Installation Operation Maintenance Scroll Liquid Chillers Models CGWF/CCAF 20-60 Tons January 2004 © 2003 American Standard Inc. All rights reserved. CGWF-SVX01A-EN NOTICE: Warnings and Cautions appear at appropriate sections through- out this literature. Read these carefully. ƽ WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. CAUTION: Indicates a situation that may 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, 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. ƽ WARNING Contains Refrigerant! System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage. 2 CGWF-SVX01A-EN Table of Contents General Information........................................................................................... 7 Literature Change History..................................................................................... 7 Unit Identification ................................................................................................. 7 Nameplates .......................................................................................................... 7 Unit Nameplates................................................................................................... 7 Compressor Nameplate ....................................................................................... 7 Evaporator Nameplate.......................................................................................... 7 Condenser Nameplate.......................................................................................... 8 Unit Inspection ..................................................................................................... 8 Inspection Checklist ............................................................................................. 8 Loose Parts Inventory .......................................................................................... 8 Unit Description.................................................................................................... 8 Unit Model Number.............................................................................................. 8 Installation Overview.......................................................................................... 12 Installation Mechanical.................................................................................... 17 Unit Storage ....................................................................................................... 17 Location Requirement ........................................................................................ 17 Noise Consideration ........................................................................................... 17 Foundation.......................................................................................................... 17 Ventilation........................................................................................................... 17 Drainage ............................................................................................................. 17 Rigging ............................................................................................................... 17 Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF Units................... 18 Lifting Procedure for 60 Ton Units ..................................................................... 20 Alternate Moving Methods................................................................................. 21 Access Restrictions............................................................................................ 21 Recommended Clearances ................................................................................ 22 Unit Isolation ...................................................................................................... 22 Direct Mounting ................................................................................................. 22 Neoprene Isolator Mounting .............................................................................. 22 Neoprene Isolator Data ...................................................................................... 22 Unit Leveling ...................................................................................................... 23 Unit Piping .......................................................................................................... 29 General Water Piping Recommendations .......................................................... 29 Water System .................................................................................................... 29 Water Flow Rates............................................................................................... 29 Pressure Drop Measurement............................................................................. 29 Evaporator Water Piping..................................................................................... 32 Evaporator Water Connections........................................................................... 32 Evaporator Piping Components.......................................................................... 32 Flow Sensing Devices ........................................................................................ 32 Evaporator Drain................................................................................................. 33 Condenser Water Piping .................................................................................... 33 Condenser Water Connections. ......................................................................... 33 Condenser Piping Components.......................................................................... 33 Condenser Drains............................................................................................... 34 Water Regulating Valve ...................................................................................... 35 Water pressure Relief Valves ............................................................................. 37 Low Temperature Operation .............................................................................. 37 Pressure Relief Valve Venting ............................................................................ 38 Refrigerant Piping (CCAF only) ........................................................................... 40 CGWF-SVX01A-EN 3 Table of Contents Liquid Line Components and Connections......................................................... 40 Liquid Line Sizing................................................................................................ 40 Discharge (hot gas) Lines ................................................................................... 40 Leak Test ............................................................................................................ 42 System Evacuation ............................................................................................. 42 Refrigerant Charging........................................................................................... 42 Installation Electrical........................................................................................ 43 General Recommendations ................................................................................ 43 Power Supply Wiring .......................................................................................... 43 Unit Power Supply.............................................................................................. 43 Equipment Grounds............................................................................................ 43 Terminal Lugs, Circuit Breakers and Non-Fused Disconnect Switches.............. 43 Scroll Compressor Electrical