Installation Operation Maintenance

Scroll Liquid Chillers

Models CGWF/CCAF 20-60 Tons

January 2004

© 2003 American Standard Inc. All rights reserved. CGWF-SVX01A-EN NOTICE: Warnings and Cautions appear at appropriate sections through- out this literature. Read these carefully.

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

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. CAUTION: Indicates a situation that may result in equipment or property- damage only accidents.

Important Environmental Concerns! Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants—including industry replacements for CFCs such as HCFCs and HFCs. Responsible Refrigerant Practices! Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them. WARNING Contains Refrigerant! System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage.

2 CGWF-SVX01A-EN Table of Contents

General Information...... 7 Literature Change History...... 7 Unit Identification ...... 7 Nameplates ...... 7 Unit Nameplates...... 7 Compressor Nameplate ...... 7 Evaporator Nameplate...... 7 Condenser Nameplate...... 8 Unit Inspection ...... 8 Inspection Checklist ...... 8 Loose Parts Inventory ...... 8 Unit Description...... 8 Unit Model Number...... 8 Installation Overview...... 12

Installation Mechanical...... 17 Unit Storage ...... 17 Location Requirement ...... 17 Noise Consideration ...... 17 Foundation...... 17 Ventilation...... 17 Drainage ...... 17 Rigging ...... 17 Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF Units...... 18 Lifting Procedure for 60 Ton Units ...... 20 Alternate Moving Methods...... 21 Access Restrictions...... 21 Recommended Clearances ...... 22 Unit Isolation ...... 22 Direct Mounting ...... 22 Neoprene Isolator Mounting ...... 22 Neoprene Isolator Data ...... 22 Unit Leveling ...... 23 Unit Piping ...... 29 General Water Piping Recommendations ...... 29 Water System ...... 29 Water Flow Rates...... 29 Pressure Drop Measurement...... 29 Evaporator Water Piping...... 32 Evaporator Water Connections...... 32 Evaporator Piping Components...... 32 Flow Sensing Devices ...... 32 Evaporator Drain...... 33 Condenser Water Piping ...... 33 Condenser Water Connections...... 33 Condenser Piping Components...... 33 Condenser Drains...... 34 Water Regulating Valve ...... 35 Water pressure Relief Valves ...... 37 Low Temperature Operation ...... 37 Pressure Relief Valve Venting ...... 38 Refrigerant Piping (CCAF only) ...... 40

CGWF-SVX01A-EN 3 Table of Contents

Liquid Line Components and Connections...... 40 Liquid Line Sizing...... 40 Discharge (hot gas) Lines ...... 40 Leak Test ...... 42 System Evacuation ...... 42 Refrigerant Charging...... 42

Installation Electrical...... 43 General Recommendations ...... 43 Power Supply Wiring ...... 43 Unit Power Supply...... 43 Equipment Grounds...... 43 Terminal Lugs, Circuit Breakers and Non-Fused Disconnect Switches...... 43 Scroll Compressor Electrical Phasing ...... 47 Correcting Improper Electrical Phase Sequence ...... 47 Unit Voltage ...... 48 Voltage Imbalance ...... 48 Control Power Supply...... 48 Modules Connections for Interconnecting Wiring...... 48 Chilled Water Flow Switch ...... 49 Chilled Water Pump Control ...... 49 Condenser Water Loss of Flow Protection ...... 49 Condenser Water Pump Starter ...... 49 Programmable Relays...... 49 External Auto/Stop...... 50 Compressor Inhibit/ High Ambient Operation ...... 50 Condenser Water Temperature Sensor Connections...... 50 Chilled Water Rest...... 50 External Chilled Water Setpoint Option...... 51 Ice Machine Control Option...... 51 Communications Interface options...... 51 Optional Tracer Communications Interface ...... 51 LonTalk Communications Interface for Chillers (LCI-C) Option ...... 52 CCAF - Fan Control ...... 54 Outdoor Air Temperature Control...... 54

Operating System ...... 55

Controls Interface ...... 57 CH530 Communications Overview ...... 57 Controls Interface ...... 57 DynaView ...... 57 TechView...... 57 DynaView Interface ...... 58 Key Functions ...... 58 Radio Buttons ...... 58 Spin Value Buttons ...... 58 Action Buttons...... 59 File Folder Tabs ...... 59 Display Screens ...... 59 Basic Screen Format ...... 59 Keypad/Display Lockout Feature ...... 60

4 CGWF-SVX01A-EN Table of Contents

Main Screens ...... 61 Reports Screen...... 65 Settings Screen ...... 67 Diagnostics Screen...... 69 TechView Interface ...... 69 Software Download...... 70 Instructions for First Time TechView Users ...... 70

Diagnostics ...... 73

Unit Start-up...... 77 Pre-Start Checklist...... 77 Unit Power Up ...... 79 Checking Operating Conditions...... 79 System Superheat...... 80 System Subcooling...... 80

Unit Shutdown ...... 81 Normal Unit Shutdown...... 81 Extended Shutdown Procedure ...... 81 System Restart After Extended Shutdown ...... 82

Unit Maintenance...... 83 Periodic Maintenance...... 83 Weekly Maintenance...... 83 Monthly Maintenance ...... 83 Annual Maintenance...... 83 Maintenance Procedures ...... 84 Mechanical Cleaning ...... 84 Chemical Cleaning...... 84 Cleaning the Evaporator (Chiller) ...... 84 Water Treatment ...... 85

Wiring Schematics ...... 89 Schematics Page 1&2 ...... 90 Component Location ...... 94 Field Wiring Diagram ...... 95 Field Layout Diagram...... 96

CGWF-SVX01A-EN 5 Table of Contents

6 CGWF-SVX01A-EN General Information

Literature Change History New manual describes the installation, operation and maintenance of CGWF/CCAF Units. Unit Identification When the unit arrives, compare all nameplate data with ordering, submittal, and shipping information. A typical unit nameplate is shown in Figure 1.

Figure 1 Unit Nameplate Nameplates

Unit Nameplates The CGWF/CCAF unit nameplate is mounted on the control panel door. The Unit nameplate provides the following information: • Unit model number. • Unit serial number. • Identifies unit electrical requirements. • Lists correct operation charge of R-22 and refrigerant oil. • Lists unit test pressures and maximum operating pressures. • Identifies installation, operation and maintenance literature. • Lists the drawing numbers for the unit wiring diagrams.

Compressor Nameplate The nameplate for the Scroll compressor is mounted on the compressor housing near the motor terminal box.

Evaporator Nameplate The evaporator ASME nameplate is mounted on the top of the evaporator supply-end tube sheet. The word “nameplate” is applied to the insulation just above the nameplate. To view the evaporator nameplate, remove the tape over the area and spread the insulation.

CGWF-SVX01A-EN 7 General Information

Condenser Nameplate The condenser ASME nameplate (30 and 60 ton condensers only) is mounted on the top of the condenser near the water outlet on 60 ton units and on the side of the condenser near the water outlet on 30 ton units. Unit Inspection Carefully inspect chiller while still on shipping conveyance. If unit is damaged or has broken free from anchorage, require inspection by transportation inspectors. File damage claims with the carrier and notify a Trane sales representative. The manufacturer is not responsible for damage occurring during transit. Do not install a damaged unit without sales office approval.

Inspection Checklist To protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit: • Inspect individual pieces of the shipment before accepting the unit. Check for obvious damage to the unit or packing material. • Check the unit for concealed damage before it is stored and as soon as possible after delivery. Concealed damage must be reported within 15 days. • If concealed damage is discovered, stop unpacking the shipment. Do not remove damaged material from 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 damage immediately by phone and by mail. Request an immediate joint inspection of the damage by the carrier and the con- signee. • Notify a Trane sales representative and arrange for repair. Do not repair the unit until damage is inspected by the carrier’s representative. Loose Parts Inventory Check all items against shipping list. Water vessel drain plugs, rigging and electrical diagrams, service literature and optional water temperature sensors are placed inside the UCP (unit control panel) for shipment before it is shrinkwrapped with waterproof plastic. When ordered, the optional neoprene isolators are secured in place on the shipping skid. Unit Description Trane Model CGWF/CCAF 20 - 60 ton Scroll Liquid Chillers, utilizing multiple Trane scroll compressors, are designed for installation indoors. Each unit is completely assembled hermetic package that is factory-piped, wired, leak-tested, dehydrated, charged and tested for proper control operation before shipment. Water inlet and outlet openings are covered before shipment. The units contain an operating refrigerant charge.The compressors are factory charged with the proper amount of refrigerant oil. Unit Model Number

Table 1 Unit Model Number FCAT FCODE M/N digit M/N value Description MODL 1-4 Chiller model CGWF CGWF Water cooled scroll chiller CCAF CCAF Scroll compressor-chiller (condenserless)

8 CGWF-SVX01A-EN General Information

Table 1 Unit Model Number FCAT FCODE M/N digit M/N value Description NTON 5-7 Unit nominal tonnage 20 020 20 nominal tons 25 025 25 nominal tons 30 030 30 nominal tons 40 040 40 nominal tons 50 050 50 nominal tons 60 060 60 nominal tons VOLT 8 Unit Voltage DULA G 208-230/60/3 power supply 380A D 380/60/3 power supply 460A 4 460/60/3 power supply 575A 5 575/60/3 power supply 400B N 400/50/3 power supply SHIPCYC 9 Ship cycle MTO (C) Made to order STK (C) Packed stock (contact BU) DSEQ 10-11 Design sequence A0 A0 Factory/ABU assigned AGLT 12 Agency listing NONE N No agency listing UL U C/UL listing CODE 13 Pressure vessel code ASME A ASME code CAN C Canadian code SPKG 14 Shipping Package FLBT A Ship via Flat Bed Truck SHRK B Ship w/Shrink Wrap Bag and Skid SKID C Ship w/Skid CDTE 15 Condenser temp range NA 0 None - CCAF units STD 1 Standard 60-90F [15.6-32.2C] entering water temp HIGH 4 High 90-130F [32.2-54.4C] entering water temp CDTT 16 Condenser tube material NA N None - CCAF units STD C Std copper finned tubes CDCO 17 Condenser water connections NA N None - CCAF units LHWC L Left hand condenser connections RHWC R Right hand condenser connections EVTL 18 Evap temp range STD 1 Standard cooling 40-60F[4.4-15.6C] LOWA 2 Ice making 26-39F[-3.3-3.9C] LOWB 3 Low temp 10-25F[-12.2-(-3.9)C] ICE 4 Standard cooling/Ice making 20-60F[-6.7-15.6C] PCON 19 Power line connection type TB T Terminal block DISC D Non-fused disconnect switch EPRO 20 Short circuit rating NONE 0 No short circuit rating SCR 1 With short circuit rating

CGWF-SVX01A-EN 9 General Information

Table 1 Unit Model Number FCAT FCODE M/N digit M/N value Description CIOP 21 Control input options NONE N No options REMS R Remote chilled water setpoint input REMC C Remote compressor inhibit and/or icemaking input REMB B Remote CWS and compressor inhibit/icemaking input COOP 22 Control output options NONE N No options PROG P Programmable relays for remote alarm, run, etc. SENS 23 Auxiliary sensor options NONE 0 None CDWT 1 Condenser water temp sensors (CGWF only) AMB 2 Outdoor temp sensor - CWR or Amb Lockout BOTH 3 Both condenser and outdoor temp sensor COMM 24 Communication options NONE 0 None COM3 3 Tracer Summit interface LCIC 5 LonTalk LCI-C interface HGBP 25 Hot gas bypass NONE N NO HGBP valve/function WITH H HGBP function included SATT 26 Sound attenuator NONE 0 No sound attenuator WITH 1 Sound attenuator - Fact installed SACC 27 Ship-with accessories - isolators, WRV, Filter-driers NONE X No ship-with accessories NIS0 N Neoprene isolators WRVA A 1.5" 2-way water reg valve x 1 (CGWF only) WRVB B 2" 2-way water reg valve x 1 (CGWF only) WRVC C 2.5" 2-way water reg valve x 1 (CGWF only) WRVD D 1.5" 2-way water reg valve x 2 (CGWF only) WRVE E 2" 2-way water reg valve x 2 (CGWF only) WRVF F 2.5" 2-way water reg valve x 2 (CGWF only) WRAN G Neo isolators + 1.5" WRV x 1 (CGWF only) WRCN H Neo isolators + 2" WRV x 1 (CGWF only) WREN J Neo isolators + 2.5" WRV x 1 (CGWF only) WRBN K Neo isolators + 1.5" WRV x 2 (CGWF only) WRDN L Neo isolators + 2" WRV x 2 (CGWF only) WRFN M Neo isolators + 1.5" WRV x 2 (CGWF only) FD1 P Filter-drier x 1 (CCAF only) FD2 Q Filter-drier x 2 (CCAF only) NFD1 R Neo isolators + 1 Filter-drier (CCAF only) NFD2 T Neo isolators + 2 Filter-driers (CCAF only) SAC2 28 Ship-with accessories - flow switches NONE 0 No flow switches FS1 1 150 psi NEMA-1 flow switch (FS4-3) x 1 2FS1 2 150 psi NEMA-1 flow switch (FS4-3) x 2 FS4 4 150 psi NEMA-4 flow switch (FS8-W) x 1 2FS4 5 150 psi NEMA-4 flow switch (FS8-W) x 2

10 CGWF-SVX01A-EN General Information

DynaView

Unit Nameplate

Relief Valve Water Condenser Outlet

Water Inlet

Figure 2 Component Location DWG

Discharge Compressor Line Nameplate

Suction Line

TXV

Evaporator Evaporator Water Inlet Water Outlet Sight Discharge Filter Glass Service Valve Dryer Liquid Line Solenoid Vale

Figure 3 Component Location DWG

CGWF-SVX01A-EN 11 General Information

Installation Overview For convenience, Table 2 summarizes responsibilities that are typically associated with the CGWF/CCAF chiller installation process.

Table 2 Installation Responsibility Chart for CGWF/CCAF Units

Requirement Trane-supplied, Trane-supplied, Field-supplied, Trane-installed Field-installed Field-installed Rigging Safety chains Clevis connectors - Lifting beam Isolation Neoprene Isolators Isolation pads Electrical Non-fused disconnects (optional) Circuit breakers or fusible disconnects (optional) Unit-mounted starter Temperature sensor (optional Terminal lugs outdoor air) Flow switches (may be field- Ground connection(s) supplied) BAS wiring (optional) Control voltage wiring Chilled water pump contactor and wiring Condenser water pump contactor and wiring Optional relays and wiring Water piping Flow switches (may be field- Thermometers supplied) Condenser water regulating valve Water flow pressure gauges (optional: may be field-supplied) Isolation and balancing valves water piping Vents and drain valves Pressure relief valves (for water boxes as required) Pressure Relief valves Vent line and flexible connector Relief

Refer to the Installation Mechanical and Installation Electrical sections of this manual for detailed installation instructions. • Locate and maintain the loose parts, e.g. isolators, flow sensors or other factory- ordered, field-installed options, for installation, as required. Loose parts are located in the starter/control panel. • Install the unit on a foundation with flat support surfaces, level within 1/4” (6.35 mm) and of sufficient strength to support concentrated loading. Place the manu- facturer-supplied neoprene isolators assemblies under the unit. • Install the unit per the instructions outlined in the Mechanical Installation section. • Complete all water piping and electrical connections.

NOTE: Field piping must be arranged and supported to avoid stress on the equipment. It is strongly recommended that the piping contractor provide at least 3 feet (914 mm) of clearance between the pre-installation piping and the planned location of the unit. This will allow for proper fit-up upon arrival of the unit at the instal- lation site. All necessary piping adjustments can be made at that time. Refer to the current engineering bulletin for further details on installation.

12 CGWF-SVX01A-EN General Information

• Where specified, supply and install valves in the water piping upstream and downstream of the evaporator and condenser water boxes, to isolate the shells for maintenance and to balance/trim the system. • Supply and install condenser water control valve(s) per Trane RLC-EB-4. • Supply and install flow switches or equivalent devices in both the chilled water and condenser water piping. Interlock each switch with the proper pump starter and CH530, to ensure that the unit can only operate when water flow is estab- lished. • Supply and install taps for thermometers and pressure gauges in the water pip- ing, adjacent to the inlet and outlet connections of both the evaporator and the condenser. • Supply and install drain valves on each water box. • Supply and install vent cocks on each water box. • Where specified, supply and install strainers ahead of all pumps and automatic modulating valves. • Supply and install refrigerant pressure relief piping from the pressure relief to the atmosphere. • If necessary, supply enough refrigerant and dry nitrogen (75 psig) for pressure testing. • Start the unit under supervision of a qualified service technician. • Where specified, supply and insulate the evaporator and any other portion of the unit, as required, to prevent sweating under normal operating conditions. • For unit-mounted starters, cutouts are provided at the top of the panel for line- side wiring. • Supply and install the wire terminal lugs to the starter. • Supply and install field wiring to the line-side lugs of the starter.

CGWF-SVX01A-EN 13 General Information

Table 3 General Data CGWF

CGWF Unit Tonnage202530405060 General Refrigerant Type R-22 R-22 R-22 R-22 R-22 R-22 Refrigerant Charge lb (kg) 50 (23) 50 (23) 90 (41) 50/50 (23/23) 50/50 (23/23) 75/75 (34/34) Oil Type Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil Charge Pints (l) 16 (7.6) 22 (10.4) 28 (13.2) 16/16 22/22 28/28 (7.6/7.6) (10.4/10.4) (13.2/13.2) Operating Weight lb (kg) 1694 (768) 1757 (797) 2249 (1020) 2747 (1246) 2977 (1350) 3905 (1771) Shipping Weight lb (kg) 1522 (690) 1600 (726) 2014 (914) 2366 (1073) 2626 (1191) 3376 (1531) Overall Dimensions Length in (mm) 122.6 (3115) 122.6 (3115) 122.6 (3115) 129.0 (3277) 129.0 (3277) 108.1 (2743) Width in (mm) 31.4 (797) 31.4 (797) 32.2 (818) 31.3 (797) 31.3 (797) 34 (864) Height in (mm) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1467) 74.6 (1894) Evaporator Water Storage gal (l) 11.7 (44) 10.7 (40) 16.4 (62) 25.7 (97) 24 (90) 39.9 (151) Minimum Flow gpm (l/s) 24 (1.5) 30 (1.9) 36 (2.3) 48 (3.0) 60 (3.8) 84 (5.3) Maximum Flow gpm (l/s) 72 (4.5) 90 (5.7) 108 (6.8) 144 (9.1) 180 (11.4) 252 (15.9) Condenser Water Storage gal (l) 8.9 (34) 8.0 (30) 11.7 (44) 19.9 (75) 18.2 (69) 23.5(89) Minimum Flow gpm (l/s) 30 (2) 36 (2) 50 (3) 60 (4) 72 (5) 90 (6) Maximum Flow gpm (l/s) 90 (6) 108 (7) 146 (9) 180 (11) 216 (14) 325 (21) All weights ±3% Operating weights include refrigerant, oil, and water charges.

14 CGWF-SVX01A-EN General Information

Table 4 General Data CCAF

CCAF Unit Tonnage202530405060 General Refrigerant Type R-22 R-22 R-22 R-22 R-22 R-22 Refrigerant Charge lb(kg) Field Field Field Field Field Field Oil Type Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil 31 Oil Charge Pints(l) 16 (7.6) 22 (10.4) 28 (13.2) 16/16 22/22 28/28 (7.6/7.6) (10.4/10.4) (13.2/13.2) Operating Weight lb(kg) 1004 (456) 1079 (490) 1274 (579) 1509 (685) 1808 (821) 1982 (900) Shipping Weight lb(kg) 1430 (649) 1605 (729) 1836 (834) 1792 (814) 2166 (984) 2494 (1133) Overall Dimensions Length in (mm) 80.1 (2035) 80.1 (2035) 80.1 (2035) 102.6 (2607) 102.6 (2607) 102.6 (2607) Width in (mm) 29.4 (745) 29.4 (745) 29.4 (745) 31.4 (591) 31.4 (591) 31.4 (591) Height in (mm) 57.8 (1467) 57.8 (1467) 57.8 (1467) 57.8 (1487) 57.8 (1487) 57.8 (1487) Evaporator Water Storage gal (l) 11.7 (44) 10.7 (40) 16.4 (62) 25.7 (97) 24 (90) 39.9 (151) Minimum Flow gpm (l/s) 24 (1.5) 30 (1.9) 36 (2.3) 48 (3.0) 60 (3.8) 84 (5.3) Maximum Flow gpm (l/s) 72 (4.5) 90 (5.7) 108 (6.8) 144 (9.1) 180 (11.4) 252 (15.9) All weights ±3% Operating weights include refrigerant, oil, and water charges.

CGWF-SVX01A-EN 15 General Information

16 CGWF-SVX01A-EN Installation Mechanical

Unit Storage Extended storage of the chiller prior to installation requires the following precautionary measures: 1. Do not remove the protective coverings from the control panel. 2. Store the chiller in a dry, 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 Trane sales office. Location Requirement

Noise Consideration Locate the unit away from sound-sensitive areas. If necessary, install the optional isolators under the unit. Refer to “Unit Isolators”. Install vibration isolators in all piping and use flexible electrical conduit. Consult an acoustical engineer for critical applications.

Foundation Provide rigid non warping mounting pads or a concrete foundation of sufficient strength and mass to support the chiller operation weight (i.e. including completed piping, and full operating charges of refrigerant, oil and water). The unit operating weights are provided in Table 3 and Table 4. Once in place, the chiller should be level within 1/4” (6.3 mm) over the length and width. The Trane Company is not responsible for equipment problems resulting from an improperly designed or constructed foundation or for improper installation.

Ventilation Make provisions to remove heat generated by unit operation from the equipment room. Ventilation must be adequate to maintain an ambient temperature lower than 125 F (52.5 C). The condenser and evaporator pressure relief valve(s) must be vented in accordance with all local and national codes. Refer to “Pressure Relief Valves”.

Drainage Locate the units near a large capacity drain so that water vessels can be emptied during shut down or repairs. Condensers and evaporators are provided with drain connections. Refer to “Unit Piping”. All local and national codes apply. Rigging Model CGWF/CCAF chillers should be moved by lifting, if the crate has been removed. Refer to Table 3 and Table 4 for typical unit lifting and operating weights. Figure 4 and Figure 5 show proper lifting methods. When on the shipping skid, the unit can be pushed from one end with a forklift, but should never be lifted using a forklift. Note: Two steel lifting angles, to be used for lifting the unit, are secured to the skid when the unit is shipped (20 -50 ton units only). Hardware is provided to mount the lifting angles on the unit.

CGWF-SVX01A-EN 17 Installation Mechanical

WARNING Unit Lifting Capacity! The capacity of the lifting equipment sued must exceed etc. Then end with failure to use properly sized lifting equipment could result in death or serious injury or equipment damage. WARNING Improper Unit Lifting! Follow the lifting procedure detailed below. Failure to follow the proper lifting procedure could result in death or serious injury or equipment damage. Lifting Procedure for 20-50 Ton CGWF 20-60 and Ton CCAF Units. 1. Remove the two sheet lifting angles from the skid. 2. Remove the unit from the shipping skid. If absolutely necessary, the chiller can be pushed or pulled across a smooth surface as long as it is bolted to the shipping skid. 3. Bolt the lifting angles to the unit as shown in Figure 4. Mount one lifting angle at each end of the unit using the nuts and bolts provided. 4. Tighten each bolt to 70ft-lbs torque. 5. Verify the lifting angle mounting bolts are tightened to 70ft-lbs torque. 6. Install clevis connectors in the 1-1/4” (32 mm) lifting holes provided on each end of the lifting angles (Figure 4). 7. Attach lifting chains or cables to the clevis connectors. Each cable alone must be strong enough to lift the chiller. 8. Attach cables to the lifting beam. Total lifting weight and centers of gravity are listed in Table 5. Required lifting beam dimensions are shown in Figure 4. A rig- ging diagram also ships with each unit. Lifting beam crossbars must be positioned so lifting cables do not contact unit piping or control panel enclosure. CAUTION Unit Damage! To prevent unit damage, position lifting beam crossbars so that cables do not contact the unit.

18 CGWF-SVX01A-EN Installation Mechanical

1. Remove lifting angles from the skid. Remove the angle support bolts from the unit legs. Attach the lift- ing angles as shown and torque the 12 mm bolts to 70 ft-lbs attaching the lifting angle. 2. Use clevis pins for attachment of chains to lifting angles, lifting chains (cables) may be adjusted for level lifting. 3. Do not Forklift Unit. 4. All units are heavier on the control panel side. Use Table 5 to adjust rigging accordingly. 5. Minimum beam length 4 ft.

Figure 4 Typical Rigging Setup For CGWF 20-50 Ton and 20-60 Ton CCAF Units.

CGWF-SVX01A-EN 19 Installation Mechanical

Lifting Procedure for 60 Ton Units WARNING Unit Lifting Capacity! The capacity of the lifting equipment sued must exceed etc. Then end with failure to use properly sized lifting equipment could result in death or serious injury or equipment damage. WARNING Improper Unit Lifting! Follow the lifting procedure detailed below. Failure to follow the proper lifting procedure could result in death or serious injury or equipment damage.

1. Dismantle shipping crate. 2. Remove the unit from the shipping skid. If absolutely necessary, the chiller can be pushed or pulled across a smooth surface as long as it is bolted to the shipping skid. 3. Attach chains or cables to lifting beam.The total lifting weight, lifting weight distri- bution and required lifting beam dimensions are shown in Figure 5. Lifting beam crossbars must be positioned so lifting cables do not contact the side of the unit. CAUTION Unit Damage! To prevent unit damage, position lifting beam crossbars so that cables do not contact the unit.

20 CGWF-SVX01A-EN Installation Mechanical

1. Use clevis pins for attachment of chains to lifting holes, lifting chains (cables) may be adjusted for level lifting. 2. Do not Forklift Unit. 3. All units are heavier on the control panel side. Use Table 5 to adjust rigging accordingly. 4. Minimum beam length 6ft.

Figure 5 Typical Rigging Setup For CGWF 60 Ton Units.

Table 5 Center of Gravity Dimensions Unit Size Location of Center of Gravity (in) XYZ CGWF 20 18 24 9 25 18 25 9 30 18 26 9 40 23 26 8 50 23 27 9 60 28 31 13 CCAF 20 28 31 8 25 28 30 8 30 28 28 8 40 33 29 8 50 33 27 8 60 33 26 8

Alternate Moving Methods If it is not possible to rig from the previous method shown inFigure 4 and Figure 5, the unit my also be moved by jacking each end high enough to move an equipment dolly under each end of the unit frame. Once securely mounted on the dollies, the unit may be rolled into position. Jacks should be positioned to lift under the lifting angles installed on the unit by the contractor. Access Restrictions All CGWF/ CCAF units will pass through a standard 36-inch doorway. Typical dimensions are shown in Figure 7 - Figure 11.

CGWF-SVX01A-EN 21 Installation Mechanical

Recommended Clearances Provide recommended access clearance for service and maintenance operations. Refer to recommendations provided in Figure 7 - Figure 11. Local codes may take precedence over recommendations. Unit Isolation There are two mounting methods that will minimize sound and vibration. They are the direct-mount method and the isolator-mount method.

Direct Mounting The unit can be direct-mounted on an isolated concrete pad or on an isolated concrete footing at each end. Refer to Table 3 and Table 4 for unit operating weights. A mounting hole is provided in the base of the unit frame at each mounting location. Provide a means of securely anchoring the unit to the mounting surface. Level the unit carefully. Refer to “Leveling the Unit”.

Neoprene Isolator Mounting Install the optional neoprene mounting isolators at each mounting location. Refer to Table 6 for isolator selection, placement and loading information. Isolators are identified by color and by the isolator part number. Bolt the isolator to the mounting surface. Do not fully tighten the mounting bolts. Mount the unit on the isolators and install a 1/2-inch (13 mm) nut on each isolator positioning pin. Maximum isolator deflection should be 1/4-inch. Level the unit carefully. Refer to “Unit Leveling”. Now fully tighten isolator mounting bolts. Neoprene Isolator Data

3 4 CGWF/CCAF 1 2

Control Panel End

Figure 6 Isolators and Locations

Table 6 RDP 3 Neoprene Isolator Selection Location Unit Size 1234 CGWF 20 Green Green Green Green 25 Green Green Green Green 30 Green Green Green Green 40 Gray Gray Gray Gray 50 Gray Gray Gray Gray 60 Gray Gray Gray Gray CCAF

22 CGWF-SVX01A-EN Installation Mechanical

Table 6 RDP 3 Neoprene Isolator Selection Location Unit Size 1234 20 Red Red Red Red 25 Red Red Red Red 30 Red Red Red Red 40 Red Red Red Red 50 Green Green Green Green 60 Green Green Green Green

Unit Leveling Before snugging down the mounting bolts, level the unit carefully. Check unit level end-to-end by using a water level, or by placing a level on the top surface of the unit frame. Unit should be level within 1/4-inch (6.35 mm) over the length. Place the level on the unit frame and check front to back level. Adjust to within1/4-inch (6.35 m) of level front-to-back. Use shims to level the unit.

CGWF-SVX01A-EN 23 Installation Mechanical

Figure 7 CGWF 20, 25, 30 Ton Unit Dimensions, Recommended Clearances, Mounting Locations, Electrical, Water Connection Size and Locations

24 CGWF-SVX01A-EN Installation Mechanical

Figure 8 CGWF 40 and 50 Ton Unit Dimensions, Recommended Clearances, Mounting Locations, Electrical, Water Connection Size and Locations

CGWF-SVX01A-EN 25 Installation Mechanical

Figure 9 CGWF 60 Ton Unit Dimensions, Recommended Clearances, Mounting Locations, Electrical, Water Connection Size and Locations

26 CGWF-SVX01A-EN Installation Mechanical

Size A B C D E F 20 Ton 8 1/2" 3' - 11 1/2" 2" 2' - 0" 1' - 3 1/2" 3' - 3" (216) (1207) (51) (610) (394) (1041) 25 Ton 8 1/2" 3' - 11 1/2" 2" 1' - 11 3/4" 1' - 3 1/2" 3' - 10" (216) (1207) (51) (603) (394) (1041) 30 Ton 7 3/4" 3' - 10 3/4" 2 1/2" 2' - 1 7/8" 1' - 5 3/8" 3' - 10" (197) (1187) (64) (657) (441) (1168)

Notes: 1. Dimensional tolerances ± 1/4" (3mm). 2. Tube installation at either end of evaporator. 3. Dimensions in ( ) are millimeters.

Figure 10 CCAF 20, 25 and 30 Ton Unit Dimensions, Recommended Clearances, Mounting Locations, Electrical, Water Connection Size and Locations

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Size A B C D E F 40 Ton 5' - 1 3/4" 1' - 3 3/4" 1' - 11 1/4" 2 1/2" 3' - 5" 1' - 4 1/4 (1568) (400) (591) (64) (1041) (413) 50 Ton 5' - 1 1/2" 1' - 3 1/2" 2' - 1 1/8" 3" 3' - 10" 1' - 6 1/8" (1562) (394) (638) (76) (1168) (480) 60 Ton 5' - 1 1/2" 1' - 3 1/2" 2' - 0 7/8" 3" 3' - 10" 1' - 6 1/8" (1562) (394) (632) (76) (1168) (480)

Notes: 1. Dimensional tolerances ± 1/4" (3mm). 2. Tube installation at either end of evaporator. 3. Dimensions in ( ) are millimeters.

Figure 11 CCAF 40, 50 and 60 Ton Unit Dimensions, Recommended Clearances, Mounting Locations, Electrical, Water Connection Size and Locations

28 CGWF-SVX01A-EN Installation Mechanical

Unit Piping

General Water Piping Recommendations Make water piping connections to evaporator and condenser(s). Isolate and support piping to prevent stress on the unit. Use flanged ells or spool-pieces to facilitate service procedures. Construct piping according to local and national codes. Insulate and flush piping before connecting to unit. CAUTION Equipment Damage! To prevent equipment damage, bypass the unit if using an acidic flushing agent.

Use a pipe sealant or teflon tape on all water connections. Minimize heat gain and prevent condensation by insulating all chilled water piping. CAUTION Piping Damage! To prevent damage to water piping, do not over-tighten connections. Water System

Water Flow Rates Establish balanced water flow through both the evaporator and condenser. Flow rates should fall between the minimum and maximum values given inTable 3 and Table 4. Flow rates above or below these values can cause equipment damage or improper unit operation.

Pressure Drop Measurement Measure evaporator water pressure drop at the pressure gauge(s) on the system water piping. Readings should approximate those shown by the pressure drop charts in Figure 12 and Figure 13. Note: Evaporator pressure drop is an approximation and is to be used as a tool to estimate flow rate and as an aid to waterside system piping design. If an accurate measurement of flow rate is required, an accurate flow meter must be installed in the system.

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Chart PD 1 CGWE Evaporator

Figure 12 Evaporator Pressure Drop

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Figure 13 Condenser Pressure Drop

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Evaporator Water Piping

Evaporator Water Connections. Internal NPTF water inlet and outlet connections are used on all 20 through 50 ton CGWF and 20-60 ton CCAF units. 60 ton CGWF use grooved pipe connectors for water inlet and outlet. Evaporator water inlet and outlet types, sizes and locations are shown in Figure 14.

Evaporator Piping Components Figure 14 illustrates typical recommended evaporator piping components. Piping components and layout vary, depending on water source and connection locations. A vent is located on top of the evaporator at the water outlet end. Provide additional vents at high points in the piping to bleed air from the chilled water system. Install pressure gauge(s) to monitor entering and leaving chilled water pressure. CAUTION Excessive Water Pressure! To prevent evaporator damage, do not exceed 300 psi for 20-60 ton CCAF and 20-50 ton CGWF, and 215 psi for 60 ton CGWF evaporator water pressure.

Provide shutoff valves in the line(s) to the gauge(s) to isolate the gauges when not in use. Use pipe unions to simplify disassembly for system service. Use vibration eliminators to prevent transmitting vibrations through the water lines. Install thermometers in the lines to monitor evaporator entering and leaving water temperatures. Install a balancing cock in the leaving water line. It will be used to establish a balanced water flow. Both the entering and leaving water lines should have shutoff valves installed to isolate the evaporator for service.

Figure 14 Recommended Piping Flow Sensing Devices Chilled water flow switches are optional, but there must be a chilled water flow interlock provided to the MP to indicate that the evaporator pump is running. To provide additional chiller protection, install and wire the flow switch in series with the chilled water pump interlock for the chilled water circuits (refer to “Chilled Water Flow Interlock”). Specific connection and schematic wiring diagrams shipped with the unit.

32 CGWF-SVX01A-EN Installation Mechanical

Flow switches must stop or prevent compressor operation if chilled water flow drops off drastically. Follow the manufacturer's recommendations for selection and installation procedures. General guidelines for flow switch installation are outlined below: 1. Mount the switch upright with a minimum of 5 pipe diameters straight, horizontal run on each side. Do not install close to elbows, orifices, or valves. Note: The arrow on the switch must point in the direction of water flow. 2. To prevent switch fluttering, remove all air from the water systems. Note: The MP provides a 6-second time delay before shutting the unit down on a loss-of-flow diagnostic. Contact a qualified service organization if nuisance machine shutdowns persist. Install a pipe strainer in the evaporator water supply line to protect components from water-borne debris.

Evaporator Drain. The evaporator drain connection should be piped to a suitable drain facility to empty the evaporator during service or shutdown. Provide a shutoff valve in the drain line. If the evaporator drain connection is not piped, remove the drain plug from its shipping location in the control panel and install it in the drain connection. CAUTION Use Pipe Strainers! To prevent evaporator or condenser damage, pipe strainers must be installed in the water supplies to protect components from water born debris. The Trane Company is not responsible for equipment-only- damage caused by water born debris. Condenser Water Piping

Condenser Water Connections. Condenser water inlet and outlet types, sizes and locations are given in Figure 7 - Figure 11.

Condenser Piping Components. Condenser piping components and layout vary, depending on water source and connection locations. Figure 15 illustrates typical piping components for a well water (city water) condensing source. Typical components for a cooling tower condensing source are ALSO shown in Figure 16. Condenser piping components generally function identically to those in the evaporator piping system. Refer to “Evaporator Piping”. In addition, cooling tower systems may include a manual or automatic bypass valve that can alter water flow rate to maintain condensing pressure. Well (city) water condensing systems should include a pressure reducing valve and water regulating valve (Figure 15). A pressure reducing valve should be installed to reduce water pressure entering the condenser. This is required only if water pressure exceeds 300 psig. This is necessary to prevent damage to the disc and seat of the water regulating valve that can be caused by excessive pressure drop through the valve.

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CAUTION Excessive Water Pressure! To prevent condenser or regulating valve damage, do not exceed 150 psi for 30 and 60 ton units and 300 psi for 20, 25, 40 and 50 ton units condenser water pressure.

The optional water regulating valve(s) maintains condensing pressure and temperature by throttling water flow leaving the condenser in response to compressor discharge pressure. Adjust the regulating valve(s) for proper operation during start-up.

Condenser Drains. The condenser shells can be drained by removing the drain plugs from the bottom of the condenser heads. Also remove the vent plugs (at the top of the condenser heads) to facilitate complete drainage. When the unit is shipped, the condenser drain plugs are located in the control panel along with the evaporator drain plug. The condenser drains can be piped to drain facilities, if desired. If they are not, install the drain plugs in the condenser drain connections on the condenser.

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Figure 15 Components for Condenser Water Circuit

Water Regulating Valve The water regulating valve maintains condensing pressure and temperature by throttling water flow leaving the condenser in response to compressor discharge pressure, decreasing water flow as pressure falls, and increasing water flow when discharge pressure rises. Install the valve on the condenser leaving water line (Figure 15). Dual circulated units (40, 50, and 60-ton) require dual regulating valves installed in parallel in the leaving water line (Figure 15).

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Locate the valve after the thermometer and before the shutoff valve (Figure 15). Run the capillary tubing from the valve(s) to the discharge service valve(s). CAUTION Refrigerant Loss! To prevent refrigerant loss, locate capillary tubing and secure it to avoid damage due to friction or vibration.

Connect the capillary tubing to the access port on the discharge service valve(s). Ensure that the valve is closed to the access port before removing flare cap. CAUTION High Pressure Refrigerant Gas! Make sure the discharge valve access port is closed before removing flare cap. Improper removal of flare cap may result in instantaneous release of high pressure refrigerant causing the cap to become a projectile and/or liquid refrigerant to contact the skin. Failure to close discharge valve access port before removing flare cap may result in minor or moderate injury.

Loosen the flare cap slowly to relieve residual pressure and connect the water regulating valve capillary tubing. Adjust the regulating valve for proper operation during unit start-up .

Figure 16 Typical Water Regulating Valve Installation

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Water Treatment Using untreated or improperly treated water in these units may result in inefficient operation and possible tube damage. Consult a qualified water treatment specialist to determine whether treatment is needed. CAUTION Proper Water Treatment! 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. Trane assume no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Water pressure Relief Valves Install a water pressure relief valve in the condenser and evaporator leaving chilled water piping (Figure 15). Water vessels with close-coupled shutoff valves have a high potential for hydrostatic pressure buildup on a water temperature increase. Refer to applicable codes for relief valve installation guidelines. CAUTION Install Water Relief Valves! To prevent shell damage, install pressure relief valves in both evaporator and condenser water systems.

Low Temperature Operation The leaving water temperature cutout setpoint is adjusted using the DynaView or TechView. There is a minimum differential that must exist between the Chilled Water Setpoint (CWSP) and the Leaving Water Temperature Cutout setpoint (LWTCS). This minimum varies depending on the design DT, the number of cooling stages and whether or not Hot Gas Bypass (HGBP) is installed. The equations to calculate LWTCS are shown below. Leaving Water Temperature Cutout Setpoint (LWTCS) is: 20-30 T for units with out HGBP T CWSP–------∆ -2+ °F = LWTCS 2

20-30 T for units with HGBP T CWSP–------∆ -4+ °F = LWTCS 2 40-60 T for units with out HGBP T CWSP–------∆ -2+ °F = LWTCS 4

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40-60 T for units with HGBP T CWSP–------∆ -4+ °F = LWTCS 4

Table 7 Percent Glycol and Freeze Solution Temperatures Ethylene Glycol Propylene Glycol % Glycol Solution Freeze Point (°F) Solution Freeze Point (°F 03232 52929.3 10 25.5 26.4 15 21.5 23.1 20 16.8 19.3 25 11.4 14.8 30 5.1 9.3 35 -2.3 2.7 40 -10.8 -5.2 45 -20.7 -14.6 50 -32.1 -25.8 54 -42.3 -36.1

Pressure Relief Valve Venting All CGWF units utilize two refrigerant-pressure relief valves for each circuit (one high side and one low side) which must be vented to the outdoor atmosphere. The high side relief valves are located at the left end of each condenser at the top (facing the control panel). The low side relief valves are located at the right end of the evaporator.Relief valve connection sizes are 5/8” flare on the condenser and 3/8” flare on the evaporator. CCAF units have evaporator relief valve(s) only. All relief valve venting is the responsibility of the installing contractor. Vent pipe size must conform to the ANSI/ASHRAE Standard 15 for vent pipe sizing. All federal, state, and local codes take precedence over any suggestions stated in this manual. Consult local regulations for any special relief line requirements. CAUTION Proper Vent Piping! Vent piping must be installed to code specifications. Failure to heed specifications could result in capacity reduction, unit damage and/or relief valve damage.

Once the relief valve has opened, it will re-close when pressure is reduced to a safe level. The valve may leak and should be replaced. Pipe each relief valve on the unit into a common vent line. Provide an access valve on the common line to connect vacuum pump discharge and vent excess refrigerant out of the mechanical room. The access valve must be located at the low point of the vent piping to enable draining of any condensate that may accumulate in the piping.

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Table 8 Pressure Relief Valve Data Valve location Quantity Relief Pressure Rated Capacity per Pipe size (psi) Relief Valve (in) (lba/min.) Condenser 1 per ckt 450 37.6 5/8” flare 20-50 ton Condenser 1 per ckt 450 37.6 5/8” flare 60 ton Evaporator 1 per ckt 300 11.5 3/8” flare WARNING Confined Space Hazards! Do not work in confined spaces where sufficient quantities of a refrigerant or other hazardous, toxic or flammable gas may be leaking. Refrigerant or other gases could displace available oxygen to breathe, causing possible asphyxiation or other serious health risks. Some gases may be flammable and or explosive. Evacuate the area immediately and contact the proper rescue or response authority. Failure to take appropriate precautions or to react properly to a potential hazard could result in death or serious injury.

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Refrigerant Piping (CCAF only) Refer to the “Trane Reciprocating Refrigeration Manual” for refrigerant piping selection information. 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 L refrigerant grade copper tubing only. The use of a lower grade tubing can cause operating problems.

Liquid Line Components and Connections Liquid line connections sizes and locations are shown in Figure 10 - Figure 11. Thermostatic expansion valves, refrigerant sight glass, solenoid valves and schraeder valves are standard components on CCAF liquid lines. A liquid line filter drier must be installed for each circuit. Install a liquid line service valve in the liquid line to isolate the drier for service.

Liquid Line Sizing Trane recommends sizing the liquid line diameter as small as possible while maintaining acceptable pressure drop. This will minimize the required refrigerant charge and increase compressor life. Liquid risers in a system an additional 0.5 psig pressure drop per each foot of vertical rise. If the riser is length exceeds 15 feet, a larger diameter and/or shorter liquid line may be required to provide required subcooling at the expansion valve. The line does not have to be pitched. Basic liquid line sizing perimeters for these units are: Liquid Velocity 100-250 fpm Maximum allowable pressure drop 3-6 psig (1F)

Liquid lines are not usually insulated. If, however, the line runs through an area of high ambient temperature (i.e. boiler room), subcooling my drop below required levels. Liquid line passing though these warm spaces should be insulated.

Discharge (hot gas) Lines 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: Maximum allowable pressure drop 6 psig (1F) 6 psig (1F) Maximum Velocity 3500 fpm Minimum Velocity (at minimum load) Horizontal lines 500 fpm Vertical lines (up flow) 1000 fpm

40 CGWF-SVX01A-EN Installation Mechanical

Figure 17 Refrigerant piping Configuration of Typical Dual-Circuit CCAF Unit

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Leak Test Once refrigerant piping is complete, thoroughly test the system for leaks.

System Evacuation For field evacuation, use a rotary-style vacuum pump capable of pulling a vacuum of 100 microns or less. Follow the pump manufacture’s instructions for proper use of the pump. The line used to connect the pump to the system should be copper and of the largest diameter that can practically be used. Using a larger line size with minimum flow resistance can significantly reduce evacuation time. Rubber or synthetic hose are not recommended for unit evacuation because they have moisture absorbing characteristics which result in excessive outgassing and pressure rise during the standing vacuum test. This makes it impossible to determine if the unit has a leak, contains excessive moisture, or is experiencing a continual high rate of pressure increase due to the hoses. NOTE: Insure that all sections of the refrigerant system are properly evacuated. CAUTION Equipment Damage! Do not use a megohm meter or apply power to compressor windings under vacuum. This may damage motor windings.

Refrigerant Charging 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 valve with the compressor(s) off. CAUTION Equipment Damage! To prevent evaporator tube rupture, never charge liquid refrigerant into a water vessel when refrigerant temperature/pressure relationship of the vessel is below freezing.

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”. Once the unit is operating, add the remainder of the required charge to the system.

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General Recommendations The wiring procedures described in this portion of the manual must be accomplished to obtain proper operation of the basic CGWF/CCAF unit. Electrical wiring instructions for all optional features and equipment are described In the “Optional Electrical Wiring” sections of this manual. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

All wiring must comply with National Electric Code (NEC) and state and local requirements. Outside the United States, the national and/or local electrical requirements of the other countries shall apply. The installer must provide properly sized system interconnecting and power supply wiring with appropriate branch circuit protection. Type and locations of disconnects must comply with all applicable codes. CAUTION Use Copper Conductors Only! Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage. All wiring must comply with applicable local and national codes.

Electrical connection locations are shown in Figure 7 - Figure 11. Minimum circuit ampacities, recommended fuse sizes and other unit electrical data are provided in Table 10 and Table 11, and on the unit nameplate. Refer to the “Field Wiring and Remote Sensor Layout Schematic” shown in the Unit Wiring section. Power Supply Wiring

Unit Power Supply The installer must connect appropriate line power supply (with fused disconnects) to the terminal block or non-fused, unit mounted disconnect in the power section of the unit control panel. Refer to Figure 2 and Figure 3. Field wiring diagrams, electrical schematics and component location drawings are also attached to the inside of the control panel door. The unit power fused disconnect switch(es) should be located in the general area of the unit to comply with NEC or local codes. The unit disconnect can be used as an emergency shutdown device. Normally, manual shutdown of the unit is accomplished at the DynaView. Then, open the line power and control power (if used) fused disconnects after the pumpdown cycle is complete. Equipment Grounds Provide proper grounding at the connection points provided in the panel (Figure 22). Terminal Lugs, Circuit Breakers and Non-Fused Disconnect Switches Proper starter/control panel line-side lug sizes are specified on the starter submittals and in Table 9. These lug sizes must be compatible with conductor sizes specified by the electrical engineer or contractor.

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Figure 18 Electrical Installation

Table 9 Customer Wire Selection Unit Size Unit Voltage Disconnect Switch Size Connection Wire Range Power wire Selection to Disconnect Switch (1S1) 30-50 Ton 208/230 Volt 250 Amp (1) #1-300 MCM 20-50 Ton 460 Volt 100 Amp (1) #14-1/0 20-60 Ton 575 Volt 100 Amp (1) #14-1/0 20-25 Ton 208/230 Volt 100 Amp (1) #14-1/0 60 Ton 208/230/460 Volt 250 Amp (1) #4-350 MCM Power Wire Selection to Disconnect Switch (1S1) High Condensing Temperature(90-130 F) Units 25-50 Ton 208/230 Volt 225 Amp (1) #1-300 MCM 60 Ton 208/230 Volt 400 Amp (1) 250-500 MCM 20-50 Ton 460 Volt 100 Amp (1) #14-1/0 20-60 Ton 575 Volt 100 Amp (1) #14-1/0 60 Ton 460 Volt 250 Amp (1) #4-350 MCM 20 Ton 208/230 Volt 100 Amp (1) #14-1/0 Power Wire Selection to Main Terminal Block 20-60 Ton 460/575 Volt 250 Amp (1) #12-2/0 20-40 Ton 208/230 Volt 250 Amp (1) #12-2/0 50-60 Ton 208/230 Volt 250 Amp (1) #6-350 MCM

Control Wire Selection For 30 Volt or Less Circuits Wire Size Maximum Length 14 AWG 5000 ft 16 AWG 2000 ft 18 AWG 1000 ft

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Table 10 Electrical Data CGWF Standard Condensing Temperature Units Unit Size Unit Wiring Data Compressor Motor Data Rated Minimum Max Fuse Size Recommended Qty - Size RLA LRA Voltage Circuit Ampac- Duel Element Fuse ity Size 20 208/230 77 110 100 2 -10 34 251 380 38 50 50 17 142 460 32 45 40 14 117 575 27 40 40 12 94 400/50 32 50 50 14 110 25 208/230 99 150 125 1 -15 52/34 376/251 380 51 70 701 - 10 27/17 215/142 460 43 60 60 23/14 178/117 575 35 50 45 18/12 143/94 400/50 42 50 45 22/14 174/110 30 208/230 117 150 150 2 - 15 52 376 380 61 80 80 27 215 460 52 70 70 23 178 575 41 50 50 18 143 400/50 50 80 80 22 174 40 208/230 145 175 175 4 - 10 34 251 380 72 80 90 17 142 460 60 70 70 14 117 575 51 60 70 12 94 400/50 60 90 90 14 110 50 208/230 185 225 225 2 - 15 52/34 376/251 380 95 110 1102 - 10 27/17 215/142 460 80 100 100 23/14 178/117 575 65 80 80 18/12 143/94 400/50 78 110 125 22/14 174/110 60 208/230 221 250 250 4 - 15 52 376 380 115 125 150 27 215 460 98 110 110 23 178 575 77 90 90 18 143 400/50 94 125 150 22 174 Notes: 1. Minimum Circuit Ampacity is 125% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, per NEC 440-32 and NEC 440-33. 2. Maximum Fuse Size is 225% of the largest compressor RLA plus 100% of the remaining compressor(s) RLS, per NEC 440-30. 3. Recommended Dual-Element Fuse Size is 175% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, Per NEC 430-152. 4. Use copper conductors only. 5.Compressor motor Voltage utilization range is: Rated Voltage--- Utilization Range 208/230 ---188-253 380 ---342-418 460 ---414-506 575 ---517-633 400/50 - 360-440

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Table 11 Electrical Data CCAF and CGWF High Condensing Temperature (90-130 F) Units Unit Size Unit Wiring Data Compressor Motor Data Rated Minimum Max Fuse Recommended Qty - Size RLA LRA Voltage Circuit Size Duel Element Ampacity Fuse Size 20 208/230 88 125 110 2 -10 39 251 380456060 20142 460385050 17117 575324540 1494 400/50 38 50 50 17 117 25 208/230 112 150 150 1 -15 58/39 376/251 380 59 80 801 - 10 31/20 215/142 460 50 70 70 26/17 178/117 575 40 60 60 21/14 143/94 400/50 48 70 70 25/17 178/117 30 208/230 131 175 175 2 - 15 58 376 380 70 100 90 31 215 460598080 26178 575476060 21143 400/50 56 80 80 25 178 40 208/230 166 200 200 4 - 10 39 251 380 85 100 100 20 142 460728090 17117 575607070 1494 400/50 72 80 90 17 117 50 208/230 209 250 250 2 - 15 58/39 376/251 380 110 125 1502 - 10 31/20 215/142 460 93 110 110 26/17 178/117 575 75 90 90 21/14 143/94 400/50 90 110 110 25/17 178/117 60 208/230 247 300 300 4 - 15 58 376 380 132 150 150 31 215 460 111 125 125 26 178 575 89 100 110 21 143 400/50 106 125 125 25 178 Notes: 1. Minimum Circuit Ampacity is 125% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, per NEC 440-32 and NEC 440-33. 2. Maximum Fuse Size is 225% of the largest compressor RLA plus 100% of the remaining compressor(s) RLS, per NEC 440-30. 3. Recommended Dual-Element Fuse Size is 175% of the largest compressor RLA plus 100% of the remaining compressor(s) RLA, Per NEC 430-152. 4. Use copper conductors only. 5.Compressor motor Voltage utilization range is: Rated Voltage--- Utilization Range 208/230 ---188-253 380 ---342-418 460 ---414-506 575 ---517-633 400/50 - 360-440

46 CGWF-SVX01A-EN Installation Electrical

Scroll Compressor Electrical Phasing It is important that proper rotation of the scroll compressor 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 A,B,C. To confirm the correct phase sequence (ABC), use a Model 45 Associated Research Phase indicator or equivalent. Basically, voltages generated in each phase of a polyphase alternator or circuit are called phase voltages. In a three-phase circuit, three sine wave voltages are generated, differing in phase by 120 electrical degrees. The order in which the three voltages of a three-phase system succeed one another is called phase sequence or phase rotation. This is determined by the direction of rotation of the alternator. When rotation is clockwise, phase sequence is usually called “ABC”, when counterclockwise, “CBA”. This direction may be reversed outside the alternator 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. Correcting Improper Electrical Phase Sequence Proper compressor motor electrical phasing can be quickly determined and corrected before starting the unit. Use a quality instrument such as an Associated Research Model 45 Phase Sequence Indicator and follow this procedure. WARNING Hazardous Voltage! During installation, testing, servicing and troubleshooting of this product, it may be 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. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

1. Turn Chiller off. 2. Open the electrical disconnect or circuit protection switch that provides line power to the line power terminal block (1TB1) in the control panel (or to the unit- mounted disconnect 1S1). 3. Connect the phase sequence indicator leads to 1TB1 (or 1S1) as follows: Phase Seq. Lead 1TB1 Terminal Black (Phase A) 1 Red (Phase B) 2 Yellow (Phase C) 3

4. Turn power on by closing the unit supply power fused disconnect switch. 5. Read the phase sequence displayed on the indicator. 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 main power disconnect and switch two line leads on 1TB1 (1S1). Reclose the main power disconnect and recheck phasing. 7. Reopen the unit disconnect and disconnect the phase indicator.

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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 following tolerances. WARNING Hazardous Voltage! During installation, testing, servicing and troubleshooting of this product, it may be 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. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

Voltage Supply

Measure each leg of supply voltage at all line voltage disconnect switches. Readings must fall within the voltage utilization range shown on the unit nameplate. If voltage on any leg does not fall within tolerance, notify the power company to correct this situation before operating the unit. Inadequate voltage to the unit will cause control components to malfunction and shorten the life of relay contacts and compressor motors. Voltage Imbalance Excessive voltage imbalance between phases in a three-phase 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 phase) 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 = 226 Volts 3 The percentage of imbalance is then:

100(226-221) = 2.2% 226 In the example above 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. Control Power Supply A panel-mounted control power transformer is standard on all units. Modules Connections for Interconnecting Wiring The wiring procedures described in this portion of the manual must be completed panel mounted LLIDs. Refer to Filed Wiring on page 95.

48 CGWF-SVX01A-EN Installation Electrical

Chilled Water Flow Switch CH530 has an input that accepts a contact closure from a proof-of-flow device such as a flow switch or pressure switch. When this input does not prove flow within a fixed time relative to transition from Stop to Auto modes of the chiller, or if the flow is lost while the chiller is in the Auto mode of operation, the chiller will be inhibited from running by a non-latching diagnostic The installer must provide a flow sensing device or a pump interlock. Refer also to the “field wiring” diagrams attached to the inside of the control panel door. Chilled Water Pump Control CH530 has an evaporator water pump output relay that closes when the chiller goes into the Auto mode. The contact is opened to turn off the pump in the event of most diagnostics to prevent the build up of pump heat. Condenser Water Loss of Flow Protection CH530 has an input that accepts a contact closure from a proof-of-flow device such as a flow switch or pressure switch. When this input does not prove flow within a fixed time from when the pump is commanded on, or if the flow is lost while a compressor is running, the chiller will be inhibited from running by a diagnostic. The installer must provide a flow sensing device or a pump interlock. Refer also to the “field wiring” diagrams attached to the inside of the control panel door. Condenser Water Pump Starter CH530 has a condenser water pump output relay that closes to indicate when the condenser water pump should be started and opens to indicate when the pump should stop. If condenser pumps are arranged in a bank with a common header, the output can be used to control an isolation valve and/or signal another device that an additional pump is required. Programmable Relays CH530 provides a flexible alarm or chiller status indication to a remote location through a hard wired interface to a dry contact closure. Four relays are available for this function, and they are provided (generally with a Quad Relay Output LLID) as part of the Alarm Relay Output Option. The events/states that can be assigned to the programmable relays are listed in the following table. Table 12 Chiller Events/Status Descriptions

Event/State Description Alarm - Latching This output is true whenever there is any active latching diagnostic that targets the Chiller, Circuit, or any of the Compressors on a circuit. Alarm - Auto Reset This output is true whenever there is any active non-latching diagnostic that targets the Chiller, Circuit, or any of the Compressors on a circuit. Alarm This output is true whenever there is any active latching or non-latching diagnostic that tar- gets the Chiller, Circuit, or any of the Compressors on a circuit. Warning This output is true whenever there is any active latching or non-latching informational diag- nostic that targets the Chiller, Circuit, or any of the Compressors on a circuit. Chiller Limit Mode This output is true whenever the chiller has been running in one of the limit modes (Con- denser, Hot Evaporator Start, Demand or Compressor Inhibit) continuously for the debounce time. A given limit or overlapping of different limits must be in effect continuously for the debounce time prior to the output becoming true. It will become false if no limits are present for the debounce time. Compressor Running The output is true whenever any compressors are running. Maximum Capacity The output is true whenever the chiller has reached maximum capacity continuously for the debounce time. The output is false when the chiller does not have all its available compres- sors running continuously for the debounce time. See the Maximum Capacity specification for more information.

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The CH530 Service Tool (TechView) is used to install and assign any of the above listed events or status to each of the four relays provided with this option. The default assignments for the four available relays are listed below. Table 13 Programable Relays LLID Name LLID Software Relay Output Name Designation Operating Status Relay 0 Status Relay 4, J2-1,2,3 Programmable Relays Relay 1 Status Relay 3, J2-4,5,6 Relay 2 Status Relay 2, J2-7,8,9 Relay 3 Status Relay 1, J2-10,11,12

External Auto/Stop CH530 accepts an isolated contact closure input to request STOP or AUTO command modes from a remote device. The contact closure status is monitored by a CH530 binary input. Contact closure represents an AUTO request, and contact opening represents a STOP request. Compressor Inhibit/ High Ambient Operation Compressor Inhibit prevents the second compressor on all circuits from running which lowers the overall power consumption and cooling capacity of the chiller. This feature may be invoked by an optional hardware input or a BAS command. Reduce Power Consumption: The 20 - 60 Ton chiller does not have a current limit feature. This feature can be used to lower power consumption by limiting the number of compressors available to the chiller. High Ambient Operation: To minimize high pressure cutouts in high ambient conditions, a thermostat can be connected to the external input to prevent operation of the 2nd compressor on each circuit. Condenser Water Temperature Sensor Connections When the optional condenser water temperature monitoring feature is specified, a pair of sensors are installed in the entering and leaving condenser water boxes. Chilled Water Rest The MP shall reset the chilled water temperature setpoint based on either return water temperature, or outdoor air temperature. The Return Reset option is standard, Outdoor Reset is optional. The following shall be selectable: 1. Reset Type Setpoint. 2. RESET RATIO Setpoints. 3. START RESET Setpoints. 4. MAXIMUM RESET Setpoints. When the chiller is running, if any type of CWR is enabled, the MP will step the CWS toward the desired CWS' at a rate of 1 degree F every 5 minutes until the Active CWS equals the desired CWS'. When the chiller is not running the CWS shall be fully reset immediately (within one minute). The chiller will then start at the Differential to Start value above a fully reset CWS or CWS' for Outdoor, Return, and Constant Return Reset.

50 CGWF-SVX01A-EN Installation Electrical

External Chilled Water Setpoint Option The MP provides inputs that will accept either 4-20 mA or 2-10 VDC signals to set the chilled water setpoint. This is not a reset function; the input level defines the setpoint. This input is used with Generic BAS installations. The MP shall accept either a 2-10 VDC or 4-20 mA analog input suitable for customer connection to set the unit external chilled water setpoint (ECWS). The 2-10 VDC and 4-20 mA shall each correspond to an ECWS range with both min_ECWS and max_ECWS configurable in Service Tool.

ECWS -vs- Input (VDC) ECWS -vs- Input (mA)

70 70 max60 max60 50 Out 50 Out Out 40 of of Out 40 of Range Range 30 of Range ECWS 30 Rang ECWS Diag 20 Diagnosti e 20 10 10 min0 min0 012345678910111213 0 2 4 6 8 101214161820222426 Input (VDC) Input (mA)

Figure 19 External Chilled Water Setpoint

Ice Machine Control Option CH530 accepts a contact closure input to initiate Ice Building. When in the ice building mode, the chiller will be fully loaded and will continue to operate until the ice contacts open or the return water temperature reaches the Ice Termination Setpoint. If terminated on return setpoint, CH530 will not allow the chiller to restart until the ice making contact is opened. Ice building operation will be indicated by an "Ice Building" operation mode that can be displayed at the unit or communicated over the communications link. Ice Building Command This is the command to enter ice building. This setpoint is defined as an Auto/On setpoint. There are four possible ways to set this, through DynaView or TechView as the Front Panel Ice Building Command, through an external interface switch closure to a low voltage binary input, and through a Tracer interface. Setting this to On will command the application into ice building if ice building is enabled. Ice Building Enable/Disable setting This setting will Enable or Disable the ice building option. It can be set through the DynaView or TechView. This setting does not start or stop ice building. The Ice Building Command starts and stops ice building. Ice Building Termination setpoint This setpoint has three possible sources DynaView or TechView as the Front Panel Ice Termination Setpoint or Tracer. This setpoint has a range of 20°F to 32°F with a default of 27°F. Communications Interface options

Optional Tracer Communications Interface This option allows the Tracer CH530 controller to exchange information (e.g. operating setpoints and Auto/Standby commands) with a higher-level control device, such as a Tracer Summit or a multiple-machine controller. A shielded, twisted pair connection establishes the bi-directional communications link between the Tracer CH530 and the building automation system.

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To prevent control malfunctions, do not run low voltage wiring (<30 V) in conduit with conductors carrying more than 30 volts. Field wiring for the communication link must meet the following requirements: • All wiring must be in accordance with the NEC and local codes. • Communication link wiring must be shielded, twisted pair wiring (Belden 8760 or equivalent). See the table below for wire size selection : Table 14 Wire Size Wire Size Maximum Length of Communication Wire 14 AWG (2.5 mm2) 5,000 FT (1525 m) 16 AWG (1.5 mm2) 2,000 FT (610 m) 18 AWG (1.0 mm2) 1,000 FT (305 m)

• The communication link cannot pass between buildings. • All units on the communication link can be connected in a “daisy chain” configuration.

LonTalk Communications Interface for Chillers (LCI-C) Option CH530 provides an optional LonTalk Communication Interface (LCI-C) between the chiller and a Building Automation System (BAS). An LCI-C LLID shall be used to provide "gateway" functionality between a LonTalk compatible device and the Chiller. The inputs/outputs include both mandatory and optional network variables as established by the LonMark Functional Chiller Profile 8040. Installation Recommendations • 22 AWG Level 4 unshielded communication wire recommended for most LCI-C installations • LCI-C link limits: 4500 feet, 60 devices • Termination resistors are required – 105 ohms at each end for Level 4 wire – 82 ohms at each end for Trane "purple" wire • LCI-C topology should be daisy chain • Zone sensor communication stubs limited to 8 per link, 50 feet each (maximum) • One repeater can be used for an additional 4500 feet, 60 devices, 8 communication stubs Table 15 LonTalk Points List

Inputs Chiller Enable/Disable Command Chilled Water Setpoint Current Limit Setpoint Chiller Mode (i.e. Heat, Cool, Free Cool, Ice) Outputs Run Modes (i.e. Off, Starting, Running, Shutting Down) Operating Modes (i.e.Heat, Cool, Free Cool, Ice) State (Alarm, Run Enabled, Local Control, Limited) Active Chilled/Hot Water Setpoint Actual Capacity (Percent Rated Load Amps) Active Current Limit Setpoint Evaporator Leaving Water Temperature Evaporator Entering Water Temperature Condenser Entering Water Temperature Condenser Leaving Water Temperature

52 CGWF-SVX01A-EN Installation Electrical

Table 15 LonTalk Points List

Alarm Description 1 Maximum Capacity Hot Gas Bypass Compressor Running Outputs Condenser Fan Running Outputs Evaporator Water Pump Request Evaporator Water Flow Status Condenser Water Pump Request Condenser Water Flow Status Outdoor Air Temperature Evaporator Refrigerant Pressure Per Circuit Evaporator Refrigerant Temperature Per Circuit Condenser Refrigerant Pressure Per Circuit Condenser Refrigerant Temperature Per Circuit Current Per Line Compressor Starts Compressor Run Time Note 1: Alarm Description denotes alarm severity and description of event Severity: no alarm, warning, normal shutdown, immediate shutdown Note 2: Regenerating, Refrigeration Circuit On, Pumping Out

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CCAF - Fan Control On air cooled chillers, heat is removed from the evaporator water loop and released to ambient air by the condenser. In order to control condensing conditions, the volume of airflow is changed to compensate for ambient air temperature and cooling load. Starting and stopping condensing fans controls airflow. Outdoor Air Temperature Control Condenser fan staging is on a per circuit basis and is a function of outdoor ambient temperature and load. The load parameter used is the number of compressors running per circuit. Fans for the various units are staged as shown in the following figures. In the chart, there are areas where more than 1 choice is possible, 1 or 2 fans for example. These are areas of hysteresis in which the current number of fans running is maintained. The number of fans running will depend upon the direction entered. When the circuit is not running the number of fans running will be initialized to 0. When the first compressor starts on a circuit, the minimum number of fans shall be started based on the outdoor air temperature, i.e. if outdoor air temperature is in a hysteresis range, use the smallest number for that range. There should always be at least one fan running when a compressor is running. Staging compressors is a horizontal movement on the fan control charts. If this movement is into a hysteresis area, then the previous number of fan stages is used. Each refrigeration circuit has two relay outputs for fan control. Depending upon how many fans are connected to each circuit, there may be either two or three air flow levels. The number of fan stages is shown on the following table for each unit size. Table 16 Fan Configuration Tons # of Fans/chiller # Relays/chiller #Fan Steps/ Circuit 20 2 2 2 25 - 30 3 2 3 40 4 4 2 50 - 60 6 4 3

For 20 and 40 ton chillers, the first fan relay will be on whenever a compressor is running. The second relay will be energized when more condenser cooling is required and de-energized when less cooling is required. The 25, 30, 50, and 60 ton chillers have 3 stages of fan flow. The first relay will be connected to one fan. The second relay will be connected to two fans. For these chillers the first relay will not always be energized. When two fans are needed the first relay will be de-energized at the same time the second relay will be energized. Energizing both relays turns on 3 fans. There is a 5 second delay between turning the fans on and starting the first compressor.

54 CGWF-SVX01A-EN Operating System

Components of a typical CGWF unit are identified in Figure 20 and Figure 21. CCAF units are basically the same only with a remote Condenser.

20-30 Ton System Diagram

Condenser Condenser Entering Water Leaving Water Temperature Temperature

Condenser Condenser Leaving Entering Condenser

Discharge Pressure Sensor Circuit 1 HPC

HGBP x Valve Motor Motor Temp Temp T-Stat T-Stat Compressor 1A Compressor 1B r te

il

F ryer D x Circuit 1 Liquid Line Solenoid Valve Evaporator Sight Glass Entering Water Temperature Suction Pressure x Circuit 1 Sensor TXV Evaporator Leaving Water Temperature Evaporator Entering Water Evaporator Evaporator Leaving Water

Figure 20 20-30 Ton CGWF

CGWF-SVX01A-EN 55 Operating System

40-60 Ton System Diagram

Condenser Leaving Water Temperature

Condenser Leaving Condenser Circuit #1

Condenser Entering Condenser Circuit #2

Circuit 2 Condenser Circuit 1 HPC Entering Water HPC Temperature Circuit 2 Circuit 1 Discharge Discharge Pressure Pressure Sensor Sensor

HGBP x Valve

Motor Motor Motor Motor Temp Temp Temp Temp T-Stat T-Stat T-Stat T-Stat Compressor 2A Compressor 2B Compressor 1A Compressor 1B Fi D lt r e r y r e r t e l e r i y F r Circuit 2 D Liquid Line x Circuit 1 olenoid Valve x Liquid Line Solenoid Valve Sight Glass Circuit 1 Suction Pressure Sight Glass Circuit 2 Circuit 1 Sensor x TXV x Circuit 2 TXV Evaporator Suction Evaporator Entering Water Pressure Leaving Water Temperature Sensor Temperature

Evaporator Evaporator Entering Leaving Water Water Evaporator

Figure 21 40-60 Ton CGWF

56 CGWF-SVX01A-EN Controls Interface

CH530 Communications Overview The Trane CH530 control system that runs the chiller consists of several elements: • The main processor collects data, status, and diagnostic information and commu- nicates commands to the starter module and the LLID (for Low Level Intelligent Device) bus. The main processor has an integral display (DynaView). • Higher level modules (e.g. starter) exist only as necessary to support system level control and communications. The starter module provides control of the starter when starting, running, and stopping the chiller motor. It also processes its own diagnostics and provides motor and compressor protection. • Low level intelligent device (LLID) bus. The main processor communicates to each input and output device (e.g. temperature and pressure sensors, low voltage binary inputs, analog input/output) all connected to a four-wire bus, rather than the conventional control architecture of signal wires for each device. • The communication interface to a building automation system (BAS). • A service tool to provide all service/maintenance capabilities. Main processor and service tool (TechView) software is downloadable from www.Trane.com. The process is discussed later in this section under TechView Interface. DynaView provides bus management. It has the task of restarting the link, or filling in for what it sees as “missing” devices when normal communications has been degraded. Use of TechView may be required. The CH530 uses the IPC3 protocol based on RS485 signal technology and communicating at 19.2 Kbaud to allow 3 rounds of data per second on a 64-device network. A typical four-compressor RTAC will have around 50 devices. Most diagnostics are handled by the DynaView. If a temperature or pressure is reported out of range by a LLID, the DynaView processes this information and calls out the diagnostic. The individual LLIDs are not responsible for any diagnostic functions. The only exception to this is the Starter module. NOTE: It is imperative that the CH530 Service Tool (TechView) be used to facilitate the replacement of any LLID or reconfigure any chiller component. TechView is discussed later in this section. Controls Interface

DynaView Each chiller is equipped with the DynaView interface. DynaView has the capability to display additional information to the advanced operator including the ability to adjust settings. Multiple screens are available and text is presented in multiple languages as factory-ordered or can be easily downloaded online.

Te c h V i e w TechView can be connected to the DynaView module and provides further data, adjustment capabilities, diagnostics information, downloadable software, and downloadable languages.

CGWF-SVX01A-EN 57 Controls Interface

DynaView Interface The display on DynaView is a 1/4 VGA display with a resistive touch screen and an LED backlight. The display area is approximately 4 inches wide by 3 inches high (102mm x 60mm).

Figure 22 DynaView

Key Functions In this touch screen application, key functions are determined completely by software and change depending upon the subject matter currently being displayed. The basic touch screen functions are outlined below. CAUTION Equipment Damage! Putting excessive pressure on the touch screen could cause damage. It takes less that 15 lbs of force to break the screen.

Radio Buttons Radio buttons show one menu choice among two or more alternatives, all visible. (the AUTO button in Figure 22.) The radio button model mimics the buttons used on old- fashioned radios to select stations. When one is pressed, the one that was previously pressed “pops out” and the new station is selected. In the DynaView, model the possible selections are each associated with a button. The selected button is darkened, presented in reverse video to indicate it is the selected choice. The full range of possible choices as well as the current choice is always in view.

Spin Value Buttons Spin values are used to allow a variable setpoint to be changed, such as leaving water setpoint. The value increases or decreases by touching the increment (+) or decrement (-) arrows.

58 CGWF-SVX01A-EN Controls Interface

Action Buttons Action buttons appear temporarily and provide the user with a choice such as Enter or Cancel.

File Folder Tabs File folder tabs are used to select a screen of data. Just like tabs in a file folder, these serve to title the folder/screen selected, as well as provide navigation to other screens. In DynaView, the tabs are in one row across the top of the display. The folder tabs are separated from the rest of the display by a horizontal line. Vertical lines separate the tabs from each other. The folder that is selected has no horizontal line under its tab, thereby making it look like a part of the current folder (as would an open folder in a file cabinet). The user selects a screen of information by touching the appropriate tab. Display Screens

Basic Screen Format The basic screen format appears as:

Main Reports Settings

File Folder Tabs Line Scroll Page Scroll Page Scroll (up/down) (up) (down)

Fixed Display

Contrast control (lighter) Contrast control (darker) The file folder tabs across the top of the screen are used to select the various display screens. The main body of the screen is used for description text, data, setpoints, or keys (touch sensitive areas). The Chiller Mode is displayed here. The double up arrows cause a page-by-page scroll either up or down. The single arrow causes a line by line scroll to occur. At the end of the page, the appropriate scroll bar will disappear. A double arrow pointing to the right indicates more information is available about the specific item on that same line. Pressing it will bring you to a sub-screen that will present the information or allow changes to settings. The bottom of the screen (Fixed Display) is present in all screens and contains the following functions. The left circular area is used to reduce the contrast/viewing angle of the display. The right circular area is used to increase the contrast/viewing angle of the display. The contrast may require re-adjustment at ambient temperatures significantly different from those present at last adjustment. The other functions are critical to machine operation. The AUTO and STOP keys are used to enable or disable the chiller. The key selected is in black (reverse video). The chiller will stop when the STOP key is touched and after completing the Run Unload mode.

CGWF-SVX01A-EN 59 Controls Interface

Touching the AUTO key will enable the chiller for active cooling if no diagnostic is present. (A separate action must be taken to clear active diagnostics.) The AUTO and STOP keys, take precedence over the Enter and Cancel keys. (While a setting is being changed, AUTO and STOP keys are recognized even if Enter or Cancel has not been pressed.) The ALARMS button appears only when an alarm is present, and blinks (by alternating between normal and reverse video) to draw attention to a diagnostic condition. Pressing the ALARMS button takes you to the corresponding tab for additional information. Keypad/Display Lockout Feature

DISPLAY AND TOUCH SCREEN ARE LOCKED

ENTER PASSWORD TO UNLOCK

1 2 3

3 5 6

7 8 9

Enter 0 Cancel

NOTE: The DynaView display and Touch Screen Lock screen is shown above. This screen is used if the Display and touch screen and lock feature is enabled. Thirty minutes after the last keystroke, this screen is displayed and the Display and Touch Screen is locked out until the sequence “159 ” is pressed. Until the proper password is entered, there will be no access to the DynaView screens including all reports, setpoints, and Auto/Stop/Alarms/Interlocks. The password “159” can not be changed from either DynaView or TechView.

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Main Screens The Main screen is a "dashboard" of the chiller. High level status information is presented so that a user can quickly understand the mode of operation of the chiller. The Main screen shall be the default screen. After an idle time of 30 minutes the CH530 shall display the Main screen with the first data fields. The remaining items (listed in the following table) will be viewed by selecting the up/ down arrow icons.

Table 17 Main Screen Items Description Units Resolution Chiller Mode (>> submodes) Text Circuit 1 Mode (>> submodes) Text Circuit 2 Mode (>> submodes) Text Evap Ent/Lvg Water Temp Temperature 0.1 Cond Ent/Lvg Water Temp Temperature 0.1 Active Chilled Water Setpoint (>>source) Temperature 0.1 Average Line Current % RLA 1 Active Demand Limit Setpoint Active Current Limit Setpoint (>>source) % RLA 1 Active Ice Termination Setpoint (>>source) Temperature 0.1 Outdoor Air Temperature Temperature 0.1 Software Type Text CGW/CCA Software Version X.XX

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Table 18 Operating Modes Chiller Level Mode Description Top Level Mode Description MP Resetting The main processor is going through reset. MP Resetting Sub Modes No Chiller Sub-Modes Top Level Mode Description Stopped The chiller is not running either circuit, and cannot run without intervention. Stopped Sub Modes Description Local Stop Chiller is stopped by the DynaView Stop button command- cannot be remotely overridden. Immediate Stop Chiller is stopped by the DynaView Immediate Stop (by pressing the Stop then Immediate Stop buttons in succession) - previous shutdown was manually commanded to shutdown immediately. No Circuits Available The entire chiller is stopped by circuit diagnostics or lockouts that may automatically clear. Diagnostic Shutdown - Manual Reset The chiller is stopped by a diagnostic that requires manual intervention to reset. Top Level Mode Description Run Inhibit The chiller is currently being inhibited from starting (and running), but may be allowed to start if the inhibiting or diagnostic condition is cleared. Run Inhibit Sub Modes Description Ice Building Is Complete The chiller is inhibited from running as the Ice Building process has been normally terminated on the evaporator entering temperature. The chiller will not start unless the ice building command (hardwired input or Building Automation System command) is removed or cycled. Starting is Inhibited by Building Automation Chiller is stopped by Tracer or other BAS system. System Starting is Inhibited by External Source The chiller is inhibited from starting or running by the "external stop" hardwired input. Diagnostic Shutdown - Auto Reset The entire chiller is stopped by a diagnostic that may automatically clear. Waiting for BAS Communications The chiller is inhibited because of lack of communication with the BAS. This is only valid 15 minutes after power up. Starting is Inhibited by Low Ambient The chiller is inhibited based on the outdoor air temperature. Temperature Top Level Mode Description Auto The chiller is not currently running but can be expected to start at any moment given that the proper conditions and interlocks are satisfied. Auto Sub Modes Description Waiting For Evaporator Water Flow The chiller will wait up to 20 minutes in this mode for evaporator water flow to be established per the flow switch hardwired input. Waiting For A Need To Cool The chiller will wait indefinitely in this mode, for an evaporator leaving water temperature higher than the Chilled Water Setpoint plus some control dead- band. Power Up Delay Inhibit: MIN:SEC On Power up, the chiller will wait for the Power Up Delay Timer to expire. Top Level Mode Description Waiting to Start The chiller is going through the necessary steps to allow the lead circuit to start. Sub Modes Description Waiting For Condenser Water Flow The chiller will wait up to 20 minutes in this mode for condenser water flow to be established per the flow switch hardwired input. Top Level Mode Description Running At least one circuit on the chiller is currently running. Running Sub Modes Description Maximum Capacity The chiller is operating at its maximum capacity. Capacity Control Softloading The control is limiting the chiller loading due to capacity based softloading setpoints.

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Table 18 Operating Modes Chiller Level Mode Description Ice Building The chiller is Building Ice, and will terminate on the Ice Termination Setpoint based on the Entering Evap Water Temperature sensor. Hot Gas Bypass Time Remaining: MIN:SEC The chiller is running in Hot Gas Bypass with the specified time remaining. Top Level Mode Description Running - Limit At least one circuit on the chiller is currently running, but the operation of the chiller as a whole is being actively limited by the controls. The sub modes that apply to the Running top modes may also be displayed along with the following limit specific modes. Sub Modes Description Demand Limit The number of compressors allowed to operate is being limited to less than the available number of compressors by either the BAS system or the front panel demand limit setpoint. Evaporator Temperature Limit The control algorithm takes action to avoid a nuisance trip when the leaving water temperature is approaching the Leaving Water Temp. Cutout Setpoint. Hot Start Limit The second compressor on a given circuit is being held off based on leaving evaporator temperature. Compressor Inhibit The KW limit binary input is open. The second compressor of each circuit shall be prohibited from starting or running. Top Level Mode Description Shutting Down The chiller is still running but shutdown is imminent. The chiller is going through a compressor run-unload. Sub Modes Description Evaporator Water Pump Off Delay: MIN:SEC The Evaporator pump is executing the pump off delay timer. Top Level Mode Description Misc. These sub modes may be displayed in most of the top level chiller modes Misc. Sub Modes Description Manual Evaporator Pump Override The evaporator water pump relay is on due to a manual command. Diagnostic Evap Pump Override The evaporator water pump relay is on due to a diagnostic. Manual Condenser Pump Override The condenser water pump relay is on due to a manual command. Manual Compressor Control Signal Chiller capacity control is being controlled by DynaView or TechView.

Table 19 Circuit Level Operating Modes Circuit Level Operating Modes: Description Top Level Mode Description Stopped The circuit is not running, and cannot run without intervention. Sub Modes Description Diagnostic Shutdown - Manual Reset The circuit has been shutdown on a latching diagnostic. Front Panel Circuit Lockout The circuit is manually locked out by the circuit lockout setting - the nonvolatile lockout setting is accessible through either the DynaView or TechView. Top Level Mode Description Run Inhibit The given circuit is currently being inhibited from starting (and running), but may be allowed to start if the inhibiting or diagnostic condition is cleared. Run Inhibit Sub Modes Description Diagnostic Shutdown - Auto Reset The circuit has been shutdown on a diagnostic that may clear automatically. Condenser Pressure Limit The circuit is being inhibited from starting due to high condenser pressure. Top Level Mode Description Auto The circuit is not currently running but can be expected to start at any moment given that the proper conditions are satisfied. Auto Sub Modes Description No Circuit Sub-Modes Top Level Mode Description

CGWF-SVX01A-EN 63 Controls Interface

Table 19 Circuit Level Operating Modes Circuit Level Operating Modes: Description Waiting to Start The chiller is going through the necessary steps to allow the lead circuit to start. Sub Modes Description No Circuit Sub-Modes Top Level Mode Description Running The compressor on the given circuit is currently running. Sub Modes Description No Circuit Sub-Modes Top Level Mode Description Running - Limit The compressor on the given circuit is currently running in a limit mode. Sub Modes Description Low Evaporator Pressure Start When LPC is open and either compressor on the circuit is running and the LPC ignore time has not yet expired. Condenser Pressure Limit The circuit is being inhibited from loading due to high condenser pressure. Top Level Mode Description Preparing Shutdown The circuit is preparing to de-energize the compressor. Preparing Shutdown Sub Modes Description Operational Pumpdown The operational pumpdown is enabled and the circuit is shutting down. Top Level Mode Description Shutting Down The chiller is going through the necessary steps after de-energizing the compressor. Sub Modes Description No Circuit Sub-Modes Top Level Mode Description Misc. These sub modes may be displayed in most of the top level circuit modes Misc. Sub Modes Description Service Pumpdown The circuit is currently performing a service pumpdown. Compressor X Running A specific compressor is running where X is A or B. Restart Time Inhibit Cprsr X: MIN:SEC If there is accumulated Restart Inhibit Time, it must expire before the compressor is allowed to start. X is denoted as compressor A or B.

64 CGWF-SVX01A-EN Controls Interface

Reports Screen The Reports tab will allow a user to select from a list of possible reports headings. Each report will generate a list of status items as defined in the following tables.

Table 20 Reports Screens Description Units Resolution Evaporator Evap Entering Water Temp Temperature + or - XXX.X Evap Leaving Water Temp Temperature + or - XXX.X Evap Water Flow Switch Status (Flow, No Flow) Circuit Evaporator Evap Sat Rfgt Temp Temperature + or - XXX.X Suction Pressure Temperature + or - XXX.X Evap Approach Temp Temperature + or - XXX.X Condenser Cond Entering Water Temp Temperature + or - XXX.X Cond Leaving Water Temp Temperature + or - XXX.X Cond Water Flow Switch Status Enumeration (Flow, No Flow) Outdoor Air Temperature Temperature + or - XXX.X Circuit Evaporator Cond Sat Rfgt Temp Temperature + or - XXX.X Discharge Pressure Temperature + or - XXX.X Cond Approach Temp Temperature + or - XXX.X Compressor Chiller Running Time hr:min XXXX:XX Circuit Compressor Compressor Starts Integer XXXX Compressor Running Time: hr:min XXXX:XX ASHRAE Chiller Log Current Time/Date Date / Time XX:XX mmm dd, yyyy Operating Mode Text Active Chilled Water Setpoint Temperature XXX.X Evap Entering Water Temp Temperature XXX.X Evap Leaving Water Temp Temperature XXX.X

CGWF-SVX01A-EN 65 Controls Interface

Table 20 Reports Screens Description Units Resolution Evap Water Flow Switch Status Text Cond Entering Water Temp Temperature XXX.X Cond Leaving Water Temp Temperature XXX.X Cond Water Flow Switch Status Text Outdoor Air Temp Temperature XXX.X Average Line Current (RLA) % X Circuit ASHRAE Log Circuit Mode Text Evap Sat Rfgt Temperature XXX.X Suction Pressure Pressure X Evap Approach Temp Temperature XXX.X Cond Sat Rfgt Temp Temperature XXX.X Discharge Pressure Pressure X Cond Approach Temp Temperature XXX.X Compressor A Starts Integer XXXX Compressor A Running Time Hours:Minute XX:XX Compressor B Starts Integer XXXX Compressor B Running Time Hours:Minute XX:XX Historic Diagnostics

66 CGWF-SVX01A-EN Controls Interface

Settings Screen The Settings screen provides a user the ability to adjust settings justified to support daily tasks. The layout provides a list of sub-menus, organized by typical subsystem. This organization allows each subscreen to be shorter in length which should improve the users navigation.

Table 21 Settings Screen Description Units Resolution, Default Chiller Front Panel Chilled Water Setpt Temperature + or - XXX.X Front Panel Demand Limit X Front Panel Ice Build Cmd Text On/Auto Front Panel Ice Termn Setpt Temperature XXX.X Design Delta Temp Temperature XXX.X Setpoint Source Text (BAS/Ext/FP, Ext/ Front Panel, Front Panel), BAS/Ext/FP Leaving Water Temp Cutout Temperature XX.X Feature Settings Low Ambient Lockout Setpoint (CCAF) Temperature XXX.X Low Ambient Lockout (CCAF) Text (Enable, Disable), Enable Chilled Water Reset Text (Constant, Outdoor, Return, Disable), Disable Return Reset Ratio Percent XXX Return Start Reset Temperature XXX.X Return Maximum Reset Temperature XXX.X Outdoor Reset Ratio Percent XXX Outdoor Start Reset Temperature XXX.X Outdoor Maximum Reset Temperature XXX.X Ext Chilled Water Setpoint Text (Enable, Disable), Disable Ice Building Text (Enable, Disable), Disable Hot Gas Bypass Text (Enable, Disable), Disable Operational Pumpdown Text (Enable, Disable), Disable ICS Address Text XX

CGWF-SVX01A-EN 67 Controls Interface

Table 21 Settings Screen Description Units Resolution, Default Manual Control Settings System Evap Water Pump Text (Auto, On), Auto Cond Water Pump Text (Auto, On), Auto Clear Restart Inhibit Timer Time X:XX Capacity Control Text Auto Circuit Manual Control Settings Cprsr A Pumpdown Text Status: (Avail, Not Avail, Pumpdown) Override Subscreen command buttons: (Abort, Pumpdown) - button is either greyed out or not shown if not available Cprsr B Pumpdown Text Status: (Avail, Not Avail, Pumpdown) Override Subscreen command buttons: (Abort, Pumpdown) - button is either greyed out or not shown if not available Front Panel Ckt Lockout Text (Not Locked Out, Locked Out), Not Locked Out Display Settings Date Format Text ("mmm dd, yyy", "dd-mmm-yyyy"), "mmm dd, yyy Date Text (4) Time Format Text (12-hour, 24-hour), 12-hour Time of Day Text (4) Keypad/Display Lockout Text (Enable, Disable), Disable (3) Display Units Text (SI, English), English Pressure Units Text (Absolute, Gauge), Gauge Language Text (English, Spanish), English

68 CGWF-SVX01A-EN Controls Interface

Diagnostics Screen The diagnostic screen is accessible by depressing the Alarms enunciator A scrollable list of the last (up to 20) active diagnostics will be presented. Performing a Reset All Active Diagnostics will reset all active diagnostics regardless of type, machine or refrigerant circuit. Compressor diagnostics, which hold off only one compressor, will be treated as circuit diagnostics, consistent with the circuit to which they belong. The scrollable list will be sorted by time of occurrence. If a diagnostic of severity = warning is present, the "Alarms" key will be present but not flashing. If a diagnostic of severity = shutdown (normal or immediate) is present, the "Alarm" key will display that is flashing. If no diagnostics exist, the "Alarm" key will not be present. The "Operating Mode At Last Diagnostic" text above the most recent diagnostic will display a sub-screen listing the operating mode and submodes at the time of the last diagnostic.

TechView Interface TechView is the PC (laptop) based tool used for servicing Tracer CH530. Technicians that make any chiller control modification or service any diagnostic with Tracer CH530 must use a laptop running the software application “TechView.” TechView is a Trane application developed to minimize chiller downtime and aid the technicians' understanding of chiller operation and service requirements. NOTE: Important: Performing any Tracer CH530 service functions should be done only by a properly trained service technician. Please contact your local Trane service agency for assistance with any service requirements. TechView software is available via Trane.com. (http://www.trane.com/commercial/software/tracerch530/) This download site provides a user the TechView installation software and CH530 main processor software that must be loaded onto your PC in order to service a CH530 main processor. The TechView service tool is used to load software into the Tracer CH530 main processor. Minimum PC requirements to install and operate TechView are: • Pentium II or higher processor • 128Mb RAM • 1024 x 768 resolution of display

CGWF-SVX01A-EN 69 Controls Interface

•CD-ROM • 56K modem • 9-pin RS-232 serial connection • Operating system - Windows 2000 • Microsoft Office (MS Word, MS Access, MS Excel) • Parallel Port (25-pin) or USB Port

NOTE: TechView was designed for the preceding listed laptop configuration. Any variation will have unknown results. Therefore, support for TechView is limited to only those operating systems that meet the specific configuration listed here. Only computers with a Pentium II class processor or better are supported; Intel Celeron, AMD, or Cyrix processors are not supported. TechView is also used to perform any CH530 service or maintenance function. Servicing a CH530 main processor includes: • Updating main processor software • Monitoring chiller operation • Viewing and resetting chiller diagnostics • Low Level Intelligent Device (LLID) replacement and binding • Main processor replacement and configuration modifications • Setpoint modifications • Service overrides Software Download

Instructions for First Time TechView Users This information can also be found at http://www.trane.com/commercial/software/ tracerch530/. 1. Create a folder called “CH530” on your C:\ drive. You will select and use this folder in subsequent steps so that downloaded files are easy to locate. 2. Download the Java Runtime installation utility file onto your PC in the CH530 folder (please note that this does not install Java Runtime, it only downloads the installation utility). – Click on the latest version of Java Runtime shown in the TechView Download table. – Select “Save this program to disk” while downloading the files (do not select “Run this program from its current location”). 3. Download the TechView installation utility file onto your PC in the CH530 folder (please note that this does not install TechView, it only downloads the installation utility). – Click on the latest version of TechView shown in the TechView Download table. – Select “Save this program to disk” while downloading the files (do not select “Run this program from its current location”). 4. Remember where you downloaded the files (the “CH530” folder). You will need to locate them to finish the installation process. 5. Proceed to “Main Processor Software Download” page and read the instructions to download the latest version of main processor installation files. Note: you will first select the chiller type to obtain the available file versions.

70 CGWF-SVX01A-EN Controls Interface

6. Select the product family. A table with the download link will appear for that prod- uct family. 7. Download the main processor software onto your PC in the CH530 folder (please note that this does not install the main processor, it only downloads the installa- tion utility). – To do this, click on the latest version of the main processor. – Select “Save this program to disk” while downloading the files (do not select “Run this program from its current location”). 8. Remember where you downloaded the files (the “CH530” folder). You will need to locate them to finish the installation process. 9. To complete the installation process, locate the installation utilities you down- loaded into the CH530 folder. If necessary, use your PC’s file manager to locate the downloaded files. 10. Install the applications in the following order by double-clicking on the install pro- gram and following the installation prompts: – Java Runtime Environment (JRE_VXXX.exe) Note: During the Java Runtime Environment installation, you may be prompted to “select the default Java Runtime for the system browsers...”. Do not select any system browsers at this step. There should be no default browsers selected for proper operation. – TechView (6200-0347-VXXX.exe) – The main processor (6200-XXXX-XX-XX.exe). – The main processor program will self extract to the proper folder within the TechView program directory, provided the TechView program is properly installed on the C:\ drive. 11. Connect your PC to the CH530 main processor using a standard 9-pin male/9-pin female RS-232 cable. 12. Run the TechView software by selecting the TechView icon placed on your desk- top during the installation process. The “Help...About” menu can be viewed to confirm proper installation of latest versions.

CGWF-SVX01A-EN 71 Controls Interface

72 CGWF-SVX01A-EN Diagnostics

The following diagnostic table contains all the diagnostics possible. Not all data is available unless tech view is connected. Code: Three digit hexadecimal code used on all past products to uniquely identify diagnostics. Diagnostic Name: Name of Diagnostic and its source. Note that this is the exact text used in the User Interface and/or Service Tool displays. Severity: Defines the severity of the above effect. Immediate means immediate shutdown of the effected portion, Normal means normal or friendly shutdown of the effected portion, Special Mode means a special mode of operation (limp along) is invoked, but without shutdown, and Info means an Informational Note or Warning is generated. Persistence: Defines whether or not the diagnostic and its effects are to be manually reset (Latched), or can be either manually or automatically reset (Nonlatched). Criteria: Quantitatively defines the criteria used in generating the diagnostic and, if nonlatching, the criteria for auto reset. If more explanation is necessary a hot link to the Functional Specification is used. Reset Level: Defines the lowest level of manual diagnostic reset command which can clear the diagnostic. The manual diagnostic reset levels in order of priority are: Local and Remote. A diagnostic that has a reset level of Local, can only be reset by a local diagnostic reset command, but not by the lower priority remote Reset command whereas a diagnostic listed as Remote reset can be reset by either.

Diagnostic Name Severity Persistence Criteria Reset Level BAS Communication Lost Special NonLatch The BAS was setup as "installed" at the MP and the Comm 3 llid lost Remote communications with the BAS for 15 continuous minutes after it had been established. Refer to setpoint arbitration to determine how setpoints and operating modes may be effected by the comm loss. The chiller follows the value of the Tracer Default Run Command which can be previously written by Tracer and stored nonvolatilely by the MP (either use local or shutdown). BAS Failed to Establish Special NonLatch The BAS was setup as "installed" and the BAS did not communicate Remote Communication with the MP within 15 minutes after power-up. Refer to setpoint arbitration to determine how setpoints and operating modes may be effected. Check Clock Warning Latch The real time clock had detected loss of its oscillator at some time in Remote the past. Check / replace battery? This diagnostic can be effectively cleared only by writing a new value to the chiller's time clock using the TechView or DynaView's "set chiller time" functions. Chilled Water Flow (Entering Immediate Latching The entering evaporator water temp fell below the leaving evaporator Remote Water Temp) water temperature by more than 2°F for 100°F-sec while at least one compressor was running. Circuit Pumpdown Warning Latching Operational Pumpdown is normally terminated by the Low Pressure Remote Terminated Cutout control. This indicates that the Low Pressure Cutout of circuit 1 or 2 did not open within 30 seconds from the start of Operational Pumpdown which may indicate a faulty liquid line solenoid valve. Going below 10 PSIG shall terminate Service Pumpdown. This indicates that the suction pressure of circuit 1 or 2 did not go below 10 PSIG within 1 minute from the start of Service Pumpdown. Condenser Entering Water Warning Latch Bad Sensor or LLID. Remote Temp Sensor Condenser Leaving Water Warning Latch Bad Sensor or LLID Remote Temp Sensor Condenser Water Flow Lost Immediate NonLatch After flow had been proven the condenser water flow input was open Remote for more than 6 continuous seconds. This diagnostic is automatically cleared once all circuits are de-energized. Condenser Water Flow Normal NonLatch Condenser water flow was not proven within 20 minutes of the Remote Overdue condenser water pump relay being energized. The condenser water pump shall not be commanded on by this diagnostic. Diagnostic is reset with return of condenser water flow (although only possible with external control of pump)

CGWF-SVX01A-EN 73 Diagnostics

Diagnostic Name Severity Persistence Criteria Reset Level Current L1 Loss Immediate Latch No current was sensed on the current transformer L1 input while Local starting or running. Time to trip shall be longer than guaranteed reset on Starter Module at a minimum, 3 seconds maximum. Actual design trip point is 10%. The actual design trip time is 2.64 seconds. If Phase reversal protection is enabled and current is not sensed on one or more current xformer inputs. Logic will detect and trip in a maximum of 0.3 second from compressor start. Current L2 Loss Immediate Latch Same as Current L1 Loss except L2 input. Local Current L3 Loss Immediate Latch Same as Current L1 Loss except L3 input. Local Discharge Pressure Normal Latch Bad Sensor or LLID Remote Transducer Emergency Stop Immediate Latch Emergency Stop input is open. Local Evaporator Entering Water Normal Latch Bad Sensor or LLID. Remote Temp Sensor Evaporator Leaving Water Normal Latch Bad Sensor or LLID Remote Temp Sensor Evaporator Water Flow Lost Immediate NonLatch After flow had been proven the chilled water flow input was open for Remote more than 6 continuous seconds. The evaporator pump shall be commanded on until the diagnostic clears even if the chiller is in STOP. 6-10 seconds of continuous flow shall clear this diagnostic. Some customers use the pump to control the chiller. Evaporator Water Flow Immediate NonLatch Evaporator water flow was not proven within 20 minutes of the Remote Overdue evaporator water pump relay being energized. The evaporator water pump relay will remain energized to support installations where the evaporator water pump is turned off to shut down the chiller. Diagnostic is reset with return of evaporator water flow. External Chilled Water Warning NonLatch a. Function Not "Enabled": no diagnostics. b. "Enabled ": Out-Of-Range Remote Setpoint Low or Hi or bad LLID, set diagnostic, default CWS to next level of priority (e.g. Front Panel SetPoint). This Warning diagnostic will automatically reset if the input returns to the normal range. High Evaporator Water Immediate NonLatch The evaporator leaving water temperature is above 115°F. This Local Temperature diagnostic shall clear once the evaporator leaving water temperature falls below 110°F. This diagnostic protects the rupture disk and plastic baffles in the evaporator. The evaporator water pump shall not run when this diagnostic is active. High Motor Temp/Overload Immediate Latch The High Motor Temperature or the Compressor Overload switch Local Trip Cprsr A input is open for compressor A. High Motor Temp/Overload Immediate Latch The High Motor Temperature or the Compressor Overload switch Local Trip Cprsr B input is open for compressor B. High Pressure Cutout Immediate Latch The high pressure cutout switch was open for more than three Local seconds. The high pressure cutout switch for R22 used on this machine is an open at 405 PSIG and a close at 300 PSIG. Low Evap Leaving Water Warning NonLatch The leaving chilled water temperature fell below the leaving water Remote Temp: Unit Off and temp cutout setting for 30 degree F seconds while the Chiller is in the Special Stop mode, or in Auto mode with no compressors running. Energize Action Evap Water pump Relay until diagnostic auto resets, then return to normal evap pump control. Automatic reset occurs when the temp rises 2°F above the cutout setting for 30 minutes. When this diagnostic is active AND Leaving Water Temperature sensor diagnostic (loss of comm or out of range) the Evap Water pump relay shall be de-energized. Low Evap Leaving Water Immediate NonLatch The chilled water temp. fell below the cutout setpoint for 30 degree F Remote Temp: Unit On and Seconds while the compressor was running. Automatic reset occurs Special when the temperature rises 2 °F above the cutout setting for 2 Action minutes. This diagnostic shall not de-energize the Evaporator Water Pump Output. If this diagnostic is active the Low Evap Leaving Water Temp: Unit Off diagnostic shall be suppressed. Low Pressure Cutout Immediate Latch · The low suction refrigerant pressure diagnostic occurred more than Local five times during a given demand period or failed to reset in 60 seconds after opening when either compressor A or B were running and the unit was not in a Service Pumpdown or Operational Pumpdown. Low Suction Refrigerant Immediate NonLatch The pressure status, described in the Low Suction Refrigerant Local Pressure Pressure Protection specification, was opened. This diagnostic will clear when the status goes closed.

74 CGWF-SVX01A-EN Diagnostics

Diagnostic Name Severity Persistence Criteria Reset Level MP: Could not Store Starts Warning Latch MP has determined there was an error with the previous power down Remote and Hours store. Starts and Hours may have been lost for the last 24 hours. MP: Non-Volatile Block Test Warning Latch MP has determined there was an error with a block in the Non-Volatile Error memory. Check settings. MP: Non-Volatile Memory Warning Latch MP has determined there was an error in a sector of the Non-Volatile Remote Reformat memory and it was reformatted. Check settings. MP: Reset Has Occurred Warning NonLatch The main processor has successfully come out of a reset and built its NA application. A reset may have been due to a power up, installing new software or configuration. This diagnostic is immediately and automatically cleared and thus can only be seen in the historic diagnostic list. Outdoor Air Temp Sensor Warning Latch Bad Sensor or LLID. If configured as a CCA this diagnostic shall turn on Remote and all fans and use a minimum LPC ignore time of 30 seconds. Special Action Phase Reversal Immediate Latch A phase reversal was detected on the incoming current. Local Power Loss Immediate NonLatch The compressor had previously established currents while running and Remote then all three phases of current were lost. Design: Less than 10% RLA, trip in 2.64 seconds. This diagnostic will preclude the Phase Loss Diagnostic from being called out. To prevent this diagnostic from occurring with the intended disconnect of main power, the minimum time to trip must be greater than the guaranteed reset time of the Starter module. This diagnostic will auto reset in 10 seconds from its occurrence, and is not active during the start mode. Starter Contactor Interrupt Immediate Latch Detected a maximum chiller current greater than 10% RLA on any or Local Failure and all phases when all compressors were commanded off. Detection Special time shall be 10 seconds maximum. On detection and until the Action controller is manually reset: generate diagnostic and energize the appropriate alarm relay. Anytime the condition is present energize the liquid line solenoid valves, continue to energize the Evaporator Pump and Condenser Pump if CGWF or if CCAF energize the Condenser Fans according to the fan staging algorithm. Starter Module Memory Error Immediate Latching Checksum on EEPROM copy of the Starter LLID configuration failed. Local Type 2 Shutdown Factor default values used. Starts/Hours Modified - Warning NonLatch A counter for compressor starts or hours has been modified by NA Compressor X TechView. The diagnostic shall indicate compressor A or B. This diagnostic is immediately and automatically cleared and thus can only be seen in the historic diagnostic list. Suction Pressure Transducer Immediate Latch Bad Sensor or LLID Remote Excessive Loss of Comm Immediate Latch Loss of comm with 20% or more of the llids configured for the system Remote has been detected. This diagnostic will suppress the call out of all subsequent comm loss diagnostics. Check power supply(s) and power disconnects - troubleshoot LLIDS buss using TechView Comm Loss: External Auto/ Normal Latch Continual loss of communication between the MP and the Functional Remote Stop ID has occurred for a 35-40 second period. Comm Loss: Emergency Normal Latch Continual loss of communication between the MP and the Functional Remote Stop ID has occurred for a 35-40 second period. Comm Loss: Ext Ice Building Warning Latch Continual loss of communication between the MP and the Functional Remote Ctrl Input ID has occurred for a 35-40 second period. Chiller shall revert to normal (non-ice building) mode regardless of last state. Comm Loss: Outdoor Air Warning Latch Continual loss of communication between the MP and the Functional Remote Temperature ID has occurred for a 35-40 second period. If configured as a CCA this diagnostic shall turn on all fans and use a minimum LPC ignore time of 30 seconds. Comm Loss: Evap Leaving Normal Latch Continual loss of communication between the MP and the Functional Remote Water Temp ID has occurred for a 35-40 second period. Comm Loss: Evap Entering Normal Latch Continual loss of communication between the MP and the Functional Remote Water Temp ID has occurred for a 35-40 second period. Comm Loss: Condenser Warning Latch Continual loss of communication between the MP and the Functional Remote Leaving Water Temp ID has occurred for a 35-40 second period. Comm Loss: Condenser Warning Latch Continual loss of communication between the MP and the Functional Remote Entering Water Temp ID has occurred for a 35-40 second period. Comm Loss: Discharge Normal Latch Continual loss of communication between the MP and the Functional Remote Pressure Transducer ID has occurred for a 35-40 second period.

CGWF-SVX01A-EN 75 Diagnostics

Diagnostic Name Severity Persistence Criteria Reset Level Comm Loss: Suction Immediate Latch Continual loss of communication between the MP and the Functional Remote Pressure Transducer ID has occurred for a 35-40 second period. Comm Loss: External Chilled Warning Latch Continual loss of communication between the MP and the Functional Remote Water Setpoint and ID has occurred for a 35-40 second period. Chiller shall discontinue Special use of the External Chilled Water Setpoint source and revert to the Action next higher priority for setpoint arbitration Comm Loss: High Pressure Immediate Latch Continual loss of communication between the MP and the Functional Remote Cutout Switch ID has occurred for a 35-40 second period. Comm Loss: Evaporator Immediate Latch Continual loss of communication between the MP and the Functional Remote Water Flow Switch ID has occurred for a 35-40 second period. Comm Loss: Condenser Immediate Latch Continual loss of communication between the MP and the Functional Remote Water Flow Switch ID has occurred for a 35-40 second period. Comm Loss: Evaporator Warning Latch Continual loss of communication between the MP and the Functional Remote Water Pump Relay ID has occurred for a 35-40 second period. Comm Loss: Condenser Warning Latch Continual loss of communication between the MP and the Functional Remote Water Pump Relay ID has occurred for a 35-40 second period. Comm Loss: Local BAS Warning NonLatch Continual loss of communication between the MP and the Functional Remote Interface and ID has occurred for a 35-40 second period. Use the last values sent Special from BAS Action Comm Loss: Compressor Warning Latch Continual loss of communication between the MP and the Functional Remote Inhibit Input and ID has occurred for a 35-40 second period. When this diagnostic is Special present the chiller should run as normal. Action Comm Loss: Solenoid Valve Normal Latch Continual loss of communication between the MP and the Functional Remote ID has occurred for a 35-40 second period. Comm Loss: Motor Temp/ Immediate Latch Continual loss of communication between the MP and the Functional Remote Overload Cprsr A ID has occurred for a 35-40 second period. Comm Loss: Motor Temp/ Immediate Latch Continual loss of communication between the MP and the Functional Remote Overload Cprsr B ID has occurred for a 35-40 second period. Comm Loss: Condenser Fan Immediate Latch Continual loss of communication between the MP and the Functional Remote Control Relays ID has occurred for a 35-40 second period. Comm Loss: Starter Immediate Latch Continual loss of communication between the MP and the Functional Remote ID has occurred for a 35-40 second period. Comm Loss: Op Status Warning Latch Continual loss of communication between the MP and the Functional Remote Programmable Relays ID has occurred for a 35-40 second period.

76 CGWF-SVX01A-EN Unit Start-up

Pre-Start Checklist Complete each step in the checklist that follows and check off each step as com- pleted. When all are accomplished, the unit is ready to run. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. CAUTION Possible Equipment Damage! To prevent overheating at connections and under-voltage 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 assume 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-only-damage caused by water born debris.

CGWF-SVX01A-EN 77 Unit Start-up

. Pre-Start Check List Receiving Verify that the unit Nameplate data corresponds to the ordering information. Inspect unit for shipping damage and any shortages of materials. Report any damages or shortages to the carrier. Unit Location and Mounting Inspect the location desired for installation and verify adequate service access clearances. Provide drainage for evaporator and condenser (CGWF only) water. Remove and discard all shipping materials (cartons, etc.) Install optional neoprene isolators, if required. Level unit and secure it to the mounting surface. Unit Check compressor oil level(s). Oil should be visible in the compressor oil level sight glass. Open (backseat) the liquid line and discharge service valve(s). Check all water temperature sensors for proper installation Electrical Wiring Inspect all wiring connections. Connections should be clean and tight. Check power supply voltage to the unit at the main power fused disconnect switch. Voltage must be within the voltage utilization range. Check compressor phase-sequencing. Check Interlock Wiring, including chilled water pump control, chilled water flow switch, condenser water pump, condenser water flow switch, external auto stop. For further details refer to the field wiring diagram. Unit Piping Flush all unit water piping before making final connections to unit. Connect water piping to the evaporator and condenser (CGWF only). Install pressure gauges and shutoff valves on the water inlet and outlet to the evap. and cond. Install water strainers in the entering chilled water and condenser water lines. Install balancing valves (discretionary) and flow switches in the leaving chilled and condenser water lines. Install drains with shutoff valves or drain plugs on the evaporator and condenser. Vent the chilled water and condenser water systems at the high points of the system piping. Pipe relief valves outdoors in accordance to ASHRAE 15 and local code. With water pump(s) running, adjust water flow and check the water pressure through the evaporator and condenser.

78 CGWF-SVX01A-EN Unit Start-up

Unit Power Up

Power Applied to CH530 Call for Cooling

Auto Chiller (Power Auto Auto Waiting to Running Level Up Start Start Delay) Enforce Power Up Confirm Evaporator Confirm Condenser CH530 Boot Time Start Delay Time Water Flow Water Flow (24 to 42 Sec) (0 to 600 Sec) (6 to 1200 Sec) (6 to 1200 Sec) Energize Energize Evaporator Water Condenser Water Pump Relay Pump Relay

Lead Auto Running Circuit Auto Auto Enforce Restart Inhibit Timer

(0 to 5 Mins) Energize Cprsr A

Open Liquid Line Solenoid Valve

Lag Auto Circuit

Figure 23 Unit Power UP Checking Operating Conditions 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 (CGWF) water flows and pressure drops. These readings should be stable at proper levels. • Check suction pressure and discharge pressure of the unit. Discharge pressures - take at discharge line service valve backseat port. Normal dis- charge pressures are: CCAF units 200 to 360 psig CGWF units 175 to 275 psig Suction pressures - take at Schraeder fitting provided on the suction line. Normal suc- tion pressures are: 40-60 F LWT = 50-85 psig 15-39 F LWT = 25-50 psig. • Check compressor oil levels. At full load, oil level should be visible in the oil level sight glass on the compressor. If it is not, add or remove oil as required. • Check the liquid line sight glasses. Refrigerant flow past the sight glasses should be clear. Bubbles in the liquid line indicate either low refrigerant charge or exces- sive pressure drop in the liquid line. Such a 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.

CGWF-SVX01A-EN 79 Unit Start-up

The system may not be properly charged although the sight glass is clear. Also consider superheat, subcooling and operating pressures. • Once oil level, amp draw and operating pressures have stabilized, measure sys- tem suction superheat. • Measure system liquid line subcooling. • If operating pressure, sight glass, superheat and subcooling readings indicate refrigerant shortage, gas-charge 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 refriger- ant shortage exists. Adding refrigerant, will result in overcharging. Add refrigerant with the unit running by charging through the Schraeder valve between the expansion valve and the evaporator refrigerant inlet until operating condi- tions are normal. CAUTION Compressor Damage! To prevent compressor damage, do not allow liquid refrigerant to enter the suction line.

To prevent compressor damage and insure 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 service valve. Do not discharge refrigerant into the atmosphere. • If the unit is equipped with hot gas bypass, check regulating and solenoid valve for proper operation. Valve operating setpoints for 44-45 F evaporator leaving water temperature are: Full open @ 61 psig, Full closed @ 69 psig For other conditions, adjust the valve so that it is full open at normal suction pressure when the unit is operating at minimum cooling level. • If the remote condenser (CCAF) is equipped with low ambient dampers, check for proper actuator and blade travel in relation to condensing pressure. Damper oper- ating setpoints are: 170 psig = Dampers fully closed; 250 psig = Dampers fully open. • Once proper unit operation is confirmed, inspect for debris, misplaced tools., etc. Secure control panel doors in place.

System Superheat Normal superheat for each circuit is 10-12 F at full load. If superheat is not within this range, adjust expansion valve superheat setting. Allow 5-10 minutes between adjust- ments for the expansion valve to stabilize on each new setting.

System Subcooling Normal subcooling for each circuit is 10 to 15 F at full load. If subcooling for either cir- cuit is not in this range check superheat for the circuit and adjust, if required. If super- heat is normal but subcooling is not, contact a qualified service technician.

80 CGWF-SVX01A-EN Unit Shutdown

Normal Unit Shutdown

( p p ) Local Stop Stopped Normal Latching Diagnostic Chiller Level Non-Latching Diagnostic Tracer Stop Run Inhibit External Auto-Stop

Stopped Chiller Running Shutting Down or Run Level Inhibit Evap Pump Off Delay Timer (0 to 30 Minutes) De-Energize Condenser De-Energize Evaporator Water Pump Relay Water Pump Relay

Shutting Down Lead Auto Circuit (Operational Pumpdown) 30 Seconds or Low Suction Rfgt Pressure

De- Energize Cprsr B EDnee-Ergniezregize Cprsr BA Close Liquid Line Solenoid Valve

Shutting Down Lag Auto Circuit (Operational Pumpdown) 30 Seconds or Low Suction Rfgt Pressure

De-Energize Cprsr B De-Energize Cprsr A Close Liquid Line Solenoid Valve

Figure 24 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. Perform "Manual Pumpdown" procedure described in this section. Be certain to perform this procedure for both circuits. 2. Test condenser and high side piping for refrigerant leakage. 3. Open electrical disconnect switches for evaporator water pump. Lock the discon- nect in open position. 4. Open the unit main electrical disconnect and unit-mounted disconnect 1S1 (if used) and lock in open position.

CGWF-SVX01A-EN 81 Unit Shutdown

CAUTION Equipment Damage! Lock evaporator water pump disconnect open to prevent pump damage.

If unit water vessels are exposed to sub-freezing ambient temperatures, take precautions to prevent unit damage. Lock unit main disconnect open to prevent compressor damage due to accidental start-up while system is in "shutdown" condition. System Restart After Extended Shutdown Use this procedure to prepare the system for restart after an extended shutdown. CAUTION Compressor Damage! To prevent compressor damage, be certain that all refrigerant valves are open before starting the unit.

1. Open (backseat) the liquid line and discharge line service valve(s). 2. Close the unit main disconnect and the unit-mounted disconnect (if used). 3. Check compressor crankcase oil levels. Oil should be visible in the compressor oil level sight glass. 4. Fill the chilled water circuit(s) if drained during shutdown. Vent the system while filling it. 5. Close the fused disconnect switch(es) for the water pumps. 6. Start the water pump(s). With water pumps running, inspect all piping connec- tions for leakage. Make any necessary repairs. 7. With water pump(s) running, adjust chilled water flow and check water pressure drop through the evaporator. 8. Check the flow switch on the evaporator outlet piping for proper operation. 9. Stop the water pump(s). 10. Proceed to "Start-Up Procedure".

82 CGWF-SVX01A-EN Unit Maintenance

Periodic Maintenance Perform all maintenance procedures and inspections at the recommended intervals. This will prolong the life of the equipment and reduce the possibility of costly equip- ment failures. Use an "Operator's Log" such as the one in this section to record a weekly "operating conditions history" for this unit. The operating log for this unit can be a valuable diag- nostic tool for service personnel. By noticing trends in the operating conditions, the operator can often foresee and prevent problem situations before they become seri- ous. If the unit does not operate properly during maintenance inspections, refer to "Trouble Analysis". 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 level after this period, have a qualified service representative add or remove oil as required. • Check suction pressure and discharge pressure. • Check the liquid line sight glasses. • If operating pressures and sight glass conditions seem to indicate refrigerant shortage, measure system superheat and system subcooling. • If operating conditions indicate an overcharge, slowly (to minimize oil loss) remove refrigerant at the liquid line service valve. • Inspect remote condenser coils for cleanliness (CCAF only) and clean if required. Refer to the condenser manufacturer's recommendations. • Inspect the entire system for unusual conditions. Use the operating log in this section to record a weekly operating conditions history for the unit. A complete operating log is a valuable diagnostic tool for service personnel.

Monthly Maintenance • Perform all weekly maintenance procedures. • Measure and record system superheat. • Measure and record system subcooling. Annual Maintenance • Perform all weekly and monthly maintenance procedures. • Have a qualified service technician check the setting and function of each control and inspect the condition of and replace compressor and control contactors if needed. • If chiller is not piped to drain facilities, make sure drain is clear to carry away sys- tem water. • Drain water from condenser (CGWF) and evaporator and associated piping sys- tems. Inspect all piping components for leakage, damage, etc. Clean out any in- line water strainers.

CGWF-SVX01A-EN 83 Unit Maintenance

• Inspect evaporator and condenser tubes and clean, if needed. • Clean and repaint any corroded surface. • Inspect the expansion valve sensing bulbs for cleanliness. Clean if required. Sensing bulbs must make good contact with suction lines and be properly insu- lated. • Clean remote condenser coils (CCAF only). Refer to the condenser manufac- turer's recommendations. Maintenance Procedures This section describes specific maintenance procedures which must be performed as a part of the normal maintenance program for this unit. Be certain that electrical power to the unit is disconnected before performing these procedures. Cleaning the Condenser (CGWF Units Only) Water available for condensing frequently contains minerals or other contaminants that collect on the inside of the condenser tubes as carbonate scale. Scale accumula- tion will accelerate with high condensing temperatures and use of water with high mineral content. Cooling towers collect dust and foreign material which also deposits on the condenser tubes, forming sludge. To maintain maximum efficiency, the condenser must remain as free of these depos- its as possible. Even a very thin layer on the inside tube surfaces reduces the heat transfer ability of the condenser. Indications of scale deposits are decreased water flow through condenser, reduced temperature differential between entering and leav- ing condensing water and abnormally high condensing temperatures. These are two accepted methods of cleaning condenser tubes. They are mechanical cleaning and chemical cleaning.

Mechanical Cleaning The mechanical cleaning method is used primarily to remove sludge and other loose material from the condenser tubes. Use the following procedure. 1. Turn off chiller and condenser water supply. 2. Break piping connections at the unions. 3. Remove the condenser heads. 4. Run a round nylon brush from end to end through the tubes to loosen deposits. 5. Flush the tubes with water. Then inspect tubes for scale accumulation. If there is no scale in the tubes reassemble condenser and piping. 6. If there is scale in the tubes, proceed with the chemical cleaning procedure.

Chemical Cleaning Chemical cleaning is the most satisfactory method of cleaning scale from condenser tubes. With this treatment, scale is dissolved and flushed away by circulating a chem- ical solution through the tubes and headers. Internal condenser components are composed of copper, steel and cast iron. With this information, water treatment firms will be able to recommend a suitable chemical for this purpose. If water treatment is not available, consult a chemical supply house.

Cleaning the Evaporator (Chiller) The evaporator water system is part of a closed loop and should not accumulate an appreciable amount of scale or sludge. If it is determined that the chiller is fouled, first attempt to dislodge any foreign material by back flushing the system several times. If this does not work satisfactorily, chemically clean the chiller using the proce- dures outlined in "Chemical Cleaning" for the condenser.

84 CGWF-SVX01A-EN Unit Maintenance

CAUTION Evaporator Damage! Evaporator internal components are composed of steel, polypropylene and copper. Do not use an acidic type cleaning agent that will damage these components. Proper Water Treatment! 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. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Water Treatment The use of untreated or improperly treated water in these units may result in the for- mation of scale, erosion, corrosion, algae or slime. It is recommended that the ser- vices of a qualified water treatment specialist be engaged to determine what treatment, if any, is required. The Trane Company assumes no responsibility for equipment failure that results from the use of untreated or improperly treated water.

CGWF-SVX01A-EN 85 Unit Maintenance

Chiller Log Run Time Main Tab 15 min 30 min 1 hr Chiller Mode Circuit 1 Mode Circuit 2 Mode Evap Ent/Lvg Water Temp Cond Ent/Lvg Water Temp Active Chilled Water Setpoint (F/C) Average Line Current (%RLA) Active Demand Limit setpoint (F/C) Active Ice Termination Setpoint (F/C) Outdoor Air Temperature (F/C) Software Type Software Version Reports Tab Evaporator System Evap Entering Water Temperature (F/C) Evap Leaving Water Temperature (F/C) Evap Water Flow Switch Status Circuit 1 Evap Sat Rfgt Temp (F/C) Suction Pressure (psia) Evap Approach Temp Circuit 2 Evap Sat Rfgt Temp (F/C) Suction Pressure (psia) Evap Approach Temp Condenser System Cond Entering Water Temperature (F/C) Cond Leaving Water Temperature (F/C) Cond Water Flow Switch Status Outdoor Air Temperature (F/C) Circuit 1 Cond Sat Rfgt Temp (F/C) Discharge Pressure (psia) Cond Approach Temp Circuit 2 Evap Sat Rfgt Temp (F/C) Suction Pressure (psia) Cond Approach Temp Compressor System Chiller Running Time Circuit 1 Compressor 1A Starts Compressor 1B Starts Compressor 1A Run Time Compressor 1B Run Time Circuit 2 Compressor 2A Starts Compressor 2B Starts Compressor 2A Run Time Compressor 2B Run Time

86 CGWF-SVX01A-EN Unit Maintenance

Settings Settings Tab Chiller Front Panel Chilled Water Setpt (F/C) Front Panel Active Demand Limit Setpoint Front Panel Ice Build Cmd (On/Auto) Front Panel Ice Termn Setpoint (F/C) Design Delta Temp (F/C) Setpoint Source Leaving Water Temp Cutout (F/C) Feature Settings Low Ambient Lockout Setpoint - CCAF (F/C) Low Ambient Lockout - CCAF (F/C) Chilled Water Reset Return Reset Ratio (%) Return Start Reset (F/C) Return Maximum Reset (F/C) Outdoor Reset Ratio (%) Outdoor Start Reset (F/C) Outdoor Maximum Reset (F/C) Ext Chilled Water Setpoint Ice Building (Enable/Disable) Hot Gas Bypass Operational Pumpdown (Enable/Disable) ICS Address Manual Control Settings Evap Water Pump Cond Water Pump Clear Restart Inhibit Timer Capacity Control Circuit 1 Compressor A Pumpdown Compressor B Pumpdown Front Panel Lockout Ckt1 Circuit 2 Compressor A Pumpdown Compressor B Pumpdown Front Panel Lockout Ckt2 Display Settings Date Format Date Time Format Time of Day Keypad/Display Lockout Display Units Pressure Units Language

CGWF-SVX01A-EN 87 Unit Maintenance

88 CGWF-SVX01A-EN Wiring Schematics

Typical field connection diagrams, electrical schematics and connections diagrams for the CGWF/CCAF units are shown in this section. NOTE: The drawings in this section are provided for reference only. These diagrams may not reflect the actual wiring of your unit. For specific electrical connection and schematic information, always refer to the wiring diagrams that were shipped with the unit.

Drawing Description IOM Page 2309-7571 Schematics Page 1&2 90 2309-7577 Component Location 94 2309-7578 Field Wiring Diagram 95 2309-7579 Field Layout Diagram 96

CGWF-SVX01A-EN 89 C ALL RIGHTSRESERVED A DIVISION OF AMERICAN STANDARD INC. INC. STANDARD A DIVISION OF AMERICAN

90 CGWF-SVX01A-EN CGWF-SVX01A-EN 91 C ALL RIGHTS RESERVED A DIVISION OF AMERICAN STANDARD INC. INC. STANDARD AMERICAN OF A DIVISION

92 CGWF-SVX01A-EN CGWF-SVX01A-EN 93 94 CGWF-SVX01A-EN CGWF-SVX01A-EN 95 96 CGWF-SVX01A-EN CGWF-SVX01A-EN 97 98 CGWF-SVX01A-EN CGWF-SVX01A-EN 99 Literature Order Number CGWF-SVX01A-EN File Number SV-RF-CGWF-SVX01A-EN-104 Trane Supersedes New A business of American Standard Companies www.trane.com Stocking Location Inland

Trane has a policy of continuous product data and product improvement and reserves For more information contact your local district office or e-mail us at [email protected] the right to change design and specifications without notice. Only qualified techni- cians should perform the installation and servicing of equipment referred to in this bul- letin.