Trane CCAF, CGWF User Manual
Scroll Liquid Chillers
Model CGWF and CCAF
20 to 60 Tons (60 Hz)
17 to 50 Tons (50 Hz)
Water-Cooled and Condenserless
Built For the Industrial and Commercial Markets
January 2004
CG-PRC012-EN
Introduction
The Trane 20-60 Ton Scroll Liquid Chiller
More Than Just Another “Improved”
Chiller
— Advanced Design
— Better Reliability
— Superior Efficiency
— New CH530 Controls
— Better Availability
— Easier To Install and Operate
Microprocessor
Operator
Interface
Design
The Trane scroll compressor is the most
advanced scroll compressor in the
industry.
Reliability
64 percent fewer compressor parts,
compared to reciprocating compressors,
mean long and reliable life.
Efficiency
CGWF scroll chillers meet and exceed
ASHRAE Standard 90.1 full and part load
efficiencies. Part load efficiencies are
simply unmatched by reciprocating
chillers.
Control
CH530 controls enable scrolling access
to inputs and operating information via
the LCD touch-screen display. Jobspecific communication options allow
greater reporting flexibility. The CH530 is
compatable with LonMark
communications.
Availability
Fast ship cycles on both stock and builtto-order specials.
Installation
Small unit size, factory wiring, easy
lifting provisions, and start-up control
logic mean quick and easy setup.
Chillers fit through standard singlewidth door.
Operation
Smart safety features and over 60
diagnostic displays mean easy and
virtually trouble-free operation.
Rugged
Trane Scroll
Compressor
Condenser
Leaving
Water
Piping
Condenser
Entering
Water
Piping
Control
Panel
Evaporator
Leaving
Water Piping
CG-PRC012-EN© 2004 American Standard Inc. All rights reserved.
Contents
Introduction
Features and Benefits
World Class Efficiency and Reliability
Options
Controls
Application Considerations
Model Number
General Data
Selection Procedure
Performance Data
Full Load Performance
Part Load Performance
Adjustment Factors
Pressure Drops
2
4
8
12
13
14
15
16
CG-PRC012-EN
Electrical Data and Connections
Typical Wiring Diagram
Field Layout
Dimensional Data
Weights
Mechanical Specifications
27
32
37
38
3
Features and
Benefits
Trane Value Means Fast Availability,
Easy Installation and Quality Service
Packed Stock For Fast Delivery
When your project is a fast-track job,
Trane can help. A wide range of chillers
are stocked and can be shipped soon
after receipt of your order.
Build To Order
Need a special chiller fast? Think Trane
scroll chillers. New manufacturing
technology and inventory control means
the fastest delivery schedule in the
industry. Wide array of standard options
provides the right chiller for the job fast.
Installation
• Only one power connection hook-up —
for fast and inexpensive installation.
• Integrated Comfort™ system means
only single pair connections are
required for control interfaces and
therefore, lower total installation costs.
• Factory refrigerant and oil charged
units help speed installation.
• All units easily fit through a standard
single width door.
• CH530 provides a wealth of
information.
• Factory testing of all Trane equipment
ensures the system works, allowing
smoother start-up & reducing follow-up
costs.
Easy Serviceability
Trane 20 through 60 ton scroll chillers
are designed with service personnel in
mind. All major components are
replaceable without complete unit
disassembly. Plus, CH530 provides
diagnostic capability to aid service
personnel in analyzing problems.
Therefore, if a problem does occur, the
chiller can be up and running in a shorter
period of time.
Single-Source Responsibility
A wide range of products designed for
complete compatibility are available with
the scroll chillers. Your entire building
comfort system can be completed using
components from Trane.
The Added Value of Applications
Expertise
You get a quality chiller, properly
selected and applied in a properly
designed system. That means a comfort
system that works, the first time!
The standard ARI rating condition
(54/44°F and 85°F/3.0 gpm per ton) and
IPLV are ARI certified. All other ratings,
including the following, are outside the
scope of the certification program and
are excluded:
Glycol.
•
50 Hz.
•
Condenserless models CCAF. Water Chiller Systems Business Unit
•
CG-PRC012-EN4
Features and
World Class Efficiency
ASHRAE Standard 90.1
meet and exceed the new efficiency
levels mandated by ASHRAE Standard
90.1. This new standard requires higher
efficiencies than past technologies can
deliver. It mandates higher efficiency
levels for scroll water chillers in
comparison to reciprocating chillers. In
fact, energy efficiency is so paramount
the US Federal Government has
adopted standard 90.1. Federal Executive
Order mandates energy consuming
devices procured must be in the top 25%
of their class. In the case of chillers,
ASHRAE 90.1 is the product standard for
measurement.
Risk.
Not only has ASHRAE 90.1 been
adopted by the US Federal Government,
it’s expected to be adopted domestically,
if not globally, in the future. Make sure
that your chillers as well as your entire
HVAC system complies, or you may be
caught retrofitting your project with new
equipment and paying extra design
dollars if the code changes during
construction.
Trane’s CGWF was designed with the
end user’s requirements in mind.
Efficiency and reliability were primary
design concerns with this latest
generation machine.
Operating Torque
All Trane chillers
Benefits
& Reliability
Leading in Efficiency and Reliability with State-Of-The-Art
Scroll Compressor Technology
Efficiency
The energy efficiency of the scroll chiller
results in energy costs lower than any
other comparable chiller. Full load
efficiencies are improved beyond
reciprocating chillers, but part load
efficiencies are simply unmatched by any
other manufacturer.
Superior efficiencies are obtained by
combining many of the traditional scroll
chiller energy efficient features with the
Trane scroll compressor technology.
HERE’S HOW:
• Scroll compressor’s positive
displacement design
• Dual refrigerant circuits (40-60 ton units)
• Multiple compressors
• Optimum system design
• Reduced friction
• No valves
• Advanced heat transfer surfaces
Scroll Chiller Energy Usage Savings
Typical Reciprocating
Chiller
Reliability
The Trane scroll chiller with many new
improvements, now brings an exciting
new compressor to the commercial
market — the Trane scroll compressor.
Trane has designed the scroll
compressor to be a leader in reliability.
HERE’S HOW:
• Simple design with 64 percent fewer
parts than equal capacity reciprocating
compressor.
• Scroll compliance allows liquid and dirt
to pass through without damaging
compressor (liquid slugging resistant).
• Advanced microelectronics protect both
compressor and motor from typical
electrical fault conditions.
• Scroll compressors have less than a
third the torque variations of a
reciprocating compressor.
• Years of laboratory testing have
optimized compressor and chiller
systems reliability.
• Water-cooled scroll chillers are factory
tested.
10-20% Annual Energy Savings
Chart illustrates low torque variation of the
Trane scroll compressor vs reciprocating
compressor.
CG-PRC012-EN
Scroll Chiller
Kilowatt Hours
Chiller Load (%)
Graph illustrates Trane scroll chiller’s superior annual energy costs vs typical reciprocating
chillers.
5
Features and
World Class Efficiency
General
The scroll compressor has two scrolls.
The top scroll is fixed and the bottom
scroll orbits. Each scroll has walls in a
spiral shape that intermesh.
Inlet-First Orbit
As the bottom scroll orbits, two
refrigerant gas pockets are formed and
enclosed.
Compression-Second Orbit
The refrigerant gas is compressed as the
volume is reduced closer to the center of
the scroll.
Discharge-Third Orbit
The gas is compressed further and
discharged through a small port in the
center of the fixed scroll.
Benefits
& Reliability
Trane Scroll Compressor
— Maximum Efficiency with Enhanced Reliability
Scroll Principal Components
This is a cutaway view of a hermetic,
scroll compressor, showing the relative
positions of the principal components.
Shown is a Trane 10-ton, 3600 rpm, 60 Hz
[3000 rpm, 50 Hz] scroll compressor as
an example.
The principle of operation of this
example compressor is as follows: The
suction gas is drawn into the compressor
at A. The gas then passes through the
gap between the rotor and stator, B,
cooling the motor, before it enters the
compressor housing, C. Here, the
velocity of the gas is reduced, causing a
separation of the entrained oil from the
gas stream. The gas then enters the
intake chamber, D, that encircles the
scrolls.
Finally, the suction gas is drawn into the
scroll assembly where it is compressed
and discharged into the dome of the
compressor. The dome of this example
compressor acts as a hot gas muffler
which dampens the pulsations before the
gas enters the discharge line, E.
CG-PRC012-EN6
Features and
Benefits
Options
Hot Gas Bypass: Hot gas bypass option
allows unit operation below the
minimum step of unit unloading. The
regulator valve, along with all associated
refrigerant piping and electrical wiring,
are factory installed and tested on one
refrigeration circuit. Unit does not start in
hot gas bypass mode. If the unit operates
in bypass mode for 30 minutes without a
call for cooling, it will pump down and
shut off. Unit starts immediately upon a
further call for cooling.
Chilled Water Reset: Front panel settable
control, microprocessor based control
strategy, and field-installed sensor for
ambient temperature based reset are
included in this option. Return water
reset sensor is standard, but panel
controller and control strategy must be
ordered as an option.
Tracer Summit Communication
Interface: Permits bi-directional
communication to the Trane Integrated
Comfort system.
LonTalk LCI-C Communication Interface:
Provides the LonMark chiller profile
inputs/outputs for use with a generic
building automation system.
Remote Input Options
Remote chilled water setpoint input
(4-20mA/2-10Vdc), compressor inhibit
which locks out the second compressor
on each circuit reducing the kW draw or
both.
Control Output Options
Programmable relays provided to
indicate: Compressor running, maximum
capacity, chiller limit mode, warning
(informational diagnostic), alarm latching
(shutdown diagnostic), alarm
nonlatching (shutdown diagnostic),
alarm latching or nonlatching.
Options
Ice Making Controls: In ice-making
mode, the unit will operate fully loaded
in response to jobsite supplied contact
closure. Ice making will terminate when
the return fluid temperature falls below
an adjustable setpoint (minimum 20°F
[-6.7°C]). When not in ice making mode,
unit will provide modulating capacity
control based on leaving chilled fluid
temperature (20-55°F) [-6.7°C to 12.8°C].
Unit Mounted Disconnect Switch: Nonfused molded case disconnect switch
factory installed in control panel for
disconnecting main three-phase power.
Isolators: Neoprene-in-shear isolators for
field installation under unit frame.
Sound Attenuation: Factory-installed
acoustical attenuation for applications
where extremely low sound level is
required.
Water Regulating Valves: Field-installed
valves provide means for control of head
pressure.
Outdoor Temperature Sensor: Fieldinstalled outdoor temperature sensor
with an adjustable setpoint provides
means for low ambient lockout.
Condenser Water Temperature Sensor:
Factory installed temperature sensor
provided for microprocessor display.
CG-PRC012-EN
7
Controls
Human Interfaces
The Trane water-cooled 20-60 ton scroll
CGWF chiller offers an easy-to-use
operator interface panel, the DynaView.
DynaView is an LCD touchscreen display
that is navigated by file tabs. This is an
advanced interface that allows the user
to access any important information
concerning setpoints, active
temperatures, modes, electrical data,
pressures, and diagnostics.
Safety Controls
A centralized main processor offers a
higher level of machine protection. Since
the safety controls are smarter, they limit
compressor operation to avoid
compressor or evaporator failures,
thereby minimizing nuisance shutdown.
™
Chiller Controls (CH530) directly
Tracer
senses the control variables that govern
the operation of the chiller: evaporator
pressure and condenser pressure. When
any one of these variables approaches a
limit condition where damage may
occur to the unit or shutdown on a
safety, Tracer Chiller Controls takes
corrective action to avoid shutdown and
keep the chiller operating. This happens
through compressor shedding. Tracer
Chiller Controls optimizes total chiller
power consumption during normal
operating conditions. During abnormal
operating conditions, the
microprocessor will continue to optimize
chiller performance by taking the
corrective action necessary to avoid
shutdown. This keeps cooling capacity
available until the problem can be
solved. Whenever possible, the chiller is
allowed to perform its function; making
chilled water. Overall, the safety controls
help keep the building or process
running and out of trouble.
Figure C1. DynaView operator interface
Standalone Controls
Interface to standalone units is very
simple; only a remote auto/stop for
scheduling is required for unit operation.
Signals from the chilled water pump
contactor auxiliary or a flow switch are
wired to the chilled waterflow interlock.
Signals from a time clock or some other
remote device are wired to the external
auto/stop input.
Standard Features
• External Auto/Stop — A jobsite
provided contact closure will turn the
unit on and off.
• Chilled Water Flow Interlock — A
jobsite provided contact closure from a
chilled water pump contactor and/or a
flow switch is required and will allow
unit operation if a load exists and flow
is proven. This feature will allow the
unit to run in conjunction with the
pump system.
• Emergency Stop — A jobsite supplied
contact opening wired to this input will
turn the unit off and require a manual
reset of the unit microcomputer. This
closure is typically triggered by a
jobsite supplied system such as a fire
alarm.
• Chilled Water Pump Control — Unit
controls provide an output to control
the chilled water pump(s). One contact
closure to the chiller is all that is
required to initiate the chilled water
system.
• Chilled Water Temperature Reset —
Reset can be based on return water
temperature or outdoor air temperature
(optional).
• Condenser Water Pump Control — Unit
controls provide an output to control
the condenser water pump(s). One
contact closure to the chiller is all that is
required to initiate the chilled water
system.
• Condenser Water Flow Protection — A
jobsite supplied contact closure from a
flow switch or pressure switch is
required and will shut down the unit if
flow is lost.
CG-PRC012-EN8
Controls
Easy Interface to A Generic Building
Management System
Controlling the scroll CGWF chiller with
building management systems is stateof-the-art, yet simple with either the
LonTalk Communications Interface for
Chillers (LCI-C) or Generic Building
Management System Hardwire Points.
Simple Interface with Other Control
Systems
CH530 controls afford simple interface
with other control systems, such as time
clocks, building automation systems,
and ice storage systems. This means
you have the flexibility to meet job
requirements while not having to learn a
complicated control system. This setup
has the same standard features as a
stand-alone water chiller, with the
possibility of having additional optional
features.
What are LonTalk, Echelon, and
LonMark?
LonTalk is a communications protocol
developed by the Echelon Corporation.
The LonMark association develops
control profiles using the LonTalk
communication protocol. LonTalk is a
unit level communications protocol,
unlike BACNet used at the system level.
LonTalk Communications
Interface for Chillers (LCI-C)
LonTalk Communications Interface for
Chillers (LCI-C) provides a generic
automation system with the LonMark
chiller profile inputs/outputs. The inputs/
outputs include both mandatory and
optional network variables. Note:
LonMark network variable names are in
parentheses when different from chiller
naming convention.
Chiller Inputs:
• Chiller Enable/Disable
• Chilled Liquid Setpoint (Cool Setpoint)
• Compressor Inhibit
• Chiller Mode (Ice Making)
Chiller Enable/Disable
Allows for chiller to be started or
stopped depending on if certain
operating conditions are met.
Chilled Water Setpoint
Allows for the external setting
independent of the front panel setpoint
to adjust the leaving water temperature
setpoint.
Compressor Inhibit
Locks out the second compressor on
each circuit, reducing the kW draw.
Ice Making
Provides interface with ice making
control systems. Please refer to page 11
for more information.
Chiller Outputs:
• On/Off
• Active Setpoint
• Average Percent RLA
• Compressor Inhibit
• Compressor Starts
• Compressor Run Times
• Leaving Chilled Water Temperature
• Entering Chilled Water Temperature
• Evaporator Refrigerant Temperature
• Evaporator Refrigerant Pressure
• Evaporator Water Pump Request &
Flow Status
• Leaving Condenser Water Temperature
• Entering Condenser Water Temperature
• Condenser Refrigerant Temperature
• Condenser Refrigerant Pressure
• Condenser Water Pump Request &
Flow Status
• Outdoor Air Temperature (CCAF)
• Alarm Descriptor
• Chiller Status
Active Setpoint
Indicates the current value of the leaving
water temperature setpoint
Average Percent RLA
Provides the current capacity level via %
RLA
Compressor Starts and Run Times
Provides the number of starts and run
time for each compressor
Alarm Descriptor
Provides alarm messages based on predetermined criteria
Chiller Status
Indicates the running modes and states
of the chiller, i.e. Running in alarm mode,
chiller enabled, chiller being locally
controlled, etc…
Generic Building Management
System Hardwire Points
GBAS may be achieved via hardware
input/output as well. The input/outputs
are as follows:
Chiller Hardwire Inputs Include:
• Chiller Enable/Disable
• Circuit Enable/Disable
• External Chilled Water Setpoint
• Compressor Inhibit
• Ice Making Enable
Programmable Relays and Alarms
The unit provides seven output options,
of which four can be chosen.
a) Compressor running indication
b) Maximum capacity
c) Chiller limit mode
d) Warning informational diagnostic
indication
e) Alarm latching shutdown diagnostic
indication
f) Alarm nonlatching shutdown
diagnostic indication
g) Alarm latching or nonlatching
shutdown diagnostic indication
CG-PRC012-EN
9
Controls
Tracer Summit controls — Interface
With The Trane Integrated Comfort
System (ICS)
Trane Chiller Plant Control
The Tracer Summit Chiller Plant Building
Management System with Chiller Plant
Control provides building automation
and energy management functions
through stand-alone control. The Chiller
Plant Control is capable of monitoring
and controlling your entire chiller plant
system.
Application software available:
• Time-of-day scheduling
• Demand limiting
• Chiller sequencing
• Process control language
• Boolean processing
• Zone control
• Reports and logs
• Custom messages
• Run time and maintenance
• Trend log
• PID control loops
And of course, the Trane Chiller Plant
Control can be used on a stand-alone
basis or tied into a complete building
automation system.
When the scroll CGWF chiller is used in
conjunction with a Trane Tracer
™
Summit system, the unit can be
monitored and controlled from a remote
location. The chiller can be controlled to
fit into the overall building automation
strategy by using time of day
scheduling, timed override, demand
limiting, and chiller sequencing. A
building owner can completely monitor
the chiller from the Tracer system, since
all of the monitoring information
indicated on the unit controller’s
microcomputer can be read off the
Tracer system display. In addition, all the
powerful diagnostic information can be
read back at the Tracer system. Best of
all, this powerful capability comes over a
single twisted pair of wires! The scroll
liquid chillers can interface with many
different external control systems, from
simple stand-alone units to ice making
systems.
A single twisted pair of wires tied directly
between the CGWF chiller and a Tracer
™
Summit system provides control,
monitoring and diagnostic capabilities.
Control functions include auto/stop,
adjustment of leaving water temperature
setpoint, compressor operation lockout
for kW demand limiting and control of
ice making mode. The Tracer system
reads monitoring information such as
entering and leaving evaporator water
temperatures and outdoor air
temperature. Over 60 individual
diagnostic codes can be read by the
Tracer system. In addition, the Tracer
system can provide sequencing control
for up to 25 units on the same chilled
water loop. Pump sequencing control
can be provided from the Tracer system.
Tracer ICS is not available in conjunction
the external setpoint capability.
Required Options
Tracer Interface
External Trane Devices Required
Tracer Summit
™
, Tracer 100 System or
Tracer Chiller Plant Control
Additional Features That May Be Used
Ice Making Control
CG-PRC012-EN10
Controls
Trane Chiller Plant Automation
Trane’s depth of experience in chillers
and controls makes us a well-qualified
choice for automation of chiller plants
using scroll liquid chillers. The chiller
plant control capabilities of the Trane
Tracer Summit
®
building automation
system are unequaled in the industry.
Our chiller plant automation software is
fully pre-engineered and tested. It is a
standard software application, not
custom programming which can prove
to be difficult to support, maintain, and
modify.
Energy Efficiency
Trane chiller plant automation
intelligently sequences starting of
chillers to optimize the overall chiller
plant energy efficiency. Individual chillers
are designated to operate as base, peak,
or swing based on capacity and
efficiency. Sophisticated software
automatically determines which chiller
to run in response to current conditions.
The software also automatically rotates
individual chiller operation to equalize
runtime and wear between chillers.
Trane chiller plant automation enables
unique energy-saving strategies. An
example is controlling pumps, and
chillers from the perspective of overall
system energy consumption. The
software intelligently evaluates and
selects the lowest energy consumption
alternative.
Keeping Operators Informed
A crucial part of efficiently running a
chiller plant is assuring that the
operations staff is instantly aware of
what is happening in the plant. Graphics
showing schematics of chillers, piping,
pumps, and towers clearly depict the
chiller plant system, enabling building
operators to easily monitor overall
conditions. Status screens display both
current conditions and upcoming
automated control actions to add or
subtract chiller capacity. CGWF and
other chillers can be monitored and
controlled from a remote location.
Tracer Summit features standard report
templates listing key operating data for
troubleshooting and verifying
performance. Reports for each type of
Trane chiller and three and six-chiller
systems are also standard. Detailed
reports showing chiller runtimes aid in
planning for preventative maintenance.
Swift Emergency Response
We understand the importance of
maintaining chilled water production
while protecting your chillers from costly
damage. If no water flow is detected to a
chiller’s piping, the start sequence is
aborted to protect the chiller. The next
chiller in the sequence is immediately
started to maintain cooling.
In the event of a problem, the operator
receives an alarm notification and
diagnostic message to aid in quick and
accurate troubleshooting. A snapshot
report showing system status just prior
to an emergency shutdown helps
operators determine the cause. If
emergency conditions justify an
immediate manual shutdown, the
operator can override the automatic
control.
Easy Documentation for Regulatory
Compliance
Comprehensive documentation of
refrigerant management practices is
now a fact of life. Trane chiller plant
automation generates the reports
mandated in ASHRAE Guideline 3.
™
Integrated Comfort
Capabilities
When integrated with a Tracer Summit
building management system
performing building control, Trane chiller
plant automation coordinates with
Tracer Summit applications to optimize
the total building operation. With this
system option, the full breadth of Trane’s
HVAC and controls experience are
applied to offer solutions to many facility
issues. If your project calls for an
interface to other systems, Tracer
Summit can share data via BACnet
™
, the
ASHRAE open systems protocol.
Ice Making Systems Controls
An ice making option may be ordered
with the 20-60 ton scroll liquid chiller.
CH530 will accept a command to initiate
ice making. When in the ice making
mode, the chiller will be fully loaded and
will continue to operate until the ice
command is removed or the evaporator
entering water temperature reaches the
active ice termination setpoint. If
terminated on the evaporator entering
water temperature, CH530 will not allow
the chiller to restart until the ice making
command is removed.
Additional Options That May Be Used In
Conjunction
Failure Indication Contacts
Communications Interface (For Tracer
Systems)
Chilled Water Temperature Reset
CG-PRC012-EN
11
Application
Considerations
Unit Location
Units should be installed indoors where
exposure to rain or water splash is
minimal. A level foundation or flooring
must be provided which will support at
least 150 percent of the operating weight
of the unit. The chiller foundation must be
rigid to reduce vibration transmission to a
minimum. Use of vibration isolators is
recommended for applications with
sensitive vibration and noise criteria.
Allow service clearance for compressor
removal as well as evaporator and
condenser tube removal.
Condenser Water Limitations
Water-cooled scroll chillers start and
operate satisfactorily over a range of load
conditions with uncontrolled entering
water temperature.
Reducing the condenser water
temperature is an effective method of
lowering the power input required.
However, by reducing the condenser
water temperature beyond certain limits,
the effect causes a reduction in the
pressure drop across the thermal
expansion valve to a point when system
instability may occur.
In general, continuous machine operation
with entering condenser water
temperature below 60°F [15.5°C] is not
recommended. When the condenser
water temperature is expected to drop
below 60°F [15.5°C], it is recommended
that some form of condenser water
temperature control be used to ensure
optimal machine performance.
Water Treatment
Use of untreated or improperly treated
water in chillers may result in scaling,
erosion, corrosion, algae or slime. It is
recommended that the services of a
qualified water treatment specialist be
engaged to determine what treatment, if
any, is advisable. Trane assumes no
responsibility for the results of untreated,
or improperly treated water.
Water Pumps
Avoid specifying or using 3600 rpm, 60
Hz [3000 rpm, 50 Hz] condenser water
and chilled water pumps. Such pumps
may operate with objectional noise and
vibration. In addition, a low frequency
beat may occur due to the slight
difference in operating rpm between
water pumps and scroll compressor
motors. Where noise and vibration-free
operation is important, Trane
encourages the use of 1750 rpm, 60 Hz
[1450 rpm, 50 Hz] pumps.
Remote Condenser
Remote condensers should be located
as close as possible to the chiller to
ensure minimum pressure drops of
discharge refrigerant. If non-Trane
condensers are provided, a subcooling
circuit must be provided in order to
achieve cataloged performances
(16°F [-8.9°C] subcooling).
CG-PRC012-EN12
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