rical

Hea

ter

12 15 16 1713 14N

AL

MF

MP

MC

2

4WV

14WV

2

8N

2120

OV

-CO

MP

RFS

U U U

othe

rwis

e, th

e sy

stem

is o

n tro

ubl e

con

ditio

n an

d al

arm

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Not

e:

2.1.

Ale

rt In

dica

tion

Inlet Sensor

Outlet Sensor

Defrosting Sensor

Defrosting Sensor

(Inst

all I

ndoo

r)

Con

trol P

anel

Pla

te H

eat E

xcha

nger

Hea

ter

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

In w

ater

circ

uit

Ele

ctric

al h

eatin

g co

ntro

l

Plat

e H

eat E

xcha

nge

Hea

ting

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

utN

-CO

M

Ener

gy S

aving

/2-W

ay V

alve I

nterl o

ck

Set C

oolin

g O

nly/

Heat

ing

Pum

p

Com

pres

sor O

verlo

ad/O

verh

eat

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

t

Fan

Mot

or O

verh

eat

Hig

h P

ress

ure

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Phas

e R

ever

sing

Con

trolle

r

4-W

ay R

ever

sing

Val

ve

Hea

ting

Con

tact

or

Hea

ting

Pro

tect

ion

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

TH4

TH2

TH1

CN

1

OV

-CO

MP

1

NL

COMP2

HT/EV1

COMP1

AL-OUT

AL-IN

A-HAT

4WV1

4WV2

EG

-SA

VE

OV

-FA

N

OV

-PU

MP

FLO

W

EN

-SA

VE

FS

OV

F2

OV

P

OV

F1

LP2

N-C

OM

PUMP

M/FAN2

H/FAN1

LP1

HP

1

OV

-CO

MP

2

SE

T/S

HP

2

LP1

HP

1

TH5

HP

2

LP2

21

Wiring Diagram

CGAK1005FB / CGAK1505DB

N30

V

MC

H03

31

Mic

ropr

oces

sor C

ontro

ller

(With

One

Com

pres

sor)

WV

UN TO

Mic

ropr

oces

sor C

ontro

ller

MC

1

MC

2C

CH

1

CC

H2

FOR

CG

AK

/R 1

505D

ON

LYMO

TOR

FAN

M 3 ~

(L3)

MF

3 ~

MO

TOR

FAN

M

R RT S

(L3)

MC

2(L

1)(L

2)

3 ~

CO

MP

1

M 3 ~

CO

MP

2

T S

MC

1(L

1)(L

2)

PU

MP

M 3 ~ M

OV

PM

P

380V

ac/5

0Hz/

3

220V

ac

RFS

RFS

2

1

CG

AK

1505

DB

CG

AK

1005

FB

Yel

low

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Whi

te

Bla

ck

Red

Bla

ck

Whi

te

Red

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

teB

lack

Bla

ckB

lack

Yel

low

Bla

ck

Yel

low

Bla

ck

Yel

low

(11)

(14)

ABC

CG

AK

1505

/175

5DB

CG

AK

1505

/175

5DB

CG

AK

1505

/175

5DB

SE

T/S

F

1010

-933

1-04

FS

MC

Plat

e H

eat E

xcha

nge

Hea

ting

Ele

ctric

al h

eatin

g co

ntro

l

AL-

OU

T/IN

N-C

OM

EN

-SA

VE

H/F

AN

PU

MP

A-H

AT

HT/

EV

1C

OM

P

MF

CC

H

OV

P

OV

F

HP

TBLP

MP

2120171615141312

MF

21

N8

76

M

MC

1M

P

NU

6

11

N

AL

OV

-CO

MP

RFS

U U

Pla

te H

eat E

xcha

nger

Hea

ter

Ale

rt In

dica

tion

(Inst

all I

ndoo

r)

Con

trol P

anel

Inlet Sensor

Outlet Sensor

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

In w

ater

circ

uit

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

utN

-CO

M

Energ

y Sav

ing/2-

Way

Valv

e Inte

rlock

Cool

ing

Onl

y/He

atin

g Pu

mp

Set

Com

pres

sor O

verlo

ad/O

verh

eat

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

t

Fan

Mot

or O

verh

eat

Hig

h P

ress

ure

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Phas

e R

ever

sing

Con

trolle

r

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

ot

herw

ise,

the

syst

em is

on

troub

le c

ondi

tion

and

alar

m

Not

e:

2.1.

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

H/FAN1

M/FAN2

PUMP

N-C

OM

4WV2

A-HAT

AL-IN

AL-OUT

COMP1

HT/EV1

COMP2

TH5

TH3

TH1

TH2

TH4

CN

1

L N

SE

T/S

F

OV

-CO

MP

2

HP

1

LP1

HP

1

LP1

FLO

W

OV

F1

OV

-PU

MP

OV

-FA

N

OV

-CO

MP

1

HP

2

LP2

EN

-SA

VE

OV

F2

OV

P

LP2

HP

2

FSEG

-SA

VE

4WV1

22

Wiring Diagram

CGAR1505FB

UV30

SM

T06

WV

UN

TB1

CO

MP

3 ~

MC C

CH

MF

R(L

3)

FAN

MM

OTO

R1

3 ~

MC

MP

OV

P

M

ST(L

2)

(L1)

M3 ~

PU

MP

380V

ac/5

0Hz/

3

220V

ac

FAN

MO

TOR

2

M 3 ~

OV

CL

RFS

RFS

TO M

icro

proc

esso

r Con

trolle

r

Tran

sfor

mer

Mic

ropr

oces

sor C

ontro

ller

CG

AR

1505

FB

Red

Whi

teB

lack

Bla

ck

Whi

te

Red

Red

Whi

teB

lack

Bla

ck

Whi

te

Red

Red

Whi

teB

lack

Bla

ckW

hite

Red

Red

Whi

te

Bla

ck

Red

Bla

ck

(With

One

Com

pres

sor)

Bla

ck

Yel

low

Bla

ck

Yel

low

Hea

ter

Aux

iliar

yE

lect

rical

Hea

ter

Exc

hang

erP

late

Hea

t

B AC

(11)

(14)

OV

-HE

AT

EN

-SA

VE

N-C

OM

PU

MP

FAN

AL-

OU

T/IN

4WV

HS

HC

1010

-933

1-05

A-H

T

CO

MP

HE

AT

CC

H

MC

MF

MP

N

TBLPHPOV

F

OV

PFS

OV

CL/

31M

CM

P

76

411

N8M

F

AL

U

63

20 2118 17161512N

OV

CH

RFS

U

4WV

Ale

rt In

dica

tion

Inlet Sensor

Outlet Sensor

Defrosting SensorC

ontro

l Pan

el(In

stal

l Ind

oor)

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

ot

herw

ise,

the

syst

em is

on

troub

le c

ondi

tion

and

alar

m

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Not

e:

2.1.

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

Ele

ctric

al h

eatin

g co

ntro

l In

wat

er c

ircui

tP

late

Hea

t Exc

hang

e H

eatin

g

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

ut

N-C

OM

Ener

gy S

aving

/2-W

ay V

alve

Inte

rlock

Hea

ting

Ove

rhea

t

Com

pres

sor O

verlo

ad/O

verh

eat

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

t

Fan

Mot

or O

verh

eat

Hig

h P

ress

ure

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Pha

se R

ever

sing

Con

trolle

r

4-W

ay R

ever

sing

Val

ve

Hea

ting

Con

tact

or

Hea

ting

Pro

tect

ion

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n


Nam

eD

escr

iptio

nN

ame

Des

crip

tion

TH3

TH1

TH2

TH4

CN

1

CO

N-S

CO

N-P

NL

COMP

4WV

PUMP

HEAT

A-HEAT

FAN

AL-IN

AL-OUT

JP6

LP1

LP1

HP

1

OV

F1

EG

-SA

VE

OV

P

HP

1

FSFL

OW

OV

-PU

MP

OV

-FA

N

OV

-CO

MP

OV

-HE

AT

EN

-SA

VE

N-C

OM

OV

CH

OV

F2

OV

CL

19

23

Wiring Diagram

CGAK1505FB

UV30

SM

T06

Mic

ropr

oces

sor C

ontro

ller

(With

One

Com

pres

sor)

VN

UW

MO

TOR

2FA

N

PU

MP

MO

TOR

1FA

N

CO

MP

CC

H

TB1

MC

MF

3 ~M3 ~M

MC

MP

3 ~

(L1)

(L2)

(L3)

MT S R

3 ~

OV

P

M

380V

ac/5

0Hz/

3

220V

ac

OV

CL

RFS

RFS

To M

icro

proc

esso

r Con

trolle

r

Tran

sfor

mer

CG

AK

1505

FB

Red

Whi

te

Bla

ckB

lack

Whi

te

Red

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Red

Whi

te

Bla

ck

Bla

ckWhi

teRed

Red

Bla

ckB

lack

Bla

ck

Yel

low

Yel

low

AC B

(11)

(14)

AL-

OU

T/IN

FAN

PU

MP

N-C

OM

EN

-SA

VE

OV

-HE

AT

1010

-933

1-06

MC

CC

H

HE

AT

CO

MP

A-H

T

MP

MF

N

FS HP

LP TBOV

PO

VF

MC

16

8N

117M

P

MF

AL

U

6

20 2118 15 16 17N 12

OV

CH

OV

CL/

RFS

U

Pla

te H

eat E

xcha

nger

Hea

ter

Ale

rt In

dica

tion

Inlet Sensor

Outlet Sensor(In

stal

l Ind

oor)

Con

trol P

anel

The

Jum

p JP

6 M

ust B

e S

hut O

ff B

efor

e In

terlo

ckin

g of

Tw

o W

ay V

alve

Whi

le th

e in

put t

erm

inal

s is

of e

lect

ric, t

he s

yste

m is

on

norm

al c

ondi

tion,

ot

herw

ise,

the

syst

em is

on

troub

le c

ondi

tion

and

alar

m

Not

e:

2.1.

Chi

ller W

ater

Pum

p C

onta

ctor

Com

pres

sor S

tart

Con

tact

or

Fan

Run

Con

tact

or

Cra

nkca

se H

eate

r

Com

pres

sor

Ele

ctric

al h

eatin

g co

ntro

lIn

wat

er c

ircui

tPl

ate

Hea

t Exc

hang

er H

eatin

g

Wat

er P

ump

Fan

Mot

or

Ale

rt O

utpu

t/Inp

utN

-CO

M

Ener

gy S

aving

/2-W

ay V

alve I

nterlo

ck

Hea

ting

Ove

rload

Com

pres

sor O

verlo

ad/O

verh

eat

Flow

SW

Wat

er P

ump

Mot

or T

herm

osta

t

Fan

Mot

or O

verh

eat

Hig

h P

ress

ure

SW

Low

Pre

ssur

e S

W

Pow

er T

erm

Blo

ck

Phas

e R

ever

sing

Con

trolle

r

Man

ufat

ure

Con

nect

ion

Jobs

ite C

onne

ctio

n

Nam

eD

escr

iptio

nN

ame

Des

crip

tion

TH2

TH1

TH4

TH3

CN

1

COMP

CO

N-P

CO

N-S

NL

A-HEAT

HEAT

4WV

AL-IN

FAN

PUMP

JP6

AL-OUT

HP

1

LP1

LP1

OV

F1

OV

-CO

MP

OV

-FA

N

OV

-PU

MP

FLO

W

EN

-SA

VE

OV

-HE

AT

N-C

OM

OV

CH

FS HP

1

OV

P OV

F2

EG

-SA

VE

OV

CL

19

24

FU1

Wiring Diagram

Wiring DiagramWiring Diagram

25

Wiring Diagram

26

Wiring Diagram Wiring Diagram


27

Wiring Diagram

28

Wiring Diagram Wiring DiagramWiring Diagram


29

30


Voltage utilization rangeElectrical 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 imbalanceExcessive 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:

Voltage Imbalance% =WhereVa = (V1 + V2 +V3) / 3(Average Voltage)V1, V2, V3 = Line VoltagesVd = Maximum Line Voltage deviation from Va.

Water flow rateEstablish a balanced water flow through the unit. Flow rates should fall between the minimum and maximum values indicated in (TABLE 5). 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.

Unit Water Pressure DropMeasure 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.)

Pre-start Checklist• Inspect all wiring connections; electrical connections should be clean and tight.• Check power supply voltage to the unit. • Fill the chilled water circuit, leaving the system air vents open. Close vents after all air is out, and the system is completely filled.

• Remove jumper wire for water system testing.• Close the fused disconnect switch and s tar t the un i t by turn ing the ON/OFF switch to ON position. Pump should start and with water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs.• Adjust the water flow rate through the chilled water circuit, and check the external available water pressure of the unit (for standard unit) or the evaporator water pressure drop for the no-pump option unit.• Stop the chilled water pump.Open all fused disconnect switches.• Make electrical connection of flow switch to terminals in the control panel.

Note: With the water pump operating, throttle the water flow to approximately 50% of the full flow rate. Following the manufacturer's instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to verify opening and closure of the flow switch contacts.

Model

030

050

060

075

100

150

Minimum Flow Rate

20.6

26.3

32.9

39.1

54.8

76.5

Rated Flow

31

39.6

49.5

58.8

82.3

115

Maximum Flow

46.4

59.3

74.2

88.2

123.4

154.4

Connector Dimmension

1"

1"

1"

1 1/4"

1 1/4"

1 1/4"

100x|Va-Vd|

Va

31


Figure19: Hydraulic Characteristics

Flow Rate (LPM)

Hyd

raul

ic (

mH

2O)

Flow Rate (LPM)

Hyd

raul

ic (

mH

2O)

CGAK/R-075

Flow Rate (LPM)

Hyd

raul

ic (

mH

2O)

CGAK/R-100

Flow Rate (LPM)

Hyd

raul

ic (

mH

2O)

Note: Pump Head

Available Head

Internal Loss

30

25

20

15

10

5

020 25 30 35 40 45

30

25

20

15

10

5

030 35 40 45 50 55 60

30

20

10

040 45 50 55 60 65 70 75 80

20

15

10

5

060 90 100 110 120

CGAK/R-030 CGAK/R-050,060

32


Flow Rate (LPM)

Hyd

raul

ic (

mH

2O)

30

20

10

070 80 90 100 110 120 130 140 150

CGAK/R-150

Note: Pump Head

Available Head

Internal Loss

33

Start-up Procedure• Close the fused disconnect switch and press MODE button to choose heat or refrigeration,then turn OFF/ON switch to ON.

• Once the unit has operated for at least 30 minutes and the system has stabilized, complete the following checklist to ensure proper unit operation.

1. Check unit water flow and pressure. These readings should be stable at proper levels.

2. Measure unit suction and discharge pressures. Normal operation should render suction pressure in the range of 50-85 psig (0.34~0.586MPa) and discharge pressure 200-310psig(1.38~2.07MPa).

3. Check compressor amp draw.

4. Check electrical power supply.

5. Check the liquid line sight glasses.

6. Measure system superheat.

Normal system superheat is 5oC to 8oCfor each circuit at ARI conditions (12.2oCentering water, 6.7oC leaving water, and 35oC ambient temperature). If the superheat measured for either circuit does not fallwithin this range, alter the setting of the superheat adjustment on the thermal expansion valve to obtain the desired reading. Allow 15 to 30 minutes between adjustments for the expansion valve to stabilize at each new setting.

7. Measure system subcooling.Normal subcooling for each circuit is 5oC to 10oC ARI conditions (12.2oCentering water, 6.7oC leaving water, and

35oC ambient temperature). If subcooling for either circuit is not in this range, check superheat for the circuit and adjust, if required. If superheat is normal but subcooling is not, contact a qualified service technician.

8. If operating pressure, sight glass, superheat and subcooling readings indicate refrigerant shortage, find andrepair leaks and, gas-charge refrigerant into each circuit. Refrigerant shortage indicated if operating pressures are low and subcooling is also low.

9. If operating pressures indicate an overcharge, slowly (to minimize oil loss) recover refrigerant at the liquid line service valve.

• Be sure that all remote sensing bulbs are properly installed in bulb well. Remote bulb capillary tubes must be secured (i.e. protected from vibration and abrasion) and undamaged.

• Inspect the unit. Remove any debris, tools and hardware. Secure all exterior panels, including the control and compressor access panels. Replace and tighten all retaining screws.

Note:• Bubbles in the liquid line may indicate either a low refrigerant charge, or excessive pressure drop in the liquid line. But bubbles are not necessarily a symptom of improper system operation.

• A clear sight glass does not necessarily mean that the system is sufficiently charged; be sure to consider system superheat, subcooling, and unit operating pressures and ambient temperatures.

• If suction and discharge pressures are low, but subcooling is normal, no refrigerant shortage exists.Adding refrigerant will result in overcharging.

Operation

34

Operation

Extended unit shut-downIf the system is taken out of operation for long periods of time for any reasons (e.g., seasonal shutdown), use this procedure to prepare the system for shutdown.

1. Check the refrigerant piping for leaks, fixing any exist.

2. Service the chilled water pump and any air handling equipment according to the manufacturer's recommendtions.

3. Open both electrical disconnect switches for the unit and chilled water pump.

Note: In winter, close all evaporator water supply valves and drain the evaporator by removing the drain plug and opening the vent on the entering water line just outside the unit. Re-install the drain plug. Since the evaporator does not drain completely, add ethylene glycol antifreeze to the remaining water through the vent or evaporator drain hole, to keep the water from freezing.

System Restart AfterExtended Shutdown1. Fill the chilled water circuit by opening the gate valves at the returning and supply water piping. Be sure to vent the system while filling it, and close the vents when system is full.

2. Remove compressor delay for testing water system.

3. Close the unit disconnect switch for power supply.

4. Turn the OFF/ON switch to ON position. With water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs.

5. Adjust the water flow rate, using the balancing valve, through the chilled water circuit, and check the water pressure rise (or drop) through the unit.

6. Adjust the flow switch (installed on the unit outlet piping) to provide proper operation.

7. Stop the unit by turning the OFF/ON switch to OFF position.

8. Replace compressor delay back to original sockets. This unit now is ready for normal operation.

Note:With the unit operating, throttle the water flow to approximately 50% of the full flow rate. Following the manufacturer's instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to check for contact opening and closure.

System Protections

Low Pressure Cutouts (LP1, LP2)These units are protected by low pressure cutouts that open and stop compressor operation if the operating pressure drops below 8 4 psig(0.055 0.0276MPa).The cutout automatically resets when the pressure reaches 25 7 psig(0.172 0.048MPa).There will be a 2 minute override to prevent nuisance trip-outs.

High Pressure Cutouts (HP1, HP2)These units have high pressure cutouts that open and stop compressor operation if the discharge pressure reaches 400 10psig(2.76 0.069MPa).The cutout automatically resets when pressure drops to 250 15psig(1.72 0.103MPa).

System Anti-freeze ProtectionIN winter when unit is on standby and water temperature is below setting anti-freeze temperature, unit will automatically start and show "AP". So in freezing winter days, unit should be made stand by.

Anti-freeze Protection of Plate-type Heat ExchangeOn cooling mode, when leaving water temperature is below 3oC,compressorwill be shut up, pump remains on and show E3.

High Pressure Protection of Plate-typeHeat ExchangeDuring cooling model of single refrigerant unit, when refrigerant pressure is above a setting value, fan or fan and compressor will be shut up and show E3.

Motor Overloads• Compressor motor over load protection, overheating protection.• Pump motor overload protection.• Fan motor overload protection.• Temperature detectors protection. When Temperature detectors break down, system will alarm and unit will shut up.

Note:All alarm cutouts should be reset manually.After obstacle avoidance, press the RESET button or restart the unit to recover the system.

Water FlowIn order to avoid low water flow, which leads to freezing on evaporator, a water flow switch (or other water flow detector) should be installed on evaporator piping. A flow value should be set in order to stop compressor operation when waterflow rate is less than 70% of full flow rate.

Unit Operation

Temperature Detector (Th1)Temperature Detector senses the entering water temperature to determine start or stop of compressor on cooling and heating mode.

Cooling Mode

For Double Refrigeration Circuit OperationAt Start-up, the pump will come on immediately. Two minutes after the pump is on and EWT(entering water temperature) is above 13oC, compressor#1 will start. One minute later, if the EWT is above 15oC, compressor#2 will start.When cooling demand is met and EWTdrops to 11oC, compressor #1 will stop, i f EWT cont inues to fa l l to 10 oC,compressor #2 will stop. Subsequently,when load builds up and EWT rises to 13oC, compressor #2 comes on, and if EWT rises further to 15oC, compressor #1 comes on. Pump remains on unless the unit is turned off.

For Single Refrigeration Circuit OperationAt Start-up, the pump will come on immediately. Two minutes after the pump

is on and EWT(entering water temperature) is above 15oC, compressor will start.When cooling demand is met and EWTdrops to 10oC, compressor will stop. Subsequently, when load builds up and EWT rises to 15oC, compressor comes on. Pump remains on unless the unit is turned off.

Heating Mode

For Double Refrigeration Circuit OperationAt start-up, pump will come on immediately.Two minutes after the pump is on and EWT (entering water temperature) is below 37oC, compressor#1 will start. One minute later, if EWT is below 39oC,compressor #2 will start.

When heating demand is met and EWTrises to 41oC, compressor#1 will stop, i f EWT continues to r ise to 42oC,compressor #2 will stop. Subsequently,when load builds up and EWT drops to 39oC, Compressor #2 comes on, and if EWT drops further to 37oC, compressor #1 comes on. Pump remains on unless the unit is turned off.

For Single Refrigeration Circuit OperationFor units with only one refrigerant circuit, the operation of water pump, fan and compressor is exactly the same. Theonly difference is the unit will operate the single compressor from any temperature below 37oC and 42oC when the compressor will stop.

TABLE Temperature Kit

35

Operation

Cooling Mode

Heating Mode

18oC ~ 43

oC

_7

oC ~ 43

oC

36


LCD MICROCOMPUTER CONTROL

1. Photo

2. Panel 8

1615

14

13

1112

10

9

17 7

6

5

4

3

21

ON

OFF

3. Illustration of Control and Display Panel :

Control Panel

1. - ON/OFF button.

2. - MODE button. Press this button before start-up to choose cooling or heating.

3. - RESET button.When malfunction alarm, press this button to reset system manually.

4. - SETTING button.Press this button to set values (Password needed).

5. - Time query/ setting button.

6. - Timer button, Press this button to select the desired timer function.

7, 8. - Press these two buttons to view or modify the set values.

Display Panel

9. - Defrosting operation display.

10. - Water pump start-up display.

11. - Anti-freeze mode display.

12. - Compressor #2 start-up display.

13. - Auxiliary electrical heater start-up display.

14. - Heating mode display.

15. - Compressor #1 start-up display.

16. - Cooling mode display.

17. - Window for temperature and values display.

4. Manipulation Introduce

1. On-offChoose required mode firstly, pressthen unit will run on this mode. Press this button again to shut down. Do not press frequently.

2. Mode selection Includeing cooling mode and heating mode. Mode should be select after shut-down.

3. Value browse The values includes entering water temperature on cooling mode, entering water temperature on heating mode, anti-freeze temperature in winter, interval of defrost and defrost time span. Press firstly, then press , to browse the value.

4. Leaving water temperature displayDuring operation, press MODE button to show leaving water temperature for 6 seconds.

5. Reset When malfunction display, press .

6. Value Setting The five values mentioned above may be set through and , .

7. Normal display On normal condition,entering water temperature, compressor, heater and water pump parameters are displayed. There will be backlight when communication fails.

37


38


1. Cooling Air Temperature Control

1-1 Control for single compressor

1-2 Control for double compressors

Control ActionThe Changing of Entering water temperature

Low temperature High temperature

Compressor #1 Start Up

Compressor #1 Stop

Temperature Illustration

Note: When temperature rises to the point the arrow show, control action happens

Setting Value

2oC 3oC

2oC 3oC

1oC 1oC

Control Action



Compressor #2 Stop

Compressor #1 Stop


The Changing of Entering water temperatureLow temperature High temperature


Setting Value

39


2. Heating Air Temperature Control

2-1 Control for single compressor

2-2 Control for double compressors

Compressor Time Delay ProtectionWhen unit starts up, compressor will not start at least 2 minutes . During unit operation, its tarts or stops automatically and compressor will delay to start at least 3 minutes.




Compressor #1 Stop



Setting Value

3oC 2oC





Compressor #2 Stop

Compressor #1 Stop


NOTE: When temperature rises to the point the arrow show, control action happens

3oC 2oC

Setting Value

40

Trouble Analyses

Sequence

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1). Control Trouble

A. Single compressor unit

Sequence

1

2

3

4

5

6

7

8

9

10

11

12

13

14

B. Double compressors unit

Input Port

TH1

TH2

TH3

TH4

OV-HEAT

FLOW

OV-PUMP

OV-FAN

OV-COMP1

HP1

LP1

U6

TH2

TH3

Trouble Description

Short/broken circuit of sensing wire of EWT

Short/broken circuit of sensing wire of LWT

Short/broken circuit of sensing wire of plate

heat exchanger

Short/broken circuit of sensing wire of defrost

Electrical heater overload

Shortage of water flow rate

Pump overload

Fan overload

Compressor #1 overload

High voltage alarm of Compressor #1

Low voltage alarm of Compressor #1

Access trouble of memory device

Low temperature of LWT on cooling mode

High pressure protection of plate heat

exchanger on heating mode

Type

A

A

A

A

B

D

B

B

C

C

C

D

D

D

Code

SE

SL

Sd

S1

H2

FL

OP

OF

C1

H1

L1

L2

E3

E3

Recommended Action

Turn off all external devices




Turn off electrical heater



Turn off all external pumps

Turn off compressor #1 only




Turn off compressor, pump and

supplementary heater

Turn off fan or fan and compressor

Input Port

TH1

TH2

TH4

TH5

OVHT/HP2

FLOW

OV-PUMP

OV-FAN

OV-COMP1

OV-COMP2

HP1

LP1

FREZ/LP2

TH2

Trouble Description

Short/broken circuit of sensing wire of EWT

Short/broken circuit of sensing wire of LWT

Short/broken circuit of sensing wire #1of

defrost

Short/broken circuit of sensing wire #2 of

defrost


Shortage of water flow

Pump overload

Fan overload






Low temperature of LWT on cooling mode

Type

A

A

A

A

E

D

B

B

C

E

C

C

E

D

Code

SE

SL

S1

S2

H2

FL

OP

OF

C1

C2

H1

L1

L2

E3

Recommended Action














Turn off compressor, pump and

supplementary heater

41

Trouble Analyses

B. Compressor Hums, But Will Not Start

2) Trouble Analysis

A. Compressor Neither Start Nor Hums

Recommended Action

Check for followings:

a. Disconnect switch openb. Fuse(s) blown


a. Defective thermostat

b. Broken or improper control wiring

c. Blown control power fuse


a. Excessive discharge pressure

b. Defective high pressure control

c. Low charge; Low pressure cut-out

d. Gate/water valve not open causing flow switch or anti-

freeze cutoff to trip

e. Fan motor internal temperature switch open

f. Defective reset relay contact


a. Defective compressor contactor

b. Improper wiring

c. Low pressure cut-out open


a. Check compressor amp draw

b. Wait for the timer to time out (10~20 minutes)

Probable Cause

(1) No power to unit

(2) No call for cooling

(3) Compressor start delay,

timer has not timed out

(4) Compressor contactor will not close

(5) Compressor winding stat open

Probable Cause

(1) Low voltage at compressor

(2) Defective compressor

(3) Insufficient starting voltage

(Single-Phase Units Only)

Recommended Action

Check for the followings:

a. Single blown fuse

b. Low line voltage

c. Defective compressor contactor

d. Loose wiring connections


a. Open motor winding

b. Excessive amp draw on all phases


a. Defective start capacitor

b. Defective start relay

42

Trouble Analyses

C. Second Stage Compressor Fails To Start

Probable Cause

(1) No call for cooling or Heating

(2) Compressor start delay, timer has not timed out

(3) Compressor contactor will not close

Recommended Action


a. Defective thermostat

b. Broken or improper control winding

See (A) item (3)

See (A) item (4)

D. Compressor Short Cycles

Probable Cause

(1) Intermittent contact in control circuit

Recommended Action


a. Defective relay contacts

b. Loose wiring connections

E. Compressor Runs Continuously

Probable Cause

(1) Unit undersized for load (cannot maintain water

temperature)

(2) Thermostat set-point too low

(3) Defective thermostat or control wiring

(4) Welded contacts on compressor contactor

(5) Leaky valves in compressor (indicated by

abnormally low discharge and high suction pressures)

Recommended Action

Check for cause of excessive load

Replace thermostatReplace or repair control wiring

Repair or replace contactor

Replace compressor

Find and repair refrigerant leakRecharge system

F. Compressor Motor Winding Stat Open

Probable Cause

(1) Excessive load on evaporator

(indicated by high supply water temperature)

(2) Lack of motor cooling

(indicated by excessive superheat)

(3) Improper voltage at compressor

(4) Internal parts of compressor damaged

Recommended Action


a. Excessive water flow

b. High return water temperature


a. Improper expansion valve setting

b. Faulty expansion valvec. Restriction in liquid line


a. Low or imbalanced line voltage

b. Loose power wiring

c. Defective compressor contactor

Replace compressor

Probable Cause

(1) Internal parts of compressor damaged or broken

(compressor knocks)

(2) Liquid flood-back (indicated by abnormally

cold suction line and low superheat)

(3) Liquid refrigerant in compressor at start-up

(indicated byabnormally cold compressor shell)

Recommended Action

Replace compressor

Check and adjust superheat

Check for refrigerant overcharge

43

Trouble Analyses

G. Compressor is Noisy

H. System Short of Capacity

Probable Cause

(1) Low refrigerant charge (indicated by high

superheat and low subcooling)

(2) Clogged filter drier (indicated by temperature

change in refrigerant line through drier)

(3) Incorrect expansion valve setting

(4) Expansion valve stuck or obstructed

(i.e., high superheat and high water temperature)

(5) Low evaporator water flow

(6) Noncondensibles in system

(7) Leaky valves in compressor (i.e., operation at

abnormally high suction and low discharge pressures)

Recommended Action

Add refrigerant

Replace filter drier or filter drier core

Readjust expansion valve

Repair or replace expansion valve

Check strainers. Adjust water flow

Evacuate and recharge system

Replace compressor

I. Suction Pressure Too Low

Probable Cause

(1) Shortage of refrigerant (i.e., high superheat, low subcooling)

(2) Thermostat set too low (i.e., low discharge

pressure, low leaving water temperature)

(3) Low water flow

(4) Clogged filter drier

(5) Obstructed expansion valve (i.e., high superheat)

Recommended Action

Find and repair leak; recharge system

Readjust thermostat

Check for clogged strainers and

correct balancing valve settings

Check for frost on filter drier. Replace if

needed

Clean or replace valve

J. Suction Pressure Too High

Probable Cause

(1) Excessive cooling load (i.e., high supply water temperatures)

(2) Expansion valve overfeeding (i.e., superheat too low, liquid

flooding to compressor)

(3) Suction valves broken (i.e. noisy compressor)

Recommended Action

See (E) above

Adjust superheat setting; verify that

remote bulb is properly attached to

suction line

Replace compressor

44

Trouble Analyses

K. Discharge Pressure Too Low

Probable Cause

(1) Shortage of refrigerant (i.e., low subcooling, high

superheat, bubbles in sight glass)

(2) Broken or leaky compressor discharge valves

(3) Defective low pressure switch

(4) Unit running below minimum operating ambient

Recommended Action

Find and repair leak; recharge system

Replace compressor

Replace defective control

Provide adequate head pressure controls,

or an ambient lockout switch

L. Discharge Pressure Too High

Probable Cause

(1) Too little or too warm condenser air; airflow

restricted

(2) Air or non-condensable gas in system (i.e.,

exceptionally hot condenser)

(3) Refrigerant overcharge (i.e., high subcooling, low

superheat, high suction pressure)

(4) Excessive system load

(5) Defective condenser fan or fan pressure control

(i.e., fan off, high condenser pressure)

Recommended Action

Clean coil; Check fans and motors for proper function

Evacuate and recharge system

Recover excess refrigerant

Reduced load

Repair or replace switch

M. System Cannot Heating Mode (CGAR Model Only)

Probable Cause

(1) Broken or improper control wiring

(2) Defective four-way valve

Recommended Action

Check control wiring

Replace four-way valve

N. Suction Pressure Too Low - Heating Mode

Probable Cause

(1) Low refrigerant charge

(2) Too little or too cold evaporator air; airflow restricted

(3) Unit running below minimum operating ambient

(4) Expansion valve power assembly has lost charge

Recommended Action

Add refrigerant

Clean coil; Check fans and motors for proper function

Provide an ambient lockout switch

Repair or replace expansion valve power head assembly

O. Discharge Pressure Too High - HeatingMode

Probable Cause

(1) Low water flow

(2) Defective heating thermostat switch

Recommended Action

Check for clogged strainers and incorrect balancing valve settings

a. Verify that sense bulb is properly inserted bulb-well of heat-

exchangerb. Replace heating thermostat switch

TraneA business of American Standard Companieswww.trane.com

For more information, contact your local districtoffice

CG-SVX10A-EN(July 2005)

New

Taicang, China

Literature Order Number

File Number

Supersedes

Stocking location

TRANE has a policy of continuous product data and product improvement and reserves the right to change design and specifications without Note.

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