Home

Trane RAUJ CAUJ 20 to 120 Tons Installation and Maintenance Manual

1. FAN GRILLE B MTG HOLES 1 2 X 4 KO 115V 5 1 2 X 2 115V 97 5 8 358 mE CONTROL PANEL 5 5 16 p 3 82 33 8 T 4 CONDUIT 16 i MAIN POWER 1 3 4 KO LOW 311 4 VOLTAGE 30V MAX 5 35 13 16 37 11 16 DETAIL A 97 5 8 DIMENSIONAL DETAIL 7 DOOR 43 1 4 W 180 DEG SWING 85 13 16 1 1 4 4 LOW AMBIENT VOLTAGE ACCESS DAMPER SEE NOTE 2 CONTROL PANEL 2 1 4 x 1 1 4 24 VOLTAGE i SEE DETAIL A CONTROLWIRING 1 4 co GRILLE d 1 fi T 1 79 1 4 jo 115 16 16 3 16 um ii 1 1 lol _ ok do Sor ol BOTTOM OF CONTROL BOX SEE DETAIL 5 3 16 20 1 16 9 51 8 fe 88 5 16 11 4 x 41 27 SLOT FOR 115 20 1 16 VOLT CONTROL 108 5 8 108 11 16 24 CAUJ SVX01D EN Dimensions and Weights Figure 18 100 and 120 ton air cooled condenser connections ONIMV YQ 2IH L3WO SI DNIMV NOILDANNOD LINN NOILV IN dI HO dO 14NVd 10H1NO2 TANVd 1081NO2 4 491 6 S 91 6 4 3815 13NVd 1OY LNOD GINO 3NI 1 39 8VH2SIG 105 ONIMV
2. 79 1 4 1 1 16 5 16 y Li LE Sor Sor ol l BOTTOM OF CONTROL rd i BOX SEE DETAIL T B 30 1 8 113 16 83 1 8 9 76 7 16 88 5 16 11 4 x 4 1 2 SLOT FOR 115 VOLT CONTROL 22 CAUJ SVX01D EN Dimensions and Weights Figure 16 80 ton air cooled condenser connections SNIMVG OItH L3AOSI NOLLO3NNOO LINN NOLLV LN3IHO I3NVd 4 SS300V ASDVLIOA LINN 40 ACIS T3NVd IOH INOO JOHINOO NOLLO3NNOO LINN 3O NV Id 3NIT398VHOSIG 8 9 94 6 92 JOHINOO gt od out py 37 6 A A Ezri i RE HE r1 2 7 8 4 91 bom 23 CAUJ SVX01D EN e TRANE Dimensions and Weights Figure 17 100 and 120 ton air cooled condenser NOTES 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT
3. 26 Installations ea ar 27 Rigging and Center of Gravity 27 Unit Isolation da aaie aa aaa a a eee 28 Leveling the Unit iiao ms ioiii i ioa aodo da aika E b ee 31 General Unit Requirements 31 PIPING Dee Ee CORA ES ONUS A RE Ee 31 Main Electrical Power Requirements 31 Field Installed Control Wiring 32 Refrigerant Piping llsssesslseseee rn 32 Liquid LINES uc km mm eoa o OE a ORG ERR x 32 Liquid Line Components 33 Discharge Hot Gas Lines 35 Discharge Hot Gas Line Components 35 Final Refrigerant Pipe Connections 36 Brazing Procedures 36 Leak Testing Procedure 37 Field Installed Power Wiring 38 Main Unit Power Wiring 39 Power Wire Sizing and Protection Device Equations 40 Field Installed Control Wiring 41 Electrical Dat sre sec EE es DR eda eae is 42 Operdting Principals har ___ Edd 43 20 60 Specs cer he ao TR
4. 42 34 1 2 CONTROL PANEL SIDE VOLTAGE ACCESS 13 8 1 16 ORIENTATION VIEW OF UNIT PLAN VIEW OF UNIT ISOMETRIC DRAWING CONNECTION DRAWING COIL DISCHARGE LINE LIQUID LINE HL lo 5 3 4 5 7 16 CONTROL PANEL SIDE VIEW OF UNIT CONNECTION DRAWING CAUJ SVX01D EN 15 e TRANE Dimensions and Weights Figure 9 40 ton air cooled condenser FAN GRILLE 3 4 6 MTG HOLES 36 1 8 88 9 16 36 1 8 DOOR 43 1 4 W 180 DEG SWING 85 5 8 CONTROL PANEL SEE DETAIL A FAN GRILLE NOTES 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT 1 2 X 4 KO 115V 1 2 X 2 KO 115V CONTROL PANEL 2 5 8 5 16 CONDUIT MAIN POWER 1 3 4 KO LOW VOLTAGE 30V MAX 37 11 16 DETAIL A BOTTOM OF CONTROL BOX LOW AMBIENT DAMPER SEE NOTE 2 cee ee e im 14 79 1 4 4 LINE VOLTAGE ACCESS 32 3 16 22 1 2 16 15 16 F A el t BOTTOM OF CONTROL BOX SEE DETAIL A 11 4 x4 1 2 SLOT FOR 115 VOLT CONTROL 88 5 16 16 5 3 16 61 8 4 3 8 88 5 16 CAUJ SVX01D EN e T
5. 3 4 X 4 MTG HOLES 4 34i 1 2 X 4 KO 115V i 1 2 X 2 KO 115V JE CONTROL PANEL 5 5 16 i 72 1 2 41 2 Tp 4 CONDUIT 314 4 MAIN POWER P 1 3 4 KO LOW VOLTAGE 30V MAX 5 35 13 16 37 1116 b2 19 a T YT i DETAIL A 4 DOOR 43 4 4 wo CONTROL BOX BOTTOM 180 DEG SWING E 1 4 5 LOW AMBIENT Bron DAMPER SEE NOTE 2 FAN GRILLE CONTROL PANEL 1 1 SEE DETAIL A 13 d 6 14 5 SS e T ii 9 7 4 LINE VOLTAGE ACCESS 11 4 x 4 1 2 4 SLOT FOR 115 VOLT CONTROL p 1 74 114 26 13 16 48 1112 jt 13 16 D lm qc RENS _ 4 3 8 CONTROL BOX BOTTOM SEE DETAIL A 6 1 8 78 5 3 16 60 3 88 5 16 12 CAUJ SVX01D EN e TRANE Dimensions and Weights Figure 6 20 ton air cooled condenser connections CONTROL PANEL SIDE NOTES 1 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 13 8 O D DISCHARGE LINE 7 8 O D LIQUID LINE CONTROL PANEL 34 1 2 CONTROL PANEL SIDE M ha ARET VOLTAGE ACCESS PLAN VIEW OF UNIT ORIENTATION VIEW OF UNIT CONNECTION DRAWING ISOMETRIC DRAWING 5716 1 T LIQUID LINE DISCHARGE LINE CONTROL PANEL SIDE VIEW OF UNIT CONNECTION DRAWING CAUJ SVX01D EN 13 e TRANE Dimensions and Weights Fig
6. Proper Field Wiring and Grounding Required All field wiring MUST be performed by qualified personnel Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards To avoid these hazards you MUST follow requirements for field wiring installation and grounding as described in NEC and your local state electrical codes Failure to follow code could result in death or serious injury AWARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury Before installing any connecting wiring refer to Figure 5 p 12 through Figure 18 p 25 for the electrical access locations provided on the unit Install appropriately sized control wiring for the 115 volt electrical components as required by the application Since the unit mounted 115V control power transformer 1711 is provided on all units it is not necessary to run a separate 115 volt control power source to the unit Note 200 230 Volt units are shipped with transformer 1T1 wired for 200 volt operation If the unit is to be operated on a 230 volt power supply rewire the transformer as shown on the unit schematic When the 115 volt control circuit is properly connected to the field provided interlock contacts 5K1 for circuit 1 and 5K2 for
7. TRANE Installation Operation and Maintenance Remote Air Cooled Condensers Models A and Later Design Sequences CAUJ C20 CAUJ C40 CAUJ C80 CAUJ C25 CAUJ C50 CAUJ D10 CAUJ C30 CAUJ C60 CAUJ D12 ASAFETY WARNING Only qualified personnel should install and service the equipment The installation starting up and servicing of heating ventilating and air conditioning equipment can be hazardous and requires specific knowledge and training Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and on the tags stickers and labels that are attached to the equipment January 2011 CAUJ SVX01D EN e TRANE Warnings Cautions and Notices Warnings Cautions and Notices Note that warnings cautions and notices appear at appropriate intervals throughout this manual Warnings are provide to alert installing contractors to potential hazards that could result in death or personal injury Cautions are designed to alert personnel to hazardous situations that could result in personal injury while notices indicate a situation that could result in equipment or property damage only accidents Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions Read this manual thoroughly before operating or servicing this unit ATTENTION Warnings Ca
8. Table 15 Liquid line amp drier refrigerant requirements Liquid Line O D Liquid Line Charge Sporlan Part No Drier Refrigerant Charge 5 8 1 827 C 305 S 1 Ib 1 oz C 307 S 1 Ib 1 oz 3 4 2728 C 417 S 1 Ib 8 oz a C 307 S 1 Ib 1 oz 78 aus C 417 S 1 Ib 8 oz 1 1 8 6 461 C 419 S 1 Ib 8 oz Note Refrigerant charge given in ounces per foot Table 16 Sample maintenance log Current Refrigerant Circuit 1 Refrigerant Circuit 2 Ambient Suct Disch Liquid Suct Disch Liquid Temp Compr Press Press Press Super Subcool Compr Press Press Press Super Subcool Date F Oil level Psig Psig Psig heat f Oillevel Psig Psig Psig heat f ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low ok ok Low Low Note Check and record the data requested above each month during the cooling season with the unit running CAUJ SVX01D EN 53 e TRANE Service and Maintenance Fuse Replacement Data Table 17 Fuse replacement selection 20 60 ton units Fuse Description Unit Size Unit Voltage Fuse Type Fuse Size Condenser Fan Fuse 200 230 Volt 25 AMP 1F1 1F3 on 20 30 ton All 460 575 Volt RK5 1F1 1F6 on 40 60 ton 380 415 Volt 15 AMP 20 30 ton All FNQ R
9. Warranty and Liability Clause 58 COMMERCIAL EQUIPMENT RATED 20 TONS AND LARGER AND RELATED ACCESSORIES PRODUCTS COVERED This warranty is extended by American Standard Inc and applies only to commercial equipment rated 20 Tons and larger and related accessories The Company warrants for a period of 12 months from initial start up or 18 months from date of shipment whichever is less that the Company products covered by this order 1 are free from defects in material and workmanship and 2 have the capacities and ratings set forth in the Company s catalogs and bulletins provided that no warranty is made against corrosion erosion or deterioration The Company s obligations and liabilities under this warranty are limited to furnishing f o b factory or warehouse at Company designated shipping point freight allowed to Buyer s city or port of export for shipment outside the conterminous United States replacement equipment or at the option of the Company parts therefore for all Company products not conforming to this warranty and which have been returned to the manufacturer The Company shall not be obligated to pay for the cost of lost refrigerant No liability whatever shall attach to the Company until said products have been paid for and then said liability shall be limited to the purchase price of the equipment shown to be defective The Company makes certain further warranty protection available on an optional extra cost basis Any
10. 460 575V 60HZ 3PH CA 20 60 Ton 2307 9125 Power Schematic Diagram Split System Condensing Unit Duplex Condenser Units CA 80 120 ton 2307 9126 Unit amp Field Connection Wiring Diagram Air Cooled Condenser Unit Duplex Condenser Unit CA 80 120 ton CAUJ SVX01D EN 59 S TRANE Trane optimizes the performance of homes and buildings around the world A business of Ingersoll Rand the leader in creating and sustaining safe comfortable and energy efficient environments Trane offers a broad portfolio of advanced controls and HVAC systems comprehensive building services and parts For more information visit www Trane com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice 2011 Trane All rights reserved CAUJ SVX01D EN 23 Jan 2012 We are committed to using environmentally dm Ingersoll Rand Supersedes CAUJ SVXO1C EN 10 Oct 2012 conscious print practices that reduce waste
11. 49 62 yfo 49 96 3 Control Control Control Panel Panel Panel 1 3o o o3 50 1 o5 70 20 30 Ton 40 60 Ton 80 120 Ton Table 3 Isolator mounting locations Mounting Location Unit Size 1 2 3 4 5 6 7 8 20 25 30 x 8 8 6 8 1 8 6 8 1 8 Y 4 10 3 4 11 4 4 10 3 4 1 1 4 40 x 8 8 3 8 1 8 3 8 1 8 6 8 1 4 6 8 1 4 7 3 1 8 11 4 7 3 1 8 1 1 4 7 31 8 1 1 4 50 60 x 8 8 4 8 7 8 4 8 7 8 8 9 3 4 8 9 3 4 Y 7 3 1 8 11 4 7 3 1 8 1 1 4 7 3 1 8 1 1 4 80 x 8 8 6 8 1 8 6 8 1 8 9 1 8 9 1 8 14 1 4 14 1 4 Y 7 3 1 8 1 1 4 7 3 1 8 1 1 4 7 3 1 8 1 1 4 7341 8 1 1 4 100 120 X 8 8 8 9 5 8 8 9 5 8 10 1 5 8 10 1 5 8 18 3 1 4 18 3 1 4 Y 7 3 1 8 1 1 4 J 3 1 8 11 4 7 3 1 8 1 1 4 7 3 1 8 1 1 4 26 CAUJ SVX01D EN S TRANE Installation Rigging and Center of Gravity Data CAUJ SVX01D EN A Rigging illustration and Center of Gravity dimensional data table is shown in Figure 20 p 28 Figure 21 p 28 and Table 2 p 26 See Table 2 p 26 for typical unit operating weights table before proceeding AWARNING Improper Unit Lift Test lift unit approximately 24 inches to verify proper center of gravity lift point To avoid dropping of unit reposition lifting point if unit is not level Failure to properly lift unit could result in unit dropping and possibly crushing operator technician which cou
12. 3 20 AMP Control Ckt Fuse 1F7 40 60 ton All FNQ R 6 25 AMP Compr Protector Fuse 1F8 on 20 60 ton All All ABC 6 6 AMP 1F9 on 40 60 ton Table 18 Fuse replacement selection 80 120 ton units Fuse Description Unit Size Unit Voltage Fuse Type Fuse Size Control Circuit Fuse 1F1 All All Bussmann SRD 3 2 3 2 AMP Transformer Fuse 200 Volt FNQ R 3 5 AMP 1F12 amp 1F13 All 230 Volt FNQ R 3 2 AMP 460 Volt FNQ R 1 6 AMP Fall Restraint Condenser Section Roof AWARNING Falling Off Equipment result in death or serious injury This unit is built with fall restraint slots located on unit top that MUST be used during servicing These slots are to be used with fall restraint equipment that will not allow an individual to reach the unit edge However such equipment will NOT prevent falling to the ground for they are NOT designed to withstand the force of a falling individual Failure to use fall restraint slots and equipment could result in individual falling off the unit which could This unit is built with fall restraint slots located on unit top that must be used during servicing Figure 29 Fall restraint slot unit location and detail 54 CAUJ SVX01D EN e TRANE Service and Maintenance Monthly Maintenance CAUJ SVX01D EN Air Handling Equipment AWARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedure
13. CP 1D 340 CP 1D 510 CP 1D 340 CP 1D 510 CP 1D 510 EE 60 2086 2136 53 0 45 8 CP 1D 340 CP 1D 340 CP 1D 510 CP 1D 510 CP 1D 510 CP 1D 510 80 3142 3212 85 3 54 3 CP 1D 675 CP 1D 510 CP 1D 510 CP 1D 340 CP 1D 510 CP 1D 340 CP 1D 675 CP 1D 510 100 13877 3960 111 4 53 9 CP 1D 675 CP 1D 510 CP 1D 675 CP 1D 510 CP 1D 675 CP 1D 510 CP 1D 675 CP 1D 510 120 4325 4451 112 2 52 6 CP 1D 900 CP 1D 510 CP 1D 675 CP 1D 510 CP 1D 675 CP 1D 510 CP 1D 675 CP 1D 510 30 CAUJ SVX01D EN e TRANE Installation Leveling the Unit Before tightening the mounting bolts level the unit carefully Use the unit base rail as a reference Level the unit to within 1 4 inch over its entire length Use shims if adjustable isolators neoprene are not used If adjustable isolators spring are used ensure that the proper isolator housing clearance is maintained while leveling the unit Isolators are identified by color and or an isolator part number Shims under the isolators may be required if the unit can not be leveled using the isolator leveling bolt General Unit Requirements Piping The checklist listed below lists steps required to successfully install a commercial air cooled condenser This checklist is intended to assist installing personnel with installation process It does not replace detailed instruction called out in the applicable sections of this manual e Verify that the power supply complies with u
14. Make minor clearance adjustments by turning the isolator leveling bolt Figure 23 p 30 clockwise to increase the clearance and counterclockwise to decrease the clearance If proper isolator clearance cannot be obtained by turning the leveling bolt level the isolators themselves A 1 4 inch variance in elevation is acceptable 6 Secure the isolator to the mounting surface using the base holes in the isolator 7 After the unit is level tighten the isolator base mounting Figure 23 Spring isolator 20 120 ton data 1 4 6mm to P 13 mm X 16 mm 5 8 1 8 13mm Clearance Leveling Bolt 15mm x 5 8 Lo ZL 2 3 4 gt 69mm F 5 5 8 OPERATING A 142mm HEIGHT 4 3 4 122mm L 6 1 72 165mm ACOUSTICAL NON SKID Eun 7 1 25 NEOPRENE PAD 1 190mm Table 5 Typical spring isolator selection and location Mdl Weights Locations Isolator Part No On Mounting Location Tons Ship Oper Y Loc 1 Loc 2 Loc 3 Loc 4 Loc 5 Loc 6 Loc 7 Loc 8 20 1163 1188 CP 1D 340 CP 1D 510 CP 1D 510 CP 1D 340 aia 25 1213 1238 CP 1D 510 CP 1D 340 CP 1D 340 CP 1D 340 30 1211 1236 CP 1D 510 CP 1D 340 CP 1D 340 CP 1D 340 40 11758 1808 CP 1D 510 CP 1D 340 CP 1D 340 CP 1D 510 CP 1D 510 CP 1D 340 50 2078 2120 52 8 45 8 CP 1D 340
15. TRANE General Information The unit control panel contains all required fan cycling controls compressor interlocks and a 115 volt control power transformer Field wiring electrical schematics and panel connection diagrams are located inside the control panel access door Figure 1 Unit component layout and shipwith locations 20 60 ton units Condenser Fans Control Panel Lifting Bracket Two per side Access Panels N Condenser Air Intake Grills NS Ni 2 N WY SNAIL S N NN KX N A 2121222 19262 OSE lt A Access 22 Panels Lifting Bracket Two per side N Condenser Air Intake Grills Shipwith Area 8 CAUJ SVX01D EN e TRANE General Information Table 1 General data 20 Ton 25 Ton 30 Ton 40 Ton 50 Ton 60 Ton 80 Ton 100 Ton 120 Ton Model Number CAUJC 20 CAUJC 25 CAUJ C30 CAUJ C40 CAUJ C50 CAUJ C60 CAUJ C80 CAUJ D10 CAUJ D12 Gross Heat Rejection MBh 350 402 456 635 819 1002 1269 1639 2004 Condenser Fan Data Quantity Fan Dia Type 2 26 Prop 3 26 Prop 3 26 4 26 Prop 6 26 Prop 6 26 Prop 8 26 Prop 12 26 Prop 12 26 Prop Fan Drive Type Direct Direct Direct Direct Direct Direct Direct Direct Direct No of Motors HP Each 2 1 0 3 1 0 3 1 0 4 1 0 6 1
16. These service procedures require working with refrigerant Do NOT release refrigerant to the atmosphere The service technician must comply with all federal state and local laws Refer to general service bulletin MSCU SB 1 latest edition Use refrigerant gas as a tracer for leak detection and use oil pumped dry nitrogen to develop the required test pressure Test the high and low side of the system at pressures dictated by local codes 1 Close the field supplied liquid line service valve s installed near the evaporator and the compressor discharge service valve to isolate the system s high side from the low side Pressure test the liquid line discharge line and condenser coils at pressures dictated by local codes Do not exceed 10 above the pressure control settings 2 Connect a refrigerant cylinder to the charging port of the liquid line service valve Use the refrigerant to raise the high side pressure to 12 to 15 psig 3 Disconnect the refrigerant cylinder Connect a dry nitrogen cylinder to the charging port and increase the high side pressure Do not exceed the condenser maximum working pressure listed on the unit nameplate 4 Use a halide torch halogen leak detector or soap bubbles to check for leaks Check all piping joints valves etc Ifaleakis located use proper procedures to remove the refrigerant nitrogen mixture break the connection and remake as a new joint Retest for leaks after making repairs 6 Repeat t
17. clearances for either a single multiple or pit application These clearances are the minimum distances necessary to assure adequate serviceability cataloged unit capacity and peak operating efficiency Equipment Damage Providing less than the recommended clearances may result in condenser coil starvation or recirculation of hot condenser air Locate the unit as close to the applicable system support equipment as possible to minimize refrigerant piping lengths Unit Dimensions amp Weight Information Overall unit dimensional data for each unit are illustrated in Figure 5 p 12 to Figure 18 p 25 A Center of Gravity illustration and the dimensional data are shown in Figure 20 p 28 Figure 21 p 28 and Table 3 p 26 Table 2 p 26 lists the typical unit operating and point loading weights Foundation If the unit is installed at ground level elevate it above the snow line Provide concrete footings at each support location or a slab foundation for support See Table 2 p 26 forthe unit operating and point loading weights when constructing the footing foundation Anchor the unit to the footings or slab using hold down bolts or isolators Isolators should be installed to minimize the transmission of vibrations into the building See Unit Isolation p 28 for isolator installation instructions For rooftop applications ensure the roof is strong enough to support the unit See Table 2 p 26 for the unit operating we
18. in conjunction with a matched indoor compressor evaporator configuration provide refrigerant condensing for these systems down to anormal ambient temperature of 40 F Operation to 0 F ambient is possible with the addition of externally mounted low ambient dampers All condenser fans are direct drive 26 inch propeller type They are driven by 1 HP thermally protected motors When wired properly the unit will start and operate satisfactorily as long as the operating temperature is above the minimum operating temperature listed in Table 13 p 52 The condensing unit operation starts and stops automatically when the cooling demand is initiated and terminated by the cooling circuit interlock relays See illustrations in diagram numbers 2307 9123 2307 9124 2307 9125 and 2307 9126 The control components are mounted in the various areas of the unit as illustrated in diagrams 2307 9123 2307 9124 2307 9125 and 2307 9126 Condenser fan cycling is accomplished through interlocking the fan operation with compressor operation 5K1 amp 5K2 liquid line pressure switches 4511 amp 4512 When the low ambient option is applied ambient temperature thermostats 1536 amp 1537 are used to provide additional fan cycling control Table 11 p 43 lists the condenser fan sequencing data and Figure 27 p 49 illustrates the condenser fan locations with their respective fan and relay designators Table 11 Condenser fan sequencing data 20 60 to
19. 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 R 410A Refrigerant under Higher Pressure than R 22 The units described in this manual use R 410A refrigerant which operates at higher pressures than R 22 refrigerant Use ONLY R 410A rated service equipment or components with these units For specific handling concerns with R 410A please contact your local Trane representative Failure to use R 410A rated service equipment or components could result in equipment exploding under R 410A high pressures which could result in death serious injury or equipment damage 2012 Trane All rights reserved CAUJ SVX01D EN e TRANE Warnings Cautions and Notices AWARNING Proper Field Wiring and Grounding Required All field wiring MUST be performed by qualified personnel Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards To avoid these hazards you MUST follow requirements for field wiring installation and grounding as described in NEC and your local state electrical codes Failure to follow code could result in death or serious injury A WARNING Personal Protective Equipment PPE Required Installing servicing this unit cou
20. 0 6 1 0 8 1 0 12 1 0 12 1 0 Nominal Total CFM 14600 20700 20700 26790 36890 40490 56490 73890 76280 Condenser Coil Data Number of Coils Size Inches 2 42x71 2 42x71 2 42x71 2 59x71 2 51x96 2 64x96 4 59x71 4 51x96 4 64x96 Size ft2 41 4 41 4 41 4 58 2 68 0 85 4 116 4 136 170 7 Rows Fin per ft 1 276 1 276 1 276 1 240 1 240 1 240 1 240 1 240 1 240 condenser Storage 18 7 18 7 18 7 23 5 25 0 31 5 47 1 50 0 62 9 Capacity Ibs gt Type Microchannel Refrigerant Data O No Refrigerant Circuits 1 1 1 2 2 2 2 2 2 Refrigerant Type R 410A R 410A R 410A R 410A R 410A R 410A R 410A R 410A R 410A Refrigerant Operating Charge Lbs 11 9 11 8 11 8 22 7 23 4 26 4 57 1 59 1 65 3 Minimum Outdoor Air Temperature for Mechanical Cooling Standard Ambient 40 125 40 125 40 125 40 125 40 125 40 125 40 125 40 125 40 125 Operating Range F Low Ambient Option F 0 0 0 0 0 0 0 0 0 a Gross Heat Rejection is at a 30 F ITD Initial Temperature Difference between condensing temperature and ambient air entering condenser includes the effect of subcooling b At conditions of 95 ambient condenser is 95 percent full c Condensing units are shipping with nitrogen holding charge only d Operating charge is for condensing unit only and does not include charge for low side or interconnecting lines CAUJ SVX01D EN e TRANE Dimensions and Weights Unit Clearances Figure 3 p 11 and Figure 4 p 11 illustrate the minimum operating and service
21. 1 for determining the MCA Minimum Circuit Ampacity MOP Maximum Over current Protection and RDE Recommended Dual Element fuse size for each unit Use Calculation 2 to determine the DSS Disconnect Switch Size for each unit Load Definitions e LOAD 1 CURRENT OF THE LARGEST MOTOR COMPRESSOR OR FAN MOTOR e LOAD 2 SUM OF THE CURRENTS OF ALL REMAINING MOTORS e LOAD 4 CONTROL POWER TRANSFORMER ANY OTHER LOAD RATED AT 1 AMP OR MORE Calculation 1 MCA MOP and RDE e 1 25 x LOAD 1 LOAD 2 LOAD 4 e 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 as listed in NEC 240 6 select the next lower standard fuse rating Note If selected MOP is less than the MCA then select the lowest standard maximum fuse size which is equal to or larger than the MCA provided the selected fuse size does not exceed 800 amps e RDE 1 5 x LOAD 1 LOAD 2 LOAD 4 Select a fuse rating equal to the RDE value If the RDE value does not equal a standard fuse size as listed in NEC 240 6 select the next higher standard fuse rating Note Note If the selected RDE is greater than the selected MOP value then select the RDE value to equal the MOP value Calculation 2 Disconnect Switch Sizing DSS e DSS 1 15 X LOAD 1 LOAD 2 LOAD 4 CAUJ SVX01D EN e TRANE Installation Field Installed Control Wiring
22. 180 220 208 254 25 6 30 6 1 0 4 1 20 7 0 9 60 CAUJ C604 460 60 3 416 508 11 3 15 6 1 0 1 8 9 0 0 9 CAUJ C605 575 60 3 520 635 8 8 15 6 1 0 1 4 7 2 0 9 CAUJ C80E 200 60 3 180 220 34 40 8 1 0 4 1 20 7 0 9 80 CAUJ C80F 230 60 3 208 254 34 40 8 1 0 4 1 20 7 0 9 CAUJ C804 460 60 3 416 508 15 20 8 1 0 1 8 9 0 0 9 CAUJ C805 575 60 3 520 635 12 15 8 1 0 1 4 7 2 0 9 CAUJ D10E 200 60 3 180 220 50 60 12 1 0 4 1 20 7 0 9 100 CAUJ D10F 230 60 3 208 254 50 60 12 1 0 4 1 20 7 0 9 CAUJ D104 460 60 3 416 508 22 25 12 1 0 1 8 9 0 0 9 CAUJ D105 575 60 3 520 635 17 20 12 1 0 1 4 7 2 0 9 CAUJ D12E 200 60 3 180 220 50 60 12 1 0 4 1 20 7 0 9 120 CAUJ D12F 230 60 3 208 254 50 60 12 1 01 4 1 20 7 0 9 CAUJ D124 460 60 3 416 508 22 25 12 1 0 1 8 9 0 0 9 CAUJ D125 575 60 3 520 635 17 20 12 1 0 1 4 7 2 0 9 Notes 1 Electric information is for each individual motor 2 Maximum fuse size is permitted by NEC 440 22 is 300 percent of one motor RLA plus the RLA of the remaining motors 3 Minimum circuit ampacity equals 125 percent of the RLA of one motor plus the RLA of the remaining motors 4 All Kw values taken at conditions of 45 F saturated suction temperature at the compressor and 95 F ambient 5 Local codes may take precedence 42 CAUJ SVX01D EN Operating Principals 20 60 Ton Specs CAUJ SVX01D EN Standard air cooled condensers function as the outdoor condensing units for appropriately sized split refrigeration systems These units operating
23. 6 61 3 16 7 8 O D LIQUID LINE PLAN VIEW OF UNIT CONNECTION DRAWING 511 571 el 7 8 O D 1 3 8 O D LIQUID LINE DISCHARGE LINE CONTROL PANEL SIDE VIEW OF UNIT CONNECTION DRAWING CAUJ SVX01D EN 1 3 8 O D DISCHARGE LINE NOTES e TRANE Dimensions and Weights 1 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION CONTROL PANEL SIDE ACCESS CONTROL PANEL ORIENTATION VIEW OF UNIT ISOMETRIC DRAWING 21 e TRANE Dimensions and Weights Figure 15 80 ton air cooled condenser NOTES 3 4 X 8 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES MTG HOLES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT FAN GRILLE 1 2 X 4 KO 115V 1 2 X 2 KO 115V CONTROL PANEL gt 5 16 1 16 3 4 4 CONDUIT 1 3 4 KO LOW MAIN POWER VOLTAGE 30V MAX 2 31 1 4 72 118 a 85 13 16 37 11 16 DETAIL A 3 4 DIMENSIONAL DETAIL 7 DOOR 43 1 4 W s 14 180 DEG SWING 85 5 8 CONTROL PANEL LOW AMBIENT SEE DETAIL A DAMPER SEE NOTE 2 FAN GRILLE 4 LINE 13 VOLTAGE ACCESS fe UT ye 2 1 4 x 1 1 4 24 VOLTAGE CONTROL WIRING
24. 8G NOILO23NNOO LINN dO M3IA NV 1d 691 8 1 06 pugs v pare v 3415 13NVd TOYLNOD 91 1 81 0 8 1 1 8 amp 1 25 CAUJ SVX01D EN e TRANE Dimensions and Weights Weights Table 2 20 to 120 ton weights and point load data Weight Weight on isolator mounting location Ibs Tons Model Shipping Operating Loc 2 Loc3 Loc4 Loc 5 Loc 6 Loc 7 Loc 8 20 CAUJC20 1163 1188 41 5 32 5 340 8 358 8 192 1 SRA 25 CAUJC25 1213 1238 41 9 32 2 300 2 318 8 261 9 30 CAUJC30 1211 1236 41 5 32 3 360 9 302 0 316 0 257 1 saa 40 CAUJC40 1758 1808 43 9 46 1 385 9 212 5 181 7 441 8 377 2 208 3 50 CAUJC50 52 8 45 8 211 3 367 5 339 4 495 5 466 6 sss 60 CAUJC60 53 0 45 8 210 9 370 2 342 2 501 6 472 8 80 CAUJC80 85 3 54 3 474 4 459 6 200 2 452 1 196 7 561 6 354 0 100 CAUIJC100 111 4 53 9 402 1 610 1 383 6 605 8 380 5 579 2 361 9 120 120 4325 4451 112 2 52 6 687 8 461 8 667 7 447 8 664 4 445 5 644 4 431 5 Point load and isolator location Figure 19 Mounting and isolator locations see Table 3 p 26 uo
25. B3 1 Fan Temperature Switch 1S43 2 Stage 2 73 F 65 F 5B1 5B4 Notes 1 Bold fan identifies fans used on CAUJ D10 amp D12 units only 2 1542 and 1543 normally closed contacts open on ambient temperature drop to OFF setpoints Contacts reclose on ambient temperature rise on ON setpoints 44 CAUJ SVX01D EN System Pre Start Procedures Use the checklist provided below in conjunction with the General Unit Requirement checklist to ensure that the unit is properly installed and ready for operation Be sure to complete all of the procedures described in this section before starting the unit for the first time AWARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury e Turn the field supplied disconnect switch located upstream of the unit to the Off position e Turn the System selection switch at the Remote Panel to the Off position and the Fan selection switch if applicable to the Auto or Off position e Check all electrical connections for tightness and point of termination accuracy e Verify that the condenser airflow will be unobstructed e Check the condenser fan blades Ensure they rotate freely within the fan orifices and are
26. E 8 GA BP 15 7 12 BBIZE 12 1 2 GA BP 15 9 5 15 5 BBIZE 15 GA BP 15 12 5 19 OZE 20 GA BP 15 15 25 OZE 25 GA BP 15 19 5 30 OZE 35 GA BP 15 23 5 45 OZE 50 GA BP 15 35 68 OZE 60 GA BP 15 52 5 70 BBIZE 1 1 2 GA BP 30 2 3 BBIZE 2 GA BP 30 2 5 3 5 BBIZE 3 GA BP 30 3 5 5 BBIZE 4 GA BP 30 4 5 7 BBIZE 5 GA BP 30 6 8 5 30 20 60T MCHE BBIZE 6 GA BP 30 7 10 BBIZE 8 GA BP 30 8 13 5 BBIZE 12 1 2 GA BP 30 11 17 5 BBIZE 15 GA BP 30 14 21 5 OZE 20 GA BP 30 17 28 5 OZE 25 GA BP 30 22 30 34 CAUJ SVX01D EN e TRANE Installation Discharge Hot Gas Lines Discharge lines should be pitched downward 1 2 inch for each 10 feet of horizontal run in the direction of hot gas flow and away from the compressor Insulate any portion of the discharge piping that is exposed to outdoor ambient temperature Discharge line sizing is based on minimum velocity required for good oil movement in system Basic discharge line parameters are e Maximum allowable pressure drop 6 psig e Maximum velocity 3500 Minimum velocities at Minimum Load e Horizontal Lines 500 fpm e Vertical Lines Refer to the Table 7 p 35 A double riser system may be necessary to meet the discharge line velocity requirements When either a single or double discharge riser is used the line should drop well below the discharge outlet of the compressor before starting the vertical rise to prevent the possibility of refrigerant draining back to
27. NNECTION LOCATION AND SIZES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT 1 2 X 4 KO 115V 1 2 X 2 KO 115V 2 5 8 CONTROL PANEL 5 5 16 CONDUIT 1 3 4 KO LOW MAIN POWER VOLTAGE 30V MAX 2 95 13 16 37 11 16 DETAIL A BOTTOM OF CONTROL BOX LOW AMBIENT d DAMPER SEE NOTE 2 i 6 1 4 T i 79 1 4 1 22 1 2 16 15 16 1 To ob 103 1 2 113 13 16 CAUJ SVX01D EN e TRANE Dimensions and Weights Figure 12 50 ton air cooled condenser connections CONTROL PANEL SIDE NOTES 1 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH LIQUID LINE INSTALLER DOCUMENTS BEFORE INSTALLATION 61 3 16 27 716 101346 74 7 16 HL L4 3 8 O D DISCHARGE LINE 67 3 8 CONTROL 10 13 16 PANEL SIDE ACCESS L CONTROL 27 716 PANEL 61 3 16 ORIENTATION VIEW OF UNIT 7 8 ISOMETRIC DRAWING LIQUID LINE PLAN VIEW OF UNIT CONNECTION DRAWING Note List 97075 jd 5 T 5 m 13 8 O D DISCHARGE LINE LIQUID LINE CONTROL PANEL SIDE VIEW OF UNIT CONNECTION DRAWING CAUJ SVX01D EN 19 e TRANE Dimensions and Weigh
28. OR Hack HR EU dd 43 80 120 Ton Specs e Re Xd ERGO ke d 44 System Pre Start Procedures ritteri Fei CR Pd 45 System Evacuation Procedures 45 Voltage Imbalance eee 48 Electrical Phasing 000s 48 StartUp iiie 2 49 Verifying Proper Condenser Fan Rotation 50 Low Ambient Damper Adjustment Factory or Field Installed 51 Charging the System cc een eens 52 4 CAUJ SVX01D EN Service and Maintenance 54 Fuse Replacement Data 54 Fall Restraint Condenser Section Roof 54 Monthly Maintenance 55 Coil Cleaning wae ee haw eR ee 56 Warranty and Liability Clause ect eens 58 Wiring Diagrams 59 CAUJ SVX01D EN 5 e TRANE Model Number Descriptions 20 to 60 Ton Digit 1 Unit Type Condenser Digit 2 Condenser A Air Cooled Digit 3 Airflow U Upflow Digit 4 Development Sequence J Fourth Digit s 5 6 7 Nominal Capacity C20 20 Tons C25 25 Tons C30 30Tons C40 40 Tons 50 50 Tons C60 60 Tons Digit 8 Power Supply 200 230 60 3 XL 4 460 60 3 XL 5 575 60 3 XL Digi
29. RANE Dimensions and Weights Figure 10 40 ton air cooled condenser connections CONTROL PANEL SIDE NOTES 1 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION L 27 uum O D LIQUID LINE 10 1 2 aise pd 7 o 1 3 8 O D 49 1 2 DISCHARGE lo s 1 i 0D 41 7 8 Tee E OM ee gt a DISCHARGE H Ay CONTI PANEL 27 8 7 7 16 27 CONTROL VOLTAGE PANEL SIDE ACCESS 7 8 O D LIQUID LINE PLAN VIEW OF UNIT ORIENTATION VIEW OF UNIT ISOMETRIC DRAWING CONNECTION DRAWING 5 11 16 5 7 16 CONTROL PANEL SIDE VIEW OF UNIT CONNECTION DRAWING CAUJ SVX01D EN 17 e TRANE Dimensions and Weights Figure 11 50 ton air cooled condenser FAN GRILLE 3 4 X6 MTG HOLES 5 48 7 8 48 7 8 1 b 2 1 8 1 8 DOOR 43 1 4 W 180 DEG SWING 85 5 8 CONTROL PANEL FAN GRILLE SEE DETAIL A NE VOLTAGE I M J ACCESS 1 1 4 x 4 112 SLOT FOR 115 VOLT CONTROL 32 1 4 BOTTOM OF CONTROL BOX SEE DETAIL A F 88 5 16 18 NOTES 1 SEE CONNECTION DRAWING FOR CO
30. RED R 3 RED 60 CAUJC60 2086 2136 R 3 BLACK R 3 BLACK R 3 RED R 3 RED R 3 RED R 3 RED Figure 22 Neoprene 20 60 ton data 1 2 NC TAP ppm 2 gam 64mm 9 16 x 2 HOLES 1 4 14mm 5mm 1 3 4 Z 4 1 8 104mm xi 6 1 2 140mm CAUJ SVX01D EN 29 e TRANE Installation Spring Isolators available for 20 120 ton units Install the spring isolators at each unit mounting load point using the following procedure 1 Elevate the unit one side at a time to allow access to the base rail mounting holes Note Use solid type blocks i e 4 X 4 wood blocks or similar material to prevent collapsing Keep hands and other body limbs clear of elevated base rail while installing isolators to prevent personal injury 2 Align the mounting holes in the base rail of the unit with the positioning pin in the top of the appropriate isolator See Table 5 p 30 for the appropriate isolator for each load point 3 Position the isolator to allow access to the mounting holes in the base of the isolator Lower the unit onto the isolator The positioning pin on the isolator must engage into the hole of the base rail The clearance between the upper and lower isolator housings should be approximately 1 4 to 1 2 inch Refer to Figure 23 p 30 A clearance greater than 1 2 inch indicates that shims are required to level the unit See Leveling the Unit p 31 5
31. and other body limbs clear of elevated base rail while installing isolators to prevent personal injury 2 Align the mounting holes in the base rail of the unit with the holes in the top of the appropriate isolator Refer to Table 4 p 29 for the appropriate isolator for each load point 3 Install a 1 2 NC bolt field supplied through the base rail of the unit into the threaded bolt hole of the isolator Position the isolator to allow access to the mounting holes in the base of the isolator then tighten securely 4 Lowertheunitandisolatoronto the mounting surface The maximum isolator deflection should be approximately 1 4 inch Secure the isolator to the mounting surface using the base holes in the isolator Level the unit carefully See Leveling the Unit p 31 After the unit is level tighten isolator base mounting bolts to secure them to the mounting surface Table 4 Typical neoprene isolator selection amp location 20 60 ton units only Shipping Operating Isolator Part No On Mounting Location Tons Model Weight Weight Loc 1 Loc 2 Loc 3 Loc 4 Loc 5 Loc 6 20 CAUJC20 1163 1188 R 3 RED R 3 RED R 3 RED R 3 BLACK 25 CAUJC25 R 3 RED R 3 RED R 3 RED R 3 RED 30 CAUJC30 R 3 RED R 3 RED R 3 RED R 3 RED 40 CAUJC40 1758 1808 R 3 RED R 3 BLACK R 3 BLACK R 3 RED R 3 RED 3 50 CAUJC50 2078 2120 R 3 BLACK R 3 BLACK R 3 RED R 3 RED R 3
32. circuit 2 if applicable proper condenser fan cycling and ambient control for the remaining fans is achieved with corresponding compressor operation Note All field wiring must conform to NEC guidelines as well as state and local codes CAUJ SVX01D EN 41 e TRANE Installation Electrical Data Table 10 Electrical data Unit Characteristics Condenser Fan Motor Minimum Maximum Allowable Circuit Fuse FLA LRA KW Nominal Electrical Voltage Ampacity Size No HP Ea Ea Tons Model No Characteristics Range 3 5 2 5 1 1 1 1 4 CAUJ C20G 200 230 60 3 180 220 208 254 9 2 15 2 1 0 4 1 20 7 0 9 20 CAUJ C204 460 60 3 416 508 4 1 15 2 1 0 1 8 9 0 0 9 CAUJ C205 575 60 3 520 635 3 2 15 2 1 0 1 4 7 2 0 9 CAUJ C25G 200 230 60 3 180 220 208 254 13 3 20 3 1 0 4 1 20 7 0 9 25 CAUJ C254 460 60 3 416 508 5 9 15 3 1 0 1 8 9 0 0 9 CAUJ C255 575 60 3 520 635 4 6 15 3 1 0 1 4 7 2 0 9 CAUJ C30G 200 230 60 3 180 220 208 254 13 3 20 3 1 0 4 1 20 7 0 9 30 CAUJ C304 460 60 3 416 508 5 9 15 3 1 0 1 8 9 0 0 9 CAUJ C305 575 60 3 520 635 4 6 15 3 1 0 1 4 7 2 0 9 CAUJ C40G 200 230 60 3 180 220 208 254 17 4 20 4 1 0 4 1 20 7 0 9 40 CAUJ C404 460 60 3 416 508 757 15 4 1 0 1 8 9 0 0 9 CAUJ C405 575 60 3 520 635 6 0 15 4 1 0 1 4 7 2 0 9 CAUJ C50G 200 230 60 3 180 220 208 254 25 6 30 6 1 0 4 1 20 7 0 9 50 CAUJ C504 460 60 3 416 508 11 3 15 6 1 0 18 9 0 0 9 505 575 60 3 520 635 8 8 15 6 1 0 1 4 7 2 0 9 CAUJ C60G 200 230 60 3
33. could result in death or serious injury e Verify the power supply meets the required power requirements of the system e Install power wiring in accordance with all applicable codes e Install and connect properly sized power supply wiring with over current protection to the main power terminal block 1TB1 in the unit control panel e Install proper grounding wires to an earth ground 31 e TRANE Installation Field Installed Control Wiring e Verify the Control transformer 1T1 is wired for the proper operating voltage e Install the interlock circuitry wiring between the unit and the appropriate compressor unit to permit condenser fan operation when the compressor starter auxiliary contacts closes Refer to the Field Connection Diagram that shipped with the unit for interlocking information e Verify the appropriate jumpers have been installed on the unit to allow proper condenser fan operation If applicable Refer to the control wiring diagram that shipped with the unit for jumper details Refrigerant Piping Refrigerant piping must be properly sized and applied These two factors have a very significant effect on both system performance and reliability Note Use Type L refrigerant grade copper tubing only Refrigerant Piping should be sized and laid out according to the job plans and specifications This should be done when the system components are selected The primary objective when sizing refrigerant pipi
34. death or serious injury Important Bridging between the main supports required before attempting to enter into the unit Bridging may consist of multiple 2 by 12 boards or sheet metal grating 2 Straighten any bent coil fins with a fin comb 3 For accessible areas remove loose dirt and debris from both sides of the coil For dual row microchannel condenser coil applications seek pressure coil wand extension through the local Trane Parts Center Note DO NOT use any detergents with microchannel coils Pressurized water or air ONLY 4 Pour the cleaning solution into the sprayer If a high pressure sprayer is used a The minimum nozzle spray angle is 15 degrees b Do not allow sprayer pressure to exceed 600 psi c Spray the solution perpendicular at 90 degrees to the coil face 5 Spray the leaving airflow side of the coil first then spray the opposite side of the coil For evaporator and reheat coils allow the cleaning solution to stand on the coil for five minutes Rinse both sides of the coil with cool clean water Inspect both sides of the coil if it still appears to be dirty repeat Steps 6 and 7 Reinstall all of the components and panels removed in Step 1 then restore power to the unit Microchannel Condenser Coil Repair and Replacement If microchannel condenser coil repair or replacement is required seek HVAC Knowledge Center information or Service Guide document RT SVB83 EN for further details 57 e TRANE
35. e airflow across the condenser by cycling the 481 486 5B1 586 on 100 amp 120 Ton units The final stage thermostats opens when the ambient temperature approaches 65 F and closes at 49 approximately 73 F The second stage opens when the ambient temperature approaches 45 F and closes at approximately 53 F Figure 28 Condenser fan locations 80 120 ton units MAIN CONTROL BOX OIO i T T T MAIN CONTROL BOX CAUJ 80 Ton CAUJ 100 amp 120 Ton Verifying Proper Condenser Fan Rotation 50 Rotating Components The following procedures involve working with rotating components Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury Open the field supplied disconnect switch or circuit protector switch that provides power to the compressor unit and lock it in the Off position Open the disconnect switch or circuit protector switch that provides power to the condensing unit To Install temporary jumpers a For 20 60 ton units install temporary jumpers ac
36. e installing or repairing a damaged unit Unit Nameplate One Mylar unit nameplate is located on the outside upper right corner of the control panel door It includes the unit model number serial number electrical characteristics weight refrigerant charge as well as other pertinent unit data Asmall metal nameplate with the Model Number Serial Number and Unit Weight is located just above the Mylar nameplate and a third nameplate is located on the inside of the control panel door When ordering replacement parts or requesting service be sure to refer to the specific model number serial number and DL number if applicable stamped on the unit nameplate Unit Description All air cooled condensing units are designed for outdoor installations with vertical air discharge These units may be installed on a flat roof or placed on a concrete slab at ground level Before shipment each unit is leak tested evacuated a Nitrogen holding charge is added and the controls are tested for proper operation The condenser coils are an all aluminum Microchannel design Louvered condenser grilles for coil protection are standard Direct drive vertical discharge condenser fans are provided with built in current and overload protection For Ship with items see Figure 1 p 8 for 20 60T units or Figure 2 p 8 for 80 120 T units If low ambient operation is required low ambient dampers are available as a field or factory installed option S
37. e the remaining Pre Start Procedures before starting the unit CAUJ SVX01D EN e TRANE System Pre Start Procedures Figure 25 Typical vacuum pump hookup Manifold Valve B 2 Valve H D To System To System Low Side High Side Vacuum Gauge 7 Valve A Vacuum b Pump m Figure 26 Evacuation time vs pressure rise 1600 Continuously increasing pressure indicates the presence of leaks moisture or both gt 1400 w 2 2 1200 5 d o 7 i State of equilibrium indicates the 1000 x true amount of moisture left in lt the system It indicates that Lu leaks are present but further E 800 evacuation is required o o i a 600 State of equilibrium indicates the true amount of moisture left in the system It indicates that no 400 leaks are present and the Initial evacuation pressure system is properly evacuated 200 10 0 10 20 30 40 50 60 70 80 90 TIME IN MINUTES CAUJ SVX01D EN 47 e TRANE System Pre Start Procedures Voltage Imbalance Excessive three phase voltage imbalance between phases will cause motors to overheat and eventually fail The maximum allowable voltage imbalance is 2 Measure and reco
38. f the rated voltage stamped on the nameplate Use only copper conductors to connect the 3 phase power supply to the unit Main Unit Power Wiring 38 NOTICE Use Copper Conductors Only Unit terminals are not designed to accept other types of conductors Failure to use copper conductors could result in equipment damage Table 8 p 39 and Table 9 p 39 list the field connection wire ranges for the main power terminal block 1TB1 Table 10 p 42 lists the condensing unit electrical data The electrical service must be protected from over current and short circuit conditions in accordance with NEC requirements Protection devices must be sized according to the electrical data on the nameplate Refer to the Electrical Service Sizing Equations for determining Electrical service wire size based on Minimum Circuit Ampacity MCA e Maximum Over Current Protection MOP device e Recommended Dual Element fuse size RDE 1 A field supplied disconnect switch must be installed at or near the unit in accordance with the National Electrical Code NEC latest addition Refer to the Electrical Service Sizing Equations DSS calculation for determining the correct size 2 Complete the unit s power wiring connections onto the main terminal block 1TB1 inside the unit control panel Refer to the customer connection diagram that shipped with the unit for specific termination points 3 Provide proper supply power with over cur
39. further warranty must be in writing signed by an officer of the Company The warranty and liability set forth herein are in lieu of all other warranties and liabilities whether in contract or in negligence express or implied in law or in fact including implied warranties of merchantability and fitness for particular use In no event shall the Company be liable for any incidental or consequential damages THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES WHETHER IN CONTRACT OR IN NEGLIGENCE EXPRESS OR IMPLIED IN LAW OR IN FACT INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Manager Product Service Trane Inc Clarksville Tn 37040 1008 PW 215 2688 Optional Extended Warranties are available for compressors and heat exchangers of Combination Gas Electric Air Conditioning Units CAUJ SVX01D EN S Wiring Diagrams Note For easier access published unit wiring diagrams individual separate diagrams for unitary product lines will become available via e Library instead of through wiring manuals after 2007 Drawing Number Description 2307 9123 Power Schematic Diagram Air Cooled Condensing Unit Line Voltage 200 230 460 575V 60HZ 3PH CA 20 60 Ton 2307 9124 Unit amp Field Connection Wiring Diagram Air Cooled Condensing Unit Line Voltage 200 230
40. h the unit nameplate specifications e Visually inspect the exterior of the unit including the roof for signs of shipping damage e Check for material shortages Refer to the Component Layout and Ship with Location illustration Important the job site inspection of the unit reveals damage or material shortages file a claim with the carrier immediately Specify the type and extent of the damage on the bill of lading before signing e Visually inspect the internal components for shipping damage as soon as possible after delivery and before it is stored Do not walk on the sheet metal base pans AWARNING No Step Surface Do not walk on the sheet metal drain pan Walking on the drain pan could cause the supporting metal to collapse resulting in the operator technician to fall Failure to follow this recommendation could result in death or serious injury Bridging between unit main supports may consist of multiple 2 by 12 boards or sheet metal grating e If concealed damage is discovered notify the carrier s terminal of damage immediately by phone and by mail Concealed damage must be reported within 15 days e Request an immediate joint inspection of the damage by the carrier and the consignee Do not remove damaged material from the receiving location Take photos of the damage if possible The owner must provide reasonable evidence that the damage did not occur after delivery e Notify the appropriate Trane office befor
41. he test procedure for the low side of the system charging through the suction pressure gauge port or through an access provided on the suction line by the installer Increase the system pressure to 100 psig 7 lfaleakis located use proper procedures to remove the refrigerant nitrogen mixture break the connection and remake as a new joint Retest for leaks after making repairs 8 Open the liquid line service valve and the compressor discharge service valve CAUJ SVX01D EN 37 e TRANE Installation Field Installed Power Wiring AWARNING Proper Field Wiring and Grounding Required All field wiring MUST be performed by qualified personnel Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards To avoid these hazards you MUST follow requirements for field wiring installation and grounding as described in NEC and your local state electrical codes Failure to follow code could result in death or serious injury An overall dimensional layouts for the field installed wiring entrance into the unit are illustrated in Figure 5 p 12 through Figure 18 p 25 To insure that the unit s supply power wiring is properly sized and installed follow the guidelines outlined below Note All field installed wiring must conform to NEC guidelines as well as State and Local codes Verify that the power supply available is compatible with the unit s nameplate ratings The available supply power must be within 10 o
42. his will defeat the isolation system of the unit Refer to the appropriate unit illustration in Figure 5 p 12 through Figure 18 p 25 for refrigerant line size connections and locations Connect the liquid line piping to the stubs provided at the liquid line shutoff valves Note The installer must cut an appropriately sized opening in the unit sheet metal for the refrigerant piping entrance into the unit 32 CAUJ SVX01D EN e TRANE Installation Liquid Line Components CAUJ SVX01D EN Filter driers and valves expansion valves charging valves etc should be provided in the liquid lines just before the evaporator Minimize the use of valves reducers and tube bends as much as possible to avoid excessive pressure drop before the expansion valve Liquid Line Filter Drier Install the filter driers provided by the installer in the liquid lines as close as possible to the expansion valves Locate them upstream of the moisture indicator and solenoid valves Solenoid valves may not be applicable Liquid Line Moisture Indicators To aid in troubleshooting charging and servicing the system install moisture indicators in the liquid lines near the evaporator down stream of the liquid line drier between the solenoid valve if applicable and the expansion valve Liquid Line Solenoid Valves Liquid line solenoid valves are not recommended on units when they are connected to DX coils Liquid line solenoid valves are recommended fo
43. hnician must comply with all federal state and local laws Refer to general service bulletin MSCU SB 1 latest edition NOTICE Coil Cleaners Coil cleaners can damage roofs surrounding buildings vehicles etc Cleaning substances should be checked to ensure that they will not cause damage to surroundings Coils and roof if applicable should be rinsed thoroughly Do not spray coil cleaners in windy conditions Regular coil maintenance including annual cleaning enhances the unit s operating efficiency by minimizing compressor head pressure and amperage draw water carryover fan brake horsepower and e static pressure losses At least once each year or more often if the unit is located in a dirty environment clean the microchannel condenser using the instructions outlined below Be sure to follow these instructions as closely as possible to avoid damaging the coils CAUJ SVX01D EN CAUJ SVX01D EN e TRANE Service and Maintenance To clean refrigerant coils use a soft brush and a sprayer Note DO NOT use detergents with microchannel condenser coils Pressurized water or air ONLY 1 Remove enough panels from the unit to gain safe access to coils AWARNING No Step Surface Do not walk on the sheet metal drain pan Walking on the drain pan could cause the supporting metal to collapse resulting in the operator technician to fall Failure to follow this recommendation could result in
44. ights AWARNING Risk of Roof Collapsing Confirm with a structural engineer that the roof structure is strong enough to support the combined weight of the roofcurb and the unit Refer to the Weights Table 2 p 26 section for typical unit and curb weights Failure to ensure proper structural roof support could cause the roof to collapse which could result in death or serious injury and property damage Anchor the unit to the roof with hold down bolts or isolators Follow the instructions in section Unit Isolation p 28 for proper isolator placement and installation Check with a roofing contractor for proper waterproofing procedures 10 CAUJ SVX01D EN e TRANE Dimensions and Weights Figure 3 Typical installation clearances for single multiple or pit applications 20 60 ton units Typical Side by Side Installation 40 Ton Unit Ilustrated Typical Single Unit Installation mS Vac i 80 Ton Unit Illustrated Typical Side by Side Installation 80 Ton Unit Illustrated CAUJ SVX01D EN 11 e TRANE Dimensions and Weights Figure 5 20 ton air cooled condenser NOTES 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES FAN GRILLE 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT
45. ing the bearings check the setscrews to ensure that the shaft is held securely to the bearings and Fan wheels Make sure that all bearing supports are tight Check the supply fan belt s If the belts are frayed or worn replace them e Verify that all wire terminal connections are tight e Generally inspect the unit for unusual conditions e g loose access panels leaking piping connections etc e Make sure that all retaining screws are reinstalled in the unit access panels once these checks are complete Condensing Unit AWARNING Rotating Components The following procedure involves working with rotating components Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in rotating components cutting and slashing technician which could result in death or serious injury e Manually rotate the condenser fans to ensure free movement and check motor bearings for wear Verify that all of the fan mounting hardware is tight e Verify that all wire terminal connections are tight 55 e TRANE Service and Maintenance Coil Cleaning 56 e Inspect the condenser coils for dirt and foreign debris If the coils appear dirty clean them according to the instructions described in the Coil Cleaning section e Inspect the compressor and condenser fan m
46. ired By restricting the airflow across the condenser coils saturated condensing temperatures can be maintained as the ambient temperatures change The low ambient damper actuator controls damper modulation for each refrigerant circuit in response to saturated condensing temperature Low Ambient Thermostat Operation 20 60 ton units In addition to the low ambient dampers on 25 30 50 amp 60 Ton units a low ambient thermostat is installed to further restrict the airflow across the condenser by cycling the 2B3 condenser fan on 25 amp 30 Ton units plus 2B6 on 50 amp 60 Ton units The thermostat opens when the ambient temperature approaches 65 F and closes at approximately 67 5 F Figure 27 Condenser fan locations 20 60 ton units PS Pressure Switch TC Ambient Thermostat Opens 65 F 28 2B6 Fan Electrical 2B1 Designators 1K5 Le 1 5 1K10 Fan Contactor _ PS x Designators u 5 E 2B3 E 2 7 8 1K7 3 Opt TC CAUJ 20 Ton CAUJ 25 amp 30 Ton 2B6 mE 261 1K10 1K8 1K8 PS PS Opt TC BV HZ 2B1 2B1 3 1K5 E i 1K5 50 2s i PS x CAUJ 40 Ton CAUJ 50 amp 60 Ton Low Ambient Thermostat Operation 80 120 ton units In addition to the low ambient dampers a two stage low ambient thermostat is installed to further restrict th
47. is heated in the presence of air Copper oxide forms To prevent copper oxide from forming inside the tubing during brazing sweep an inert gas such as dry nitrogen through the tubing Nitrogen displaces air in the tubing and prevents oxidation of the interior surfaces A nitrogen flow of one to three cubic feet per minute is sufficient to displace the air Use a pressure regulating valve or flow meter to control the flow 2 Ensure that the tubing surfaces to be brazed are clean and that the ends of the tubes have been carefully reamed to remove any burrs 3 Make sure the inner and outer tubes of the joint are symmetrical and have a close clearance providing an easy slip fit If the joint is too loose the tensile strength of the connection will be significantly reduced The overlap distance should be equal to the diameter of the inner tube 4 Wrap the body of each refrigerant line component with a wet cloth to keep it cool during brazing Move any tube entrance grommets away for the brazing area Note Use 40 to 45 silver brazing alloy BAg 7 or BAg 28 on dissimilar metals Use BCup 6 brazing alloy on copper to copper joints 5 If flux is used apply it sparingly to the joint Excessive flux can enter the system which will contaminate the refrigerant system 6 Apply heat evenly over the length and circumference of the joint to draw the brazing material into the joint by capillary action Remove the brazing rod and flame from the joint as s
48. ld result in death or serious injury and possible equipment or property only damage Heavy Objects Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted Each of the cables chains or slings hooks and shackles used to lift the unit must be capable of supporting the entire weight of the unit Lifting cables chains or slings may not be of the same length Adjust as necessary for even unit lift Other lifting arrangements could cause equipment or property damage Failure to follow instructions above or properly lift unit could result in unit dropping and possibly crushing operator technician which could result in death or serious injury Note Use spreader bars as shown in diagram Refer to installation manual or nameplate for unit weight Refer to installation instructions located inside control panel for further rigging information 1 Rig the condensing unit as shown in Figure 20 p 28 and Figure 21 p 28 Attach adequate strength lifting slings to all four lifting brackets in the unit base rail Do not use cables chains or slings except as shown 2 Install spreader bars as shown in Figure 20 p 28 and Figure 21 p 28 to protect the unit and to facilitate a uniform lift The minimum distance between the lifting hook and the top of the unit should be 7 feet 3 Test lift the unit to ensure it is properly rigged and balanced make any necessary rigging adjust
49. ld result in exposure to electrical mechanical and chemical hazards e Before installing servicing this unit technicians MUST put on all Personal Protective Equipment PPE recommended for the work being undertaken ALWAYS refer to appropriate MSDS sheets and OSHA guidelines for proper PPE e When working with or around hazardous chemicals ALWAYS refer to the appropriate MSDS sheets and OSHA guidelines for information on allowable personal exposure levels proper respiratory protection and handling recommendations e If there is a risk of arc or flash technicians MUST put on all Personal Protective Equipment PPE in accordance with NFPA 70E or other country specific requirements for arc flash protection PRIOR to servicing the unit Failure to follow recommendations could result in death or serious injury Trademarks Trane and the Trane logo are trademarks of Trane in the United States and other countries All trademarks referenced in this document are the trademarks of their respective owners CAUJ SVX01D EN 3 e TRANE Table of Contents Model Number Descriptions 0 s 6 General Information 7 Unit Inspection ewido eee epe 7 Dimensions and Weights 0 10 Unit Clearances oie sasaa aiae ie aaee 10 Unit Dimensions amp Weight Information 10 Weights sese sreskega ehe 26 Point load and isolator location
50. line gauge ports for each circuit 3 Charge liquid refrigerant into the liquid line of each refrigerant circuit with the required amount of R 410A Refrigerant should be charged into the system by weight Use an accurate scale or a charging cylinder to monitor the amount of refrigerant entering the system Refer to Table 14 p 52 for the recommended refrigerant capacities for the condensing unit The weight of refrigerant required for the liquid line and liquid line driers are listed in Table 15 p 53 If the pressure within the system equalizes with the pressure in the charging cylinder before charging is completed complete the process by vapor charging into the suction low side of the system after the system has been started Table 13 p 52 gives the minimum starting temperatures for both Standard amp Low Ambient units Do not attempt to charge the system with the low ambient dampers and or hot gas bypass operating if applicable Disable the low ambient dampers in the Open position refer to the Low Ambient Damper Adjustment section and de energize the hot gas bypass solenoid valves before proceeding 4 On units with dual circuits start only one circuit at a time To disable the second circuit compressors refer to the compressor sequencing information that shipped with the compressor unit 5 With the compressors operating slowly open the Low Side valve on the manifold gauge set The remainder of
51. ments 4 Lift the unit and position it into place 27 e TRANE Installation Figure 20 Rigging and center of gravity data 20 60 ton units m 8 0 2438 mm Spreader Bars 58s Field Supplied Control Box Lifting Brackets 2 1 2 64 mm 4 Figure 21 Rigging and center of gravity data 80 120 ton units 8 0 2438 mm Spreader Bars Field Supplied he Control Box Lifting Brackets X 4 Unit Isolation To minimize unit sound and vibration transmission us one of the following installation methods 1 Install the unit directly on an isolated detached concrete pad or on isolated concrete footings located at each unit load point 2 Install the optional spring isolators at each mounting location See Spring Isolators available for 20 120 ton units p 30 Note 20 60 ton units may install the optional neoprene isolators at each mounting location instead of the spring isolator If this is the case see Neoprene Isolators available for 20 60 ton units only p 29 28 CAUJ SVX01D EN Neoprene Isolators available for 20 60 ton units only e TRANE Installation Install the neoprene isolators at each unit mounting load point using the following procedure 1 Elevate the unit one side at a time to allow access to the base rail mounting holes Note Use solid type blocks i e 4 X 4 wood blocks or similar material to prevent collapsing Keep hands
52. minal block 1TB1 is ABC as outlined in the Electrical Phasing section Some Fans are Rotating Backwards 1 Open the field supplied disconnect switch upstream of the unit Lock the disconnect switch in the Open position while working at the unit 2 Interchange any two of the fan motor leads at the fan contactor for each fan that is rotating backwards 3 Remove all temporary jumpers previously installed in step 3 of Verifying Proper Condenser Fan Rotation Low Ambient Damper Adjustment Factory or Field Installed CAUJ SVX01D EN When a unit is ordered with the low ambient option i e Digit 11 is a 1 in the model number a damper is factory installed over the lead condenser fan for each refrigeration circuit See Figure 27 p 49 and Figure 28 p 50 for damper locations For field installation mount the dampers over the condenser fans at the locations shown in Figure 27 p 49 and Figure 28 50 and connect the actuator controller and sensor for each circuit Refer to the Installation Instructions provided with each low ambient damper kit The controller has a factory default setpoint of 80 F This setpoint can be adjusted by installing a field supplied resistor on 2TB34 in the low ambient control panel located in the back of the main control panel See the low ambient wiring diagram that shipped with the unit or with the field kit for resistance values and installation location Inspect
53. n units Controlling Device 3 Fan ON Fan OFF Fan Identification Customer Interlock Circuit 1 5K1 Closed 5K1 Open 2B1 2B2 2B3 1 Customer Interlock Circuit 2 5K2 Closed 5K2 Open 2B4 2B5 2B6 1 1536 2 67 50 F 65 F 2B3 1 Fan Temperature Switch 1537 2 67 50 F 65 F 2B6 4S11 444 psi 255 psi 281 1 Fan Pressure Switch pag ES 4S12 444 psig 255 psig 2B6 Notes 1 Bold fan identifies fans used on 25 30 50 amp 60 Ton units only 2 1S36 and 1S37 normally closed contacts open on ambient temperature drop to 65 F Contacts reclose on ambient temperature rise to 65 F and 67 5 F 43 e TRANE Operating Principals 80 120 Ton Specs Condenser fan cycling is accomplished through interlocking the fan operation with compressor operation 6K1 amp 6K2 and ambient temperature thermostats 1542 amp 1543 are used to provide additional fan cycling control Table 12 p 44 lists the condenser fan sequencing data and Figure 28 p 50 illustrates the condenser fan locations with their respective fan and relay designators Table 12 Condenser fan sequencing data 80 120 ton units Controlling Device Fan ON Fan OFF Fan Identification Customer Interlock Circuit 1 6K1 Closed 6K1 Open 4B2 4B5 4B6 1 Customer Interlock Circuit 2 6K2 Closed 6K2 Open 5B2 5B5 5B6 1 Stage 1 53 F 450 F 4B3 1 Fan Temperature Switch 1542 2 Stage 2 739 F 65 F 4B1 4B4 1 Stage 1 53 F 45 F 5
54. ng for this unit is to make refrigerant line sizes as small as possible while avoiding excessive refrigerant pressure drops Sizing refrigerant lines as small as possible minimizes the required refrigerant charge and maximizes compressor life Trane recommends that the Refrigerant Line Sizing program in the Trane C D S Application Toolbox be used to size the refrigerant lines This program supersedes the line sizing tables in both the Trane Reciprocating Refrigeration publication and the Trane Air Conditioning Manual If you do not have access to this program contact your local Trane Commercial Sales office for assistance Liquid Lines Basic sizing parameters with the system operating at full load for liquid lines are e Maximum Liquid velocity 600 fpm e Maximum allowable pressure drop 7 psig F As the pressure drop in the liquid line increases the potential for liquid flashing due to reduced refrigerant pressure corresponding to a reduced liquid temperature subcooling increases Under these conditions liquid lines exposed to high surrounding ambient temperatures must be insulated Note Adding refrigerant to a system with improperly sized refrigerant lines will only decrease system performance and reliability and accentuate poor operating condition Isolate all refrigerant lines from the building This prevents transferring line vibration to the structure Do not secure the lines rigidly to the building at any point since t
55. ngs of a compressor while it is under a vacuum Electrical shorting between motor windings and or housing can occur while in a vacuum causing motor burnout 45 e TRANE System Pre Start Procedures 46 The lines used to connect the pump to the system should be copper and of the largest diameter that can practically be used Using larger line sizes with minimum flow resistance can significantly reduce evacuation time Rubber or synthetic hoses are not recommended for system evacuation because they have moisture absorbing characteristics which result in excessive rates of evaporation causing pressure rise during the standing vacuum test This makes it impossible to determine if the system has a leak excessive residual moisture or a continual or high rate of pressure increase due to the hoses An electronic micron vacuum gauge should be installed in the common line ahead of the vacuum pump shutoff valve as shown in Figure 25 p 47 Close Valves B and and open Valve A Start the vacuum pump after several minutes the gauge reading will indicate the maximum vacuum the pump is capable of pulling Rotary pumps should produce vacuums of 100 microns or less Open Valves B and C Evacuate the system to a pressure of 300 microns or less As the vacuum is being pulled on the system there could be a time when it would appear that no further vacuum is being obtained yet the pressure is high It is recommended that during the evacuation proces
56. nit nameplate specifications e Check the unit for shipping damage and material shortage file a freight claim and notify Trane office e Verify installation location of the unit will has required clearance for proper operation e Install appropriate isolators if required e Install properly sized liquid line s between the liquid line connections on the unit and the evaporator i e DX evaporator or an EVP Chiller Barrel Refer to the Refrigerant Piping p 32 section for recommended liquid line components and guidelines e Install properly sized discharge hot gas line s between the discharge line connections on the unit and the compressor unit Refer to the Refrigerant Piping p 32 section for recommended discharge line components and guidelines e Install shutoff valves in the liquid line s to isolate the filter drier s for service e Install proper filter driers in each liquid line Leaktestthe system Referto the Leak Testing Procedure p 37 for recommended procedures Main Electrical Power Requirements CAUJ SVX01D EN Proper Field Wiring and Grounding Required All field wiring MUST be performed by qualified personnel Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards To avoid these hazards you MUST follow requirements for field wiring installation and grounding as described in NEC and your local state electrical codes Failure to follow code
57. oon as a complete fillet is formed to avoid possible restriction in the line 7 Visually inspect the connection after brazing to locate any pin holes or crevices in the joint The use of a mirror may be required depending on the joint location 36 CAUJ SVX01D EN e TRANE Installation Leak Testing Procedure Hazard of Explosion Never use an open flame to detect gas leaks It could result in an explosion Use a leak test solution for leak testing Failure to follow recommended safe leak test procedures could result in death or serious injury or equipment or property only damage AWARNING Hazard of Explosion Use only dry nitrogen with a pressure regulator for pressurizing unit Do not use acetylene oxygen or compressed air or mixtures containing them for pressure testing Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion Refrigerant when used as a trace gas should only be mixed with dry nitrogen for pressurizing units Failure to follow these recommendations could result in death or serious injury or equipment or property only damage When Leak testing a refrigerant system observe all safety precautions Trane condensing units are shipped with a Nitrogen holding charge If there is no pressure the unit must be leak tested to determine the location of leak as follows Note
58. otor contactors If the contacts appear severely burned or pitted replace the contactor Do not clean the contacts e Check the compressor oil level Compressors Off System operation Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury e Close the main power disconnect switch for the condensing unit and all system support equipment Turn all system control circuit switches to the On position e With the unit running check and record the ambient temperature compressor oil level each circuit compressor suction and discharge pressures each circuit superheat and Subcooling each circuit e Record this data on an operator s maintenance log similar to the one illustrated in the Final Setup section of this manual If the operating pressures indicate a refrigerant shortage measure the system Superheat and system Subcooling For guidelines refer to the System Start Up section Note Do Not release refrigerant to the atmosphere If adding or removing refrigerant is required the service tec
59. r refrigerant migration control when they are connected to an EVP chiller and should be connected as described in the Electrical Wiring section Thermostatic Expansion Valve TXV Trane recommends a balance ported externally equalized valve to maintain satisfactory superheat control down to lower valve loading conditions and to compensate for pressure drops between expansion valve and superheat control point evaporator refrigerant outlet For fin and tube evaporator applications a 30 bleed port TXV is required for 20 60T units and a 15 bleed port is required for 80 120T units For proper refrigerant distribution into coil an expansion valve is required for each coil distributor NOTICE Equipment Damage Do not use any solenoid valve as a pumpdown device Equipment damage will occur 33 e TRANE Installation Table 6 Valve selections Capacity Bleed Applicable Units Selection Minimum Maximum BBIZE 1 1 2 GA 2 2 BBIZE 2 GA 2 3 BBIZE 3 GA 2 5 4 BBIZE 4 GA 3 5 5 5 BBIZE 5 GA 4 5 6 5 BBIZE 6 GA 5 5 7 5 0 Any BPHE or any Fin and BBIZE 8 GA 6 5 10 5 Tube OK Coils BBIZE 12 1 2 GA 8 5 13 5 BBIZE 15 GA 11 16 5 OZE 20 GA 13 22 OZE 25 GA 17 26 OZE 35 GA 20 5 39 OZE 50 GA 30 5 59 OZE 60 GA 45 5 70 BBIZE 1 1 2 GA BP 15 2 2 5 BBIZE 2 GA BP 15 2 5 3 BBIZE 3 GA BP 15 3 4 5 BBIZE 4 GA BP 15 4 6 BBIZE 5 GA BP 15 5 7 5 BBIZE 6 GA BP 15 6 9 TEENS BBIZ
60. rd the voltage between phases 1 2 and 3 and calculate the amount of imbalance as follows Voltage Imbalance 100 X AV VD AV where AV Average Voltage Volt 1 Volt 2 Volt 3 3 V1 V2 V3 Line Voltage Readings VD Line Voltage reading that deviates the farthest from the average voltage Example If the voltage readings of the supply power measured 221 230 and 227 the average volts would be 221 230 227 3 226 Avg VD reading farthest from average 221 The percentage of Imbalance equals 100 X 226 221 226 2 2 The 2 2 imbalance in this example exceeds the maximum allowable imbalance of 2 0 This much imbalance between phases can equal as much as a 20 current imbalance with a resulting increase in motor winding temperatures that will decrease motor life If the voltage imbalance is over 2 notify the proper agencies to correct the voltage problem before operating this equipment Electrical Phasing 48 Proper electrical phasing can be quickly determined and corrected before starting the unit by using an instrument such as an Associated Research Model 45 Phase Sequence Indicator and following the steps below e Turn the field supplied disconnect switch that provides power to terminal block 1TB1 to the Off position AWARNING High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 151 To prevent injury or death form electrocution it is the responsibility of
61. rent protection to the Compressor unit and Air Handling unit No Control VAV and Constant Volume applications For chilled water systems provide a properly sized power supply to the circulating pump motor EVP control applications Be certain that these components are properly grounded 4 Provide proper grounding for the unit in accordance with local and national codes CAUJ SVX01D EN CAUJ SVX01D EN e TRANE Installation Table 8 Customer connection wire range 20 60 ton units Customer wire selection and fuse replacement Power Wire Selection to Main Terminal Block 1TB1 Unit Voltage Terminal Block Size Connector Wire Range All 175A 1 14 2 0 Control Wire Selection to Control Terminal Block 1TB2 See Note 6 Wire Gauge OHMS per 1000 Feet 18 8 16 5 14 3 12 2 Table 9 Customer connection wire range 80 120 ton units Customer wire selection and fuse replacement Power Wire Selection to Main Terminal Block 1TB1 Unit Voltage Terminal Block Size Connector Wire Range All 175 AMP 1 12 2 0 Control Wire Selection to Control Terminal Block 1TB4 See Note 6 Wire Gauge OHMS per 1000 Feet Max Wire Length 18 8 500 FT 16 5 1000 FT 14 3 2000 FT 12 2 3000 FT 39 e TRANE Installation Power Wire Sizing and Protection Device Equations 40 To correctly size the main power wiring for the unit use the appropriate calculation s listed below Read the load definitions that follow and use Calculation
62. ross terminals 1TB2 1 to 1TB2 3 1TB2 1 to 1TB2 8 and the applicable cycling controls i e pressure switches and ambient thermostats to start the condenser fans as illustrated in Figure 27 p 49 b For 80 120 ton units Install temporary jumpers across terminals 1TB4 7 to 1TB4 9 1TB4 7 to 1TB4 11 and the applicable cycling controls i e pressure switches and ambient thermostats to start the condenser fans as illustrated in Figure 28 p 50 Close the disconnect switch or circuit protector switch that provides power to the condensing unit Turn the control circuit switch 155 to the On position The fans will start when the power is applied Check the condenser fans for proper rotation The direction of rotation is clockwise when viewed from the top of the unit All Fans are Rotating Backwards 1 Turn the field supplied disconnect switch or circuit protector switch that provides power to the condensing unit to the Off position Lock the disconnect switch in the open position while working at the unit Interchange any two of the field connected main power wires at the unit terminal block 1TB1 in the unit control panel Remove all temporary jumpers previously installed in step 3 of Verifying Proper Condenser Fan Rotation CAUJ SVX01D EN Note Interchanging Load side power wires at the fan contactors will only affect the individual fan rotation Ensure that the voltage phase sequence at the main ter
63. s the vacuum be Broken to facilitate the evacuation process To break the vacuum Shutoff valves A B amp C and connect a refrigerant cylinder to the charging port on the manifold Purge the air from the hose Raise the standing vacuum pressure in the system to zero 0 psig gauge pressure Repeat this process two or three times during evacuation Note It is unlawful to release refrigerant into the atmosphere When service procedures require working with refrigerants the service technician must comply with all Federal State and local laws Refer to the General Service Bulletin MSCU SB 1 latest edition Standing Vacuum Test Once 300 microns or less is obtained close Valve A and leave valves B and C open This will allow the vacuum gauge to read the actual system pressure Let the system equalize for approximately 15 minutes This is referred to as a standing vacuum test where time versus pressure rise The maximum allowable rise over a 15 minute period is 200 microns If the pressure rise is greater than 200 microns but levels off to a constant value excessive moisture is present If the pressure steadily continues to rise a leak is indicated Figure 26 p 47 illustrates three possible results of the standing vacuum test If a leak is encounter repair the system and repeat the evacuation process until the recommended vacuum is obtained Once the system has been evacuated break the vacuum with refrigerant and complet
64. s to ensure the power can not be inadvertently energized Failure to disconnect power before servicing could result in death or serious injury Before completing the following checks turn the system control circuit switch 152 and 551 to the Off position Open the main power disconnect switch for the Condensing Unit and Air Handling Unit and lock it in the Off position before removing any access panels e Inspect the return air filters Clean or replace them if necessary e Check the evaporator drain pan and condensate piping to ensure that there are no blockages e Inspect the evaporator coils for dirt If the coils appear dirty clean them according to the instructions described in the Coil Cleaning section e Inspect the economizer damper hinges and pins if applicable to ensure that all moving parts are securely mounted Clean the blades as necessary e Verify that all damper linkages move freely lubricate with white grease if necessary Check Supply Fan motor bearings repair or replace the motor as necessary Check the fan shaft bearings for wear Replace the bearings as necessary e Lubricate the supply fan bearings Refer to the equipment manufacturer for their recommended greases Note Over lubrication can be just as harmful as not enough grease Use a hand grease gun to lubricate these bearings add grease until a light bead appears all around the seal Do not over lubricate Note After greas
65. securely fastened to the fan motor shaft Compressor Damage Do not allow liquid refrigerant to enter the suction line Excessive liquid accumulation in the liquid lines may result in compressor damage e Verify that all compressor service valves discharge service valves and liquid line service valves is back seated on each circuit e Inspect the interior of the unit for tools and debris System Evacuation Procedures CAUJ SVX01D EN Each refrigeration circuit for split system applications must be evacuated before the unit can be started Use a rotary type vacuum pump capable of pulling a vacuum of 100 microns or less Verify that the unit disconnect switch and the system control circuit switches are OFF The oil in the vacuum pump should be changed each time the pump is used with a high quality vacuum pump oil Before using any oil check the oil container for discoloration which usually indicates moisture in the oil and or water droplets Moisture in the oil adds to what the pump has to remove from the system making the pump inefficient When connecting the vacuum pump to a refrigeration system it is important to manifold the vacuum pump to both the high and low side of the system liquid line access valve and suction line access valve Follow the pump manufacturer s directions for the proper methods of using the vacuum pump Motor Damage Do not under any circumstances use a megohm meter or apply power to the windi
66. t 9 Condenser Circuit 1 Single 20 30 Ton 2 Dual 40 60 Ton Digit 10 Design Sequence Factory Assigned Digit 11 Ambient Control 0 Standard 1 OF Digit 12 Agency Approval 0 None 3 cULus Digits 13 14 Miscellaneous Corrosion Protected Cond Coil Spring Isolators Rubber Isolators ou gu Note The service digit for each model number contains 14 digits all 14 digits must be referenced 80 to 120 Ton Digit 1 Unit Type Condenser Digit 2 Condenser A Air Cooled Digit 3 Airflow U Upflow Digit 4 Development Sequence J Digits 5 6 7 Nominal Capacity C80 80 Tons D10 100 Tons D12 120 Tons Digit 8 Power Supply F 230 60 3 4 460 60 3 5 575 60 3 E 200 60 3 Digit 9 Condenser Circuit 2 Dual Circuit Digit 10 Design Sequence First Digit 11 Ambient Control 0 Standard 1 OF Digit 12 Agency Approval 0 None 2 CSA 3 cULus Digits 13 14 Miscellaneous Corrosion Protected Cond Coil Spring Isolators Note The service digit for each model number contains 14 digits all 14 digits must be referenced CAUJ SVX01D EN TRANE General Information Unit Inspection CAUJ SVX01D EN As soon as the unit arrives at the job site e Verify nameplate data matches data on sales order and bill of lading including electrical data Verify that the power supply complies wit
67. the compressor during the Off cycle Table 7 Minimum vertical line velocities Line Dia Minimum Velocity fpm Line Dia Minimum Velocity fpm 7 8 470 2 1 8 750 1 1 8 540 2 5 8 825 1 3 8 600 3 1 8 915 1 5 8 650 3 5 8 975 Discharge Hot Gas Line Components CAUJ SVX01D EN Field supplied hot gas mufflers pipe anchors single or double risers oil traps etc as applicable should be provide to prevent excessive line vibration and assure proper oil return to the compressor for proper system operation A field supplied discharge shutoff valve in each hot gas line near the condenser is recommended to facilitate refrigerant storage in the condenser during service procedures A constant drain oil trap is illustrated below and can be used as an alternative to a double riser application The constant drain oil trap assures adequate oil return to the suction line even at part load conditions Refer to Reciprocating Direct Expansion Piping Systems AM REF 1 82 for suggested piping arrangement details Figure 24 Hot gas line components Hot Gas 1 4 Solenoid Valve 4 Oil Trap Oil Return Line 5 Drip Leg 5 feet of 1 8 ES Copper Tubing 35 e TRANE Installation Final Refrigerant Pipe Connections To access the refrigerant pipe connections remove the louvered side grills Refer to Fig
68. the damper blades for proper alignment and operation Dampers should be in the closed position during the Off cycle NOTICE Actuator Damage To prevent damage do not depress actuator clutch while actuator is energized If adjustment is required AWARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury 1 Remove the sensor leads from the input terminals 6 and 7 for circuit 1 and or 11 and 12 for circuit 2 Controller output signal will go to 0 0 VDC and the damper will drive to the closed position Loosen the actuator clamp Firmly hold the damper blades in the closed position Retighten the acuator clamp 51 To check damper operation jumper between the sensor input terminals 6 and 7 and or 11 and 12 if applicable Controller output signal will go to 10 VDC and the damper will drive to the full open position Charging the System 52 1 Verify that all discharge service valves and liquid line service valves for each circuit is back seated Attach a set of service gauges onto the liquid line and discharge
69. the refrigerant will be drawn into the system 6 Once the charging for the operating circuit has been completed check and record the ambient temperature compressor oil level each circuit compressor suction and discharge pressures each circuit superheat and subcooling each circuit Record this data on an operator s maintenance log like the one shown in Table 16 p 53 If the operating pressures indicate a refrigerant shortage measure the system superheat and system subcooling Repeat steps 1 through 6 for the second refrigeration circuit if applicable Table 13 Minimum starting ambient temperatures Standard Units Low Ambient Units Unit Size With HGBP No HGBP With HGBP No HGBP 20 60 Ton Units 40 30 10 0 80 120 Ton Units 80 120 Ton Units 40 10 0 Note Minimum starting ambients in degrees F based on unit at minimum step of unloading and 5 mph wind across condenser Table 14 Recommended refrigerant capacities Unit Size Operating Charge per Circuit Condenser Storage Capacity C20 12 19 C25 12 19 CAUJ SVX01D EN Table 14 Recommended refrigerant capacities Unit Size Operating Charge per Circuit Condenser Storage Capacity2 C30 12 19 C40 11 24 C50 12 25 C60 13 32 C80 29 47 D10 30 50 D12 33 63 Notes 1 CAUJ C20 C30 are single circuit units CAUJ 40 C60 are dual circuit units CAUJ 80 120 are dual circuit units 2 Pounds R 410A per circuit 95 F ambient 95 full
70. the technician to recognize this hazard and use extreme care when performing service procedures with the electrical power energized e Connect the phase sequence indicator leads to the terminal block or to the Line side of the optional factory mounted disconnect switch as follows Black phase A to L1 Red phase B to L2 Yellow phase C to L3 e Close the main power disconnect switch or circuit protector switch that provides the supply power to the condensing unit e Observe the ABC and CBA phase indicator lights on the face of the sequencer The ABC indicator light will glow ifthe phase is ABC If the CBA indicator light glows open the disconnect switch or circuit protection switch and reverse any two power wires e Restore the main electrical power and recheck the phasing e fthe phasing is correct open the main power disconnect switch or circuit protection switch and remove the phase sequence indicator CAUJ SVX01D EN Start Up CAUJ SVX01D EN TRANE Low Ambient Damper Operation Low Ambient Dampers are available as a factory installed option or can be field installed Dampers are used to extend the operation of these units from the standard operational temperatures to a minimum of 0 F without hot gas bypass or 10 F with hot gas bypass These values apply when wind speed across the condenser coil is less than 5 m p h If typical wind speeds are higher than 5 m p h a wind screen around the unit may be requ
71. ts Figure 13 60 ton air cooled condenser NOTES 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT FAN GRILLE 3 4 X6 MTG HOLES 1 2 X 4 KO 115V 54 1 2 X2 115V gie CONTROL PANEL 5 16 48 7 8 41 2 33 8 1 1 3 4 KO LOW 29 1 4 4 CONDUIT 33 1 114 VOLTAGE 30V MAX 31 1 4 MAIN POWER 5 35 13 16 37 11 16 48 7 8 DETAIL 14 8 18 BOTTOM OF CONTROL BOX UM YT ri DOOR 43 1 4 W 4 180 DEG SWING i 855 8 LOW AMBIENT CONTBODPANEL DAMPER SEE NOTE 2 SEE DETAIL A FAN GRILLE SSeS q I 13 61 4 5 o 1 T T zm a 4 LINE VOLTAGE i ACCESS 79 1 4 5 32 3 16 1 22 1 2 15 16 L i BOTTOM OF CONTROL 1 BOX SEE DETAIL A 103 1 2 5 3 16 88 5 16 11 4 x 4 1 2 113 13 16 SLOT FOR 115 VOLT CONTROL 20 CAUJ SVX01D EN Figure 14 60 ton air cooled condenser connections CONTROL PANEL SIDE LIQUID LINE 61 3 16 p 7 16 1 y 67 3 8 10 13 16 oa 10 13 16 74 7 1
72. ure 5 p 12 through Figure 18 p 25 These condensing units are shipped with a Nitrogen holding charge Install pressure gauges to the appropriate access valve s and take a reading If no pressure is present refer to the Leak Testing Procedure section If pressure is present relieve the pressure before attempting to unsweat the seal caps If refrigerant connections are not capped but are spun end tubes use a tubing cutter to remove the end from the pipe NOTICE Equipment Damage To prevent damage to the system do not drill a hole in the seal caps or saw the ends off pipe stubs This could introduce copper chips into the system piping Brazing Procedures Proper brazing techniques are essential when installing refrigerant piping The following factors should be kept in mind when forming sweat connections A WARNING Hazard of Explosion Use only dry nitrogen with a pressure regulator for pressurizing unit Do not use acetylene oxygen or compressed air or mixtures containing them for pressure testing Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion Refrigerant when used as a trace gas should only be mixed with dry nitrogen for pressurizing units Failure to follow these recommendations could result in death or serious injury or equipment or property only damage 1 Whencopper
73. ure 7 25 and 30 ton air cooled condenser FAN GRILLE 3 4 X 4 MTG HOLES 72 1 2 88 1 2 8 DOOR 43 1 4 W 180 DEG SWING 1 4 57 5 8 Z CONTROL PANEL SEE DETAIL A 4 LINE VOLTAGE ACCESS 1 1 4 x 4 1 2 SLOT FOR 115 VOLT CONTROL 27 1 4 m 60 1 8 CONTROL BOX BOTTOM SEE DETAIL A 14 NOTES 1 SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES 2 LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT 1 2 X 4 KO 115V 1 2 X 2 KO 115V 2 5 8 5 16 1 3 4 LOW VOLTAGE 30V MAX 3 3 8 CONTROL PANEL 41 2 _ 29 4 4 4 CONDUIT MAIN POWER 35 13 16 37 11 16 DETAILA CONTROL BOX BOTTOM LOW AMBIENT FAN GRILLE DAMPER SEE NOTE 2 13 16 5 3 16 6 1 4 74 114 HO E Mam LEH H y aa d 61 8 78 88 5 16 CAUJ SVX01D EN e TRANE Dimensions and Weights Figure 8 25 and 30 ton air cooled condenser connections CONTROL PANEL SIDE NOTES 1 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION CONTROL PANEL 7 8 O D LIQUID LINE 13 8 O D DISCHARGE LINE
74. utions and Notices appear at appropriate sections throughout this literature Read these carefully AWARNING Indicates a potentially hazardous situation which if not avoided could resultin death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided could resultin minor or moderate injury It could also be used to alert against unsafe practices NOTICE Indicates a situation that could result in equipment or property damage only accidents Important 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 The Federal Clean Air Act Section 608 sets forth the requirements for handling reclaiming

Trane RAUJ CAUJ 20 to 120 Tons Installation and Maintenance Manual

Contents

Download Pdf Manuals

Related Search

Related Contents