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

Unit Piping

Vibration Eliminator

Optional

Water

Regulating

Valve

UNIT

FACTORY

INSTALLED

OPTIONS

(IF ORDERED)

Condenser Out

Condenser In

Bypass Valve

Isolation Valve

Pressure Gauge

Temperature Gauge

Valve for Pressure Measurement

CUSTOMER PIPING

Figure 4. Condenser piping schematic

22 CG-SVX038A-EN

Water Pressure Drop Curves

Pressure Drop, ft of H2O

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

20.00

052002051001050

Pressure Drop, psi

Flow, GPM

20 TON

30 TON

40 TON

50 TON

65 TON

Pressure Drop, ft of H2O

0.00

5.00

10.00

15.00

20.00

25.00

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

0.0 50.0 100.0 150.0 200.0 250.0

Pressure Drop, psi

Flow, GPM

30 TON

50 TON

40 TON

65 TON

20 TON

Figure 5. Evaporator water pressure drop

Unit Piping

Figure 6. Condenser water pressure drop

CG-SVX038A-EN 23

Unit Piping

Low Suction Temperature and Pressure Cutouts/ Percent Glycol Recommendations

Tab l e 9 shows the low suction temperature and pressure

cutouts for different glycol levels.

Additional glycol beyond the recommendations will adversely affect unit performance. The unit efficiency will be reduced and the saturated evaporator temperature will

For some operating conditions this effect can be significant.

If additional glycol is used, then use the actual percent glycol to establish the Low and Unsafe refrigerant suction pressure cutout set points.

be reduced.

Table 9. Minimum recommended setpoints

Ethylene Glycol/Water Propylene Glycol/Water

(°F)

38.0

36.9

35.9

35.4

34.8

33.5

32.2

30.6

29.0

28.2

27.3

25.6

23.9

21.9

19.7

18.7

17.4

15.2

15.0

(c)(d)

(e)

Glycol

Mass)

(By

0 2 4

5 6 8

10 12 14

15 16 18

20 22 24

25 26 28

30 32 34

35 36 38

40 42 44

45 46 48

Solution

Freeze

Point

(°F)

32.0

30.9

29.7

29.1

28.5

27.3

26.1

24.8

23.6

22.9

22.1

20.7

19.2

17.5

15.6

14.6

13.7

11.5

9.2

6.6

3.9

2.5

0.8

-2.5

-6.0

-9.8

-14.0

-16.1

-18.3

-23.1

LOW

SUCTION

(psig)

101.12

98.87

96.46

95.26

94.08

91.75

89.45

87.00

84.78

83.51

82.0

79.57

76.96

74.07

70.92

69.30

67.86

64.42

60.95

60.65

60.6

60.65

(a)

UNSAFE

(b)

SUCT

(psig)

71.58

69.79

67.86

66.91

65.97

64.12

62.29

60.35

58.60

57.59

56.45

54.49

52.43

50.16

47.69

46.42

45.30

42.62

39.91

39.68

FREEZE

CORE FREEZE

Glycol

Mass)

(a) “LOW SUCTION” refers to the low suction pressure cutout. (b)“UNSAFE SUCT” refers to the unsafe suction pressure cutout. (c) “FREEZE” refers to the low leaving fluid temperature cutout. (d)The minimum leaving fluid temperature set point, “CW OUT TRGT,” should not be less than 5°F above the low fluid temperature cutout, “FREEZE,” and

(e) “CORE FREEZE” refers to the evaporator core fluid temperature cutout.

Solution

(By

Point

(°F)

Freeze

10 12 14

15 16 18

20 22 24

25 26 28

30 32 34

35 36 38

40 42 44

45 46 48

50 -28.9 60.65 39.68 15.0 50 -28.3 60.65 39.68 15.0

the core fluid temperature cutout, “CORE FREEZE.”

32.0

30.9

29.9

29.4

28.8

27.5

26.2

24.6

23.0

22.2

21.3

19.6

17.9

15.9

13.7

12.7

11.4

9.2

6.7

4.2

1.4

-0.2

-1.5

-4.6

-8.1

-11.7

-15.5

-17.6

-19.7

-24.0

LOW

SUCTION

(psig)

101.12

98.87

96.86

95.86

94.67

92.13

89.64

86.63

83.69

82.24

80.63

77.65

74.75

71.42

67.86

66.28

64.27

60.95

60.65

(a)

UNSAFE

(b)

SUCT

(psig)

71.58

69.79

68.18

67.39

66.44

64.42

62.44

60.06

57.73

56.59

55.32

52.98

50.69

48.08

45.30

44.07

42.50

39.91

39.68

FREEZE

CORE FREEZE

(°F)

38.0

36.9

35.7

35.1

34.5

33.3

32.1

30.8

29.6

28.9

28.1

26.7

25.2

23.5

21.6

20.6

19.7

17.5

15.2

15.0

(c)(d)

(e)

24 CG-SVX038A-EN

Unit Piping

Refrigerant Piping (CCAR only)

Note: If using a Trane CAUJ air-cooled condenser with a

Trane CCAR compressor chiller, please refer to the Application Guide - Pairing Trane CCAR Compressor Chillers with Trane CAUJ Air-Cooled Condensers SS-APG014*-EN. This guide provides line sizing, field-component selection, application considerations and more. If not using a Trane CAUJ air-cooled condenser, please consider the following general guidelines and recommendations when designing your split system.

Refer to the industry standards for refrigerant piping selection information; contact the factory if you do not have access to this data. Refrigerant pipe size selected must be within the velocity and pressure drop limitations required for proper system operation. It is essential that refrigerant piping be properly sized and applied since these factors have a significant effect on performance.

Note: Use Type K refrigerant-grade copper tubing only.

The use of a lower grade tubing can cause operating problems.

General Guidelines

Keep these general guidelines in mind as you review the recommendations specific to field piping refrigerant lines:

• Limit overall line length. Enough sub-cooling may be lost as refrigerant travels up the liquid riser to cause flashing. Review any questionable applications with the factory.

• Pipe sizing software suc Toolbox can help to quickly determine proper sizes for refrigerant lines based on current engineering data.

Liquid Line

Sufficient sub-cooling must be maintained at the expansion valve. To provide proper operation throughout the range of operating conditions, the liquid-line pressure drop should not exceed the unit’s minimum sub-cooling value less 5°F. To achieve this objective, keep these liquidline considerations in mind:

1. Select the smallest, practical line size for the application. Limiting the refrigerant charge improves compressor reliability.

2. When designing the liquid l conditioning application (i.e., one with an operating range of 40°F to 110°F), remember that every 10 feet of

tical rise will reduce sub-cooling by 2.8°F, while

ver every 10 feet of vertical drop will add 1.1°F of subcooling.

3. Provide a 1-inch pitch toward the e 10 feet of run.

h as Trane Engineering

ine for a typical air-

vaporator for every

4. If the liquid line must be routed through an area armer than outdoor air temperature, insulate the line

w to prevent the refrigerant from flashing.

5. A replaceable core liquid line filter drier must be stalled as close as possible to the compressor chiller.

in The core should be changed whenever the system is opened for service. Trane compressor chillers do not include a filter-drier as standard, but one may be ordered if the installing contractor desires a factory type.

6. A moisture-indicating sight glass permits

check of the liquid column for bubbles. Sight glasses are included on the Trane compressor-chiller. However, never use the sight glass to determine whether the system is properly charged! Instead, either charge the system based on the required sub-cooling or calculate the amount of refrigerant needed and add it based on weight.

a visual

Discharge (Hot Gas) Line

Limit the pressure drop in the discharge line to 6 psid whenever possible to minimize the adverse effect on unit capacity and efficiency. While a pressure drop of as much as 10 psid is usually permissible, note that a 6-psid pressure drop reduces unit capacity by 0.9 percent and efficiency by 3 percent.

Pitch discharge lines in the direction of hot gas flow at the rate of 1/2-inch per each 10 feet of horizontal run. Discharge line sizing is based on required velocity to provide good oil movement. Basic discharge line parameters are:

Max allowable pressure drop 6 psig (1F) Maximum Velocity 3500 fpm Minimum Velocity (at minimum load)

Horizontal lines 500 fpm Vertical lines (up flow) 1000 fpm

To design the discharge line properly, follow the recommended guidelines:

• Choose the shortest route from the compre

condenser.

• Use different pipe sizes for horizontal and vertical lines

make it easier to match line pressure drop and

to refrigerant velocity to discharge-line requirements.

• To assure proper oil entrainm

sound levels, size the discharge line so refrigerant velocity equals or exceeds the minimum velocity in

Ta bl e 10 and remains below 3,500 fpm.

• Prevent oil and condensed refrigerant from flowing

k into the compressor during “off” cycles by:

bac

a. pitching the discharge line tow

and

b. routing the discharge line so that it rises to the top

of the condenser, then drops to the level of the condenser inlet, creating an inverted trap.

ent and avoid annoying

ard the condenser,

ssor to the

CG-SVX038A-EN 25

Unit Piping

• Double risers are generally unnecessary. The scroll compressors in Trane units unload to the extent that a single, properly sized riser can transport oil at any load condition.

Table 10. Minimum discharge-line velocities for oil

entrainment

Refrigerant Velocity, fpm

Nom. Pipe Size, in. Riser

7/8 375 285 1-1/8 430 325 1-3/8 480 360 1-5/8 520 390 2-1/8 600 450

• Riser traps are also unnecessary. Avoid using riser traps. If the discharge riser is sized to maintain the proper refrigerant velocity, adding a trap will only increase the pressure drop.

Reliability determines the success of a split airconditioning system. Intercon play an instrumental role in that success. It’s up to us to ensure that our system design practices evolve with equipment technologies.

This can be summarized as five fundamental “rules”:

1. Choose the right system (i.e., don’t specify splitsystem equipment when a packaged chiller is best suited for the job).

2. Size the interconnecting lines to av and double risers.

3. Slope the liquid lines tow

4. Minimize the length of the interconnecting tubing.

5. Keep the system clean.

necting refrigerant lines

ard the evaporator.

Horizontal

oid the use of traps

Final Leak Test

WARNING

Hazard of Explosion!

Failure to follow instructions below could result in death or serious injury or equipment or property-only damage. Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxygen or compressed air or mixtures containing them for pressure testing. Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should only be mixed with dry nitrogen for pressurizing units.

Once refrigerant piping is completed, thoroughly test the system for leaks.

System Evacuation

WARNING

Risk of Internal Arc Flash!

Failure to follow instructions could result in death, serious injury and compressor damage. Do not use a megohmmeter or apply power to compressor windings under vacuum as it could result in an arc flash inside the compressor.

For field evacuation after leak checking, use a vacuum pump capable of pulling a vacuum of 100 microns or less. Follow the pump manufacturer’s instructions for proper use of the pump. Insure that all sections of the system are properly evacuated before proceeding.

Refrigerant Charging

Initial Leak Test

As shipped, Trane compressor-chillers contain a holding charge of nitrogen only. Before connecting refrigerant piping, momentarily crack open a Schraeder valve on the liquid line to insure that the unit is still pressurized. If no gas escapes thru the valve, leak test the unit to determine the source of the refrigerant leak prior to installation and repair any leaks located.

Refrigerant Piping Sizes

Refer to the Trane guide TRG-TRC006-EN and/or ASHRAE publications to determine piping selection information. Refrigerant pipe sizes selected must be within the velocity and pressure drop limitations required for proper system operations. It is essential that refrigerant piping be properly sized and applied since these factors have a significant effect on system performance and reliability.

26 CG-SVX038A-EN

NOTICE:

Equipment Damage!

To prevent damage to the evaporator and condenser, never charge liquid refrigerant into either of these vessels without adequate flow to prevent the temperature/pressure relationship to fall below 35°F.

Once the system is properly installed, leak tested and evacuated, refrigerant charging can begin. Liquid refrigerant must be charged into each circuit through the liquid line access with the compressor(s) off.

Charge refrigerant into the system by weight. Use an accurate scale or charging cylinder to determine the exact charge entering the system. Failure to charge the system accurately can lead to under or over-charging and result in unreliable operation.

If system pressure equalize before the full charge enters the system, close the charging port and proceed to start-up procedure.

Electrical Wiring

WARNING

Proper Field Wiring and Grounding Required!

General Recommendations

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and on the tags, stickers, and labels 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 following instructions: Unless specified otherwise, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks.

Power and Control Wiring

Unit Power Wiring

The installing contractor must connect appropriate power wiring (with fused disconnects) to the terminal block or non-fused, unit-mounted disconnect in the power section of the unit control panel. Electrical schematics and component location drawings are also mounted on the inside of the control panel door.

The unit power fused disconnect switch should be located in the general area of the unit, to comply with NEC or local codes. Some codes require line-of-sight disconnect locations. The optional unit unfused disconnect can be used as an emergency shutdown device.

Scroll Compressor Electrical Phasing

General

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized.

NOTICE:

Compressor Damage!

Operating compressors in reverse rotation will cause damage or failure of the compressor.

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result in equipment damage as the equipment was not designed or qualified to accept other types of conductors.

The wiring procedures, as described in this portion of the manual, must be accomplished to obtain proper operation of the unit.

All wiring must comply with National Electrical Code (NEC) and state and local requirements. Outside the United States, the national and/or local electrical requirements of other countries shall apply. The installer must provide properly sized system interconnecting and power supply wiring with appropriate fused disconnect switches. Type and locations of disconnects must comply with all applicable codes.

Minimum circuit ampacities, recommended fuse sizes and other unit electrical data are provided on the unit nameplate.

CG-SVX038A-EN 27

It is critical that proper rotation of the scroll compressors be established before the machine is started. Proper motor rotation requires confirmation of the electrical phase sequence of the power supply. The motor is internally connected for clockwise rotation with the inlet power supply phased “ABC” or “L1, L2, L3”.

The order in which the three voltages of a three-phase system succeed one another is called phase sequence or phase rotation. When rotation is clockwise, phase sequence is usually called “ABC” and when counterclockwise, “CBA”.

This direction may be reversed by interchanging any two of the line wires. It is this possible interchange of wiring that makes a phase sequence indicator necessary, if the operator is to quickly determine the phase rotation of the motor.

Setting Proper Electrical Phase Sequence

Proper compressor motor electrical phasing can be quickly determined and, if necessary, corrected before starting the unit. Use a quality instrument, such as an Associated

Electrical Wiring

Research Model 45 Phase Sequence indicator or equivalent and follow this procedure.

1. Verify that all operating controls for the unit are in the “Off” position.

2. Disconnect power to the power distribution block in the unit control panel

3. Connect the phase sequence indicator power distribution block as follows:

Phase Seq. Lead Terminal ID

Black (Phase A) L1

Red (Phase B) L2

Yellow (Phase C) L3

4. Turn power on by closing the unit supply power fused disconnect switch.

5. Read the phase sequence disp The “ABC” LED on the face of the phase indicator will glow if phase sequence is ABC.

6. If the “CBA” indicator glows instead, open the unit

ain power disconnect and switch two line leads on

m the power distribution block in the unit control panel. Close the main power disconnect and recheck phasing.

7. Open the unit disconnect and re indicator.

layed on the indicator.

leads to the

move the phase

Voltage Imbalance

Excessive voltage imbalance between phases in a threephase system will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2 percent. Voltage imbalance is defined as 100 times the maximum deviation of the three voltages (three phases) subtracted from the average (without regard to sign), divided by the average voltage.

Example:

If the three voltages measured at the line voltage fused disconnect are 221 volts, 230 volts and 227 volts, the average would be:

221 + 230 + 227

The percentage of imbalance is then:

100 (226-221)

In the preceding example, 221 is used because it is the farthest from the average. The 2.2 percent imbalance that exists exceeds maximum allowable imbalance by

0.2 percent. This much imbalance between phases can equal as much as 20 percent current imbalance with a resulting increase in winding temperature that will decrease compressor motor life.

= 226 volts

= 2.2%

226

Unit Voltage

Electrical power to the unit must meet stringent requirements for the unit to operate properly. Total voltage supply and voltage imbalance between phases should be within the tolerances discussed below.

Voltage Supply

WARNING

Live Electrical Components!

Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks.

Measure each leg of supply voltage at the line voltage disconnect switches. Readings must fall within the range of 187-254 volts for units with a nameplate voltage of  208/230 volt and 414-508 volts for units with a nameplate voltage of 460 volts. If voltage on any leg does not fall within tolerance, notify the power company and request correction of this situation before operating the unit. Inadequate voltage to the unit will shorten the life of relay contacts and compressor motors.

Control Power Supply

A fused, panel-mounted control power transformer is standard on all units. Replacement fuses are listed on the “Fuse Schedule” decal located adjacent to the transformer inside the control box.

External Contacts

Chilled Water Flow Switch

The unit controller has an input that accepts a contact closure from a proof-of-flow device such as a flow switch or other factory approved flow proving device. When this input does not prove flow within a fixed time relative to transition from enabled to run modes of the chiller, or if the flow is lost while the chiller is in the running mode of operation, the chiller will be prohibited from running. The installer must provide and install this flow proving device. See also wiring diagrams attached to the inside of the control panel door. Failure to provide this flow proving device voids unit warranty.

28 CG-SVX038A-EN

NOTICE:

Unexpected Chiller Start!

CCAR Condenser Fan Staging or VFD Control

The CCAR compressor chiller unit controller has the ability to control fan staging, fan VFDs and damper control in order to improve the stability of discharge pressure at various ambient conditions.

Unit controller capability single circuit compressor chillers (CCAR 20, and 30) have three dry contact relays to cycle condenser fan motors to control discharge pressure, as well as one 0 to 10 Vdc analog output to control a VFD or fan damper. Dual circuit compressor chillers (CCAR 40, 50, and 65) have six dry contact relays to cycle condenser fan motors to control discharge pressure, as well as two 0 to 10 Vdc analog output to control a VFD or fan damper.

CCAR unit controller must control condenser ambient control devices such as fan cycling and optional low ambient dampers. As a result the interconnecting field wiring must be done by others. For pairing CCAR compressor chiller with CAUJ air cooled condenser, the following field wiring is to be done by others.

• Fan cycling control

• One con

common must be run between CCAR compressor chiller and CAUJ condenser.

• Required fan control wiring for CCAR compressor

chillers matched with CAUJ condensers utilizing fan control are covered by schematic, instructions, and associated footnotes on Figure 21, p. 53 and

Figure 22, p. 54.

• Low Ambient Dampers (when applicable)

• One shielded pair for each condenser damper

assembly must be run between CCAR compressor chiller and CAUJ air cooled condenser.

• Required damper control wiring for CCAR

compressor chillers matched with CAUJ condensers utilizing low ambient control damper assembly are covered by schematic, instructions and associated footnotes on Figure 23, p. 55 and

Figure 24, p. 56.

trol wire for each condenser fan plus a

Electrical Wiring

CGWR Condenser Water Loss of Flow Protection

The controller logic will sense a loss of flow through the condenser. No flow switches are necessary with the standard unit controller configuration.

CGWR Condenser Control

CGWR units have one dry contact relay to start a condenser pump. These chillers also have one 0 to 10 Vdc analog output to control a head pressure control valve.

Consult wiring diagram located inside the control box door for connection point(s).

Equipment Grounds

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result in equipment damage as the equipment was not designed or qualified to accept other types of conductors.

Provide proper grounding at the connection point provided in the unit control panel.

Unit Controller

Note: The unit controller section in this IOM contains only

a brief overview of the unit controller. Please consult the Unit Controller Version 17 Manual Rev.

3.0 for Cold Generator™ Chillers (CG-SVX030*-EN) which documents the function of the unit controller including setpoint definitions, points lists and much more.

The unit controller is a rugged microprocessor based controller designed for the hostile environment of the HVAC/R industry. It is designed to be the primary manager of the CCAR/CGWR product.

The unit controller provides flexibility with setpoints and control options that can be selected prior to commissioning a system or when the unit is live and functioning. Displays, pressures, temps, alarms and other interfaces are accomplished in a clear and simple language that informs the user as to the status of the controller. Refer also to the wiring diagram attached to the inside of the control panel door.

A password is required to access controller setpoints. Use password code 2112 to access many of these features. A factory code may be required to allow access to critical areas, and can only be entered by a factory representative.

A RS-485 port is provided for communication with other manufacturers’ systems. Additionally, a built-in RS-485 to RS-232 converter allows communication over the RS-485 port via the RS-232 port. Other features include the integration of BACnet controller. An optional gateway card allows

IP and MODBUS® into the unit

CG-SVX038A-EN 29

Electrical Wiring

communication via BACnet® MSTP, Johnson N2, and

ONWORKS

, and this should be ordered with the chiller if required. An ethernet connection is also provided on each unit. While field changes can be made, please insure that the unit is ordered set up for required communications to insure that factory testing includes end user configuration.

A complete software support package is available for your PC allowing for system configuration, dynamic on-line display screens, remote communication, graphing and more. See “Downloading and Installing Unit Controller

(MCS-Connect) Software,” p. 31 for download

instructions. All information needed to run the unit is available from the unit display; however, a laptop computer is invaluable for ease of use of diagnosing or changing the unit setpoints.

Note: Not all setpoints can be changed with

MCS-Connect; some require a configuration change.

A serial cable is included in each shipment for the convenience of the field tech. If you do not have a laptop with a serial port, you will require a converter such as a Black Box item number #IC199A-R3 serial-to-USB adaptor.

The standard configuration allows for unit to start at lowest stage possible, then add compressors as needed to meet demand.

Important: All configuration changes need to be done

by factory representatives to ensure proper operation of the unit within design parameters. Refer to MCS unit controller manual for sequence of operation and additional details.

30 CG-SVX038A-EN

Unit Controller—Software Installation and Setup

Downloading and Installing Unit Controller (MCS-Connect) Software

Go to www.nappstech.com. Click on Downloads in the grey bar and select MCS-CONNECT. Select SAVE. After downloading, open and select RUN. Follow prompts and software will be installed on your computer.

If your computer does not have a serial port, you will need to purchase a USB to Serial adapter. (Computer stores should have this.) Install the software for the adapter. If your computer has a serial port, you will not need an adapter.

You will need to know which Port your computer uses as the COM PORT. In Microsoft

PANEL and select DEVICE MANAGER. Look for PORTS (COM & LPT), expand and you should see a COM PORT

number. Windows

Start the MCS-CONNECT software. Select

SETUP>COMMUNICATIONS and then change LOCAL COM PORT to match your computer. Select SAVE and

then OK.

7 is similar.

Connecting to the Chiller

Connect the supplied NULL MODEM cable between your USB adapter or serial port to the chiller. A standard serial cable will not work. Start the MCS-CONNECT software and select LOCAL SERIAL. You will see the site info page. The software should scan and find the chiller. (If you see a Failed to open comm port error, or it scans and does not find the chiller, your comm port settings are not correct.) Click the 1-CCAR/CGWR tab. The screen shows real time data.

Set Point Changes

Click the VIEW ONLY button. Enter the password code

2112. Select OK. Button should say SERVICE. Go to set points and double-click on a value. Change and select OK.

Viewing and Troubleshooting ALARMS

The unit controller will record and store 30-second sensor input data prior to and up to any LOCKOUT ALARM. Select the ALARM tab, then INFO next to the alarm you want to analyze. This will pop up a screen that shows operating conditions just prior to the trip. You can easily determine if the fault was caused by a sudden or gradual change. For instance, a sudden increase in discharge pressure might suggest a condenser pump or fan failure etc. (This data can also be viewed from the chiller LCD screen. Select LOCKOUT ALARMS.)

Vista, go to th e CONTROL

Downloading and Viewing Graphs

The unit controller continuously records and stores sensor input and relay/analog output data. This data is collected in 10-second (default) intervals. The controller stores 1008 packets of data replacing the oldest with the newest. With the time interval set at 10 seconds, you can download graph data with a time span of 168 minutes. The time interval is adjustable.

In the MCS-CONNECT software, select GRAPH. Data will be downloaded and then a graph setup page will appear. Select the input and output data you want to look at. Type in Y-axis parameters and select OK. Use the scroll bar at the bottom of the graph to view. You can go back to the setup page at any time to change selections. You may save the graph to view later. You don’t have to be connected to view a saved graph file. Your saved graph will be located in a folder called GRAPH inside another folder called MCS on your C: drive.

To change the default 10-second interval, make changes and select SAVE and then OK on the setup page. The controller will now record data at this new interval.

To view a saved graph, select LOAD A GRAPH FILE. These files can be e-mailed to us for analysis if needed.

Updating Chiller Software and Configuration Files

Trane chillers are programmed, set up, and tested prior to shipment. Sometimes after a unit arrives at the jobsite, the customer may want to enable an option such as 0–5 Vdc target reset or chilled water pump control etc. These options require a configuration change. We will either have you download the configuration file from the chiller and e-mail it to us where we will modify it and return it to you, or we will modify a default configuration file we have here at the factory and send it to you. Modifying a configuration file you send us will save any setpoint changes that have been made on site. Otherwise, the controller will be set back to default factory settings.

To e-mail us a copy of your chiller’s configuration file, in the MCS-CONNECT software, establish communication with the chiller and select RECEIVE CFG. Name it something and e-mail it to engineering@nappstech.com

To load a configuration file, turn off circuit enable switches and select TRANSMIT CFG. Locate the new file and press OPEN. The file will be uploaded to the controller. The controller will reboot itself.

Routine software (HEX FILE) updates are NOT necessary. However, if we think a software update is necessary to resolve an operating issue you may be having, we will e-mail the hex file in a zipped folder. Save the zipped folder to your desktop. Right click folder and select EXTRACT ALL. This will create another folder by the same name on your desktop. Inside this folder you’ll find the hex file. It should be about 2300 KB large.

CG-SVX038A-EN 31

Unit Controller—Software Installation and Setup

In the MCS-CONNECT software, select TRANSMIT SW. Locate the extracted hex file and select Transmi t . Watch the chiller LCD screen. After the file is uploaded, the Trane MCS Digital Controller will verify that it’s a valid file and then erase the flash memory. Next, it will write the new hex to memory. When completed, the controller will reboot itself. This process may take 15 or 20 minutes. After the reboot is completed, close and restart the MCS-CONNECT software to reestablish communication with the chiller.

32 CG-SVX038A-EN

Unit Startup Procedures

Power Applied to Unit Controller

Chiller Level

Call for Cooling

AutoAuto

Auto (Power up Start Delay)

Running

Unit Controller

Boot Time

Enforce Power Up

Start Delay Time

Conrm Evaporator

Water Flow

(24 to 90 Sec)

(30 to 120 Sec)

(6 to 600 Sec)

Auto Auto Auto

Auto

Running

Enforce Restart

Inhibit Timer

(0 to 5 Mins)

Waiting to

Start

Energize

Condenser Water

Pump Relay

(Only if Chiller

Controls Pump)

Lead Circuit

Open

Solenoid

Valve

Energize

Lead

Compressor

Lag Circuit

(0 to 5 Sec)

NOTICE:

Compressor Failure!

To protect compressors from premature failure the unit must be powered and crankcase heaters energized at least 24 hours BEFORE compressors are started.

Prior to calling for start-up services or commissioning, CG-ADF005*-EN (CGWR Installation Completion Check List and Request for Trane Service) or CG-ADF006*-EN (CCAR Installation Completion Check List and Request for Trane S e r vice), as appropriate, must be completed and submitted. Once CG-ADF005*-EN or CG-ADF006*-EN has been submitted, CG-ADF007*-EN (Start-up Check List for CGWR and CCAR Chillers) must be followed and submitted.

Pre-Start Up Procedures Check List

Complete each step in the “Pre-Start Up Procedures” check list included in CG-ADF007*-EN (Start-up Check List for CGWR and CCAR Chillers) and check off each step as completed.

WARNING

Hazardous Voltage!

NOTICE:

Equipment Damage!

• To prevent overheating at connections and undervoltage conditions at the compressor motor, check tightness of all connections in the compressor power circuit.

• To prevent compressor damage, do not operate the unit with discharge or liquid line service valves closed.

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

• To prevent evaporator or condenser damage, pipe strainers must be installed in the water supplies to protect components from water born debris. Trane is not responsible for equipment damage caused by water born debris.

Sequence of Operation

CG-SVX038A-EN 33

Unit Startup Procedures

Checking Operating Conditions

NOTICE:

Evaporator/Condenser Damage!

Water (fluid) flow must be established in evaporator and condenser before adding refrigerate, removing refrigerate, or pulling vacuum, to protect heat exchangers from freezing.

NOTICE:

Compressor Damage!

Do not allow liquid refrigerant to enter the suction line as excessive liquid accumulation in the liquid lines could result in compressor damage.

To prevent compressor damage and ensure full cooling capacity, use refrigerants specified on the unit nameplate only.

• If operating conditions indicate an overcharge, slowly (to minimize oil loss) remove refrigerant at the liquid line Schrader fitting. Do not discharge refrigerant into the atmosphere.

• If the remote condenser (CCAR) is equipped with low ambient dampers, check for proper actuator and blade travel in relation to condensing pressure.

• Once proper unit operation is confirmed, inspect for debris, misplaced tools., etc. Secure control panel doors in place.

Once the unit has been operating for about 10 minutes and the system has stabilized, check operating conditions and complete the checkout procedures that follow.

• Recheck evaporator water and condenser (CGWR) water flows and pressure drops. These readings should be stable at proper levels.

• Check suction pressure and di unit.

Discharge pressures—take at Sch the discharge line. Normal discharge pressures are:

CCAR units: 315 psig to 500 psig

CGWR units: 275 psig to 430 psig

Suction pressures— take at Schrader fitting provided on the suction line. Normal suction pressures are:

42°F–60°F LWT: 104–155 psig

15°F–39°F LWT: 60–103 psig

• Check compressor oil levels. At full load, oil level

ould be visible in the oil level sight glass on the

sh compressor. If it is not, add or remove oil as required.

• Check the liquid line sight glasses. R past the sight glasses should be clear. Bubbles in the liquid line indicate either low refrigerant charge or excessive pressure drop in the liquid line. Such a

scharge pressure of the

rader fitting provided on

efrigerant flow

restriction can often be identified by a noticeable temperature differential on either side of the restricted area. Frost often forms on the outside of the liquid line at this point also.

The system may not be properly charged although the sight g sub-cooling and operating pressure.

• Once oil level, amp draw and operating pressures have stabiliz

• Measure system liquid line sub-cooling.

• If operating pressure, sight glass, superheat and subcoo refrigerant into each circuit. Refrigerant shortage is indicated if operating pressures are low and subcooling is also low.

If suction and discharge pressures are low but subcooling is normal, no refrigerant shortage exists. Adding refrigerant, will result in overcharging.

Add refrigerant with the unit running by metering liquid refrigerant through the Schrader valve between the expansion valve and the evaporator refrigerant inlet until operating conditions are normal.

lass is clear. Also consider superheat,

ed, measure system suction superheat.

ling readings indicate refrigerant shortage, charge

System Superheat

Normal superheat for each circuit is 10°F–16°F at full load. If superheat is not within this range, adjust expansion valve superheat setting. Allow 5–10 minutes between adjustments for the expansion valve to stabilize on each new setting.

System Sub-cooling

Normal sub-cooling for each circuit is 5°F to 10°F at full load where saturated discharge pressure and liquid line temperature are measured at chiller liquid line.

34 CG-SVX038A-EN

Unit Shutdown

Chiller

Level

Local Stop Normal Latching Diagnostic Chiller Level Non-Latching Diagnostic Tracer Stop External Auto-Stop

Stopped

Shutting Down

De-Energize Condenser Water Pump Relay (If Chiller Controls Pump)

Stopped

or Run Inhibit

Running

Run Inhibit

Evap Pump Off Delay Timer

(0 to 30 Minutes)

Circuit 1

Shutting Down

Auto

Shutting Down

Auto

Circuit 2

De-Energize Current Lead Cprsr

De-Energize Current Lag Cprsr

Close Liquid Solenoid Valve

De-Energize Cprsr

(1 to 5 Sec)

Normal Unit Shutdown

Extended Shutdown Procedure

If the system is taken out of operation for long periods of time, use this procedure to prepare the system for shutdown.

1. Test condenser and high side piping for refrigerant leakage.

2. Open electrical disconnect switches for evaporator water pump. Lock the disconnect in an open position.

3. Open the unit main electrical disconnect and unitmounted position.

disconnect (if used) and lock in open

CG-SVX038A-EN 35

Unit Restart

Unit Restart After Extended Shutdown

Use this procedure to prepare the system for restart after an extended shutdown.

NOTICE:

Compressor Failure!

To protect compressors from premature failure the unit must be powered and crankcase heaters energized at least 24 hours BEFORE compressors are started.

NOTICE:

Compressor Damage!

To prevent compressor damage, be certain that all refrigerant valves are open before starting the unit.

1. Close the unit main disconnect(s) and the unitmounted disconnect (if used).

2. Check compressor crankcase oil levels. Oil should be visible in the compressor oil level sight glass.

3. Fill the chilled water circuit(s) if drained during

utdown. Vent the system while filling it.

4. Close the fused disconnect switc pumps.

5. Start the water pump(s). With w inspect all piping connections for leakage. Make any necessary repairs.

6. With water pump(s) running, adjust and check water pressure drop through the evaporator.

7. Check the flow switch on the for proper operation.

8. Stop the water pump(s).

9. Complete each step in Trane literature CGWR-ADF0 CCAR Chillers).

10. Energize Crankcase Heaters (Must be energized 24 hours before startup).

02*-EN (Start-up Check List for CGWR and

h(es) for the water

ater pumps running,

chilled water flow

evaporator outlet piping

36 CG-SVX038A-EN

Maintenance

WARNING

Hazardous Service Procedures!

Because scroll compressors are a uniquely different design from traditional reciprocating compressors, their operating characteristics and requirements are a departure from the reciprocating compressor technology.

Compressor Oil

The R-410A scroll compressor uses POE oil as required by the manufacturer of the compressor. Refer to compressor manufacturer for exact type and amount of oil in the specific model in question.

Scroll Compressor Functional Test

Since the scroll compressor does not use discharge or suction valves, it is not necessary to perform a pumpdown capability test, i.e. a test where the liquid line valve is closed and the compressor is pumped in a vacuum to see if it will pump-down and hold. If fact, this kind of test may actually damage the scroll compressor!

NOTICE:

Compressor Damage!

Do not pump the scroll compressor into a vacuum. Scroll compressors can pull internal low vacuums when the suction side is closed or restricted. This, in turn, may cause the internal Fusite in compressor damage or failure. It may also trip the circuit breakers, blow fuses, or trip the discharge thermostat.

The proper procedure for checking scroll compressor operation is outlined below:

1. Verify that the compressor is recei ving supply power of the proper voltage.

2. With the compressor running, measure the suction and discharge pressures/temperatures to determine whether or not they fall within the compressor operating map shown in figure below.

See “Checking Operating Conditions,” p. 34 for normal operating pressure ranges for the unit.

terminal to arc, resulting

Oil Level. While the compressor is running, the oil level

may be below the sight glass but still visible through the sight glass. The oil level should NEVER be above the sight

glass!

Oil Appearance. If the oil is dark and smells burnt, it was

overheated because of compressor operation at extremely high condensing temperatures, a compressor mechanical failure, or occurrence of a motor burnout. If the oil is black and contains metal flakes, a mechanical failure has occurred. This symptom is often accompanied by a high amperage draw at the compressor motor.

Notes:

• If a motor burnout is suspected, use an acid test kit to

check the condition of the oil. If a burnout has occurred, test results will indicate an acid level exceeding

0.05 mg KOH/g.

• The use of commercially available oil additives is not recommended. Liability for any detrimental effects that the use of non-approved products may have on equipment performance or longevity must be assumed by the equipment owner, equipment servicer, or the oil additive manufacturer.

CG-SVX038A-EN 37

Maintenance

100

110

120

130

140

150

-100 1020304050607080

Compressor Operating Map

Saturated Condensing Temperature (°F)

Saturated Evaporating Temperature (°F)

Figure 7. Compressor operating map

Compressor Operational Noises

Because the scroll compressor is designed to accommodate liquids (both oil and refrigerant) and solid particles without causing compressor damage, there are some characteristic sounds that differentiate it from those typically associated with a reciprocating compressor. These sounds, which are described below, are normal and do not indicate that the compressor is defective.

At low ambient startup: When the compressor starts up under low ambient conditions, the initial flow rate of the compressor is low. Under these conditions, it is not unusual to hear the compressor rattle until the suction pressure climbs and the flow rate increases. These sounds are normal and do NOT affect the operation or reliability of the compressor.

Excessive Amp Draw

Excessive Amp Draw occurs either because the compressor is operating at an abnormally high condensing temperature OR because of low voltage at the compressor motor.

Motor amp draw may also be excessive if the compressor has internal mechanical damage. In this situation, vibration and discolored oil can also be observed.

Low Suctions

Continuous low suction pressures are most likely caused by low evaporator load coupled with a system anomaly. Symptoms that may accompany low suctions include a rattling sound emitted from the compressor or an open motor winding thermostat or discharge thermostat.

38 CG-SVX038A-EN

Note: Operation of the chiller with saturated suction

temperatures below freezing will cause damage to the evaporator. If this occurs immediately stop the machine, diagnose and correct the problem.

Periodic Maintenance

Perform all of the indicated maintenance procedures at the intervals scheduled. This will prolong the life of the unit and reduce the possibility of costly equipment failure.

Weekly Maintenance

Once the unit has been operating for about 10 minutes and the system has stabilized, check operating conditions and complete the checkout procedures that follow.

• Check compressor oil levels. Oil should be visible in the sight glass when the compressor is running. Operate the compressors for a minimum of three to four hours when checking oil level, and check level every 30 minutes. If oil is not at proper have a qualified service representative add or remove oil as required.

• Check suction pressure and disc

• Check the liquid line sight glasses.

• If operating pressures and sight glass conditions seem to indicate

refrigerant shortage, measure system

superheat and system sub-cooling.

• If operating conditions indicate an overcharge, slowly

nimize oil loss) remove refrigerant at the liquid

(to mi line service valve.

• Inspect remote condenser c only) and clean if required. Refer to the condenser manufacturer’s recommendations.

level after this period,

harge pressure.

oils for cleanliness (CCAR

Inspect the entire system for unusual conditions. Use an operating log to record a weekly operating conditions history for the unit. A complete operating log is a valuable diagnostic tool for service personnel.

Monthly Maintenance

Once the unit has been operating for about 10 minutes and the system has stabilized, check operating conditions and complete the checkout procedures that follow.

• Perform all weekly maintenance procedures.

• Check refrigerant superheat at the compressor line. Superheat should be in the range of 10°F–20°F.

Note: A superheat calculated va

into the unit controller.

• Inspect the entire system fo Review the weekly operating log for conditions history for the unit and take note of any unusual trends in performance. Take appropriate preventative actions if necessary.

lue is incorporated

r unusual conditions.

suction

Annually

Perform all weekly and monthly maintenance procedures.

• Have a qualified service technician check the setting

function of each control and inspect the condition

and of and replace compressor and control contacts if needed.

• If chiller is not piped to drain facili is clear to carry away system water.

• Drain water from condenser (CGWR only) and

porator and associated piping systems. Inspect all

eva piping components for leakage, damage, etc. Clean out required evaporator strainer.

• Inspect condenser tubes a

• Clean and repaint any corroded surface.

• Clean remote condenser coils (CCAR only). R condenser manufacturer’s recommendations.

ties, make sure drain

nd clean, if needed.

efer to the

Maintenance

CG-SVX038A-EN 39

Electrical Schematics

CGWR Field Wiring 0

WEIGHT:

SIZE

DWG. NO.

REV.

NAME

DATE DRAWN CHECKED

BAR

MFG APPR. Q.A.

ENG APPR.

SMH

3/22/17

Diagram

COMMENTS:

SHEET 1 OF 1

3/22/17

CGWR Field Wiring

SCALE:1:5

14 9

PANEL GROUND

(Factory Installed)

PDB1

UNIT CONTROLLER

23 24

2118 19

20 2118 19 22

16 17

16 171514

10 11

131210 11

8657

Optional: Disconnect

REQUIRED

out and start-up procedures have

DSW1

A-1

: For CGWR 20-30 ton,

A-2

been completed.

Cooling Tower Pump Enable

Drawing covers single source power only. All field wiring must be in accordance with National Electric Code and State & Local

CAUTION

Do not energize the unit until check-

GND

TBA

: Remote Run/Stop

Control Panel Representation

Optional

: For CGWR 40-65 ton,

Cooling Tower Pump Enable

Hazardous voltage!

Optional

WARNING

Disconnect all electrical power

Optional

: Alarm Dry

Contacts

Optional

: Flow Switch (flow

proving device)

Interface

requirements.

including remote disconnects before

(Required) Factory supplied or approved alternate field installed flow

5. proving device connection.

Use copper conductors only!

CAUTION

Failure to do so can cause death or

equipment damage.

to use copper conductors may cause

accept other type conductors. Failure

Unit terminals are not designed to

serious injury.

cannot be inadvertently energized.

tagout procedures to ensure power

servicing unit. Follow proper lockout/

Notes

All three-phase motors supplied with the unit are protected under

1. primary single-phase failure conditions.

All customer control-circuit wiring must have a minimum rating of

2. 150V.

All field wiring must be in accordance with applicable local codes.

3. Line voltage options. Single or dual source power may be specified.

CGWR Water-Cooled Chillers

CGWR Field Wiring

Figure 8. Field wiring for 20 to 65 ton, R-410A CGWR water-cooled chillers

40 CG-SVX038A-EN

Electrical Schematics

LONGVIEW, TX

75606-3066

P.O. BOX 3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNE

R410A CGWR CHILLERS

20 - 30 TON WATER-COOLED CHILLERS

POWER/CONROL WIRING DIAGRAM

07/26/17

HMSHMS

3F1F F2

+5 GND SI

+ - GND

R80500011

11 12

BAR

(CT 1)

(CT 2)

POWER IN

TBA4

HP1SW

BLACK

WHITE

SHIELD

WHITE

LIQUID SOLENOID

LLS 1

RELAY M-1

LLS 1

RELAY M-2

RELAY M-4

SPARE

HGS 1

RELAY M-3

SPARE

RELAY M-5

RELAY M-7

SPARE

RELAY M-6

GNDNL/L1

BLACK

WHITE

SHIELD

SENSOR M-11

CKT 1 SUC TMP

AMPS COMP 2

SENSOR M-6

SENSOR M-5

AMPS COMP 1

CKT 1 DIS PSI

SENSOR M-4

SENSOR M-3

CKT 1 SUC PSI

CW OUT

SENSOR M-2

+5 GND SI

DIGITAL ANALOG

WHITE

RED

BLACK & SHIELD

DIGITAL ANALOG

+5 GND SI

SENSOR M-1

CW IN

DIGITAL ANALOG

Termination

HGS 1

HOT GAS SOLENOID

LP1SW

TBA10

TBA11

TBA20

RED 3

UNIT CONTROLLER

SENSOR M-16

REM RUN/STOP

CMP1&2 ENABLE

SENSOR M-13

GND

+12V GND ??

ETHERNET

WRV

Com NO NC

(Shield tied at this end)

ETHERNET

+12VMCS IORS485

SENSOR 12

SENSOR 11

SENSOR 10

SENSOR 9

SENSOR 8

SENSOR 7

SENSOR 5

SENSOR 6

SENSOR 3

SENSOR 4

SENSOR 1

SENSOR 2

DI-15

DI-16 DI-13

DI-14

+5+5

DIGITAL INPUTS

ANALOG OUTS

A-3A-4 A-1A-2

gnd

-485

+485

SCL SDA

GND

+12V

KEYPAD LCD

115v

Voltage

Com NO NC

Com NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NC

TBA6

TBA19

TBA17

TBA18

TBA1616TBA15

Comp 2

Comp 1

44A

TBA1

TBA2

FLOW-Field

TBA7

TBA3

TBA24

TBA23

TBA22

TBA21

RELAY M-8

RELAY M-9

RELAY M-10

ALARM

SPARE

CONTACTOR

SENSOR M-14

OPT PWM

PWR MONITOR

SENSOR M-10

SENSOR M-9

SHIELD

BLACK &

BLACK

SHIELD

WHITE

To Customer Interface or

Communications Board

To Optional Exp Board

Comm to SI16 or eq

WHITE

OPTIONAL FIELD

CND ENBL1

WHITE TO TBC3

SHIELD

BLACK/

(PUMP)

SHIELD

WHITE

RED

BLACK & SHIELD

BLACK &

SHIELD

WHITE

TO AO1

TBC3

Bellimo WRV

(OPTIONAL)

120 VAC

TR3

(OPTIONAL)

24 VAC

TBC2

TBC1

120

VAC

FU1

FU2

FU3

RED

WHITE

TR1

T3T2T1

L2L1

L3L2

MOTOR

C2 AUX 2

CCH 2

COMPRESSOR

T3T1 T2

CCH 1

SENSOR M-15

TO KEYPAD / DISPLAY

OPTIONAL

COMPRESSOR

MOTOR

COMPR

L2L1

PDB1

DSW1

DISCONNECT

(OPTIONAL)

PWM

(OPTIONAL)

FU4 FU5 FU6

GROUND

PANEL

WHITE

RED 3B

TBA-2

TBA-4

SHIELD

SENSOR M-12

CORE TEMP

BLACK

WHITE

SENSOR M-7

SENSOR M-8

SPARE

COMPR

C1 AUX 1

SPARE

TO UNIT

CONNECTOR

-485

+485

SDA

SCL

Gnd

+12v

V+

L N

V-

or Ethernet Switch

(OPTIONAL TOUCHSCREEN CONNECTIONS)

CONTOLLER

KEYPAD/LCD

Ethernet Connection

POWER SOURCE)

To Unit Controller

(OPTIONAL TOUCHSCREEN

TBA5

CGWR Power/Control Wiring

Refer to name plate on control box door (inside) for electrical data and wiring diagram.

Figure 9. Power/control wiring schematic for 20 to 30 ton, R-410A CGWR water-cooled chillers

CG-SVX038A-EN 41

Electrical Schematics

LONGVIEW, TX

75606-3066

P.O. BOX 3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICTTRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNE

R410A CGWR CHILLERS

POWER/CONTROL WIRING SCHEMATIC

40 - 65 TON WATER-COOLED CHILLERS

08/30/13

1.5"=12"

HMSHMS

EXPANSION BOARD INTERFACE

(CT 1)

(CT 3)

(CT 2)

+5 GND SI

+ - GND

R80500012

1211

F2 F3F1

1211

}

BAR

}

POWER IN

CONTACTOR

V+

V-

HP1SW

KEYPAD/LCD

CONTOLLER

BLACK

WHITE

SHIELD

WHITE

LIQUID SOLENOID

LLS 1

RELAY M-1

LLS 1

RELAY M-2

RELAY M-4

HGS 1

RELAY M-3

LLS 2

RELAY M-5

RELAY M-7

HGS 2

RELAY M-6

GNDNL/L1

BLACK

WHITE

SHIELD

SENSOR M-11

CKT 1 SUC TMP

AMPS COMP 3

SENSOR M-6

SENSOR M-5

AMPS COMP 1

CKT 1 DIS PSI

SENSOR M-4

SENSOR M-3

CKT 1 SUC PSI

CW OUT

SENSOR M-2

+5 GND SI

DIGITAL ANALOG

WHITE

RED

BLACK & SHIELD

DIGITAL ANALOG

+5 GND SI

SENSOR M-1

CW IN

DIGITAL ANALOG

Termination

HGS 1

HOT GAS SOLENOID

LP1SW

TBA10

TBA11

TBA20

RED 3

UNIT CONTROLLER

FLOW-Field

SENSOR M-16

REM RUN/STOP

CMP1&3 ENABLE

SENSOR M-13

SENSOR M-15

Com NO NC

ETHERNET

+12VMCS IORS485

SENSOR 12

SENSOR 11

SENSOR 10

SENSOR 9

SENSOR 8

SENSOR 7

SENSOR 5

SENSOR 6

SENSOR 3

SENSOR 4

SENSOR 1

SENSOR 2

DI-15DI-16 DI-13DI-14

+5+5

DIGITAL INPUTS

ANALOG OUTS

A-3A-4 A-1A-2

gnd

-485

+485

SCL SDA

GND

+12V

KEYPAD LCD

115v

Voltage

Com NO NC

Com NO NCCom NO NCCom NO NCCom NO NCCom NO NC

867

TBA6

TBA19

TBA17

TBA18

CKT1 Comp 1

44A

TBA1

TBA2

TBA7

TBA3

TBA24

TBA23

TBA22

TBA21

RELAY M-8

RELAY M-9

RELAY M-10

ALARM

CND ENBL

CONTACTOR

SENSOR M-14

SENSOR M-10

AMPS COMP 2

SENSOR M-9

SHIELD

BLACK &

BLACK

SHIELD

(OPTIONAL TOUCHSCREEN

CONNECTOR

TO UNIT

Optional Touchscreen

OPTIONAL FIELD

SPARE

WHITE (TO TBC3)

SHIELD (TO TBC1)

BLACK/

SHIELD

WHITE

RED

BLACK & SHIELD

BLACK &

SHIELD

WHITE

TO AO1

TBC-3

Bellimo WRV #1

WHITE

RED 3B

120 VAC

TR3

(OPTIONAL)

24 VAC

TBC-2TBC-1

120 VAC

FU1

FU2

FU3

RED

WHITE

TR1

T3T2T1

L2L1

C1 AUX 1

CCH 1

T3T1

WHITE

To Customer Interface or

Communications Board or

CCH 3

COMPR

CKT 1

L2L1

PDB1

DSW1

DISCONNECT

(OPTIONAL)

PWM

(OPTIONAL)

FU4 FU5 FU6

GROUND

PANEL

+12v

Gnd

SCL

SDA

+485

-485

T3T2

COMPR

C3 AUX 3

COMPR

CKT 2

C2 AUX 2

CCH 2

L3L2L1

COMPRESSOR

MOTOR

COMPRESSOR

MOTOR

COMPRESSOR

MOTOR

MTR MOD 2

BLUE

YELLOW

CKT 1 Comp 3

LIQUID SOLENOID

LLS 2

TBA12

13A

CKT2 Comp 2

CONTACTOR

SENSOR 2-8

SENSOR 1-8

120 VAC POWER IN

+ - GND

LINE NEUT GND

6 8

3 4

ADDRESS

Termination

MCS I/O

WHITE

BLACK

SPARE2-8

TRANSFORMER

SPARE1-8

BLACK

+5 GND SI

ANALOG

SPARE2-6

SENSOR 2-7

SPARE2-7

SENSOR 2-6

SENSOR 2-5

SENSOR 2-4

SENSOR 2-3

SENSOR 2-2

SENSOR 2-1

DIGITAL

SHIELD

WHITE

SPARE 1-6

SPARE 1-7

SENSOR 1-7

SENSOR 1-6

SENSOR 1-5

SPARE 1-5

SPARE 1-4

CORE TEMP

SENSOR 1-4

SENSOR 1-3

SENSOR 1-2

TRGT RST

PWR MONITOR

SENSOR 1-1

Opt

COM

ALARM

SENSOR 9

+5 GND SI

ANALOG

DIGITAL

SENSOR 10

+5 GND SI

ANALOG

DIGITAL

SENSOR 11

+5 GND SI

ANALOG

DIGITAL

SENSOR 12

+5 GND SI

ANALOG

DIGITAL

SENSOR 13

+5 GND SI

ANALOG

DIGITAL

SENSOR 14

+5 GND SI

ANALOG

DIGITAL

SENSOR 15

+5 GND SI

ANALOG

DIGITAL

SENSOR 16

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

+12 +12 +12

S1 GND +5

S1 GND +5 S1 GND +5

SENSOR 2

SENSOR 3

SENSOR 4

SENSOR 5

SENSOR 6

SENSOR 7

SENSOR 8

SENSOR 1

To SI Board

11A

TBA9

HP2SW

LP2SW

TBA8

1010A

CKT 2 SUC PSI

SENSOR M-7

CKT 2 DIS PSI

SENSOR M-8

WHITE

RED

BLACK & SHIELD

WHITE

RED

BLACK & SHIELD

BLACK

WHITE

SHIELD

SENSOR M-12

CKT 2 SUC TMP

CONTROL PWR SWITCH

ON/OFF

WHITE

(OPTIONAL)

WHITE

TBA-2

TBA-4

TBA2

TBA3

WRV

TO KEYPAD / DISPLAY

CMP2 ENABLE

WHITE

SHIELD

BLACK &

BLACK

SHIELD

WHITE

HGS 2

HOT GAS SOLENOID

TBA13

16A

ANALOG

DIGITAL

SPARE2-5

SPARE2-4

MTR MOD 2

SPARE2-2

SPARE2-1

A3 GND A4

ANALOG OUTPUTS

A1 GND A2

SPARE

11A

SHIELD

BLACK

WHITE

TBC-1

To SI Board

(PUMP)

OPTIONAL

POWER SOURCE)

ETHERNET

TBC-2

or Ethernet Switch

+12V GND ??

(OPTIONAL TOUCHSCREEN CONNECTIONS)

To Unit Controller

Ethernet Connection

Figure 10. Power/control wiring schematic for 40 to 65 ton, R-410A CGWR water-cooled chillers

42 CG-SVX038A-EN

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

ENGINEER'S SEAL DATE

REVISION

SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT

20-30TON WATER-COOLED CHILLER 208-230V

NOITCUDORP 02000508R 11

10/2/13

1:1

SMH

KLDR3

TRANSFORMER

SECONDARY /

2 1

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5563

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR3

LITTELFUSE

FOR 208-230V UNITS

1 - CPS On/Off

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLER

COMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

TR1

2143

TBC

2143

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

2143

756 8

56 8

1110 12131110 12 13

14 15 1716

14 15 17 2261

221918 21

1918 21

2423

120/24 VAC TRANSFORMER FOR WRVTR3

2 - CKT1 Enable

TBA

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

PWM

DIGITAL POWER MONITOR

TERMINAL BLOCK FOR WATER REGULATING VALVETBC

SMH BAR

TOOGLE SWITCHESSW

GND GROUND LUG

TBA TERMINAL BLOCK

TR3

TBA

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

WRV

TBC

Figure 11. Control panel layout for 20 to 30 ton, 208V, R-410A CGWR water-cooled chillers

Electrical Schematics

CG-SVX038A-EN 43

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

CGWR SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT

20 - 30 TON WATER-COOLED CHILLER 460V

NOITCUDORP 12000508R 11

8/11/17

SMH

CLASS

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

FOR 460V UNITS

1 - CPS On/Off

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

120/24 VAC TRANSFORMER FOR WRVTR3

TR1

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

214

756 8

56 8

1110 12131110 12 13

14 15 1716

14 15 17 226

221918 2120

18 2120

2423

BAR

2 - CKT1 Enable

TBA

TR3

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

***

TBC

3412

GROUND LUG

TERMINAL BLOCKTBA

GND

TOOGLE SWITCHSW

TERMINAL BLOCK FOR WATER REGULATING VALVE

TBC

PWM

DIGITAL POWER MONITOR

SMH

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

WRV

TBA

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

Electrical Schematics

Figure 12. Control panel layout for 20 to 30 ton, 460V, R-410A CGWR water-cooled chillers

44 CG-SVX038A-EN

Figure 13. Control panel layout for 20 to 30 ton, 575V, R-410A CGWR water-cooled chillers

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNE BY

SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT

20-30 TON WATER-COOLED CHILLER 575V

NOITCUDORP 22000508R 11

10/25/2011

1:1

PMK

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

2 1

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSE

TRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564A

FOR 575V UNITS

GND

TERMINAL BLOCKTBA

POWER DISTRIBUTION BLOCK

PDB1

600 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLER

COMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

120/24 VAC TRANSFORMER FOR WRVTR3

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

TR1

2143

TBC

2143

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

2143

756 8

56 8

1110 12

1110 12 13

14 15 1716

14 15 17 2261

221918 21

1918 21

2423

GROUND LUG

2 - CKT1 Enable

TBA

TR3

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

***

PWM

DIGITAL POWER MONITOR

TERMINAL BLOCK FOR WATER REGULATING VALVETBC

TOOGLE SWITCHSW

1 - CPS On/Off

TBA

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

WRV

TBC

Electrical Schematics

CG-SVX038A-EN 45

Electrical Schematics

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5563

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR3

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3

FOR 208-230V UNITS

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT 208/230V

40 - 65 TON WATER-COOLED CHILLER

NOITCUDORP 32000508R 11

9/26/13

1:1

SMH SMH BAR

FUSE SCHEDULE FOR 208-230V UNITS

DESIGNATION LOCATION FUSE TYPE CLASS AMPS VOLTS

FU1, FU2

PRIMARY

TRANSFORMER

CC 3 1/2 600

FU3

SECONDARY

TRANSFORMER

LITTELFUSE

KLDR3

CC 3 1/2 600

FU4, FU5, FU6 *

DIGITAL POWER

MONITOR *

0 061

1K T

K N

O R TIMI

LITTELFUSE

KLDR3

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

FU4-6

230V

TR1

FU3

SCHEDULE

FUSE

PWM

FU1,2

C3C1

GND

DSW1

CT3

CT2CT1

PDB1

TBA

TR3

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

TBC

3421

COM

143

2143

56 8

756 8

1110 121311

10 12 13

14 15 171614 15 17

2261

18 2120

1918 2120

1 - CPS On/Off

2 - CKT1 Enable

GND

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT3

120/24 VAC TRANSFORMER FOR WRVTR3

TBC

WRV

DIGITAL POWER MONITOR PWM

EXPANSION BOARD SI 16-A04EXP1

TBA

TOGGLE SWITCHESSW

TERMINAL BLOCKTBA

TERMINAL BLOCK FOR WATER REGULATING VALVETBC

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

GROUND LUG

Figure 14. Control panel layout for 40 to 65 ton, 208V, R-410A CGWR water-cooled chillers

46 CG-SVX038A-EN

Figure 15. Control panel layout for 40 to 65 ton, 460V, R-410A CGWR water-cooled chillers

FUSE TYPE

LITTELFUSE

TRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3/

TRANSFORMER FUSE SCHEDULE

FOR 460V UNITS

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

ENGINEER'S SEAL DATE

REVISION

CGWR SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT

40-65 TON WATER-COOLED CHILLER 460V

NOITCUDORP 42000508R 11

9/27/13

1:1

SMH SMH BAR

FUSE SCHEDULE FOR 460V UNITS

DESIGNATION LOCATION FUSE TYPE CLASS AMPS VOLTS

FU1, FU2

PRIMARY

TRANSFORMER

LITTELFUSE KLDR1

CC 1 1/2 600

FU3

SECONDARY

TRANSFORMER

LITTELFUSE

KLDR3

CC 3 1/2 600

FU4, FU5, FU6 *

DIGITAL POWER

MONITOR *

0061KTK NORTIMIL

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

FU4-6

230V

TR1

FU3

SCHEDULE

FUSE

PWM

FU1,2

C3C1

GND

DSW1

CT3

CT2CT1

PDB1

TBA

TR3

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

TBC

3421

COM

143

2143

56 8

756 8

1110 121311

10 12 13

14 15 171614 15 17

2261

18 2120

1918 2120

242324

1 - CPS On/Off

2 - CKT1 Enable

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT3

120/24 VAC TRANSFORMER FOR WRV

TBC

WRV

DIGITAL POWER MONITOR PWM*EXPANSION BOARD SI 16-A04EXP1

TBA

TOGGLE SWITCHESSW

TERMINAL BLOCKTBA

TERMINAL BLOCK FOR WATER REGULATING VALVE

TBC

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

GROUND LUGGND

TR3

Electrical Schematics

CG-SVX038A-EN 47

CC 3/

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

FOR 460V UNITS

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

SCROLL 410A

WATER-COOLED CHILLER

CONTROL PANEL LAYOUT

40-65 TON WATER-COOLED CHILLER 575V

NOITCUDORP 52000508R 11

9/27/13

1:1

SMH SMH BAR

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

TBA

FU4-6

230V

TR1

FU3

SCHEDULE

FUSE

PWM

FU1,2

C3C1

GND

DSW1

CT3

CT2

CT1

PDB1

TR3

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

TBC

3421

COM

143

2143

56 8

756 8

1110 121311

10 12 13

14 15 171614 15 17

2261

18 2120

1918 2120

242324

1 - CPS On/Off

2 - CKT1 Enable

POWER DISTRIBUTION BLOCK

PDB1

600 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT3

120/24 VAC TRANSFORMER FOR WRVTR3

TBC

WRV

DIGITAL POWER MONITOR

PWM

EXPANSION BOARD SI 16-A04EX P1

TBA

TOGGLE SWITCHESSWTERMINAL BLOCKTBA

TERMINAL BLOCK FOR WATER REGULATING VALVETBC

PWM CIRCUIT FUSES - KTK OR EQ

FU4,5,6

GROUND LUG

GND

Electrical Schematics

Figure 16. Control panel layout for 40 to 65 ton, 575V, R-410A CGWR water-cooled chillers

48 CG-SVX038A-EN

CCAR Compressor Chillers

UNIT CONTROLLER

GROUND

(Factory Installed)

PDB1

PANEL

Disconnect

Damper Control

23 24

2118 19

20 2118 19 22

16 17

16 171514

10 11

131210 11

8657

Optional:

Optional

DSW1

A-1 A-2

GND

A-1

WARNING

A-2

Disconnect all electrical power

Hazardous voltage!

Condensing Unit Fan 1

GND

TBA

Control Panel Representation

Condensing Unit Control Power

Interface

: Alarm Dry

Contacts

REQUIRED

: Flow Switch (flow

Condensing Unit Fan 2

: Remote Run/Stop

proving device)

Optional

including remote disconnects before

indoor chiller.

CAUTION

Do not energize the unit until checkout and start-up procedures have been completed.

Wiring to be 2-wire shielded cable between outdoor unit and Trane If installing with a Trane CAUJ air-cooled condenser, more specific

7. field wiring instructions can be found in the operations and maintenance manual.

Use copper conductors only!

CAUTION

Failure to do so can cause death or

equipment damage.

to use copper conductors may cause

accept other type conductors. Failure

Unit terminals are not designed to

serious injury.

cannot be inadvertently energized.

tagout procedures to ensure power

servicing unit. Follow proper lockout/

Notes

All three-phase motors supplied with the unit are protected under

1. primary single-phase failure conditions. All customer control-circuit wiring must have a minimum rating of

2. 150V. All field wiring must be in accordance with applicable local codes.

3. Line voltage options. Single or dual source power may be specified.

4. Drawing covers single source power only. All field wiring must be in accordance with National Electric Code and State & Local requirements. (Required) Factory supplied or approved alternate field installed flow

5. proving device connection. (Optional) Damper control option. Refer to operation and

6. maintenance manual for additional information. This point intended to operate a low ambient damper on a remote air-cooled condenser.

Condensing Unit Fan 3

Field Wiring Single Circuit CCAR

WEIGHT:

SIZE

DWG. NO.

REV.

NAME

DATE DRAWN CHECKED ENG APPR. MFG APPR. Q.A.

SMH

3/22/17

SHEET 1 OF 1

COMMENTS:

Diagram

BAR

3/22/17

CCAR 20-30 Ton

Field Wiring

SCALE:1:5

CCAR Field Wiring

Figure 17. Field wiring diagram for 20 to 30 ton, R-410A CCAR compressor chillers

Electrical Schematics

CG-SVX038A-EN 49

Electrical Schematics

Dual Circuit CCAR Field Wiring

WEIGHT:

SIZE

DWG. NO.

REV.

NAME

DATE DRAWN CHECKED

COMMENTS:

MFG APPR.

Q.A.

BAR

3/23/17

SMH

SHEET 1 OF 1

ENG APPR.

Diagram

3/23/17

CCAR 40-65 Ton

Field Wiring

SCALE:1:5

UNIT CONTROLLER

9382

GROUND

(Factory Installed)

PDB1

TBD

PANEL

Disconnect

Damper Control

23 24

2118 19

20 2118 19 22

16 17

16 171514

10 11

131210 11

8657

3412

34 921

4375

842

Optional:

DSW1

A-1 A-2

GND

A-1

WARNING

A-2

Circuit 1 Fan 2

Disconnect all electrical power

Hazardous voltage!

Circuit 2 Fan 1

GND

TBA

Control Panel Representation

servicing unit. Follow proper lockout/

including remote disconnects before

Condensing Unit Control Power

Optional

Interface

: Alarm Dry

Contacts

REQUIRED

: Flow Switch (flow

Circuit 1 Fan 1

: Remote Run/Stop

proving device)

tagout procedures to ensure power

Optional

unit and Trane indoor chiller.

CAUTION

Do not energize the unit until checkout and start-up procedures have been completed.

damper per AO. Wiring to be 2-wire shielded cable between outdoor If installing with a Trane CAUJ air-cooled condenser, more specific

7. field wiring instructions can be found in the operations and maintenance manual.

Use copper conductors only!

CAUTION

Failure to do so can cause death or

equipment damage.

to use copper conductors may cause

accept other type conductors. Failure

Unit terminals are not designed to

serious injury.

cannot be inadvertently energized.

Notes

All three-phase motors supplied with the unit are protected under

1. primary single-phase failure conditions. All customer control-circuit wiring must have a minimum rating of

2. 150V. All field wiring must be in accordance with applicable local codes.

3. Line voltage options. Single or dual source power may be specified.

5. proving device connection. (Optional) Damper control option. Refer to operation and

6. maintenance manual for additional information. This point intended to operate low ambient dampers on a remote air-cooled condenser, (1)

Circuit 2 Fan 2

Circuit 1 Fan 3

Circuit 2 Fan 3

Figure 18. Field wiring diagram for 40 to 65 ton, R-410A CCAR compressor chillers

50 CG-SVX038A-EN

Electrical Schematics

LONGVIEW, TX

75606-3066

P.O. BOX 3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNE

R410 CCAR COMPRESSOR CHILLERS

POWER/CONTROL WIRING SCHEMATIC

20 - 30 TON COMPRESSOR CHILLER

08/03/17

HMSHMS

3F1F F2

+5 GND SI

+ - GND

R80500013

1211

11 12

BAR

(CT 1)

(CT 2)

POWER IN

TBA7

HP1SW

BLACK

WHITE

SHIELD

WHITE

LIQUID SOLENOID

LLS 1

RELAY M-1

LLS 1

RELAY M-2

RELAY M-4

SPARE

HGS 1

RELAY M-3

SPARE

RELAY M-5

RELAY M-7

FAN 1

RELAY M-6

GNDNL/L1

BLACK

WHITE

SHIELD

SENSOR M-11

CKT 1 SUC TMP

AMPS COMP 2

SENSOR M-6

SENSOR M-5

AMPS COMP 1

CKT 1 DIS PSI

SENSOR M-4

SENSOR M-3

CKT 1 SUC PSI

CW OUT

SENSOR M-2

+5 GND SI

DIGITAL ANALOG

WHITE

RED

BLACK & SHIELD

DIGITAL ANALOG

+5 GND SI

SENSOR M-1

CW IN

DIGITAL ANALOG

Termination

HGS 1

HOT GAS SOLENOID

LP1SW

TBA10

TBA11

TBA20

RED 3

UNIT CONTROLLER

FLOW-Field

SENSOR M-16

REM RUN/STOP

CMP1&2 ENABLE

V+

(OPTIONAL TOUCHSCREEN

DAMPER CONTROL

TO KEYPAD / DISPLAY

Com NO NC

(Shield tied at this end)

ETHERNET

+12VMCS IORS485

SENSOR 12

SENSOR 11

SENSOR 10

SENSOR 9

SENSOR 8

SENSOR 7

SENSOR 5

SENSOR 6

SENSOR 3

SENSOR 4

SENSOR 1

SENSOR 2

DI-15DI-16 DI-13DI-14

+5+5

DIGITAL INPUTS

ANALOG OUTS

A-3A-4 A-1A-2

gnd

-485

+485

SCL SDA

GND

+12V

KEYPAD LCD

115v

Voltage

Com NO NC

Com NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NC

TBA6

TBA19

TBA17

TBA18

TBA1616TBA15

Comp 2

Comp 1

44A

TBA1

TBA2

TBA4

TBA3

TBA24

TBA23

TBA22

TBA21

RELAY M-8

RELAY M-9

RELAY M-10

ALARM

FAN 3

CONTACTOR

SENSOR M-14

OPT PWM

PWR MONITOR

SHIELD

BLACK &

BLACK

SHIELD

WHITE

To Optional Exp Board

Comm to SI16 or eq

WHITE

OPTIONAL FIELD

FAN 2

SHIELD

BLACK/

SHIELD

WHITE

RED

BLACK & SHIELD

BLACK &

SHIELD

WHITE

120 VAC

FU1

FU2

FU3

RED

WHITE

TR1

T3T2T1

L2L1

L3L2

MOTOR

C2 AUX 2 CCH 2

COMPRESSOR

T3T1 T2

CCH 1

SENSOR M-13

SENSOR M-15

OPTIONAL

COMPRESSOR

MOTOR

COMPR

L2L1

PDB1

DSW1

DISCONNECT

(OPTIONAL)

PWM

(OPTIONAL)

FU4 FU5 FU6

GROUND

PANEL

SHIELD

SENSOR M-12

CORE TEMP

BLACK

WHITE

COMPR

C1 AUX 1

15B

15A

Optional Touchscreen

To Customer Interface or

TO UNIT

CONNECTOR

-485

+485

SDA

SCL

Gnd

+12v

Communications Board or

CONTOLLER

KEYPAD/LCD

POWER SOURCE)

ETHERNET

GND

+12V GND ??

(OPTIONAL TOUCHSCREEN CONNECTIONS)

or Ethernet SwitchV-To Unit Controller

Ethernet Connection

TBA5

CCAR Power/Control Wiring

Refer to name plate on control box door (inside) for electrical data and wiring diagram.

Figure 19. Power/control wiring schematic for 20 to 30 ton, R-410A CCAR compressor chillers

CG-SVX038A-EN 51

Electrical Schematics

LONGVIEW,TX

75606-3066

P.O. BOX 3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNE

R410 CCAR COMPRESSOR CHILLERS

POWER/CONTROL WIRING SCHEMATIC

40 - 65 TON COMPRESSOR CHILLER

HMSHMS71/72/70

(CT 1)

(CT 3)

(CT 2)

+5 GND SI

+ - GND

R80500014

1211

F3F1

1211

}

BAR

}

NC NO COMNC NO COM

NC NO COMNC NO COMNC NO COM

COM NO NCCOM NO NCCOM NO NC

COM NO NC

POWER IN

CKT1 FAN2

To Customer Interface or

HP1SW

BLACK

WHITE

SHIELD

WHITE

LIQUID SOLENOID

LLS 1

RELAY M-1

LLS 1

RELAY M-2

RELAY M-4

SPARE

RELAY M-3

LLS 2

RELAY M-5

RELAY M-7

HGS 2

RELAY M-6

GND

L/L1

BLACK

WHITE

SHIELD

SENSOR M-11

CKT 1 SUC TMP

AMPS COMP 3

SENSOR M-6

SENSOR M-5

AMPS COMP 1

CKT 1 DIS PSI

SENSOR M-4

SENSOR M-3

CKT 1 SUC PSI

CW OUT

SENSOR M-2

+5 GND SI

DIGITAL ANALOG

WHITE

RED

BLACK & SHIELD

DIGITAL ANALOG

+5 GND SI

SENSOR M-1

CW IN

DIGITAL ANALOG

Termination

LP1SW

TBA10

TBA20

RED 3

UNIT CONTROLLER

FLOW-Field

SENSOR M-16

REM RUN/STOP

CMP1&3 ENABLE

SENSOR M-13

SENSOR M-15

Com NO NC

ETHERNET

+12VMCS IORS485

SENSOR 12

SENSOR 11

SENSOR 10

SENSOR 9

SENSOR 8

SENSOR 7

SENSOR 5

SENSOR 6

SENSOR 3

SENSOR 4

SENSOR 1

SENSOR 2

DI-15DI-16 DI-13DI-14

+5+5

DIGITAL INPUTS

ANALOG OUTS

A-3A-4 A-1A-2

gnd

-485

+485

SCL SDA

GND

+12V

KEYPAD LCD

115v

Voltage

Com NO NC

Com NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NCCom NO NC

TBA6

TBA19

CKT1 Comp 3

CKT 1 Comp 1

44A

TBA1

TBA2

TBA7

TBA3

TBA24

TBA23

TBA22

TBA21

RELAY M-8

RELAY M-9

RELAY M-10

ALARM

CONTACTOR

SENSOR M-14

SPARE

SENSOR M-10

AMPS COMP 2

SENSOR M-9

SHIELD

BLACK &

BLACK

SHIELD

WHITE

OPTIONAL FIELD

SHIELD

BLACK/

SHIELD

WHITE

RED

BLACK & SHIELD

BLACK &

SHIELD

WHITE

120 VAC

FU1

FU2

FU3

RED

WHITE

TR1

T3T2T1

L2L1

C1 AUX 1

CCH 1

T3T1

(OPTIONAL TOUCHSCREEN

POWER SOURCE)

CCH 3

COMPR

CKT 1

L2L1

PDB1

DSW1

DISCONNECT

(OPTIONAL)

GROUND

PANEL

+12v

Gnd

SCL

SDA

+485

-485

T3T2

COMPR

C3 AUX 3

COMPR

CKT 2

C2 AUX 2

CCH 2

L3L2L1

COMPRESSOR

MOTOR

COMPRESSOR

MOTOR

COMPRESSOR

MOTOR

MTR MOD 2

BLUE

YELLOW

11B

LIQUID SOLENOID

LLS 2

TBA12

13A

CKT2 Comp 2

CONTACTOR

SENSOR 2-8

SENSOR 1-8

120 VAC POWER IN

+ - GND

LINE NEUT GND

6 8

3 4

ADDRESS

Termination

MCS I/O

BLACK

WHITE

SPARE2-8

TRANSFORMER

SPARE1-8

BLACK

+5 GND SI

ANALOG

SPARE2-6

SENSOR 2-7

SPARE2-7

SPARE2-5

SENSOR 2-6

SENSOR 2-5

MTR MOD 2

SPARE2-4

SENSOR 2-4

SENSOR 2-3

SPARE2-2

SENSOR 2-2

SPARE2-1

SENSOR 2-1

DIGITAL

SHIELD

WHITE

SPARE 1-6

SPARE 1-7

SENSOR 1-7

SENSOR 1-6

SENSOR 1-5

SPARE 1-5

SPARE 1-4

CORE TEMP

SENSOR 1-4

SENSOR 1-3

SENSOR 1-2

TRGT RST

PWR MONITOR

SENSOR 1-1

Optional

COM

ALARM

SENSOR 9

+5 GND SI

ANALOG

DIGITAL

SENSOR 10

+5 GND SI

ANALOG

DIGITAL

SENSOR 11

+5 GND SI

ANALOG

DIGITAL

SENSOR 12

+5 GND SI

ANALOG

DIGITAL

SENSOR 13

+5 GND SI

ANALOG

DIGITAL

SENSOR 14

+5 GND SI

ANALOG

DIGITAL

SENSOR 15

+5 GND SI

ANALOG

DIGITAL

SENSOR 16

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

ANALOG

DIGITAL

+12 +12 +12

SI GND +5

SENSOR 2

SENSOR 3

SENSOR 4

SENSOR 5

SENSOR 6

SENSOR 7

SENSOR 8

SENSOR 1

To SI Board

11A

TBA9

HP2SW

LP2SW

TBA8

1010A

CKT 2 SUC PSI

SENSOR M-7

CKT 2 DIS PSI

SENSOR M-8

WHITE

RED

BLACK & SHIELD

WHITE

RED

BLACK & SHIELD

BLACK

WHITE

SHIELD

SENSOR M-12

CKT 2 SUC TMP

CONTROL PWR SWITCH

ON/OFF

WHITE

TBA2

DAMPER CONTROL

TO KEYPAD / DISPLAY

CMP2 ENABLE

WHITE

SHIELD

BLACK &

BLACK

SHIELD

WHITE

HGS 1

HOT GAS SOLENOID

HGS 1

TBA11

FU6

FU5FU4

PWM

RO 10

RO 9

RO 8

RO 7

RO 6

RO 5

RO 4

RO 3

RO 2

TRANSFORMER

RO 1

+ - GND

MCS I/O

Termination

ADDRESS

RO10

LINE NEU

L1 L2

115V

GND

TBA5 TBA1

TBD3TBD6

TBD4

TBD2

TBD7

TBD1

SI GND +5 SI GND +5

SI GND +5

TBA18

TBA17

16A

HGS 2

TBA13

HOT GAS SOLENOID

SPARE

TBD8

Optional Touchscreen

CKT1 FAN1

CKT1 FAN3CKT2 FAN1

CKT2 FAN2CKT2 FAN3

JUMPERS

A1 GND A2

ANALOG OUTPUTS

A3 GND A4

WHITE

BLACK

SHIELD

TBA-4

TBA-2

24 VAC

TR3

120 VAC

TBA3

V-

RED 3H

WHITE

or Ethernet Switch

(OPTIONAL TOUCHSCREEN CONNECTIONS)

+12V GND ??

ETHERNET

V+

To SI Board

OPTIONAL

Ethernet ConnectionNTo Unit Controller

Communications Board or

Figure 20. Power/control wiring schematic for 40 to 65 ton, R-410A CCAR compressor chillers

52 CG-SVX038A-EN

Figure 21. Power schematic, CAUJ condenser control circuit modification:

1TB2-1

1TB3-5

1TB3-4

1TB3-6

1TB3-9

1TB3-10

1TB3-11

fan cycling control by CCAR compressor chillers

Electrical Schematics

CG-SVX038A-EN 53

Electrical Schematics

Instructions

Circle

Remove wire 65C and/or the jumper installed. Connect 1TB3-6 to TBD 3 at Trane Chiller.

Remove wire 64E. Connect 1TB3-5 to TBD 2 at Trane Chiller. This is the first fan on and last fan off.

NOTES:

2 3

Remove wire 63A. Connect 1TB3-4 to TBD 4 at Trane Chiller. This is the last fan on and

Ambient t-stat will not be used. This is the second fan on and second fan off.

Remove wire 63A. Connect 1TB3-4 to TBA 18 at Trane Chiller. This is the last fan on and

Circle

Instructions

Step

Remove wire 64E. Connect 1TB3-5 to TBA 16 at Trane Chiller. This is the first fan on and last fan off.

Reference

Ambient t-stat will not be used. This is the second fan on and second fan off.

COMPLETE

Reference

Connect 1TB2-1 to TBA 15 at Trane Chiller.

Remove wire 65C and/or the jumper installed. Connect 1TB3-6 to TBA 17 at Trane Chiller.

first fan off. The installed pressure switch will not be used.

Step

Connect 1TB2-1 to TBA 15 at Trane Chiller.

first fan off. The installed pressure switch will not be used.

Circle

Remove wire 64E. Connect 1TB3-5 to TBA 16 at Trane Chiller. This is the first fan on and last fan off.

FOR CONTROL OF 3 FAN CONDENSER:

FOR CONTROL OF 2 FAN CONDENSER:

Connect 1TB2-1 to TBD 1 at Trane Chiller.

Instructions

Step

Initial/Date

from the CCAR Compressor Chiller to the CAUJ condenser.

Initial/Date

FOR CONTROL OF 4 FAN CONDENSER:

COMPLETE

Connect 1TB2-1 to TBD 1 at Trane Chiller.

Remove wire 77E. Connect 1TB3-10 to TBD 6 at Trane Chiller.This is the first fan on and last fan off.

CCAR units are designed for operation down to a minimum of 40°F ambient.

first fan off. The installed pressure switch will not be used.

Instructions

Reference

The installed pressure switch will not be used.

Remove wire 64E. Connect 1TB3-5 to TBD 2 at Trane Chiller. This is the first fan on and last fan off.

COMPLETE

Circle

Remove wire 76A. Connect 1TB3-9 to TBD 7 at Trane Chiller. This is the last fan on and first fan off.

first fan off. The installed pressure switch will not be used.

Step

Remove wire 63A. Connect 1TB3-4 to TBA 17 at Trane Chiller. This is the second fan on and

Remove wire 63A. Connect 1TB3-4 to TBD 3 at Trane Chiller. This is the last fan on and

COMPLETE

Ambient t-stat will not be used. This is the second fan on and second fan off.

Remove wire 77E. Connect 1TB3-10 to TBD 6 at Trane Chiller. This is the first fan on and last fan off.

Initial/Date

FOR CONTROL OF 6 FAN CONDENSER:

Remove wire 78C and/or the jumper installed. Connect 1TB3-11 to TBD 7 at Trane Chiller.

The installed pressure switch will not be used.

Remove wire 76A. Connect 1TB3-9 to TBD 8 at Trane Chiller. This is the last fan on and first fan off.

All CCAR/CAUJ applications require that the CCAR Compressor Chiller control the condenser fan cycling. For Fan Cycling Control - One control wire for each condenser fan plus a common must be run

Reference

CAUJ Condenser Control Wiring Modification:

Fan Cycling Control by CCAR Compressor Chillers

Trane CAUJ Condenser Control Wiring Modification

Fan Cycling Control by Trane CCAR Compressor Chillers

THREE PLACE DECIMAL

JOB #:

09/19/13

TRANE. ANY REPRODUCTION IN PART

R80500015B

LAH

09/19/13

DRAWING IS THE SOLE PROPERTY OF

BAR

EGN

SCALE:1:1

DWG. NO.

09/19/13

REV.

OR AS A WHOLE WITHOUT THE WRITTEN

75606-3066

PERMISSION OF TRANE IS PROHIBITED.

COMMENTS:

SHEET 1 OF 1

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS

DO NOT SCALE DRAWING

SIZE

SMH

NAME

MATERIAL

DATE

FINISH

DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL

LONGVIEW, TX

P.O. BOX 3066

Figure 22. Instructions — CAUJ condenser control circuit modification:

fan cycling control by CCAR compressor chillers

54 CG-SVX038A-EN

Figure 23. Low ambient damper schematic wiring and connections diagrams —

839

851

(-) J2-3

P2-3 848A

2TB34-9

851

2TB34-10

839

2U83

(+) J2-4

P2-4 849A

851A

839F

CJ2C

2U83

2TB34

Low Ambient Schematic Wiring Diagram

Low Ambient Connections Diagram

CAUJ condenser control circuit modification: low ambient damper control by CCAR compressor chillers

Electrical Schematics

CG-SVX038A-EN 55

Electrical Schematics

Disconnect and tape wire 851A from 2TB34-9. main board Analog Out (A-1) to 2TB34-9.

Connect 0-10VDC signal from Trane chiller

Disconnect and tape wire 839F at 2TB34-10. Connect 0-10VDC signal from Trane chiller main board Analog Out (A-2) to 2TB34-10

Disconnect and tape wire 851A from 2TB34-9. Connect 0-10VDC signal from Trane chiller main board Analog Out (A-1) to 2TB34-9.

Step

Disconnect plug 2U83P2 from the existing damper control board.

COMPLETE

FOR TWO DAMPER ASSEMBLIES:

Ambient Damper Control by Trane

(Leave the remaining plugs connected to the board for grounding.)

Initial/Date

FOR ONE DAMPER ASSEMBLY:

CCAR Compressor Chiller

Initial/Date

Circuit Modification:

Circle

Instructions

Step

(Leave the remaining plugs connected to the board for grounding.)

Disconnect plug 2U83P2 from the damper control box.

Ambient Damper Control by Trane CCAR Compressor Chiller

Reference

Circle

Instructions

Reference

Trane CAUJ Condenser Control

Trane CAUJ Condenser Control Circuit Modification

COMPLETE

NOTES:

All CCAR/CAUJ applications require that the CCAR Compressor Chiller control the condenser ambient dampers (when applicable). For Ambient Control Dampers when applicable - One shielded pair for each damper assembly must be run from the CCAR Compressor Chiller to the CAUJ condenser. CCAR units are designed for operation down to a minimum of 40°F ambient.

DRAWING IS THE SOLE PROPERTY OF

THREE PLACE DECIMAL

R80500016B

09/19/13

TRANE. ANY REPRODUCTION IN PART OR

JOB #:

LAH

09/19/13

75606-3066

09/19/13

BAR

EGN

PERMISSION OF TRANE IS

DWG. NO.

09/19/13

REV.

MATERIAL

SCALE:1:1

PROHIBITED.

COMMENTS:

SHEET 1 OF 1

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

THE INFORMATION CONTAINED IN THIS

PROPRIETARY AND CONFIDENTIAL

DO NOT SCALE DRAWING

AS A WHOLE WITHOUT THE WRITTEN

SIZE

NAME

SMH

DATE

FINISH

DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL

LONGVIEW, TX

P.O. BOX 3066

Figure 24. Instructions — CAUJ condenser control circuit modification: 

low ambient damper control by CCAR compressor chillers

56 CG-SVX038A-EN

SMH

P.O BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

ENGINEER'S SEAL DATE

REVISION

BAR

CCAR SCROLL 410A

COMPRESSOR CHILLER

CONTROL PANEL LAYOUT

20 - 30 TON COMPRESSOR CHILLER 208V

NOITCUDORP 62000508R 11

8/11/17

SMH

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5563

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR3

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

FOR 208-230V UNITS

GND GROUND LUG

TBA

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

TR1

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

214

756 8

56 8

1110 12131110 12 13

14 15 1716

14 15 17 226

221918 2120

18 2120

2423

TOOGLE SWITCH

2 - CKT1 Enable

TBA

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

***

DIGITAL POWER MONITOR

PWM

1 - CPS On/Off

TERMINAL BLOCK

TBA

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

Figure 25. Control panel layout for 20 to 30 ton, 208V, R-410A CCAR compressor chillers

Electrical Schematics

CG-SVX038A-EN 57

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

CCAR SCROLL 410A

COMPRESSOR CHILLER

CONTROL PANEL LAYOUT

20 - 30 TON COMPRESSOR CHILLER 460V

NOITCUDORP 72000508R 11

8/11/17

SMH

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

FOR 460V UNITS

GROIUND LUG

GND

TBA

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

TR1

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

214

756 8

56 8

1110 12131110 12 13

14 15 1716

14 15 17 226

221918 2120

18 2120

2423

2 - CKT1 Enable

TBA

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

***

SMH BAR

DIGITAL POWER MONITOR

PWM

TOOGLE SWITCH

1 - CPS On/Off

TERMINAL BLOCK

TBA

PWM CIRCUIT FUSES - KTK OR EQ

FU4,5,6

Electrical Schematics

Figure 26. Control panel layout for 20 to 30 ton, 460V, R-410A CCAR compressor chillers

58 CG-SVX038A-EN

P.O. BOX 3066L

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

CCAR SCROLL 410A

COMPRESSOR CHILLER

CONTROL PANEL LAYOUT

20 - 30 TON COMPRESSOR CHILLER 575V

NOITCUDORP 82000508R 11

8/11/17

SMH

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSE

TRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564A

FOR 575V UNITS

GND

TOOGLE SWITCH

POWER DISTRIBUTION BLOCK

PDB1

600 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C2

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT2

ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS

TR1

GND

FU1,2

DSW1

PDB1

CT1

CT2

FUSE

SCHEDULE

FU3

92143

214

756 8

56 8

1110 12131110 12 13

14 15 1716

14 15

GROUND LUG

2 261221918 2120

18 2120

2423

TERMINAL BLOCK

2 - CKT1 Enable

TBA

UNIT CONTROLLER

115v

RELAY M-8

RELAY M-9

Voltage

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

PWM

COM

FU4-6

***

PWM

DIGITAL POWER MONITOR

SMH BAR

TBA

1 - CPS On/Off

TBA

PWM CIRCUIT FUSES - KTK OR EQ

FU4,5,6

Figure 27. Control panel layout for 20 to 30 ton, 575V, R-410A CCAR compressor chillers

Electrical Schematics

CG-SVX038A-EN 59

Electrical Schematics

600

VOLTS

100-5563

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR3

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

2 1

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSE

TRANSFORMER

LOCATION

CLASS

FOR 208-230V UNITS

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

NOISIVERETADLAES S'REENIGNEBY

CCAR SCROLL 410A

COMPRESSOR CHILLER

CONTROL PANEL LAYOUT

40 - 65 TON COMPRESSOR CHILLER 208V

NOITCUDORP 920000508R 11

8/8/2013

1:1

SMH BAR SMH

FUSE SCHEDULE FOR 208-230V UNITS

DESIGNATION LOCATION FUSE TYPE CLASS AMPS VOLTS

FU1, FU2

PRIMARY

TRANSFORMER

CC 3 1/2 600

FU3

SECONDARY

TRANSFORMER

LITTELFUSE

KLDR3

CC 3 1/2 600

FU4, FU5, FU6 *

DIGITAL POWER

MONITOR *

00611KTK NORTIMIL

LITTELFUSE

KLDR3

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

TBD

TR1

FU3

SCHEDULE

FUSE

PWM

FU1,2

C3C1

GND

DSW1

CT3

CT2CT1

PDB1

TBA

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

COM

143

2143

56 8

756 8

1110 121311

10 12 13

14 15 1716

14 15 17 2261

18 2120

1918 2120

24232423

FU4-6

230V

EXP2

TERMINAL BLOCK

TBD

EXPANSION BOARD RO10

62135

TBD

1 - CPS On/Off

2 - CKT1 Enable

EXP2

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSDUCER MODULES

CT1-CT3

DIGITAL POWER MONITOR

PWM

EXPANSION BOARD SI 16-A04

EXP1

TBA

TOGGLE SWITCHES

TERMINAL BLOCK

TBA

PWM CIRCUIT FUSES - KTK OR EQ

FU4,5,6

GROUND LUG

GND

Figure 28. Control panel layout for 40 to 65 ton, 208V, R-410A CCAR compressor chillers

60 CG-SVX038A-EN

Figure 29. Control panel layout for 40 to 65 ton, 460V, R-410A CCAR compressor chillers

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

CC /

FOR 460V UNITS

P.O. BOX 3066

LONGVIEW, TX

75606-3066

APP'D BY:

CHECKED BY:

DRAWN BY:

DATE:

SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

TRANE.

WITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OF

MUST BE MAINTAINED IN STRICT

TRANE,

WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

ENGINEER'S SEAL DATE

REVISION

CCAR SCROLL 410A

COMPRESSOR CHILLER

CONTROL PANEL LAYOUT

40 - 65 TON COMPRESSOR CHILLER 460V

NOITCUDORP 03000508R 11

9/27/13

1:1

SMH SMH BAR

FUSE SCHEDULE FOR 460V UNITS

DESIGNATION LOCATION FUSE TYPE CLASS AMPS VOLTS

FU1, FU2

PRIMARY

TRANSFORMER

LITTELFUSE KLDR1

CC 1 1/2 600

FU3

SECONDARY

TRANSFORMER

LITTELFUSE

KLDR3

CC 3 1/2 600

FU4, FU5, FU6 *

DIGITAL POWER

MONITOR *

0061KTK NORTIMIL

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

CT1

TR1

FU3

SCHEDULE

FUSE

PWM

FU1,2

GND

DSW1

CT3

CT2

PDB1

TBA

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

COM

143

2143

56 8

756 8

1110 121311

10 12 13

14 15 1716

14 15 17 2261

18 2120

1918 2120

24232423

FU4-6

230V

EXP2

EXPANSION BOARD R010

EXP2

TBD

1 - CPS On/Off

2 - CKT1 Enable

POWER DISTRIBUTION BLOCK

PDB1

208,240,480/120 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT3

DIGITAL POWER MONITOR

PWM

EXPANSION BOARD SI 16-A04

EXP1

TBA

TOGGLE SWITCHESSW

TERMINAL BLOCK

TBA

TERMINAL BLOCK

TBD

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

GROUND LUGGND

Electrical Schematics

CG-SVX038A-EN 61

Electrical Schematics

CC 3

TRANSFORMER FUSE SCHEDULE

FUSE TYPE

LITTELFUSETRANSFORMER

LOCATION

CLASS

600

VOLTS

100-5564

600

DESIGNATION

FU1, FU2

FU3

AMPS

PRIMARY KLDR1

LITTELFUSE

KLDR3

TRANSFORMER

SECONDARY /

FOR 460V UNITS

75606-3066

REVISIONDATEENGINEER'S SEAL

IMPORTANT

THE INFORMATION CONTAINED HEREON,

WHICH IS THE PROPERTY OF

TRANE,

MUST BE MAINTAINED IN STRICT

CONFIDENCE AND NO PORTION OF

THIS MATERIAL MAY BE REPRODUCED

OR USED FOR ANY PURPOSE

WITHOUT THE EXPRESS WRITTEN CONSENT OF

TRANE.

REV.SHEET NO. .ON BOJ SPPANREBMUN GNIWARD

TITLE:

DWG. SIZE

SCALE:

DATE:

DRAWN BY:

CHECKED BY:

APP'D BY:

P.O. BOX 3066

LONGVIEW, TX

BARSMHSMH

1:1

9/30/13

11 PRODUCTION R80500031

40 - 65 TON COMPRESSOR CHILLER 575V

CONTROL PANEL LAYOUT

CCAR SCROLL 410A

COMPRESSOR CHILLER

NOTES:

1. ITEMS MARKED WITH * ARE OPTIONAL

AND ARE NOT ON ALL UNITS.

TR1

PDB1

FU3

SCHEDULE

FUSE

PWM

FU1,2

C3C1

GND

DSW1

CT3

CT2CT1

TBA

EXP1

3 - CKT2 Enable

RELAY M-1

RELAY M-2

RELAY M-3

UNIT CONTROLLER

RELAY M-5

RELAY M-4

RELAY M-6

RELAY M-8

RELAY M-7

RELAY M-9

Voltage

115v

RELAY M-10

COM

143

2143

56 8

756 8

1110 12

10 12 13

14 15 1716

14 15 17

2261

221918 2120

2120

2423

FU4-6

230V

EXP2 EXPANSION BOARD R010

TERMINAL BLOCKTBD

TBD

1 - CPS On/Off

2 - CKT1 Enable

EXP2

POWER DISTRIBUTION BLOCK

PDB1

600 VAC 250 VA TRANSFORMER

TR1

COMPRESSOR CONTACTORS

TR1 SECONDARY CIRCUIT FUSE - KLDR OR EQ

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

DISCONNECT SWITCH

FU1, FU2

FU3

DSW1

C1-C3

LEGEND

UNIT CONTROLLERUCCOMMUNICATIONS MODULE

COM

CURRENT TRANSFORMER MODULESCT1-CT3

DIGITAL POWER MONITOR PWM

EXPANSION BOARD SI 16-A04EXP1

TBA

TOGGLE SWITCHES

TERMINAL BLOCKTBA

PWM CIRCUIT FUSES - KTK OR EQFU4,5,6

GROUND LUGGND

Figure 30. Control panel layout for 40 to 65 ton, 575V, R-410A CCAR compressor chillers

62 CG-SVX038A-EN

Appendix

The MCS-MAGNUM-N

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

MCS-CT300

Description

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

Revision 2015-08-07

Part # MCS-CT300

Dimensions:

Height ...................................................4.00”

Width ....................................................2.38”

Depth ....................................................1.56”

Wire Hole ..............................................1.00”

Amperage Rating..................................0-300A

Accuracy ...............................................± 3 amps

Sensor Output Voltage .........................0-5vdc

Supply Voltage......................................Induced

Operating T emperature ......................-40°F to +158°F (-40°C to +70°C)

Storage T emperature ..........................-40°F to +158°F (-40°C to +70°C)

The MCS-CT300 electrical equipment. The magnitude of the current is converted to a linear 0 to 5vdc output signal which can be read as a standard analog input signal. The signal is used by MCS micro controllers for the following:

1. For slide valve positioning on screw machines

2. For high amp motor overload protection

4. Used in kw calculations

The MCS-CT300 is a solid-core version, so the conductor runs through the sensor. No cutting, taping or rerouting is required. It is accurate, reliable, easy to install and requires no service.

The MCS-CT300 has an accuracy of ± 3 amps in the frequency range from 50-60Hz. The sensor outputs a 0 to 5vdc signal. The sensor power is induced from the current being monitored.

On the printed circuit board, a resistor is mounted across the CT terminals, which eliminates danger from induced current. A removable three-position terminal block is provided for easy wiring.

A two-conductor shielded cable must be used. The shield must be cut at the MCS-CT300 end and tied to ground at the MCS micro controller terminal block.

Amps Volts dc

10 0.13

20 0.30

30 0.48

40 0.65

50 0.82

60 0.99

70 1.16

80 1.34

90 1.51

100 1.68

110 1.85

120 2.02

130 2.19

140 2.36

150 2.53

Amps Volts dc

160 2.71

170 2.88

180 3.05

190 3.22

200 3.39

210 3.56

220 3.73

230 3.91

240 4.06

250 4.23

260 4.40

270 4.58

280 4.74

290 4.91

300 5.08

Vendor Data Sheet

MSC-CT300 Current Transducer Data Sheet

CG-SVX038A-EN 63

Appendix

The MCS-MAGNUM-N

S e e

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

f ce 39- 9 -0089 Fa 39- 9 -0031 www.mcscontrols.com

MCS-667B-xx

e S e

Description

Speci c tions

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

f ce 39- 9 -0089 Fa 39- 9 -0031 www.mcscontrols.com

e ision - 01 -0 - 1

Part # MCS-667B-xx

Pressure Range...............0 to psi seale gauge

Housing ...........................Stainless Steel

Sealing Material ...............Neoprene

Electrical Connection .......

Operating Temperature .... - 0 F to 5 F - 0 C to 1 5 C

Accuracy .......................... .0 - 0 F to - F - 0 C to - 0 C

1.5 - F to 3 F - 0 C to 0 C

1.0 3 F to 1 F 0 C to 80 C

1.5 1 F to

8 F 80 C to 1 0 C .0 8 F to 5 F 1 0 C to 1 5 C

Agency Approvals ............CE, L E3 390 , RoHS

Proof Pressure.................ma

000

Burst Pressure ...................ma

3000

Ran

om i ration ...........5 G @ 33Hz

nput oltage....................5v c 0. 5 c

Input Current.................... 10 ma 0.01 amps

Output oltage .................0.5 to .5 c ratio metric

Connection ...................... SAE Female Flare tting

arhcS

er valve

1 - 0 NF threa

Option Cable:

Connector ........................Packar

with Silicone seal

Length..............................

0 , 0 or 0 feet

Type .................................3-con

uctor, 0 awg stran e

Shiel

...............................Foil shiel with 5 overlap

Drain ................................Stran

e tinne copper rain

When ordering replace -xx with:

....................................... 0 0 or 0 wire length

The ca

le is availa le in either 0, 0

0 lengths with a remova le Packar

connector to provi

e easy servicea ility.

The wire is seale

an crimpe to the

Packar

connector provi ing a li ui

tight environment an

strain relief.

100 10 200 1.70 300 2.30 400 2.90 500 3.50 600 4.10

56 110 16 210 1.76 310 2.36 410 2.96 510 3.56 610 4.16

62 120 22 220 1.82 320 2.42 420 3.02 520 3.62 620 4.22

68 130 28 230 1.88 330 2.48 430 3.08 530 3.68 630 4.28

74 140 1.34 240 1.94 340 2.54 440 3.14 540 3.74 640 4.34

80 150 1.40 250 2.00 350 2.60 450 3.20 550 3.80 650 4.40

86 160 1.46 260 2.06 360 2.66 460 3.26 560 3.86 660 4.46

0.92 170 1.52 270 2.12 370 2.72 470 3.32 570 3.92 667 4.50

0.98 180 1.58 280 2.18 380 2.78 480 3.38 580 3.98

04 190 1.64 290 2.24 390 2.84 490 3.44 590 4.04

*IP66 Rating A

le to protect against powerful water ets ater pro ecte in powerful ets 1 .5 mm

nozzle

against the enclosure from any irection shall have no harmful effects. ater

volume

100 litres . gals per minute

Pressure

100 kPa 1 .50psi at istance of 3 m 9.8 ft 1 meter in epth.

The MCS-667B pressure trans ucer is specially esigne for use in high pressure H

AC refrigeration applications,

in the most

eman ing environments, where low cost is

nee

e yet maintaining high accuracy, long term relia ility,

long life.

Features inclu

e, high accuracy, wi e temperature range,

refrigerant me

ia compati ility an rugge esign for out-

oor use.

The MCS-

B pressure trans ucer is CE, L an RoHs

compliant. It is capa

le of surviving high vi ration. MCS- B

is a seale

gage pressure trans ucer with a cavity uilt out of stainless steel with a Neoprene sealing material, ¼” SAE Female Flare

tting Schra er valve 1 - 0 NF pipe threa which

creates a leak-proof, all metal seale

system that makes the

MCS-

B i eal for use with rugge H AC environments using

refrigerant Me

ia.

L 90180

MADE IN USA

MSC-667F Pressure Transducer Data Sheet

64 CG-SVX038A-EN

The MCS-T100 Specifications and Description

The MCS-MAGNUM-N

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

MCS-T100

Description

For complete temperature chart, refer to the MCS-T100 spec sheet

5580 Enterprise Pkwy., Fort Myers, FL 33905

Standard T emperature Range...............

Standard Temperature Accuracy ..

......

Resistance Range ........................

.......

Input Voltage.................................5vdc

Sensor Resistance ...........................

Dimensions ...................................

Material ......................................... Stainless Steel

Environmental rating.....................

Testing ..........................................10,000 freeze/thaw thermal

selcyc

Length...........................................

Wire .................................................

Shield............................................

Drain ................................................Stranded tinned copper drain

............................................................

htgnel eriw

The for demanding environments. It is ideal for high moisture locations with continuous freeze and thaw cycles. The sensor is potted with a thermally conductive RTV Cure Silicon Adhesive to guarantee

Part #

Temp

(°F / °C)

Resist

(ohms)S1(vdc)

Temp

(°F / °C)

Resist

(ohms)S1(vdc)

Temp

(°F / °C)

Resist (ohms)S1(vdc)

Temp

(°F / °C)

Resist (ohms)S1(vdc)

Temp

(°F / °C)

Resist (ohms)S1(vdc)

-40/-40 4,015,500 0.121 32/0 351,020 1.109 95/35 63,480 3.058 158/70 15,500 4.329 208/97.7 5,981 4.718

-35/37.2 3,324,096 0.146 35/1.6 320,976 1.188 100/37.7 56,200 3.201 160/71.1 14,881 4.352 210/98.8 5,773 4.727

-30/34.4 2,760,524 0.175 38/3.3 293,758 1.270 104/40 51,050 3.310 165/73.8 13,456 4.407 212/100 5,573 4.736

-25/-31.6 2,299,670 0.208 40/4.4 277,040 1.326 105/40.5 49,846 3.337 167/75 12,930 4.428 215/101.6 5,289 4.749

-20/-28.9 1,921,640 0.247 45/7.2 239,686 1.472 110/43.3 44,287 3.465 170/76.6 12,185 4.457 218/103.3 5,020 4.761

-15/-26.1 1,610,592 0.292 50/10 207,850 1.624 113/45 41,290 3.539 175/79.4 11,052 4.502 220/104.4 4,849 4.769

-10/-23.3 1,353,866 0.344 55/12.7 180,647 1.782 115/46.1 39,420 3.586 180/82.2 10,033 4.544 223/106.1 4,605 4.780

-5/-20.6 1,141,345 0.403 58/14.4 166,243 1.878 120/48.8 35,149 3.697 183/83.8 9,474 4.567 225/107.2 4,449 4.787 0 /-17.7 964,963 0.470 60/15.5 157,353 1.943 125/51.6 31,399 3.805 185/85 9,121 4.582 227/108.3 4,299 4.794 5/-15.0 818,070 0.545 65/18.3 137,363 2.106 130/54.4 28,093 3.903 190/87.7 8,303 4.617 230/110 4,085 4.804

10/-12.2 695,433 0.629 70/21.1 120,169 2.271 135/57.2 25,173 3.994 195/90.5 7,567 4.648 233/111.6 3,886 4.813

15 /-9.4 592,755 0.722 75/23.9 105,347 2.435 140/60 22,590 4.079 198/92.2 7,162 4.666 235/112.7 3,760 4.819 20/-6.6 506,560 0.824 80/26.7 92,541 2.597 145/62.8 20,309 4.156 200/93.3 6,906 4.677 240/115.5 3,463 4.833 25/-3.8 434,007 0.936 85/29.4 81,454 2.756 150/65.5 18,284 4.227 203/95 6,541 4.693 245/118.3 3,191 4.845 30/-1.1 372,778 1.058 90/32.2 71,838 2.910 155/68.3 16,484 4.292 205/96.1 6,310 4.703 248/120 3,040 4.852

Appendix

CG-SVX038A-EN 65

Appendix

Warranty

I. Limited Product Warranty & Service Policy

Napps Technology, Inc. (NAPPS) warrants for a period of twelve (12) months from date of original shipment that all products, manufactured by NAPPS, with the exception of packaged refrigeration products, are free from defects of material and workmanship when used within the service, range, and purpose for which they were manufactured. Packaged refrigeration products shall be so warranted for a period of twelve (12) months from date of start-up or eighteen (18) months from date of original shipment, whichever may first occur. Service Parts shall be so warranted for a period of ninety (90) days from date of installation, or twelve (12) months from date of original shipment, whichever may first occur.

In case material is rejected on inspection by the buyer as defective, NAPPS shall be notified in writing within ten (10) days from receipt of said material. NAPPS will then have the option of re-inspection at the buyer’s plant or its own plant before allowing or rejecting the buyer's claim. Expenses incurred in connection with claims for which NAPPS is not liable may be charged back to the buyer. No claim for correction will be allowed for work done in the field except with the written consent of NAPPS. Defects that do not impair service shall not be cause for rejection. NAPPS assumes no liability in any event for consequential damages. No claim will be allowed for material damaged by the buyer or in transit. Defective equipment or parts shall be returned to NAPPS freight prepaid.

NAPPS will, at its option, repair, replace or refund the purchase price of products found by NAPPS to be defective in material or workmanship provided that written notice of such defect requesting instruction for repair, replacement or refund is received by NAPPS within ten (10) days of determination of said defect, but not more than one (1) year after the date of shipment, and provided that any instructions given thereafter by NAPPS are complied with.

Any products covered by this order found to NAPPS' satisfaction to be defective upon examination at NAPPS' factory will, at NAPPS’ option, be repaired or replaced and returned to Buyer via lowest cost common carrier, or NAPPS may, at its option, grant Buyer a credit for the purchase price of the defective article.

Without limitation of the foregoing, this warranty shall not apply to (i) deterioration by corrosion or erosion of material or any cause or failure other than defect of material or workmanship; (ii) the performance of any system of which NAPPS’ products are a component part; or (iii) any of NAPPS’ products or parts thereof which have been subjected to alteration or repair by anyone other than NAPPS or someone authorized by NAPPS, or subjected to misuse, neglect, free chemicals in system, corrosive atmosphere, abuse or improper use or misapplication such as breakage by negligence, accident, vandalism, the elements, shock, vibration or exposure to any other

service, range or environment of greater severity than that for which the products were designed, or if operation is contrary to NAPPS’ or manufacturer’s recommendation, or if the serial number has been altered, defaced or removed.

Hermetic motor/compressors furnished by NAPPS are subject to the standard warranty terms set forth above, except that the hermetic motor/compressor replacements or exchanges shall be made through the nearest authorized wholesaler of the hermetic motor/compressor manufacturer (not NAPPS’ factory) and no freight shall be allowed for transportation of the hermetic motor/ compressor to and from the wholesaler. For TRANE hermetic motor/compressors, the nearest wholesaler referred to herein shall be the nearest TRANE PARTS CENTER. The replacement hermetic motor/compressor shall be identical to the model of the hermetic motor/ compressor being replaced. Additional charges, which may be incurred through the substitution of other than identical replacements, are not covered by this warranty. Evaporator failure due to fluid freezing that is the result of low fluid flow or inadequate fl applications with leaving fluid temperatures below 40°F, is not covered by this warranty.

The Warranty provided above is the only Warranty made by NAPPS with respect to its products or any parts therefore and is made expressly in lieu of any other Warranties, by course of dealing, usages of trade or otherwise, expressed or implied, including but not limited to any implied Warranties of fitness for any particular purpose or of merchantability under the uniform commercial code. It is agreed that this Warranty is in lieu of and buyer hereby waives all other warranties, guarantees or liabilities arising by law or otherwise. NAPPS shall not incur any other, obligations or liabilities or be liable to buyer or any customer of buyer for any anticipated or lost profits, incidental or consequential damages, or any other losses or expenses incurred by reason of the purchase, installation, repair, use or misuse by buyer or third parties of its products (including any parts repaired or replaced); and NAPPS does not authorize any person to assume for NAPPS any other liability in connection with the products or parts therefore. NAPPS shall not be responsible for the loss or replacement of or the addition of compressor oil, or refrigerant.This Warranty cannot be extended, altered or varied except by a written instrument signed by NAPPS and buyer.

uid freeze protection, for

II. Limitation Of Liability

NAPPS shall not be liable, in contract or in tort, for any special, indirect, incidental or consequential damages, such as, but not limited to, loss of profits, or injury or damage caused to property, products, or persons by reason of the installation, modification, use, repair, maintenance or mechanical failure of any NAPPS product.

66 CG-SVX038A-EN

Ingersoll Rand (NYSE:IR) advances the quality of life by creating comfortable, sustainable and efficient

ingersollrand.com

environments. Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results.

Ingersoll Rand has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

CG-SVX038A-EN 11 Sep 2017

(NEW)

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

Specifications and Main Features

Frequently Asked Questions

User Manual