Installation

Operation
Maintenance

Air-Cooled Water Chiller

Air-Cooled Water Chiller
with Heat Pump Option
3~30 Tons

CGA-SVX01B-EN
 TABLE OF CONTENTS

MODEL NOMENCLATURE 3

INSTALLATION 4
RIGGING
MOUNTING
WATER PIPING
FIGURE 1 : RECOMMENDED HOISTING ARRANGEMENT
FIGURE 2 : DIMENSION FOR MOUNTING
FIGURE 3 : SERVICE & MAINTENANCE CLEARANCE
ELECTRICAL WIRING
UNIT POWER SUPPLY
FIGURE 4 : TYPICAL PIPING ARRANGEMENT
FIGURE 5 : TYPICAL SYSTEM APPLICATION

ELECTRICAL DATA 11

FLOW SWITCH INTERLOCK 12

CIRCUIT DIAGRAM 1 : FOR CGAK 030~075
CIRCUIT DIAGRAM 2 : FOR CGAR 030~075
CIRCUIT DIAGRAM 3 : FOR CGAK 100~200
CIRCUIT DIAGRAM 4 : FOR CGAR 100~200
CIRCUIT DIAGRAM 5 : FOR CGAK 250~300
INSTALLATION CHECKLIST

PRE-START PROCEDURE 18
VOLTAGE UTILIZATION RANGE
VOLTAGE IMBALANCE
WATER FLOW RATE
UNIT WATER PRESSURE DROP
FIGURE 6 : HYDRAULIC CHARACTERISTIC
PRE-START CHECKLIST

OPERATION 23
START-UP PROCEDURE
EXTENDED UNIT SHUT-DOWN/WINTERIZATION
STANDARD AMBIENT OPERATION
OPTIONAL LOW AMBIENT OPERATION (CGAK)
OPTIONAL HEAT PUMP OPERATION (CGAR)
ELECTRICAL CONTROL & PROTECTION SYSTEM

MAINTENANCE 27

TROUBLE ANALYSIS 28
© American Standard Inc. 2004 2 CGA-SVX01B-EN
MODEL NOMENCLATURE

CGA K 050 5 D F R M R N A
1,2,3 4 5,6,7 8 9 10 11 12 13 14 15

DIGIT 1,2,3 DIGIT 9 - Development Sequence

CGA=Air-Cooled Water Chiller D=Fourth Design

DIGIT 4 - Model DIGIT 10 - Controls

K=Cooling Only F=Fixed Entering Water Temperature Control
R=Cooling With Heat Pump Option (Standard Option)
A=Microprocessor Controller
DIGIT 5,6,7 - Nominal Capacity (tons) (Adjustable Entering Water Temperature)
030 (For CGAK Models as Optional)
040 (For CGAR Models as Standard Option)
050
075 DIGIT 11- Water Pump
100 N = No Pump
125 R = Standard Pump
150 (Standard Option)
175
200 DIGIT 12 - Refrigerant Pressure Gauges
250 M = No
300 (Standard Option)
G = With High/Low Pressure Gauges
DIGIT 8 - Voltage
1=220V/60Hz/1Ph DIGIT 13 - Temperature Kit
(For model 030,040,050) R = Standard Ambient Temperature Kit
2=220V/60Hz/3Ph (Standard Option)
(For model 050,075,100,125,150,175,200,250,300) L = Low Ambient Temperature Kit
3=380V/60Hz/3Ph (For CGAK Models Only)
(For model 050,075,100,125,150,175,200,250,300)
4=460V/60Hz/3Ph DIGIT 14 - Other Options
(For model 050,075,100,125,150,175,200,250,300) M = Standard Fin + Standard Grille Cover
5=380V/50Hz/3Ph C = Blue Fin + Standard Grille Cover
(For model 050,075,100,125,150,175,200,250,300)
6=400V/50Hz/3Ph DIGIT 15 - Service Sequence
(For model 050,075,100,125,150,175,200,250,300) A = First
7=415V/50Hz/3Ph
(For model 050,075,100,125,150,175,200,250,300)

3 CGA-SVX01B-EN
 INSTALLATION

Complete the “Installation Checklist” during MOUNTING Table 1 : Unit Shipping Weights
installation to verify completion of all Model Maximum Shipping Weight (Kg)
Mounting methods that will minimize sound
recommended procedures before unit and vibration problems are: 030 230
start-up.
040 250
1. Mount the unit directly on an isolated
concrete pad or on isolated concrete 050 260
RIGGING 075 320
footings at each unit mounting point.
Each unit is bolted to a shipping skid for
100 370
shipment to the job site. Move the unit using 2. Install the optional neoprene or spring
125 450
a forklift of suitable capacity. See Table 1 for isolators at each mounting location.
150 530
unit shipping weights.
Refer to Figure 2 for unit and base 175 550
Locate the unit near a large-capacity drain to
dimensions and Figure 3 for recommended 200 570
allow system drainage during unit shutdown
service clearance. 250 750
and repair. Rig the unit using canvas belt.
300 800
Fasten the belt to the unit over the unit’s
base as show in Figure 1. WATER PIPING
Thoroughly flush all water system piping
before making the final piping connections to
the unit.

© American Standard Inc. 2004 4 CGA-SVX01B-EN

Figure 1 :
Recommended Hoisting Arrangement
(CGAK-075 As Shown)

5 CGA-SVX01B-EN
Figure 2 :
Dimension for Mounting
(CGAK-075 As Shown)
Note: All Dimensions in Millimeter

© American Standard Inc. 2004 6 CGA-SVX01B-EN

Figure 3 :
Service and Maintenance Clearance
(CGAK-075 As Shown)

7 CGA-SVX01B-EN
CAUTION: If using an acidic commercial
flushing solution, construct a temporary
bypass around the unit to prevent
damage to the evaporator.
CAUTION: To avoid possible equipment
damage, do not use untreated or
improperly treated water.
For unit’s water connection sizes and
locations, please refer to Figure 2.
CAUTION: To prevent unit damage, do
not reverse system piping connections to
the unit; water entering the unit must
enter at the designated “Water In” and
leaving water must exit the unit through
the designated “Water Out” connection.
Figure 4 illustrates typical unit piping
components. Components and layout will
vary slightly depending upon the locations
of the connections and water source.
Figure 5 gives a schematic of a typical
system application for this unit.
Provide vents at high points in the piping to
bleed air from the chilled water system.
Install pressures gage(s) to monitor entering
and leaving chilled water pressure.
CAUTION: To prevent damage to the
waterside components of unit, do not
allow evaporator pressure to exceed 100
psig (i.e. maximum working pressure).
Use an expansion tank to isolate this
pressure if water pressure exceeds this
value.
© American Standard Inc. 2004
ELECTRICAL WIRING FLOW SWITCH INTERLOCK
To avoid possible evaporator freeze-up
WARNING: To prevent injury or death,
resulting from reduced water flow, install a
disconnect electrical power source
flow switch ( or other flow sensing device) in
before completing wiring connections to
the evaporator outlet water line. This
the unit.
sensing device must be adjusted to stop
CAUTION: Use only copper conductors compressor operation if water flow to the
for terminal connections to avoid evaporator drops below 70% of the system
corrosion or over heating. design full-flow rate.
Figure 2 shows the location of the unit The installer must provide interconnecting
electrical access openings. Table 2 provides wiring between the unit control panel and
minimum circuit ampacities, recommended the water flow sensing switch in the
fuse sizes, and motor electrical data. evaporator water line.
UNIT POWER SUPPLY
Refer to the unit wiring schematic fixed to
the control panel cover. The installer must
provide a power supply of proper voltage
and a fused disconnect switch to the unit.
Run properly sized power wirings through
the electrical access opening on the side of
the unit, and connect it to the Voltage
Terminal Block (1TB1) in the unit control
panel. Install a fused disconnect switch as
required by local codes. Provide proper
equipment grounds for the ground
connections in the unit control panel and at
the fused disconnect switch.
Refer to wiring diagrams from Page 12 to
Page 16 for reference of a typical unit
installation. For actual wiring diagram, refer
to the one fixed to the control panel cover.
8 CGA-SVX01B-EN
Figure 4 :
Typical Piping Arrangement
(CGAK-075 As Shown)

9 CGA-SVX01B-EN
Figure 5 :
Typical System Application
(CGAK-075 And Fans As Shown)

© American Standard Inc. 2004 10 CGA-SVX01B-EN

 ELECTRICAL DATA

Table 2 : Electrical Data

60Hz
Electrical Water Comp Comp Fan Fan Unit Rec. Max
Model Power Pump
1
2
1
2 MCA Fuse Fuse
(V/Hz/Ph) FLA RLA RLA FLA FLA Size Size
030 220/60/1 4.4 14.4 - 2.8 - 25.2 28.8 39.6
040 220/60/1 4.4 19.4 - 2.8 - 31.5 36.3 50.9
050 220/60/1 4.4 24.4 - 2.8 - 37.7 43.8 62.1
100 220/60/1 6.5 24.4 24.4 4.3 - 65.7 71.8 90.1
050 220/60/3 2.7 15.3 - 3.0 - 24.8 28.7 40.1
050 380/60/3 1.6 8.8 - 1.7 - 14.3 16.5 23.1
075 220/60/3 4.2 23.0 - 3.0 - 36.0 41.7 59.0
075 380/60/3 2.4 13.3 - 1.7 - 20.7 24.1 34.0
100 220/60/3 4.2 15.3 15.3 4.5 - 43.1 47.0 58.4
100 380/60/3 2.4 8.8 8.8 2.6 - 24.8 27.0 33.6
125 220/60/3 5.4 17.4 17.4 4.5 - 49.1 53.4 66.5
125 380/60/3 3.1 10.1 10.1 2.6 - 28.4 31.0 38.5
150 220/60/3 5.4 23.0 23.0 3.0 3.0 63.2 68.9 86.2
150 380/60/3 3.1 13.2 13.2 1.7 1.7 36.2 39.5 49.4
175 220/60/3 6.0 26.0 26.0 4.5 4.5 73.5 80.0 99.5
175 380/60/3 3.5 15.0 15.0 2.6 2.6 42.5 46.2 57.5
200 220/60/3 9.1 32.4 32.4 4.5 4.5 91.0 99.1 123.4
200 380/60/3 5.3 18.7 18.7 2.6 2.6 52.6 57.3 71.3
250 220/60/3 9.1 35.0 51.0 4.5 4.5 116.9 129.6 167.9
250 380/60/3 5.3 20.0 29.0 2.6 2.6 66.8 74.0 95.8
300 220/60/3 11.3 51.0 51.0 4.5 4.5 135.1 147.8 186.1
300 380/60/3 6.5 29.0 29.0 2.6 2.6 77.0 84.2 106.0

50Hz
Electrical Water Comp Comp Fan Fan Unit Rec. Max
Model Power Pump
1
2
1
2 MCA Fuse Fuse
(V/Hz/Ph) FLA RLA RLA FLA FLA Size Size
050 380-415/50/3 1.1 7.4 - 1.5 - 11.9 13.7 19.3
075 380-415/50/3 1.4 11.6 - 1.5 - 17.4 20.3 29.0
100 380-415/50/3 1.4 7.4 7.4 2.2 - 20.3 22.1 27.7
125 380-415/50/3 1.7 8.7 8.7 2.2 - 23.5 25.7 32.2
150 380-415/50/3 1.7 11.6 11.6 1.5 1.5 30.8 33.7 42.4
175 380-415/50/3 2.0 13.0 13.0 2.2 2.2 36.5 39.8 49.5
200 380-415/50/3 2.8 15.1 15.1 2.2 2.2 41.2 45.0 56.3
250 380-415/50/3 2.8 15.0 25.0 2.2 2.2 53.5 59.7 78.5
300 380-415/50/3 5.9 25.0 25.0 2.2 2.2 66.6 72.8 91.6
Note:
• All voltages supply must fall within the utilization range of ±10 %
• Minimum Circuit Ampacity (MCA) = Largest Load x 1.25 + Sum of additional Loads. (Used for sizing wire)
• Recommended Fuse Size (REC) = Largest Load x 1.5 + Sum of additional Loads. (Select closest fuse size)
• Maximum Fuse Size (MFS) = Largest Load x 2.25 + Sum of additional Loads. (Select equal or next lower fuse size)

11 CGA-SVX01B-EN
 FLOW SWITCH INTERLOCK

Circuit Diagram 1 :
For CGAK 030~075

© American Standard Inc. 2004 12 CGA-SVX01B-EN

Circuit Diagram 2 :
For CGAR 030~075

13 CGA-SVX01B-EN
Circuit Diagram 3 :
For CGAK 100~200

© American Standard Inc. 2004 14 CGA-SVX01B-EN

Circuit Diagram 4 :
For CGAR 100~200

15 CGA-SVX01B-EN
Circuit Diagram 5 :
For CGAK 250~300

© American Standard Inc. 2004 16 CGA-SVX01B-EN

INSTALLATION CHECKLIST
RECEIVING

Verify that unit nameplate data
corresponds with sales order information.

Inspect unit for shipping damages and
material shortages; report any damages
or shortages found to the carrier.
UNIT LOCATION AND MOUNTING

Inspect unit installation location for
adequate ventilation.

Provide drainage facilities for water
accumulated from the base.

Remove and discard any shipping
materials (e.g. cartons, crates, etc.)

Inspect to determine that service access
clearances are adequate.

Install optional unit neoprene-in-shear or
spring isolators.

Secure unit to mounting surface.

Level the unit.
EVAPORATOR PIPING

Flush and clean all chilled water piping.
CAUTION: If using an acidic commercial
flushing solution, construct a temporary
bypass around the unit to prevent
damage to the evaporator.
CAUTION: To avoid possible equipment
damage, do not use untreated or
improperly treated water.

Make evaporator water connections.

Vent the air from chilled water system at
high points.

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

Install water strainer in evaporator supply
line.

Install balancing valve and flow switch on
water outlet piping.
17
ELECTRICAL WIRING
CAUTION: Use only copper conductors
to prevent galvanic corrosion and
overheating at terminal connections.

Connect unit power supply wiring (with
fused disconnect) to appropriate
terminals on terminal block (TB) in power
section of unit control panel.

In order to turn on/off the chiller from
indoors, connect wiring across reserved
terminals 2 & 3 in the unit control panel
from an indoor REMOTE OFF/ON switch.

Properly ground the unit, the chilled water
pump motor, all disconnects, and other
devices which require grounds.

Install wiring to connect flow switch to unit
control panel.
FOR NO-PUMP OPTION ONLY

Connect chilled water pump power supply
wiring (with fused disconnect) to the
proper terminals of the chilled water
pump.

Install wiring to connect chilled water
pump switch to chilled water pump
starter.

Connect auxiliary contacts of chilled
water pump starter to flow switch and unit
control panel.
CGA-SVX01B-EN

VOLTAGE UTILIZATION
RANGE
Electrical power to the unit must meet
stringent requirements for unit to operate
properly. Total voltage supply and voltage
imbalance between phases should be within
the following tolerances.
Measure each leg supply voltage at all line
voltage disconnect switches. Readings must
fall within the voltage utilization range shown
on the unit nameplate (±10%). If voltage on
any leg does not fall within the tolerance,
notify the power company to correct this
situation before operating the unit.
Inadequate voltage to the unit will cause
control components to malfunction and
shorten the life of electrical components and
compressor motors.
© American Standard Inc. 2004
PRE-START PROCEDURES
VOLTAGE IMBALANCE The 2.2% imbalance that exists in the
example above exceeds maximum
Excessive voltage imbalance between
phases in all 3-phase system will cause allowable imbalance by 0.2 %. This much
imbalance between phases can equal as
motors to overheat and eventually fail.
Maximum allowable imbalance is 2 %. much as 20 % current imbalance with a
resulting increase in winding temperature
Voltage imbalance is defined as follows:
that will decrease compressor motor life.
100x Va-Vd
% Voltage Imbalance =
Va
WATER FLOW RATE
Where
Establish a balanced water flow through the
Va = (V1 + V2 +V3) / 3(Average Voltage)
unit. Flow rates should fall between the
V1, V2, V3 = Line Voltages
minimum and maximum values indicated in
Vd = Maximum Line Voltage deviation from Va
TABLE 3. Evaporator water flow rates below
Example: the minimum acceptable values will result in
If the three voltages measured at the line 221 a stratified flow; this reduces heat transfer
Volts, 230 Volts, and 227 Volts, the average and causes either loss of expansion valve
(Va) would be: control or repeated nuisance low pressure
Va = (221 + 230 + 227)/3 = 226 Volts cutouts. Conversely, excessively high flow
then Vd = 221 Volts rate may cause erosion in the water system.
The percentage of imbalance is then:
100x 226-221

2.2%
226
18 CGA-SVX01B-EN
Table 3 : Unit Water Flow Rate UNIT WATER PRESSURE
60Hz Units: LPM
DROP
Model Minimum Flow Rated Flow Maximum Flow
Measure the water pressure rise across the
030 18.5 27.7 38.8
standard unit (with built-in pump). The
040 22.9 34.3 48.0 Externally Available Head (E.A.H) should
050 30.2 45.3 63.4 approximate those indicated by the E.A.H.
075 44.9 67.3 94.2 curves, with the corresponding flow rates.
100 59.1 88.7 124.2 For units (without built-in pump) with field-
125 74.7 112.0 150.0 installed pump outside the unit, water
150 89.5 134.3 150.0 pressure drop across the unit should
approximate those indicated by the Internal
175 102.6 154.0 175.0
Pressure Loss (I.P.L.) curves, with the
200 120.0 180.0 240.0
corresponding flow rates.
250 147.3 221.0 290.0
300 175.3 263.0 350.0 For standard unit with built-in pump, refer to
the E.A.H. curve for the system hydraulic
design. For optional unit without a built-in
50Hz Units: LPM
pump, refer to the I.P.L. curves. (Refer to
Model Minimum Flow Rated Flow Maximum Flow
Figure 6 for hydraulic characteristics of all
050 25.1 37.7 56.6
models.)
075 37.3 56.0 84.0
100 49.1 73.7 110.6
125 62.1 93.3 140.0
150 74.4 111.7 150.0
175 85.5 128.3 160.0
200 98.3 149.0 190.0
250 124.6 187.0 240.0
300 148.6 223.0 300.0

19 CGA-SVX01B-EN
Figure 6 :
Hydraulic Characteristics - 60Hz

© American Standard Inc. 2004 20 CGA-SVX01B-EN

50Hz

21 CGA-SVX01B-EN
 PRE-START CHECKLIST NOTE: With the water pump operating,

Inspect all wiring connections; electrical
throttle the water flow to approximately
connections should be clean and tight. 50% of the full flow rate. Following the

Check power supply voltage to the unit at
manufacturer’s instructions, adjust the
the main power fused disconnect switch. flow switch contacts to open at this

Fill the chilled water circuit, leaving the
point. Use an ohmmeter to verify opening
system air vents open. Close vents after and closure of the flow switch contacts.
all air is out, and the system is completely
Stop the chilled water pump.
filled.
Open all fused disconnect switches.

Remove jumper wire across terminals 1
Make electrical connection of flow switch
and 5 (in the control panel) for water to terminals 1 & 5 in the control panel.
system testing.

Close the fused disconnect switch and
start the unit by turning the REMOTE/
OFF/ON switch to ON position. Pump
should start and with water circulating
through the chilled water system, inspect
all piping connections for leaks and make
any necessary repairs.

Adjust the water flow rate through the
chilled water circuit, and check the
external available water pressure of the
unit (for standard unit) or the evaporator
water pressure drop for the no-pump
option unit.

© American Standard Inc. 2004 22 CGA-SVX01B-EN


START-UP PROCEDURE

Close the fused disconnect switch and
turn REMOTE/OFF/ON switch to ON.
Pump will start immediately. After 2
minutes, compressors
1 will start. 1
minute later, compressor
2 will start
(only in units with two refrigerant circuits).

For CGAR models, turn REMOTE/OFF/
ON switch to ON as described above,
turn the already installed indoors cooling
and heating mode switch to cooling
mode, then the operation of the chiller
would be similar to what is described
above. As for start-up with heating mode,
first turn REMOTE/OFF/ON switch to
OFF. Then, turn the cooling and heating
mode switch to heating. Finally, turn the
REMOTE/OFF/ON switch to ON (see
section on electrical wiring of the
installation checklist).
Once the unit has operated for at least 30
minutes and the system has stabilized,
complete the following checklist to ensure
proper unit operation.

Re-check unit water flow and pressure
rise (for no built-in pump unit with field-
installed pump system). These readings
should be stable at proper levels.

Measure unit suction and discharge
pressures by installing pressure gauges
on the discharge and suction line access
ports. Normal operation should render
suction pressure in the range of 50-85
psig and discharge pressure 200-310
psig.
OPERATION

Check compressor amp draw.

Check electrical power supply.

Check the liquid line sight glasses.
NOTE: Bubbles in the liquid line may
indicate either a low refrigerant charge,
or excessive pressure drop in the liquid
line. Such a restriction can often be
identified by a noticeable difference in
line temperature on either side of the
restricted area. (Frost often forms on the
outside of the liquid line at the point of
restriction, as well). Bubbles are not
necessarily a symptom of improper
system operation.
CAUTION: A clear sight glass does not
necessarily mean that the system is
sufficiently charged; be sure to consider
system superheat, subcooling, and unit
operating pressures and ambient
temperatures.
Proper unit refrigerant charge-per circuit-is
indicated on the unit nameplate.

Measure system superheat.
Normal system superheat is 6.7°C to 8.3°C
for each circuit at ARI conditions (12.2°C
entering water, 6.7°C leaving water, and
35°C ambient temperature). If the superheat
measured for either circuit does not fall
within this range, alter the setting of the
superheat adjustment on the thermal
expansion valve to obtain the desired
reading. Allow 15 to 30 minutes between
adjustments for the expansion valve to
stabilize at each new setting.
23

Measure system subcooling.
Normal subcooling for each circuit is 6.7°C
to 12.2°C ARI conditions (12.2°C entering
water, 6.7°C leaving water, and 35°C
ambient temperature). If subcooling for
either circuit is normal but subcooling is not
in this range, check superheat for the circuit
and adjust, if required. If superheat is normal
but subcooling is not, contact a qualified
service technician.

If operating pressure, sight glass,
superheat and subcooling readings
indicate refrigerant shortage, find and
repair leaks and, gas-charge refrigerant
into each circuit. Refrigerant shortage is
indicated if operating pressures are low
and subcooling is also low.
CAUTION: If suction and discharge
pressures are low, but subcooling is
normal, no refrigerant shortage exists.
Adding refrigerant will result in
overcharging.
Add refrigerant vapor with the unit running
by charging through the access port on the
suction line until operating pressures are
normal.

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

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

Inspect the unit. Remove any debris,
tools and hardware. Secure all exterior
panels, including the control and
compressor access panels. Replace and
tighten all retaining screws.
CGA-SVX01B-EN
EXTENDED UNIT SHUT-DOWN/
WINTERIZATION
If the system is taken out of operation for
long periods of time for any reasons (e.g.,
seasonal shutdown), use this procedure to
prepare the system for shutdown.
1. Check the refrigerant piping for leaks,
fixing any that exist.
2. Service the chilled water pump and any
air handling equipment according to the
manufacturer
s recommendtions.
3. Open both electrical disconnect switches
for the unit and chilled water pump; lock
both disconnects in the open position.
WINTERIZATION: Close all evaporator
water supply valves and drain the
evaporator by removing the drain plug
and opening the vent on the entering
water line just outside the unit. Re-install
the drain plug. Since the evaporator does
not drain completely, add ethylene glycol
antifreeze to the remaining water through
the vent or evaporator drain hole, to keep
the water from freezing. Protect system
to 5.5°C below the expected ambient
temperature.
SYSTEM RESTART AFTER EXTENDED
SHUTDOWN
1. Remove winterization antifreeze as it can
reduce system capacity.
2. Fill the chilled water circuit by opening the
gate valves at the returning and supply
water piping. Be sure to vent the system
while filling it, and close the vents when
system is full.
© American Standard Inc. 2004
3. Remove compressor delay on timer(s)
(TR1, TR2). Record down the original
socket for the respective timer so that the
correct timer(s) are replaced correctly
later.
4. Close the unit disconnect switch for power
supply.
5. Turn the REMOTE/OFF/ON switch to ON
position. With water circulating through
the chilled water system, inspect all
piping connections for leaks and make
any necessary repairs.
6. Adjust the water flow rate, using the
balancing valve, through the chilled water
circuit, and check the water pressure rise
(or drop) through the unit.
7. Adjust the flow switch (installed on the
unit outlet piping) to provide proper
operation.
NOTE: With the unit operating, throttle
the water flow to approximately 50% of
the full flow rate. Following the
manufacturer’s instructions, adjust the
flow switch contacts to open at this
point. Use an ohmmeter to check for
contact opening and closure.
8. Stop the unit by turning the REMOTE/
OFF/ON switch to OFF position.
9. Replace compressor delay on timer (TR1,
TR2) back to their original sockets.
This unit now is ready for normal operation.
24
STANDARD AMBIENT
OPERATION
Standard unit will operate in outdoor ambient
temperature down to 15°C.
OPTIONAL LOW AMBIENT
OPERATION (CGAK)
A factory installed Low Ambient Unit (LAU)
option will enable units to operate at outdoor
low ambient temperature (see Table 4).
OPTIONAL HEAT PUMP
OPERATION (CGAR)
A factory installed heat pump unit (CGAR)
option will enable units to get either cooling
and heating performance (not simultaneous).
When the unit is switched to heating mode,
the four-valve is activated. Evaporator
becomes the condenser while the condenser
becomes the evaporator. There are two
liquid lines in a CGAR unit. One is for cooling
mode while another is for heating mode.
To carefully measure the high pressure,
there are two access ports in these two
liquid lines. If you operate this unit in cooling
mode, connect high pressure gauge to the
access port of the cooling liquid line. While
operating this unit in heating mode, must
change the connection to the access port of
the heating liquid line.
A timer override low pressure switch delays
for 2 minutes to prevent nuisance trip-outs.
CGA-SVX01B-EN
ELECTRICAL CONTROL &
PROTECTION SYSTEM
Low Pressure Cutouts (LP1, LP2)
These units are protected by low pressure
cutouts that open and stop compressor
operation if the operating pressure drops
below 25 ± 4 psig . The cutout automatically
resets when the pressure reaches 50 ± 4
psig. The LP is a SPDT device and if it
opens at low ambient start-up, there will be
a 2 minute override to prevent nuisance
trip-outs ( for LAU only).
High Pressure Cutouts (HP1, HP2)
These units have high pressure cutouts that
open and stop compressor operation if the
discharge pressure reaches 400 ± 7 psig.
The cutout automatically resets when
pressure drops to 300 ± 20 psig.
Reset Relays (CR1,CR2)
If the unit is shut down by safety devices
(LP, HP, FS, FU, KF etc.) the reset relay
locks out the compressor contactor (MC1,
MC2). This prevents the system from
recycling until the condition that caused the
safety devices to trip is determined and
corrected.
CAUTION: To prevent unit damage, do
not reset the control circuit until the
cause of the safety lockout is identified
and corrected.
To reset CR1 and CR2, open and reclose
the unit REMOTE/OFF/ON switch.
Anti-freeze Cutout (FS1, FS2, FU)
The FS and FU are designed to protect the
evaporator from freeze damage in the event
of a water temperature thermostat (WTT)
malfunction or restricted water flow. The
FU’s remote sensing bulb is mounted at the
outlet end of the evaporator, where it
monitors leaving water temperature. If
during normal unit operation, the leaving
chilled water temperature falls to the trip
point, the FU will open to interrupt compres-
sor operation.
When leaving chilled water temperature falls
down, the suction temperature also falls
down. For further protection to avoid freeze
damage, another freezestat ( FS1 , FS2 ) in
contact with the suction line. If suction
temperature falls to the trip point , the FS1
(FS2) will open to interrupt compressor
operation.
Motor Overloads
These units have internal compressor and
condenser fan motor overloads to protect
the motors from overcurrent and overheat-
ing conditions and automatically reset as
soon as they cool sufficiently. Pump motor
has thermal overload installed at the load
contactor. Pump overload needs manual
reset.
Cooling Mode
Water Temperature Thermostat
Operation (TS1, TS2) for cooling mode
For Double Refrigeration Circuit Operation
At Start-up, the pump will come on
immediately. Two minutes after the pump is
on and EWT(entering water temperature)is
above 14.0 °C, compressor
1 will start.
One minute later, if the EWT is above 13.
5°C, compressor
2 will start.
When cooling demand is met and EWT
drops to 10.0 °C. Compressor
1 will stop,if
EWT continues to fall to 9.5 °C,compressor

2 will stop. Subsequently,when load
builds up and EWT rises to 13.5 °C com-
pressor
2 comes on, and if EWT rises
further to 14.0°C, compressor
1 comes on.
Pump remains on unless the unit is turned
off.
25
For Single Refrigeration Circuit Operation
For units with only one refrigerant circuit, the
operation of water pump, fan and compres-
sor is exactly the same. The only difference
is the unit will operate the single compressor
from any temperature over 14.0 °C and 10.
0°C when the compressor will stop.
Heating Mode
Water Temperature Thermostat
Operation (TS3, TS4) for cooling mode
For Double Refrigeration Circuit Operation
At start-up, pump will come on immediately.
Two minutes after the pump is on and EWT
(entering water temperature)is below 38.
0°C, compressor
1 will start. One minute
later, if EWT is below 39.0 °C, compressor

2 will start.
When heating demand is met and EWT
rises to 42.0 °C, compressor
1 will stop, if
EWT continues to rise to 43.0 °C,compres-
sor
2 will stop. Subsequently,when load
builds up and EWT drops to 39.0 °C,
compressor
2 comes on, and if EWT
drops further to 38.0 °C, compressor
1
comes on. Pump remains on unless the unit
is turned off.
For Single Refrigeration Circuit Operation
For units with only one refrigerant circuit, the
operation of water pump, fan and compres-
sor is exactly the same. The only difference
is the unit will operate the single compressor
from any temperature below 38.0 °C and 42.
0 °C when the compressor will stop.
CGA-SVX01B-EN
Table 4 : Range of Operating Ambient
Model Standard Unit Low Ambient Unit (If LAU option is added)
All Models Cooling Mode 15˚C-46˚C 7°C-46°C
All Models Heating Mode Above 10˚C Above -4˚C

Table 5 : Control Settings and Time Delays

Control Description Electrical Designation Contacts Open Contacts Close (Reset)
High Pressure Cutoff HP1, HP2 400
7 psig 300
20 psig
Low Pressure Cutoff LP1, LP2 25
4 psig 50
4 psig
Antifreeze Cutout (Refrigerant Side) FS1, FS2 -3˚C
2.0˚C 3˚C
2.0˚C
Antifreeze Cutout (Water Side) FU 1.8˚C
1.5˚C 7˚C
1.5˚C
1st compressor On Delay TR1 Normally Open, Time Closed 2 Minutes
2nd compressor On Delay TR2 Normally Open, Time Closed 3 Minutes
Low Suction Pressure Override Delay (CGAR) TR3, TR4 Normally Closed, Time Open 2 Minutes

© American Standard Inc. 2004 26 CGA-SVX01B-EN


Once the unit has been operating for about
30 minutes and the system has stabilized,
check operating conditions and complete the
checkout procedure described below:
Maintenance
Monthly

Check suction and discharge pressures
for normal operating pressures.

Check the liquid line sight glass indicator
for normal operating conditions.

If operating pressures and sight glass
conditions indicate a refrigerant shortage,
measure system superheat and
subcooling.

If operating conditions indicate an
overcharge, slowly (to minimize oil loss)
recover refrigerant from the schraeder
valve.

Open the unit disconnect switch; then
manually rotate the condenser fan(s) to
ensure proper orifice clearance.

Inspect the fan mounting bolts for
tightness.

Check fan set screws for tightness.

Please clean up internal and pipe’s
strainer once the unit first starts running
and monthly after use.
27
Annually

Perform all monthly maintenance
procedure.

Have a qualified service technician check
the setting and function of each control
and inspect the condition of all contactors
and replace as necessary.

Drain water from unit. Inspect piping for
damage. Clean out the built-in water
strainer and any other in-line water
strainer.

Clean and repaint any corroded surfaces.

Clean condenser coil with soft brush and
water spray.

Inspect the expansion valve(s) sensing
bulbs for cleanliness; clean if required.
These bulbs must make good contact
with the suction lines and must be
properly insulated.

Clean condenser fan.
CGA-SVX01B-EN
 TROUBLE ANALYSIS

A. Compressor Neither Starts Nor Hums

Probable Cause Recommended Action
(1) No power to unit Check for followings:
a. Disconnect switch open
b. Fuse(s) blown
(2) No call for cooling Check for followings:
a. Defective thermostat
b. Broken or improper control wiring
c. Blown control power fuse
(3) Compressor start delay (TR1,TR2) timer has not timed out time out Wait at least 2 minutes for the timer to time out
(4) Unit locked out by reset relay (CR) Check for the followings:
a. Excessive discharge pressure
b. Defective high pressure control
c. Low charge; Low pressure cut-out
d. Gate/water valve not open causing flow switch or anti-freeze
cutoff to trip
e. Fan motor internal temperature switch open
f . Defective reset relay contact
(5) Compressor contactor will not close Check for the followings:
a. Defective compressor contactor
b. Improper wiring
c. Reset relay (CR) open
d. Low pressure cut-out open
(6) Compressor winding stat open Check compressor amp draw

B. Compressor Hums, But Will Not Start

Probable Cause Recommended Action
(1) Low voltage at compressor Check for the followings:
a. Single blown fuse
b. Low line voltage
c. Defective compressor contactor
d. Loose wiring connections
(2) Defective compressor Check for the followings:
a. Open motor winding
b. Excessive amp draw on all phases
(3) Insufficient starting voltage (Single-Phase Units Only) Check for the followings:
a. Defective start capacitor
b. Defective start relay

© American Standard Inc. 2004 28 CGA-SVX01B-EN

C. 2nd Stage Compressor Fails To Start
Probable Cause Recommended Action
(1) Time delay contacts fail to close Replace time delay relay
(2) No call for cooling Check for the followings:
a. Defective thermostat
b. Broken or improper control winding
(3) Unit locked out by reset relay (CR) See (A) item (4)
(4) Compressor contactor will not close See (A) item (5)

D. Compressor Short Cycles

Probable Cause Recommended Action
(1) Intermittent contact in control circuit Check for the followings:
a. Defective relay contacts
b. Loose wiring connections

E. Compressor Runs Continuously

Probable Cause Recommended Action
(1) Unit undersized for load (cannot maintain water temperature) Check for cause of excessive load
(2) Thermostat setpoint too low Readjust thermostat
(3) Defective thermostat or control wiring Replace thermostat
Replace or repair control wiring
(4) Welded contacts on compressor contactor Repair or replace contactor
(5) Leaky valves in compressor (indicated by abnormally low Replace compressor
discharge and high suction pressures)
(6) Shortage of refrigerant (indicated by reduced capacity, high Find and repair refrigerant leak
superheat, low subcooling, and low suction pressure) Recharge system

F. Compressor Motor Winding Stat Open

Probable Cause Recommended Action
(1) Excessive load on evaporator (indicated by high supply water Check for the followings:
temperature) a. Excessive water flow
b. High return water temperature
(2) Lack of motor cooling (indicated by excessive superheat) Check for the followings:
a. Improper expansion valve setting
b. Faulty expansion valve
c. Restriction in liquid line
(3) Improper voltage at compressor Check for the followings:
a. Low or imbalanced line voltage
b. Loose power wiring
c. Defective compressor contactor
(4) Internal parts of compressor damaged Replace compressor

29 CGA-SVX01B-EN
G. Compressor is Noisy
Probable Cause Recommended Action
(1) Internal parts of compressor damaged or broken (compressor Replace compressor
knocks)
(2) Liquid floodback (indicated by abnormally cold suction line and Check and adjust superheat
low superheat)
(3) Liquid refrigerant in compressor at start-up (indicated by Check for refrigerant overcharge
abnormally cold compressor shell)

H. System Short of Capacity

Probable Cause Recommended Action
(1) Low refrigerant charge (indicated by high superheat and low Add refrigerant
subcooling)
(2) Clogged filter drier (indicated by temperature change in Replace filter drier or filter drier core
refrigerant line through drier)
(3) Incorrect expansion valve setting Readjust expansion valve
(4) Expansion valve stuck or obstructed(i.e., high superheat and Repair or replace expansion valve
high water temperature)
(5) Low evaporator water flow Check strainers. Adjust water flow
(6) Noncondensibles in system Evacuate and recharge system
(7) Leaky valves in compressor (i.e., operation at abnormally high Replace compressor
suction and low discharge pressures)

I. Suction Pressure Too Low

Probable Cause
(1) Shortage of refrigerant (i.e., high superheat, low subcooling)
(2) Thermostat set too low (i.e., low discharge pressure, low leaving
water temperature)
(3) Low water flow
(4) Clogged filter drier
(5) Expansion valve power assembly has lost charge
(6) Obstructed expansion valve (i.e., high superheat)
Recommended Action
Find and repair leak; recharge system
Readjust thermostat
Check for clogged strainers and ncorrect balancing valve settings
Check for frost on filter drier. Replace if needed
Repair or replace expansion valve power head assembly
Clean or replace valve

J. Suction Pressure Too High

Probable Cause Recommended Action
(1) Excessive cooling load (i.e., high supply water temperatures) See (E) above
(2) Expansion valve overfeeding (i.e.,superheat too low, liquid Adjust superheat setting; verify that remote bulb is properly attached
flooding to compressor) to suction line
(3) Suction valves broken (i.e. noisy compressor) Replace compressor

© American Standard Inc. 2004 30 CGA-SVX01B-EN

K. Discharge Pressure Too Low
Probable Cause Recommended Action
(1) Shortage of refrigerant (i.e., low subcooling, high superheat, Find and repair leak; recharge system
bubbles in sight glass)
(2) Broken or leaky compressor discharge valves Replace compressor
(3) Defective low pressure switch Replace defective control
(4) Unit running below minimum operating ambient Provide adequate head pressure controls, or an ambient lockout
switch

L. Discharge Pressure Too High

Probable Cause Recommended Action
(1) Too little or too warm condenser air; airflow restricted Clean coil; Check fans and motors for proper function
(2) Air or non-condensable gas in system (i.e., exceptionally hot Evacuate and recharge system
condenser)
(3) Refrigerant overcharge (i.e., high subcooling, low superheat, Recover excess refrigerant
high suction pressure)
(4) Excessive system load Reduced load
(5) Defective condenser fan or fan pressure control (i.e., 1 fan off, Repair or replace switch
high condenser pressure)

M. System Cannot Heating Mode (CGAR Model Only)

Probable Cause Recommended Action
(1) Broken or improper control wiring Check control wiring
(2) Defective four-way valve Replace four-way valve

N. Suction Pressure Too Low - Heating Mode (CGAR Model Only)

Probable Cause Recommended Action
(1) Low refrigerant charge Add refrigerant
(2) Too little or too cold evaporator air; airflow restricted Clean coil; Check fans and motors for proper function
(3) Unit running below minimum operating ambient Provide an ambient lockout switch
(4) Expansion valve power assembly has lost charge Repair or replace expansion valve power head assembly

O. Discharge Pressure Too High - Heating Mode (CGAR Model Only)

Probable Cause Recommended Action
(1) Low water flow Check for clogged strainers and incorrect balancing valve settings
(2) Defective heating thermostat switch a. Verify that sense bulb is properly inserted bulbwell of
heat-exchanger
b. Replace heating thermostat switch

31 CGA-SVX01B-EN
 FM
38631
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North American Group Literature Order Number CGA-SVX01B-EN-0404

The Trane Company
File Number CGA-IOM-7
3600 Pammel Creek Road
La Crosse, Wl 54601-7599 Supersedes CGA-SVX01A-EN-0701

http : // www.trane.com Stocking location Taipei, Taiwan

Since The Trane Company has a policy of continuous product improvement, it reserves the right to change design and
An American-Standard Company specifications without notice.