Trane CGWR30, CGWR65, CCAR30, CCAR20, CGWR40 Installation, Operation And Maintenance Manual

...

Installation, Operation, and Maintenance

Cold Generator™ Scroll Liquid Chillers Model CGWR and CCAR

20 to 65 Tons (60 Hz) Water-Cooled and Compressor Chillers

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.

September 2017

SAFETY WARNING

CG-SVX038A-EN

Introduction

Read this manual thoroughly before operating or servici ng this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING

CAUTIONs

NOTICE

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 and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important 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 according to local rules. For the USA, 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.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. 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.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Material Safety Data Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate MSDS/SDS and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Ingersoll Rand personnel must follow Ingersoll Rand Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. All policies can be found on the BOS

site. Where local regulations are more stringent than

these policies, those regulations supersede these policies.

• Non-Ingersoll Rand personnel should always follow local regulations.

WARNING

Refrigerant under High Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage. 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 nonapproved refrigerants, refrigerant substitutes, or refrigerant additives.

Introduction

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

CG-SVX038A-EN 3

Table of Contents

Model Number Descriptions . . . . . . . . . . . . . . 5

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . 6

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Inspection Check List and Unit Identification 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Dimensions and Weights . . . . . . . . . . . . . . . . 11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . 27

Unit Controller—Software Installation and  Setup

Unit Startup Procedures . . . . . . . . . . . . . . . . . 33

Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 35

Unit Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Electrical Schematics . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4 CG-SVX038A-EN

Model Number Descriptions

Digit 1, 2, 3, 4 — Unit Type

CGWR=Water-Cooled Chiller CCAR= Compressor Chiller

Digit 5, 6, 7 — Unit Nominal

Tonnage

020 = 20 Nominal Tons 030 = 30 Nominal Tons 040 = 40 Nominal Tons 050 = 50 Nominal Tons 065 = 65 Nominal Tons

Digit 8 — Unit Voltage

A = 208V/60/3 B = 230V/60/3 F = 460V/60/3 G = 575V/60/3

Digit 9, 10 — Design Sequence

A0 = Factory Assigned

Digit 11 — Agency Listing

N= None E = ETL/ETL-C Listed to meet U.S. 

and Canadian Safety Standards

Digit 12 — Condenser Water

Regulating Valve

0=None 1=With

Digit 13 — Evaporator Wye

Strainer

0=None 1 = Nominal Flow Wye Strainer

2 = Nominal Flow Wye Strainer with

installation kit

Digit 14 — Evaporator Temp

Range

0 = Standard Cooling 

42 to 60°F [4.4 to 5.5°C]

1 = Standard Cooling/Ice Making 

20 to 60°F [-6.7 to 15.6°C]

Digit 15 — Power Connection

T = Terminal Block D = Non-Fused Disconnect Switch F = Fused Disconnect Switch

Digit 16 — Short Circuit Rating

(SCCR)

0 = Standard 5 kA Rating 1 = Optional 100 kA Rating

Digit 17 — Sound Attenuator

0 = No Sound Attenuation 3 = Compressor Sound Blanket(s) 9 = Factory Sound Enclosure 

Cabinet(s)

Digit 18 — Local Unit Controller

Interface

0 = Keypad with Dot Pixel Display 1 = Color Touchscreen

Digit 19 — Remote BMS

Interface (Digital Comm)

0=None 2=LonTalk 4=BACnet® Ms/TP 5 = BACnet IP 6=MODBUS 8 = Johnson N2

Digit 20 — Power Monitor

0=None 1=With

Digit 21 — Neoprene Isolator Pads

0=None 1=With

Digit 22 — Flow Switch

0=None 1=With

Digit 23 — Evaporator Fluid Type

0=Water 2 = Ethylene Glycol 3 = Propylene Glycol 4=Methanol

Digit 24 — Condenser Fluid Type

0=Water 2 = Ethylene Glycol 3 = Propylene Glycol 4=Methanol 9 = Not Applicable — 

Compressor-Chiller

Digit 25 — Special Options

0=None 1=With

Nominal flow wye strainer installation kit includes pipe adaptors, differential pressure ports and blowdown valve.

CG-SVX038A-EN 5

Unit Components

Forklift Pockets

Optional Disconnect

Switch Location

Evaporator Water

Inlet (Vic)

Evaporator Water

Outlet (Vic)

Condenser Water

Outlet (FPT)

Condenser Water

Inlet (FPT)

Power Wiring

Location

Unit Nameplate

(inside door)

Optional 15.4” Color Touchscreen

(Keypad w/ Display comes standard)

Rigging Bracket Install Pockets

Removable Water Plate on Shell-andTube Condenser

Suction Line

(1 per circuit)

TXV (1 per circuit)

Charging Port (1 per circuit)

Relief Valve (1 per circuit)

Filter Drier (1 per circuit)

Hot Gas Injection Solenoid Valve (1 per circuit)

Liquid Line (1 per circuit)

Solenoid Valve

(1 per circuit)

Sight Glass

(1 per circuit)

Compressor

Nameplate

6 CG-SVX038A-EN

General Data

Table 1. General data for CGWR water-cooled chillers

Unit Size 20 30 40 50 65 Compressor

Quantityeach22333

Nominal Tons tons 10/10 15/15 10/10, 20 12/12, 25 15/15, 30

Steps of Unloading % 100-50 100-50 100-75-50-25 100-75-50-25 100-75-50-25

Compressor Sound Data

Compressor Sound Data with Sound

Blankets Only(a)

Evaporator

Water Storage gal 2.1 3.0 3.1 3.7 4.6 Minimum Flowgpm30456682104

Maximum Flow gpm 104 151 207 237 295

Condenser (each)

Water Storage (each) gal 3.0 4.5 5.5 7.4 9.2 Minimum Flow (each)gpm2839496484

Maximum Flow (each) gpm 119 167 207 271 342

General Unit

Refrigerant R-410A R-410A R-410A R-410A R-410A

Number of Independent

Refrigerant Circuits

Refrigerant Charge per Circuit (approx.) lb 25 37 24, 24 26, 26 31, 31

Oil Charge (each compressor) oz 112/112 113/113 112/112, 227 112/112, 227 112/112, 227

Notes:

1. Data containing information on two circuits formatted as follows: Circuit 1, Circuit 2

2. Nominal compressor sizes based on 60 Hz.

(a)Compressor manufacturer sound power reported at rated compressor AHRI conditions measured in free space for individual compressors.

(a)

dBA 81.0 84.0 87.2 87.5 90.2 dBA 75.0 78.0 82.8 83.0 85.8

11222

Oil Type POE 160SZ POE 160SZ POE 160SZ POE 160SZ POE 160SZ

Table 2. General data for CCAR compressor chillers

Unit Size 20 30 40 50 65 Compressor

Quantityeach22333

Nominal Tons tons 10/10 15/15 10/10, 20 12/12, 25 15/15, 30

Steps of Unloading % 100-50 100-50 100-75-50-25 100-75-50-25 100-75-50-25

Compressor Sound Data

Compressor Sound Data with Sound

Blankets Only

Evaporator

Water Storage gal 2.1 3.0 3.1 3.7 4.6 Minimum Flowgpm30456682104

Maximum Flow gpm 104 151 207 237 295

General Unit

Refrigerant R-410A R-410A R-410A R-410A R-410A

Number of Independent

Refrigerant Circuits

Refrigerant Charge per Circuit (approx.) lb 16 19 12,12 13,13 16,16

Oil Charge (each compressor) oz 112/112 113/113 112/112, 227 112/112, 227 112/112, 227

Notes:

1. Data containing information on two circuits formatted as follows: Circuit 1, Circuit 2

2. Nominal compressor sizes based on 60 Hz.

(a)Compressor manufacturer sound power reported at rated compressor AHRI conditions measured in free space for individual compressors.

(a)

dBA 81.0 84.0 87.2 87.5 90.2 dBA 75.0 78.0 82.8 83.0 85.8

11222

Oil Type POE 160SZ POE 160SZ POE 160SZ POE 160SZ POE 160SZ

CG-SVX038A-EN 7

General Data

Ambient Limits — CCAR/CAUJ Combination

Minimum Ambient Temperature Limit

Refer to SS-APG014*-EN Application Guide – Pairing Trane CCAR Compressor Chillers (20 to 65 tons) with Trane CAUJ Air-Cooled Condensers (20 to 80 tons).

In general, the minimum outdoor ambient temperature for operation of CCAR compressor chiller in combination with a CAUJ air cooled condenser is 40°F. In some cases, with

factory application approval, the CCAR/CAUJ combination can be operated down to the 20°F ambient.

This minimum is primarily driven by compressor chiller starting considerations and not by effectiveness of condenser ambient controls once the system is up and running. Fan cycling and optimal low ambient dampers do not mitigate the low ambient starting challenge. On a cold day with outdoor ambient temperature below 40°F, the liquid line pressure at the expansion valve inlet, in most circumstances, is extremely low. On start, the suction pressure tends to plunge into the freezing range potentially causing a nuisance fault.

Contact the factory to request application approval for applications where CCAR/CAUJ combination is intended for operation with ambient temperature below 40°F.

Maximum Ambient Temperature Limit

The maximum ambient temperature limit for the CCAR/ CAUJ operation is 110°F.

8 CG-SVX038A-EN

Inspection Check List and Unit Identification

To protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit.

• Inspect the individual pieces of the shipment before accepting the unit. Check for obvious damage to the unit or packing material.

• Inspect the unit for concealed damage as soon as

ssible after delivery and before it is stored.

po Concealed damage must be reported within 15 days.

• If concealed damage is discovered, stop unpacking the

ipment. Do not remove damaged material from the

sh receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery.

• Notify the carrier’s terminal of the damage

mediately, by phone and by mail. Request an

im immediate, joint inspection of the damage with the carrier and the consignee.

• Notify the Trane sales representati repair. Do not repair the unit, however, until damage is inspected by the carrier’s representative.

After completing the in with the unit nameplate, packing list and ordering information. The unit nameplate is mounted inside the control box.

Refer to “Model Number Descriptions,” p. 5 for additional data that can be found on the nameplate.

Check all items against the shipping list. Verify that it is the correct unit and that it is properly equipped. If optional neoprene or spring isolators (or other ship-loose items) are ordered, they are secured in place on the shipping skid or inside the unit control box.

The Installation, Operation, and Maintenance manual can also be found in the unit control box. Be sure to read all of this literature before installing and operating the unit.

spection checklist, identify the unit

ve and arrange for

Each unit is completely assembled with refrigerant piping, power and control wiring, and top coated with two-part epoxy. Refrigeration circuits are leak-tested and dehydrated prior to introduction of refrigerant. CGWR and CCAR units are then fully charged with compressor oil and refrigerant, and run tested prior to shipment.

• CGWR units are shipped with full operating charge of compressor oil

• CCAR units are shipped with a compressor oil and a holding charge of dry nitrogen. CCAR units are to be field piped to condenser, dehydrated and charged with refrigerant by others. Note that compressor oil charge may have to be adjusted. See SS-APG014*-EN, Application Guide, Pairing Trane CCAR Compressor Chillers with Trane CAUJ Air-Cooled Condensers for application guidelines.

and refrigerant.

nominal charge of

Unit Description

Trane CGWR water-cooled chillers and CCAR compressor chillers (condenserless chillers) are designed for installation on a prepared surface in a suitable, weatherproof location above freezing (32°F).

• CGWR/CCAR 20 and 30 ton chiller units have one refrigerant c compressor set piped in parallel.

• CGWR/CCAR 40, 50 and 65 ton chiller units have two refrigerant circuits. One refrigerant circuit is fit a manifolded scroll compressor set piped in parallel, and the other refrigerant circuit has a single scroll compressor.

Units also have brazed plate e condenser (CGWR only) and control box with integral control panel, all mounted on a common frame.

CG-SVX038A-EN 9

ircuit fitted with a manifolded scroll

vaporator, shell-and-tube

ted with

Electrical Data

Table 3. Electrical data — CGWR water cooled chillers & CCAR compressor chillers

Unit Wiring Data Compressors

Unit Size

200-230/3/60 88 125 100

Notes:

1. Data containing information on two circuits formatted as follows: Circuit 1, Circuit 2

2. Add 31 VA to control power for optional water regulating valve (WRV)

3. Use copper conductors only.

4. Local codes may take precedence.

5. Voltage Utilization Range:

460/3/60 42 60 50 19/19 142/142 98 575/3/60 35 50 40 15/15 103/103 98

200-230/3/60 108 150 125

460/3/60 56 80 60 25/25 197/197 98 575/3/60 50 70 60 22/22 135/135 98

200-230/3/60 162 225 175

460/3/60 78 110 90 19/19, 33 142/142, 215 159 575/3/60 64 80 70 15/15, 26 103/103, 175 159

200-230/3/60 185 250 225

460/3/60 88 125 100 19/19, 40 147/147, 260 159 575/3/60 69 90 80 17/17, 29 122/122, 210 159

200-230/3/60 232 300 250

460/3/60 113 150 125 25/25, 51 197/197, 320 159 575/3/60 93 125 110 22/22, 38 135/135, 235 159

Rated Voltage

208-230/3/60 460/3/60 380/3/60 575/3/60

Circuit

Ampacity

Utilization Range

187-253 414-506 342-418 518-632

Maximum Fuse Size

Minimum

Recommended

Dual Element

Fuse Size Qty

Refrig.

Circuits

2 1 10/10

2 1 15/15

3 2 10/10, 20

3 2 12/12, 25

3 2 15/15, 30

Nom.

Tons

RLA

(ea)

39/39 267/267 98

48/48 351/351 98

39/39, 67 267/267, 485 159

41/41, 82 304/304, 560 159

48/48, 109 351/351, 717 159

LRA

(ea)

Control

KWRated Voltage

10 CG-SVX038A-EN

Dimensions and Weights

T (4 PLACES)

13 14

Dimensions

The Trane application manual and/or project submittals contain dimensional data, application data, and electrical data as required.

Figure 1. CGWR/CCAR 20 to 30 ton mechanical drawing

Refer to name plate on control box door (inside) for specific unit electrical data.

These documents can be forwarded for specific jobs as part of a job submittal package upon request.

CG-SVX038A-EN 11

Dimensions and Weights

Table 4. CGWR/CCAR 20 to 30 ton — in (mm)

Dimension CGWR 20 CGWR30 CCAR 20 CCAR30

(a)

B 59.8 (1519) 59.8 (1519) 45.8 (1163)* 45.8 (1163)* C 19.3 (490) 20.1 (511) N/A N/A D 26.7 (678) 26.7 (678) 26.7 (678) 26.7 (678) E 28.9 (734) 28.9 (734) 28.9 (734) 28.9 (734)

F 37.0 (940) 37.0 (940) 37.0 (940) 37.0 (940) G 17.0 (432) 17.0 (432) 17.0 (432) 17.0 (432) H 20 (508) 20 (508) N/A N/A

I 36 (914) 36 (914) 36 (914) 36 (914)

(b)

K(b) 36 (914) 36 (914) 36 (914) 36 (914)

L 24 (610) 24 (610) 24 (610) 24 (610) M 36 (914) 36 (914) 36 (914) 36 (914) N 53.5 (1359) 53.5 (1359) 39.5 (1003)* 39.5 (1003)* R 33.1 (841) 33.1 (841) 19.1 (485)* 19.1 (485)* S 13.4 (240) 13.4 (240) N/A N/A

T 0.6 (15) 0.6 (15) 0.6 (15) 0.6 (15) U 10.2 (259) 10.2 (259) 10.2 (259) 10.2 (259) V 10.3 (262) 10.4 (264) N/A N/A W 13.9 (353) 15.3 (389) N/A N/A 1 2 (51) VIC 2.5 (64) VIC 2 (51) VIC 2.5 (64) VIC 2 2 (51) VIC 2.5 (64) VIC 2 (51) VIC 2.5 (64) VIC 3 2 (51) FPT 2.5 (64) FPT N/A N/A 4 2 (51) FPT 2.5 (64) FPT N/A N/A

76.6 (1946) 77.5 (1969) 70.4 (1788) 70.4 (1788)

36 (914) 36 (914) 36 (914) 36 (914)

Reference

1 Evaporator Water Inlet 9

2 Evaporator Water Outlet 10 3 Condenser Water Inlet (CGWR only) 11 Condenser (CGWR only)

4 Condenser Water Outlet (CGWR only) 12 Evaporator 5 Power Disconnect (Optional) 13 Panel Power Section — door swing 24 in (610 mm) 6 Power Wire Entry 14 Panel Control Section — door swing 24 in (610 mm)

7 Control Wire Entry 15

8 Control Panel 16

(a)For CGWR020 and 030: If water regulating valve option is ordered, the overall length is 90.9 in and 93.1 in, respectively. (b)Exceptions:

1. A minimum clearance of 42 in (1067mm) is required to other electrically grounded parts.

2. A minimum clearance of 48 in (1220mm) is required betw een two u nits opp osit e eac h oth er (front-t o-front o r back-to - back) o r to other electrically live parts. See Section 110.26 of National Electrical code (NEC).

Condenser Return Waterbox End (CGWR only)- minimum clearance (for maintenance)

Condenser Inlet/Outlet End (CGWR only) minimum clearance (for maintenance)

Additional minimum clearance needed for units with w ater regulating valve option

Location of CCAR refrigerant line connections, 7/8 in liquid line and 1-3/8 in discharge lines

12 CG-SVX038A-EN

Figure 2. CGWR/CCAR 40 to 65 ton mechanical drawing

(4 PLACES)

13 14

Dimensions and Weights

CG-SVX038A-EN 13

Dimensions and Weights

Table 5. CGWR/CCAR 40 to 65 ton — in (mm)

Dimension CGWR40 CGWR50 CGWR65 CCAR40 CCAR50 CCAR65

(a)

B 59.8 (1519) 59.8 (1519) 59.8 (1519) 45.8 (1163)* 45.8 (1163)* 45.8 (1163)* C 13.1 (333) 13.6 (345) 13.6 (345) N/A N/A N/A D 26.7 (678) 26.7 (678) 26.7 (67 8) 26.7 (678) 26.7 (678) 26.7 (678) E 29.6 (752) 29.9 (759) 29.9 (759) 29.0 (737) 29.0 (737) 29.0 (737)

F 51.0 (1295) 51.0 (1295) 51.0 (1295) 51.0 (1295) 51.0 (1295) 51.0 (1295) G 19.2 (488) 19.2 (488) 19.2 (488) 19.2 (488) 19.2 (488) 19.2 (488) H 20 (508) 20 (508) 20 (508) N/A N/A N/A

I 36 (914) 36 (914) 36 (914) 36 (914) 36 (914) 36 (914)

(b)

K(b) 36 (914) 36 (914) 36 (914) 36 (914) 36 (914) 36 (914)

L 24 (610) 24 (610) 24 (610) 24 (610) 24 (610) 24 (610) M 36 (914) 36 (914) 36 (914) 36 (914) 36 (914) 36 (914) N 49.6 (1260) 49.6 (1260) 49.6 (1260) 35.6 (904)* 35.6 (904)* 35.6 (904)* R 34.0 (864) 34.0 (864) 34.0 (864) 20.0 (508)* 20.0 (508)* 20.0 (508)* S 13.4 (340) 13.4 (340) 13.4 (340) N/A N/A N/A T 0.6 (15) 0.6 (15) 0.6 (15) 0.6 (15) 0.6 (15) 0.6 (15) U 12.2 (310) 12.2 (310) 12.2 (310) 12.2 (310) 12.2 (310) 12.2 (310) V 10.6 (269) 11.0 (279) 11.0 (279) N/A N/A N/A

W 15.5 (394) 16.8 (427) 16.8 (427) N/A N/A N/A

1 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 2 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3.0 (76) VIC 3 2.5 (64) FPT 3.0 (76) FPT 4.0 (102) FPT N/A N/A N/A 4 2.5 (64) FPT 3.0 (76) FPT 4.0 (102) FPT N/A N/A N/A

83.8 (2128) 83.8 (2128) 83.8 (2128) 87.6 (2225) 87.6 (2225) 87.6 (2225)

36 (914) 36 (914) 36 (914) 36 (914) 36 (914) 36 (914)

Reference

1 Evaporator Water Inlet 9

2 Evaporator Water Outlet 10 3 Condenser Water Inlet (CGWR only) 11 Condenser (CGWR only)

4 Condenser Water Outlet (CGWR only) 12 Evaporator 5 Power Disconnect (Optional) 13 Panel Power Section — door swing 31.3 in (795 mm) 6 Power Wire Entry 14 Panel Control Section — door swing 31.3 in (795 mm)

7 Control Wire Entry 15

8 Control Panel 16

(a)For CGWR040, 050 and 065: If water regulating valve option is ordered, the overall length is 93.8 in, 95.0 in, and 96.2 in respectively. (b)Exceptions:

1. A minimum clearance of 42 in (1067mm) is required to other electrically grounded parts.

2. A minimum clearance of 48 in (1220mm) is required between two units opposite each other (front-to-front or back-to-back), or to other electrically live parts. See Section 110.26 of National Electrical code (NEC).

Condenser Opposite Inlet/Outlet End (CGWR only) — minimum clearance (for maintenance)

Condenser Inlet/Outlet End (CGWR only) — minimum clearance (for maintenance)

Additional minimum clearance needed for units with w ater regulating valve option

Location of CCAR refrigerant line connections, (2) 1-1/8 in liquid line and (2) 1-3/8 in discharge lines

14 CG-SVX038A-EN

Weights

Table 6. Weights

Shipping Operating

Unit Size lbs kg lbs kg

20 1116 506 1042 473 30 1252 568 1242 563

CGWR

CCAR

40 1659 753 1577 715 50 1847 838 1833 831 65 2039 925 2005 909 20 846 384 732 332 30 909 412 809 367 40 1265 574 1110 503 50 1304 591 1152 523 65 1484 673 1336 606

Dimensions and Weights

CG-SVX038A-EN 15

Installation

General Installation Information

• Where specified, supply and install valves in the water piping upstream and downstream of the evaporator and condenser, to isolate the heat exchangers for maintenance and to balance/trim the system.

• Supply and install condense Refer also to Trane publication RLC-PRB021-EN available from Trane Sales Offices for additional technical assistance. Provisions must be made for the control of condenser water that results in stable Saturated Discharge Pressure between 80°F and 128°F through all steady state, part load and transient operating conditions. Trane recommends optional factory installed integral Water Regulating Valve operated by onboard controller.

• Optional Water Regulating Valv installed and integrated water regulating valve designed to stabilize discharge pressure at all full and part load conditions. Factory installed water regulating valve is controlled by the chiller’s unit controller and is available on all models.

• Supply and install an approved f flow proving device, in the chilled water line as shown in Figure 3, p. 21. Flow switch must be interlocked with chiller’s unit controller to ensure the unit cannot

perate when chilled water flow through the unit is

o below the minimum chilled water flow limit. See fieldwiring diagram for flow proving device connection points. A factory approved flow switch may be ordered with the unit as a shipped-loose option, for field installation by others.

• Supply and install drain vent points both chilled and condenser water line to vent air and drain lines and equipment for service.

• Install a wye strainer ahead of all system pumps and control valve

Note: A w

installed in the chilled water pipe immediately adjacent to the evaporator inlet. See Figure 3, p. 21. A factory approved wye strainer may be ordered with the unit as a shipped-loose option, for field installation by others.

• Supply and install su piping from the pressure relief to the atmosphere if required. Follow ANSI/ASHRAE 15-2007 guidelines, relief manu standards when working with relief piping.

• If necessary, supply enough refrigerant and dry nitrogen (1

• Start the unit under supervision of a qualified service

hnician.

tec

• Where specified, supply and insulate the chilled water

ping as required, to prevent sweating under normal

ye strainer with twenty mesh screen must be

itable refrigerant pressure relief

facturer’s guidelines, and industry

50 psig) for pressure testing (CCAR).

r water control valve.

e — Trane offers a fully

low switch, or suitable

with valves on

operating conditions. Trane provides factory insulation on evaporator and related components.

Storage

NOTICE:

Store Units Above Freezing!

Store these units in a protected area above freezing (32°F) only. Do not store outdoors with a protective covering such as a plastic shroud. This can result in excessive water condensation that could damage controls and other components.

These units are designed for indoor installation above freezing (32°F) only. Store the unit in a suitable weatherproof location above 32°F, vibration free, and secure area. Periodically check the pressure in each refrigerant circuit to verify that the refrigerant charge is intact. If it is not, contact a qualified service organization and the appropriate sales office. If the unit is still under factory warranty, you must follow warranty procedure prior to calling for service.

Noise Considerations

Locate the unit away from sound-sensitive areas. If necessary, install the optional isolators under the unit and/ or the optional factory sound attenuation compressor blankets or attenuation cabinet. Install vibration isolators in all piping and use flexible electrical conduit. Consult an acoustical engineer for critical applications.

Foundation

A base or foundation is recommended for most installations. Provide a level surface strong enough to support the unit. Refer to “Dimensions and Weights,” p. 11 for dimensions and weights. A flexible (isolated) concrete foundation or footings at each loading point will reduce transmission of vibration. Install anchor bolts in the concrete to secure the unit. If the floor is warped, uneven or in poor condition, make necessary repairs before positioning the unit. Once the unit is in place, it should be level, within 1/4 inch over its entire length and width.

Clearances

Provide enough space around the unit to allow the installation and maintenance personnel unrestricted access to all service points. Unit dimensions are given in

“Dimensions and Weights,” p. 11. There should be

adequate clearance for condenser and compressor servicing. A minimum of three feet is recommended for effective compressor service. A minimum clearance of 3 ft.-6 inches is required to open the control panel doors.

16 CG-SVX038A-EN

Installation

40"

BACK VIEW

LEFT END VIEW

A minimum clearance of 42 in (2067 mm) is required to other electrically grounded parts. A minimum clearance of 48 in (1220 mm) is required between two units opposite each other (front-to-front or back-to-back) or to other electrically live parts. See Section 110.26 of National Electrical Code (NEC).

Important: In all cases, local codes will take precedence

over these recommendations.

Ventilation

Provisions must be made to remove heat generated by unit operation from the equipment room. Ventilation must be adequate to maintain an ambient temperature lower than 125°F.

The condenser relief valve on these units must be vented in accordance with all local and national codes.

Drainage

Locate the unit near a large capacity drain for condenser drain-down during shutdown or repair.

Handling

Rigging/Lifting Procedure

If the CGWR/CCAR is not moved using a forklift and the forklift pockets provided as part of the chiller's frame, then the chiller should be lifted and moved by using the lifting rails as outlined in Step 1 through Step 8.

A set of lifting rails is shipped loose and attached to the unit skid. Install the lifting rails and lift as shown below:

WARNING

Heavy Objects!

Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property-only damage. 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.

CCAR and CGWR units are shipped stretch-wrapped and bolted to a shipping skid (unless other than standard shipping is selected).

The skidded unit can be moved by using a fork truck of suitable capacity. Refer to “Dimensions and Weights,”

p. 11 for unit weights.

When moving the unit, the lifting forks must be positioned under the shipping skid as wide as possible where labeled. Lift the unit and move it to the desired location.

Once the unit is at the installation location, remove the stretch wrap. Inspect the unit for damage and report if damage is found.

The optional unit isolators (if ordered) are secured to the shipping skid or in the unit control panel. Other optional “ship loose” items may be attached to the skid or shipped separately depending on options selected.

WARNING

Heavy Objects!

CG-SVX038A-EN 17

Installation

1. Remove the stretch wrap from the unit as described In the Handling section, leaving the unit mounted to the skid. The lifting rails should be mounted to the skid. Remove the rails from the skid.

2. The hardware used to secure the lifting rails to the unit frame can be found in a box in the unit control panel. Insert the lifting rails as shown in the above figure. Using the mounting hardware, secure the lifting rails to the unit frame by torquing the 1/2” bolts to 70 ft-lbs.

3. Install clevis connectors or equivalent in the 1-1/4 inch

ifting holes provided at each end of the lifting rails.

4. Attach certified lifting chains (cables) to these points.

ach chain (cable) alone must be strong enough to lift

E the unit.

5. Attach chains (or cables) to a li chains (cables) so that they do not contact the unit piping or the unit control panel. Use a suitable spreader bar to insure proper weight distribution.

fting beam. Position the

NOTICE:

Equipment Damage!

To prevent damage to the unit, position the lifting beam and chains (cables) so that they do not contact the unit piping or the unit control panel.

6. Remove the bolts that secure the unit to the shipping skid.

7. Raise the unit just off the skid is level when lifted. Adjust chain (cable) lengths as required for level lifting.

8. Lift the unit off of the skid a location.

to make sure that the unit

nd place in the installation

Access Restrictions

All CCAR/CGWR units are designed to pass through a standard 36-inch doorway. Refer to outline drawings for other important dimensions.

Trane does not recommend disassembling a CGWR/CCAR to gain access through challenging rigging paths and installation locations. If disassembly/reassembly of a chiller does take place, please note the following:

1. A qualified Trane technician must perform the task

2. Use technical support for any questions that m during the task

3. Be aware that disassembly/reassembly could possibly

fect warranty status of the chiller, especially if failure/

af issues occur that point toward improper reassembly & installation

4. All required installation and star required to be completed and promptly returned for review, including the required running data log as instructed in the startup checklist

tup checklists are still

ay arise

Direct Mounting

The unit can be installed directly on an isolated, rigid mounting surface as long as the surface is level and will support the weight of the unit. A mounting hole is provided at each of the unit mounting locations. Provide a means of securely anchoring the unit to the mounting surface. Level the unit carefully.

Neoprene Isolator Pad Mounting (Optional)

The optional neoprene isolator pads are to be placed between the direct mounting surface and each of the chiller's mounting locations. To help distribute the chiller's load to the neoprene pads, place the 6" x 6" mounting plates between each pad and the chiller. Provide a means of securely anchoring the chiller to the mounting surface.

Level the unit carefully as instructed in “Unit Leveling,”

p. 18.

Compressor Mounting

All compressors are rigidly bolted with compressor isolation mounts to compressor mounting rails (tandem compressor sets) or directly to the unit base. No additional isolation or leveling is required. Inspect prior to start up to insure bolts are present and tight, and that no shipping damage has occurred.

Unit Leveling

Before tightening the mounting bolts, level the unit frontto-back and end-to-end. Unit must be level within 1/4” from front-to-back and within 1/4” over the length of the unit. The unit’s base deck can be used for leveling. Use shims as required to properly level unit base.

Compressor Nameplate

The nameplate for the hermetic scroll compressor is mounted on the compressor housing, near the motor terminal junction box.

Evaporator Nameplate

The evaporator nameplate is mounted on evaporator under the insulation. To view the evaporator nameplate, remove the insulation over the area if covered and spread the insulation. The serial number information is also on record at the factory.

Condenser Nameplate

The condenser ASME nameplate is mounted on the side of the condenser.

18 CG-SVX038A-EN

Unit Piping

Water Piping — General

Make water piping connections to the evaporator and condenser (CGWR only). Isolate and support piping to prevent stress on the unit. Use unions, flanges or grooved lock type fittings to simplify disassembly and facilitate service procedures. Use vibration eliminators to prevent transmitting vibrations to the water lines. Install thermometers in the lines to monitor evaporator and condenser water temperatures. Install balancing cocks in both the leaving chilled water and condenser water lines. These valves can be used to establish a balanced water flow. Entering and leaving chilled and condenser water lines should have shutoff valves installed to isolate the heat exchanger for service. See Figure 3, p. 21 for chilled water piping schematic and Figure 4, p. 22 for condenser water piping schematic.

Do not overtighten connections. Use a pipe sealant such as

Te fl o n piping before attaching to the unit. Unit MUST be bypassed if using a flushing agent.

tape on all threaded water connections. Flush all

NOTICE:

Equipment Damage!

To prevent equipment damage, you MUST follow instructions below:

• Bypass unit if using a flushing agent.

• Chilled water piping must rise above the chiller to insure the evaporator is full of water and void of air at all times.

• Do not overtighten connections.

waterside system design. If an accurate measurement of flow rate is required, an accurate flow measurement device must be installed in the water line.

Water Treatment

NOTICE:

Proper Water Treatment Required

The use of untreated or improperly treated water in this unit could 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 water treatment, if any, is required. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Using untreated or improperly treated water in these units may result in inefficient operation and possible tube and/ or brazed plate damage. Consult a qualified water treatment specialist to determine if treatment is needed.

NOTICE:

Waterborne Debris!

To prevent evaporator or condenser damage, evaporator and condenser strainers must be installed in the water supplies to protect components from water born debris. Removal of wye strainer or screen will void the warranty on the brazed plate evaporator.

Chilled Water Piping

Piping and specialties must be installed in accordance with national and local codes.

Water Flow Rates

Establish balanced water flow through both the evaporator and condenser. Flow rates should fall between the minimum and maximum values given in General Data

Tab l e 1 and Table 2, p. 7. Flow rates above or below these

values can cause equipment damage or improper unit operation. Measure the evaporator and condenser water pressure drop at the gauge ports located adjacent to the heat exchanger, before any piping specialty components, such as wye strainer. Evaporator water pressure drop curves are shown in Table 5, p. 23. Condenser pressure drop curves are shown in Table 6, p. 23.

Optional inlet wye strainer has an outlet port that can be used for measuring inlet evaporator water pressure, if it is installed immediately adjacent to the evaporator inlet.

Note: Evaporator and condenser pressure drop

measurement is for an approximation and is to be used as a tool to estimate flow rate and as an aid in

CG-SVX038A-EN 19

Chilled water piping and associated components shall be installed in accordance with Figure 3, p. 21. Chilled water inlet and outlet types, sizes and locations are provided in

Table 4, p. 12 and Table 5, p. 14. Chilled water piping must

rise above the chiller to ensure the evaporator is full of water and void of air at all times. All chilled water lines must be insulated to minimize heat gain and prevent condensation.

Brazed Plate Evaporator

Trane CGWR/CCAR chillers are equipped with brazed plate evaporators made of stamped stainless steel plates, furnace brazed together with copper to form a durable high efficiency heat exchanger. Because of the small complex geometry of the flow passages, it is imperative customers take all precautions to ensure these evaporators are not fouled by large particles or internal mineral deposits. For this reason, a 20 mesh wye strainer is required in the inlet chilled water line. Operation of the chiller without this wye strainer or the wye strainer 20 mesh screen will void the chiller warranty. Chemical

Unit Piping

treatment of the chilled water loop is required and must be performed by a qualified water specialist.

NOTICE:

Proper Water Treatment!

The use of untreated or improperly treated water could 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 water treatment, if any, is required. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Wye Strainer — Required

A wye strainer with 20 mesh screen must be installed immediately adjacent to the inlet water connection to the evaporator.

Important: Operation of the chiller without this wye

strainer AND 20 mesh screen in place will void the unit warranty.

Flow Proving Device — Required

unacceptable system control problems and the potential for evaporator failure.

Table 7. Minimum system volumes

CGWR/CCAR Unit Size

(tons)

20 157 30 226 40 311 50 355 65 442

Minimum System Volume

(gal)

Condenser Water Piping

Condenser water piping and associated components shall be installed in accordance with condenser water piping schematic Figure 4, p. 22. Condenser water inlet and outlet types, sizes and locations are provided in Table 4, p. 12 and

Table 5, p. 14.

NOTICE:

Excessive Water Pressure!

To prevent condenser or regulating valve damage, do not exceed nameplate condenser water pressure.

NOTICE:

Unexpected Chiller Start!

Failure to follow instructions could cause the chiller to start unexpectedly which could result in equipment or property damage. An external source (EMS, time clock or any other means) should not be allowed to bring on a pump that would trigger the flow switch to start the chiller. The flow switch is meant to act as a safety switch and not a start/stop mechanism.

Optional chilled water flow switch or other factory approved flow proving device is mandatory. It is fieldinstalled by others. Flow switch is to be installed and maintained in accordance with manufacturer’s recommendations and interconnected to the unit control panel as described in the field-wiring diagram. To provide additional chiller protection, wire the flow proving device control circuit in series with a chilled water pump starter normally open auxiliary contact to create a chilled water pump interlock. See “Chilled Water Flow Switch,” p. 28.

Chilled Water System Volume

Trane requires minimum system volumes as indicated in

Tab l e 7 . Special applications may allow deviation from

these volumes, but only with approval of Trane engineering. Operation below these volumes will cause

Discharge Pressure Control/ Optional Factory-Installed Water Regulating Valve

A means of maintaining stable discharge pressure during full-load, part-load and transient conditions is required. Saturated discharge temperature must be maintained between 80°F and 128°F. Trane offers an optional factory installed water regulating valve that is controlled by the unit controller. The optional water regulating valve maintains condensing pressure and temperature by throttling water flow leaving the condenser in response to compressor discharge pressure. Field-supplied water regulating valves must be adjusted for proper operation during full-load, part-load and transient conditions. Fieldsupplied water regulating valves must also b e a d ju s te d fo r proper positioning when unit is off.

Alternative field-supplied methods for condensing pressure/temperature control include the use of cooling tower control strategies. Cooling tower systems may include a manual or automatic bypass valve that can alter water flow rate and basin temperature to maintain stable condensing temperature at the chiller.

Well or city water condensing systems should include a water regulating valve and potentially a pressure reducing valve. A pressure reducing valve should be installed to reduce water pressure entering the condenser if water pressure can exceed tube-side maximum allowable working pressure as indicated on the condenser nameplate. This is also necessary to prevent damage to

20 CG-SVX038A-EN

disc and seat type water regulating valves caused by excessive pressure drops through the valve.

Under full load AHRI standard conditions, and with approximately 3 gpm/ton cooling water flow through the condenser, the temperature rise across the condenser will be approximately 10°F. In all cases, the minimum inlet condenser water temperature is 65°F.

Figure 3. Chilled water piping schematic

Unit Piping

UNIT

Table 8. Reference numbers

Item Description

1Bypass Valve 2 Isolation Valves 3 Vibration Eliminators 4 Evaporator Heat Exchangers 5 Inlet and Outlet Chilled Water Lines 6 Valves for Pressure Measurement

(a)

Strainer with 20 mesh screen

8 Evaporator Manual Air Vent Valve w/Plug A Isolator Unit for initial water loop cleaning

(b)

Arrangement for Measuring Differential Pressure

(c)

Water Flow S witch

Pi Pressure Gauge T1 Evaporator outlet temperature sensor T2 Evaporator inlet temperature sensor T3 Evaporator core temperature sensor T4 Chiller inlet temperature gauge T5 Chiller outlet temperature gauge

(a) Strainer with 20 mesh screen is required. (b)Must account for water head differenc e when calculating tot al unit pres-

sure differential.

B 6

CUSTOMER PIPING

CG-SVX038A-EN 21

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Trane CGWR30, CGWR65, CCAR30, CCAR20, CGWR40 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual