Options Guide - Trane...1 CG-PRB018-E4 compressors August 2013 CG-PRB018-E4 Air-cooled Liquid...

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August 2013 CG-PRB018-E4

Air-cooled Liquid Chillers with Scroll

compressors

Models CGAM 020 to 170

Options Guide

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Table of Contents

1.1. Aquastream 3G™ Air-cooled liquid chiller range ...................................................................7 1.2. CGAM Range .........................................................................................................................8

5.1. Application ................................................................................................................... 12 5.2. Description ................................................................................................................... 12 5.3. Operation ..................................................................................................................... 13 5.4. Benefits ........................................................................................................................ 13 5.5. Incompatibilities ........................................................................................................... 13 5.6. More detail .................................................................................................................. 13

7.1. Ice making Digit 21 = C ........................................................................................................ 14 9.1. Lanced Aluminum Fins Digit 23 = A...................................................................................... 18

9.1.1. Application ................................................................................................................... 18 9.1.2. Description ................................................................................................................... 18 9.1.3. Operation ..................................................................................................................... 18 9.1.4. Benefits ........................................................................................................................ 18 9.1.5. Incompatibilities ........................................................................................................... 18

9.3. Non-lanced Aluminum Fins with Pre-coated Black Epoxy Digit 23 = E ............................. 19 9.3.1. Application ................................................................................................................... 19 9.3.2. Description ................................................................................................................... 19 9.3.3. Operation ..................................................................................................................... 19 9.3.4. Benefits ........................................................................................................................ 19 9.3.5. Inconvenience .............................................................................................................. 19 9.3.6. Incompatibilities ........................................................................................................... 20

9.4. More detail.......................................................................................................................... 20 10.1. Partial Heat Recovery (PHR) Digit 24 = 2 ............................................................................. 21

10.1.1. Application ....................................................................................................................... 21 10.1.2. Description ...................................................................................................................... 21 10.1.3. Operation ........................................................................................................................ 21

Water piping PHR .................................................................................................................... 22

10.1.3.1 How does Partial Heat Recovery ( PHR) work .............................................................. 22

10.1.4. Benefits............................................................................................................................ 23 10.1.5. Incompatibilities .............................................................................................................. 23

10.2. Total Heat Recovery Digit (THR) 24 = 3 ................................................................................ 24 10.2.1. Application ....................................................................................................................... 24 10.2.2. Description ...................................................................................................................... 24 10.2.3. Operation ........................................................................................................................ 24

10.2.3.1. How does Total Heat Recovery (THR) work ................................................................ 25


11.1. Across the Line Starter/Direct on Line Digit 26= A ............................................................... 28 11.2. Solid-state Soft Starter Digit 26 = B ..................................................................................... 28

11.2.1. Application ....................................................................................................................... 28 11.2.2. Description ...................................................................................................................... 28 11.2.3. Operation ........................................................................................................................ 29 11.2.4. Benefits............................................................................................................................ 29 11.2.5. Incompatibilities .............................................................................................................. 29

11.3. More detail.......................................................................................................................... 29 11.3. More detail.......................................................................................................................... 30 12.1. LonTalk LCI-C Interface with Modbus Interface Digit 31 = 1 ................................................ 31

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12.1.1. Application ....................................................................................................................... 31 12.1.2. Description ...................................................................................................................... 31 12.1.3. Operation/Benefits .......................................................................................................... 31 12.1.4. Incompatibilities .............................................................................................................. 32

12.2. LCI-C Card (LonTalk Communication Interface) Digit 31 = 2 ................................................. 33 12.2.1. Application ....................................................................................................................... 33 12.2.2. Description ...................................................................................................................... 33 12.2.3. Operation/Benefits .......................................................................................................... 33 12.2.4. Incompatibilities .............................................................................................................. 34

12.3 Time of Day Scheduling Digit 31 = 3..................................................................................... 35 12.3.1. Application ....................................................................................................................... 35 12.3.2. Description/Operation ..................................................................................................... 35

12.3.2.1. Scenarios ................................................................................................................... 35


12.4. BCI-C (BACnet Communication Interface) Digit 31 = 4 ......................................................... 37 12.4.1. Application ....................................................................................................................... 37 12.4.2. Description ...................................................................................................................... 37 12.4.3. Operation/Benefits .......................................................................................................... 37 12.4.4. Incompatibilities .............................................................................................................. 37

13.1. External Chilled Water and Demand Limit Setpoint with .................................................... 38 4-20 mA Digit 32 = A ....................................................................................................................... 38


13.2. External Chilled Water and Demand Limit Setpoint ............................................................ 39 2-10 VDC Digit 32 = B ...................................................................................................................... 39


13.3. Second leaving water temperature setpoint Digit 32 = C .................................................... 40 14.1. Application ................................................................................................................... 41 14.2. Description ................................................................................................................... 41 14.3. Operation ..................................................................................................................... 41

14.3.1. Example ....................................................................................................................... 41

14.4. Benefits ........................................................................................................................ 42 14.5. Incompatibilities ........................................................................................................... 42 15.1. Application ................................................................................................................... 43 15.2. Description ................................................................................................................... 43 15.3. Operation ..................................................................................................................... 44 15.4. Benefits ........................................................................................................................ 44 15.5. Incompatibilities ........................................................................................................... 44

16.1. Starter type for Pump Digit 35 = 1, 2, 3, 4 ........................................................................... 46 16.1.1. Benefits of TeSys U........................................................................................................... 46

2. Pump Insulation .................................................................................................................. 46 17.1. Pump Flow Controlled by Balancing Valve Digit 36 = A ....................................................... 47


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17.2. Pump Flow Controlled by Variable Speed Drive Digit 36 = B ............................................... 48 17.2.1. Application ....................................................................................................................... 48 17.2.2. Description ...................................................................................................................... 48 17.2.3. Operation ........................................................................................................................ 48 17.2.4. Benefits............................................................................................................................ 48 17.2.5. Incompatibilities .............................................................................................................. 49 17.2.6. More detail ...................................................................................................................... 49

17.2.6.1. Pump flow adjustment by Variable Speed Drive......................................................... 49

17.2.6.2. Detailed example pay back time ................................................................................ 50

18.1. Application ................................................................................................................... 52 18.2. Description ................................................................................................................... 52 18.3. Operation ..................................................................................................................... 53 18.4. Benefits ........................................................................................................................ 53 18.5. Incompatibilities ........................................................................................................... 53

19.1. Elastomeric Isolators Digit 39 = 1 ........................................................................................ 54 19.1.1. Application ....................................................................................................................... 54 19.1.2. Description ...................................................................................................................... 54 19.1.3. Operation/Benefits .......................................................................................................... 54 19.1.4. Incompatiblities ............................................................................................................... 54

19.2. Neoprene Pads Digit 39 = 4 ................................................................................................. 55 19.2.1. Application ....................................................................................................................... 55 19.2.2. Description ...................................................................................................................... 55 19.2.3. Operation/Benefits .......................................................................................................... 55 19.2.4. Inconvenience .................................................................................................................. 55 19.2.5. Incompatibilities .............................................................................................................. 55 20.1. Application ................................................................................................................... 56 20.2. Description ................................................................................................................... 56 20.3. Operation ..................................................................................................................... 57 20.4. Benefits ........................................................................................................................ 57 20.5. Incompatibilities ........................................................................................................... 57 20.6. More detail .................................................................................................................. 57

21.1. Compact unit Digit 41 = 1 .................................................................................................... 58 21.2. Super quiet unit Digit 41 = 3 ................................................................................................ 58 21.3. Super quiet with Night Noise setback Digit 41 = 4 ............................................................... 58 21.4. Comprehensive acoustic package unit Digit 41 = 5 .............................................................. 58 22.1 No Appearance option Digit 42 = X ...................................................................................... 59 22.2. Architectural Louvered Panels Digit 42 = A .......................................................................... 59


23.1. Digit 45= X ........................................................................................................................... 61 23.2. Digit 45= 1 ........................................................................................................................... 61

23.1.1. Application ....................................................................................................................... 61 23.1.2. Description ...................................................................................................................... 61 23.1.3. Operation ........................................................................................................................ 62 23.1.4. Benefits............................................................................................................................ 62 23.1.5. Incompatibilities .............................................................................................................. 62 23.1.6. Summary ......................................................................................................................... 62

24.1. Unit Containerization Package Digit 46 = A ......................................................................... 63 Annexe 1: Wilo pumps curves. ........................................................................................................ 64

DPL or IL50/120-1,5/2 .................................................................................................................. 64 DPL or IL50/130-3/2 .................................................................................................................... 64 DPL or IL65/120-3/2 .................................................................................................................... 65

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DPL or IL65/130-4/2 .................................................................................................................... 65 DPL or IL65/140-5,5/2 .................................................................................................................. 66 DPL or IL80/155(127)-7,5/2 ......................................................................................................... 66 DPL or IL80/150-11/2................................................................................................................... 67 DPL or IL40/160-4/2 .................................................................................................................... 67 DPL or IL40/160-5,5/2 .................................................................................................................. 68 DPL or IL65/175(143)-7,5/2 ......................................................................................................... 68 DPL or IL80/160-11/2................................................................................................................... 69 DPL or IL80/170(165)-15/2 .......................................................................................................... 69

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1. Range Overview

1.1. Aquastream 3G™ Air-cooled liquid chiller range

Before explaining the different options and accessories available, let’s first take a look at the current range and review the definition of the Aquastream 3G™ Air-cooled liquid chillers

Illustration 1. Range Overview

The Aquastream 3G™ Air-cooled liquid chillers family covers a capacity range between 50

kW and 450 kW, which includes Cooling only and Heat pump units. For the “Cooling only”

unit, it is called CGAM and the other unit is named CXAM. The units come in 3 families

which are Simplex (1 circuit), Duplex V (2 circuits) and Duplex W (2 circuits). S1, S2, V1,

V2, W1, W2, W3 and W4 are the cabinet depending on the unit’s size and the unit’s

sound level. If the units are in the same cabinet, it’s mean that they have the same

dimensions(length,width,height). Section with grey colour means there is no units for the

specific sizes and the chosen sound level.

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1.2. CGAM Range

Illustration 2. CGAM range

CGAM range is Eurovent certified

Performances are available on website

www.eurovent-certification.com

http://www.eurovent-certification.com/

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2. Unit appearance

Unit appearance is different according to its acoustic level. There are 3 types of

acoustic level, Compact, Super Quiet or Super Quiet with Night Noise Setback

(fan operation on low speed, reducing sound level during the night) and

Comprehensive Acoustic Package. For each type, the unit will be provided with

different size of compressor, type of fan and compressor insulation. The difference of

unit appearance can be noticed easily by compressor insulation.

2.1. Compact Compressors are not covered.

2.2. Super quiet and SQ + NNSB A black jacket covers the compressors.

2.3. Comprehensive acoustic package The compressors are installed in a box

Illustration 3. Compressor’s appearance for compact unit

Illustration 4. Black jackets cover the compressor for Super quiet unit

Illustration 5. Box is used to cover the compressors for comprehensive acoustic package

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3. Compressor size

The table below shows the compressor size for each size of the unit.

Table 1. Compressor size in ton

Explication on how compressor staging is done

For the 2-compressor circuits:

If the compressors are equally sized, we can start with any of them first.

If not, we want to start the smaller compressor first.

Thus, for sizes up to 120 nominal tons, we always do A, AB for circuit 1 and B, AB for circuit 2.

For the 3-compressor circuits:

For 140 and 170 ton units, the smallest compressor is the B compressor. 140 ton was not qualified to run compressor B alone. 170 ton was qualified to run compressor B alone. Thus, they get different sequences.

On 150 & 160, we act similar to a duo, and do A, AB, ABC on circuit 1, and C, CB, CBA on circuit 2.

Compressor staging pattern circuit 1 A, AB = 0 A, AB, ABC = 1 B, BA, BAC = 8 A, AB, ABC (Not B) = 9

Compressor staging pattern circuit 2 B, AB = 3 C, CB, CBA = 7 B, BA, BAC = 8 A, AB, ABC (Not B) = 9

1A 1B 1C 2A 2B 2C

# of Circuits Size Circuit 1 Circuit 2

1 10 10 020 0

1 10 13 023 0

1 13 13 026 0

1 15 lc 15 lc 030 0

1 15 20 035 0

1 20 20 039 0

1 20 25 045 0

1 25 25 050 0

2 10 10 10 10 040 0 3

2 10 13 13 10 046 0 3

2 13 13 13 13 052 0 3

2 15 lc 15 lc 15 lc 15 lc 060 0 3

2 15 20 20 15 070 0 3

2 20 20 20 20 080 0 3

2 20 25 25 20 090 0 3

2 25 25 25 25 100 0 3

2 25 30 30 25 110 0 3

2 30 30 30 30 120 0 3

2

2 25 20 25 25 20 25 140 9 9

2 25 25 25 25 25 25 150 1 7

2 25 25 30 30 25 25 160 1 7

2 30 25 30 30 25 30 170 8 8

W

Comp. Manifold CKT1 Comp. Manifold CKT2

CGAM/CXAM

SLAN

TV

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4. Operating Map

Fan control Low ambient

Standard ambient

High ambient

Wide ambient

Min. outdoor air temperature

-18°C +7°C +7°C -18°C

Max. outdoor air temperature

+46°C +46°C +52°C +52°C

Min. leaving water temperature

-12°C -12°C -12°C -12°C

Max. leaving water temperature

+20°C +20°C +20°C +20°C

Table 2. Cooling only units (CGAM)

Illustration 6. Operating map for cooling only

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5. Freeze Protection(CH530) Digit 18 = 2

5.1. Application

- When the unit is exposed to ambient temperature between 0°C and -18°C.

- When the unit needs to be protected from freezing (no glygol in the water loop).

- By electric heaters activation.

5.2. Description

- Heaters on all cold parts.

- Heaters used are heat mat and heating cables.

- Freeze protection is integrated into the main power of the unit.

From May 2013

Illustration 7. Pump package anti-freeze heater

An anti-freeze heater is installed in water pumps for pump freeze protection.

Pump package anti-freeze heater power Buffer tank anti-freeze heater power

S type units = 530 W S type units = 860 W

V type units = 530 W V type units = 800 W

W type units = 1030 or 1150 W* W type units = 800 or 1200 W*

* (depends on unit size,efficiency and sound level)

Note: The water piping between the chiller and the building has to be protected

against freezing by installing heating cable

Buffer heaters are heat mat,

attached at the lower part as

the heated water can go

upwards by nature

convection

Illustration 8. Heaters of buffer tank

S type units V type units W type units

heater heater heater

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5.3. Operation

- Freeze protection via the CH530 control turns on the heaters based on ambient

temperature.

5.4. Benefits

- All the components are protected.

- No additional or dedicated electrical connection when installing.

5.5. Incompatibilities

- No incompatibility.

5.6. More detail

- On the evaporator a blanket heater is installed at the bottom of the brazed plate

heat exchanger(BPHE).

6. Freeze Protection digit 18 = X

No heaters are provided but the anti freeze protection is possible with the pump

activation by CH530 control (pump ON from 2°C down to negative ambient

temperature; pump OFF up to 5°C) using external temperature sensor. This system

allows to reduce the price of the unit.

Illustration 9. Blanket heater

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7. Evaporator Application Digit 21

Illustration 10. Range of evaporator application option

The illustration above shows the application that can be adapted for evaporator. In

standard, the evaporator is provided with standard cooling application which the

evaporator leaving temperature is in a range of 5.5°C to 20°C. Low temperature

processing with the range of leaving water temperature between -12°C and 5.4°C is an

option.

7.1. Ice making Digit 21 = C

The other option for evaporator is ice making(ice building) with a wide range of leaving

water temperature between -12°C and 20°C. This option can be applied when the chiller

is used to make ice at night. The frozen water (ice) serves as thermal storage that can be

melted to produce cooling. 2 set points enable the customer to control the chiller for this

option. One set point used for the day time and the other one used during the night time.

At night, unit generates ice when utility rates are low (off-peak period) and uses ice for

cooling during the day when utility rates are high (on-peak period). During the night, the

chiller cools the mixture of glycol/water to a very low leaving water temperature (i.e. -7°C)

which is then circulated through coils inside a tank containing water to create ice. During

the day, heat load is carried through the chilled water system to the ice storage tanks.

The ice melts and cools the glycol/water mixture (i.e. 5°C), then is routed to the cooling

coils and cools the building. The chiller will start and run all available compressors (no

stagging). The chiller will load at its maximum rate. Softloading is not in effect in ice

making. The condenser control in ice making shall be the same as normal cooling.

Control on ice making

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.

Standard cooling

Low temperature processing

Ice making

-12°C 5.5°C 20°C

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Initiating Ice Building (Ice Building Command)

Ice Building can be initiated through the following means:

The external ice building command binary input (optional). BAS ice building command (optional). Front panel ice building command (set from DynaView or TechView).

If any one of these inputs command the chiller to make ice and the ice building feature is enabled the chiller will attempt to make ice.

Benefits of ice making

Reduces or even replaces mechanical cooling durind the day

Reduces the electricity consumption cost

Avoid over sizing the chiller

More detail

The ice bank tank for ice making is manufactured by Calmac. Ice making can be used in

Air conditioning

Eliminates peak-hours load ( explained in paragraph above)

Limitation of power absorbed

During the day, the chiller used the ice to cool the building. Thus, the energy

used during the peak period is reduced.

Industrial application

Poultry

Fisheries

In process

Chemical process

Food process

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8. Water Connection Digit 22

There are 3 ways which are suggested by Trane for water pipe connections (cold

water and HR hot water (if any) connections) .

8.1. Grooved pipe connection(standard) digit 22 = 1

This type of pipe has a grooved end.

This groove provides a gripping area for the coupling to engage around the full

pipe circumference.

Easy to connect the piping .

8.2. Grooved pipe connection with flange adapter digit 22 = 2

This kind of pipe connection comes with a flange adapter which is used to convert

both water connections from grooved pipe to flanged PN 10 connections.

To connect the grooved pipe with the grooved flange adapter, a victaulic

coupling is used between them.

Illustration 11. Grooved pipe connection

Grooved area

Victaulic

coupling

flange

Illustration 12. Grooved pipe with flange adapter

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8.3. Grooved pipe connection with coupling and pipe stub digit 22 = 3 Used when tube is welded.

Weld

sleeve

Pipe stub

Illustration 13. Grooved pipe and coupling

Victaulic coupling

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9. Condenser Fin Materiel Digit 23

9.1. Lanced Aluminum Fins Digit 23 = A

9.1.1. Application

- When the chiller is installed in standard condition

Non polluted ambiance

Non corrosive ambiance

9.1.2. Description

- Aluminum fin is a standard fin used on all air-chillers.

- Also known as slit fins.

- The slit is located between of two collar.

Illustration 14. Aluminum slit fin

9.1.3. Operation

- The aluminum fins increase the capacity of heat exchange between the

refrigerant and the ambient air flow.

- Slit increases the air turbulences.

- It allows more heat transfers between the two fluids than non-lanced aluminum

fins.

9.1.4. Benefits

- Increases the condenser and chiller performance.

9.1.5. Incompatibilities

- Heat pump as it slows down defrost cycle

Slit

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9.3. Non-lanced Aluminum Fins with Pre-coated Black Epoxy Digit 23 = E

9.3.1. Application

- When chiller is needed for coastal or salt mist environments.

- When the aluminum fin is exposed to hard weather conditions(acid rain,

moisture,pollution, salt …)

9.3.2. Description

- Condenser black epoxy coated.

- Edges treated.

9.3.3. Operation

- Black epoxy slows down the corrosion process on the aluminum fins when the

unit is installed on sea side or in a polluted area.

9.3.4. Benefits

- This option allows installation near the sea and avoids aluminum corrosion.

- Trane coating also includes edges of the fins. If edges are not treated, then the

corrosion starts at this point and the coil would be quickly destroyed.

- The black epoxy also provides a barrier protection at the fin collar to stop

galvanic corrosion action between the aluminum fins and the copper tubes.

9.3.5. Inconvenience

Illustration 15. Black epoxy fin

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- Aluminum fin is painted with black epoxy, it is covered by 3 layers of

protection.Thus, this action will decrease slightly the capacity of heat transfer

( ≈ 2%) between the refrigerant and the ambient air.


- Lanced/slit aluminum fins.

9.4. More detail

For information, there are 192 fins per foot installed in the condenser.

Resin Polyurethane, color black

Resin Black Epoxy

Phosphochromate

Aluminum 0.12 mm thickness

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10. Condenser Heat Recovery Digit 24

10.1. Partial Heat Recovery (PHR) Digit 24 = 2

10.1.1. Application

- When a portion of rejected heat around 25% needs to be recovered.

- Usually used to pre-heat hot water services

10.1.2. Description

- Braze Plate Heat Exchanger (BPHE) for PHR is installed between the

downstream of the compressor and air cooled condenser.

- Two BPHE Partial Heat Recovery for dual circuits.

- An antifreeze protection is supplied by Trane to protect the heat exchangers in

area where negative temperature can occur.

- A control algorithms is used for partial heat recovery when this feature is

installed.

- The HR condensers and water lines are insulated to prevent heat loss.

- Insulation is factory provided on the PHR BPHE

10.1.3. Operation

- The Braze Plate Heat Exchanger cools down the gas at the discharge of the

compressor and heats water.

- The heat exchanger uses desuperheating effect of discharge gas.

- Partial Heat Recovery can be executed either in cooling mode or heating mode

Partial heat

recovery BPHE

Illustration 16. Installation BPHE for partial heat recovery in V type unit

Illustration 17. Partial heat recovery system

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PHR anti-freeze heater power

In duplex ‘V’ and ‘W’, there are two PHR circuit which means the heater is installed in

each BPHE and water piping of PHR.

Table 3. PHR anti-freeze heater power

10.1.3.1 How does Partial Heat Recovery ( PHR) work

The customer shall provide the water loop for partial heat recovery as shown in figure 18. The circulation pump provides constant water flow rate from the tank. The three-way valve adjusts the water flow of PHR heat exchanger based on the heat exchanger leaving water temperature. As the leaving water temperature increases, the PHR water flow rate increases. The main heater supply additional heat if needed. CH530 does not control the three-way valve. For domestic hot water in lodging applications, a separate heat exchanger is needed

for potable water.

Unit type BPHE PHR Water piping PHR

Slant 100 W 60 W

Duplex ‘V’ 100 W x 2 60 W x 2

Duplex ‘W’ 100 W x 2 60 w x 2

Trane supplied Field supplied

Illustration 18. Water loop in partial heat recovery

Hot water

to building

Cold

water

from city

network

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PHR operating map

• PHR LWT (°C) = 45 - 70 °C • Ambient temperature (°C) = 10 – 52 °C

As shown in the figure above, the maximum delta Temperature between PHR EWT

and PHR LWT is 10°C. This means, for example, for 45°C of PHR LWT, the customer

can provide 35°C for PHR EWT.

PHR is not compatible with low leaving water temperature options. For application with

ELWT below +5.5°C, please contact sales support team.

With PHR option, there is no control on the CGAM air flow.

10.1.4. Benefits

- Up to 25% heat recovered from the cooling/heating load.

- Heat recovered can be used for pre-heat of boiler system or domestic water

(i.e. swimming pool,laundry facilities).

- Energy saving.

- For process which needs chilled water and hot waterat the same time.

In office blocks,during winter,computer rooms still need cooling while offices

need heating.


- Total heat recovery.

- Low temperature processing

- Ice making

Illustration 19. Cooling priority map (ambient temperature VS PHR LWT)

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10.2. Total Heat Recovery Digit (THR) 24 = 3

10.2.1. Application

- When a large portion of rejected heat around 80% needs to be recovered.

- When there must be a simultaneous need for chilled water and hot water unless

a larger hot water storage is available.

10.2.2. Description

- Braze Plate Heat Exchanger (BPHE) for THR is installed between the

compressor and air cooled condenser.

- An antifreeze protection is supplied by Trane to protect the heat exchangers

and water piping in area where negative temperature can occur.

- 3 way valve and liquid receiver are installed on THR circuit.

- A control algorithms is used for total heat recovery when this feature is installed.

- The HR condensers and water lines are insulated to prevent heat loss.

- Insulation is factory provided.

10.2.3. Operation

- The Braze Plate Heat Exchanger cools down the gas at the discharge of the

compressor and heat water.

- The heat exchanger uses desuperheating plus condensing effect of discharge

gas.

- The 3 way valve factory installed is used to adjust the water flow of Total Heat

Recovery heat exchanger to provide as much heat capacity as possible without

causing defaults.

- Liquid receiver is installed on the condenser to serve to accumulate the reserve

liquid refrigerant, to provide a storage for off-peak operation in order to have

always have enough refrigerant.

Illustration 20. Installation of THR components in the unit

3 way valve

condenser

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THR anti-freeze heater power

THR is installed in duplex ‘V’ and ‘W’ unit only. In Duplex ‘V’ unit, there are two circuits

of THR and for each circuit, a BPHE is installed. Meanwhile, in Duplex ‘W’, there is

only one BPHE installed for two circuits of THR. Every circuit is applied with heater for

anti-freeze protection.

Unit type BPHE Water piping

Slant - -

Duplex ‘V’ 100 W x 2 60 W x 2

Duplew ‘W’ 120 W 100 W x 2 Table 4. THR anti-freeze heater power

10.2.3.1. How does Total Heat Recovery (THR) work

Illustration 21. Total heat recovery system

Hot watet to

building

Cold water

from city

network

Trane supplied Field supplied

Illustration 22. Water loop in total heat recovery

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Illustration 22 shows the THR water loop in application. The components in red dash

box are mounted in factory and in the blue dash are provided by customer. The main

heater supply additional heat if needed. The circulation pump provides constant water

flow rate from the tank. The 3 way valve is controlled by CH530 to adjust the water

flow of THR heat exchanger to provide as much heat capacity as possible without

causing defaults and to maintain optimal condensing parameters. THR is applied to

the cooling unit only. The chiller will always maintain the leaving chilled water

temperature according to its set point.

The goal of the water flow control is to provide suitable water flow rate in order to

recover as much heat capacity as possible from THR BPHE.

With THR option, on heat recovery mode, condenser air flow is controlled in order to

recover a maximum capacity in the plate heat exchanger. However, recovered

capacity depends on the compressors load and is also dependant of the air ambient

temperature. TOPSS selection give the HR capacity for chiller at full load.

Below 15°C ambient temperature, HR capacity cannot be predicted due to non

controlled air flow variations.

THR operating map

• THR LWT (°C) = 30 - 55 °C • Ambient temperature (°C) = 7 - 52 °C

The customer can get 30 – 55 °C of THR LWT. The maximum delta Temperature

between THR EWT and THR LWT is 10°C. This means, for example, for 45°C of THR

LWT, the customer can provide 35°C for THR EWT.

In the chart above, the minimum ELWT that can operate THR is 4.4 °C and the

maximum is 15.6 °C.

4,4 ; 46

6,7 ; 46

15,6 ; 42

15.6 , 74.4 , 7

4,4 ; 52 6,7 ; 52

15,6 ; 44

4,4 ; 52

15,6 ; 52

7; 35

0

10

20

30

40

50

60

2 4 6 8 10 12 14 16 18

Am

b T

(C

)

Evap LWT (C)

THR Operation Map (Amb VS Evap LWT) (SI Units)

SE Unit OM

SE Unit Part Load

HE Unit OM

HE Unit Part Load

Rating Point

Illustration 23. THR operating map

27

CG-PRB018-E4

10.2.4. Benefits

- Up to 80 % of cooling capacity recovered.

- Energy saving.

- Heat recovered can be used for pre-heat of boiler system or domestic water

(i.e. swimming pool,laundry facilities).

- Typically for hotel applications.


- Partial Heat Recovery

- Low temperature processing

- Ice making

28

CG-PRB018-E4

11. Starter Type Digit 26

Starters installed have an IP-54 gasketed enclosure. It is a protection index which is

able to protect the starters againts dust and water projection from all directions.

11.1. Across the Line Starter/Direct on Line Digit 26= A

This is the standard starter located in electrical panel of the unit.

11.2. Solid-state Soft Starter Digit 26 = B

11.2.1. Application

- To reduce inrush current when the compressors start.

11.2.2. Description

- Factory-installed , located in eletrical panel of the unit.

Illustration 24. Circuit of direct on Line

contactors

Illustration 25. Soft starter

29

CG-PRB018-E4

11.2.3. Operation

- In this circuit, the soft starter replaces the direct on line starter.

- It controls the current flow which will generate the compressors to start

gradually.

11.2.4. Benefits

- With the soft stater, the starting current drops down to 2.5 - 3 IN

(IN:nominal intensity).

- The compressor can start smoothly as the starting current is reduced.

- Smooth starting reduces motor and compressor wear.

- Less stress on the power supply.

- Reduce cable size.


- Direct on Line.

11.3. More detail

- There is a device called Silicon Controlled Rectifier(SCR) that soft starter

works with. The SCR is an electronic switch which allows current to flow

through it only when electronic signal is applied to its gate.

Illustration 26. Solid-state soft starter installed for W unit

30

CG-PRB018-E4

11.3. More detail

Comparison between across line starter and soft starter

By installing soft starter in the circuit, it will reduce the starting current.There are 6

different sizes of compressor.

Compressor size

10 13 15 20 25 30

Across Line Starter (A)

142 158 160 215 260 320

Soft Starter (A)

85 95 96 129 156 192

% current reduction

40 40 40 40 40 40

Table 5. Inrush current

Compressor size

10 13 15 20 25 30

Across Line Starter (ms)

70 100 68 61 70 70

Soft Starter (ms)

400 300 280 320 320 250

Table 6. Startup time (ms)

As shown in table 5,inrush current is reduced by installing soft starter to the electrical

circuit. Thus, the compressor will be started up with small quantity of current and it

improves the stability of the power supply. In table 6, it shows that the compressor

with soft starter will take more time to run than with across the line starter. It means

that the compressor starts progressively.

31

CG-PRB018-E4

12. Remote Interface Digit 31

12.1. LonTalk LCI-C Interface with Modbus Interface Digit 31 = 1

12.1.1. Application

- When the unit needs to interface with Modbus.

12.1.2. Description

- Protocol Interface Controller( PIC) is a gateway for converting LonTalk

protocols to Modbus protocols.

12.1.3. Operation/Benefits

- The layout shown above is the connectors to the PIC.( see table below).

Illustration 27. PIC Illustration 28. PIC layout

Table 7. Connectors’ definition

32

CG-PRB018-E4

- Wiring PIC with RS-232 and RS-485 Modbus BMS.


- BCI-C.

Illustration 29. Installation of Modbus RS-232

Illustration 30. Installation of Modbus RS-485

33

CG-PRB018-E4

12.2. LCI-C Card (LonTalk Communication Interface) Digit 31 = 2

12.2.1. Application

- When a communication interface between a Tracer™ CH530 controller and a

LonTalk network is needed.

- When the chiller needs to communicate with building automation system(BAS).

12.2.2. Description

- The LCI-C is factory installed with the chiller controller, located in the control

panel box.


- The hardware of an LCI-C consists of a low-level intelligent device (LLID),

which is an electronic board that allows the Tracer CH530/531 controller to

communicate on a LonTalk network.

- LCI-C shall be used to provide “gateway” functionality between the LonTalk

protocol and the IPC3 (Intra Processor Communication) protocol.

- The LCI-C LLID and CH530 Main Processor shall collaborate to ensure that

data synchronization is maintained under reasonable failure modes, which

include:

Message loss or corruption between the BAS and the LCI-C LLID.

Message loss or corruption between the LCI-C LLID and the

CH530 Main Processor.

Temporary power loss/brownout conditions on the LCI-C LLID,

CH530 Main Processor, or both simultaneously.

Illustration 31. LCI-C card

34

CG-PRB018-E4

- The LLID is designed to be mounted in an enclosure so that it is protected from

the environment. The chiller control panel box, where the other Tracer

CH530/531 LLIDs reside, provides a convenient place for the LCI-C.


- BCI-C

- Time of day scheduling

Illustration 32. The installation of LCI-C card, LCI-C LLID and IPC3 communication bus ribbon cable

35

CG-PRB018-E4

12.3 Time of Day Scheduling Digit 31 = 3

12.3.1. Application

- Provides a means of scheduling the chiller operation on a daily basis.

- When the user needs to set up events.

12.3.2. Description/Operation

- The users can set the schedules up through Trane CH530 panel.

- No need of building automation system (BAS).

- The schedule shall consist of 10 events.

- Each event shall have an enable and disable. An event shall store which days

of the week it is active.

- Each event shall have a trigger time, which is the time (on the active days of the

week) that the event will occur.

12.3.2.1. Scenarios

Note: The following example is meant to demonstrate the flexibility of the local time of

day schedule and is notmeant to indicate the proper way to run a chiller. Events not

displayed are considered disabled.

“I want the chilled water set to 7°C during work hours (event 1) and then in

the evenings 9°C (event 2). Saturday I want the chilled

water set to 8°C from 10:00am to 2:00pm (event 3) and after that disabled

until Monday morning (event 4).”

Monday Tuesday Wednesday Thursday Friday Saturday Sunday

00 :00

02 :00

04 :00

06 :00

08 :00 Event 1 Event 1 Event 1 Event 1 Event 1

10 :00 Event 3

12 :00

14 :00 Event 4

16 :00

18 :00 Event 2 Event 2 Event 2 Event 2 Event 2

20 :00

22 :00

Table 8. Events schedule

36

CG-PRB018-E4

12.3.3. Benefits

- Allows the user to set up to ten events in a seven day time period.

- Allows the customer to perform simple chiller scheduling without the need for a

building automation system.

- This function gives a simple and reliable solution to control the chiller.

- Energy saving as the user do not have to do daily set up.


- Communication cards.

37

CG-PRB018-E4

12.4. BCI-C (BACnet Communication Interface) Digit 31 = 4

12.4.1. Application

- When the unit needs to communicate with BACnet systems and devices.

12.4.2. Description

- factory-installed in the chiller control panel.

- There are three rotary switches on the front of the BCI-C device that are used to

define a three-digits address when the BCI-C is installed on a BACnet

communications network.


- Used with CH530 main processor (MP) 2.00 and TechView 12.1 SP2 or higher.


- LCI-C.

- Time of day scheduling

Illustration 34. BCI-C layout Illustration 33. BCI-C

38

CG-PRB018-E4

13. External Chilled Water and Demand Limit Setpoint Digit 32

13.1. External Chilled Water and Demand Limit Setpoint with 4-20 mA Digit 32 = A

13.1.1. Application

- When the chilled water setpoint needs to be set by sending an external signal.

- When the number of compressors allowed to start needs to be limited in order

to control chiller power consumption by sending an external signal.

13.1.2. Description

- CH530 accepts two 4-20 mA analog input suitable for customer connection to

set the unit external chilled water setpoint ( ECWS ) and the external demand

limit setpoint ( EDLS).

- There is one input to reset the chilled water setpoint and one input to limit the

number of compressors allow to start.

13.1.3. Operation

- External chilled water and demand limit setpoint set via the DynaView.

- 4-20 mA correspond to an external chilled water setpoint range with both

minimum and maximum external chilled water setpoint configurable.

- 4-20 mA correspond to an external demand limit setpoint range with a minimum

of 0% and a maximum of 100%.

- If the power draw is exceeding set thresholds, this application can send a

demand limit request to the chiller.

- For input signals beyond the 4-20mA range, the end of range value shall be

used. For example, if the customer inputs 21 mA, the external chilled water

setpoint and external demand limit setpoint shall limit itself to the corresponding

20 mA external chilled water setpoint/external demand limit setpoint.

13.1.4. Benefits

- Provides external signals to set the chilled water setpoint and to limit the

number of compressor allowed to run.

- Energy saving as the user do not need to set the application on site

39

CG-PRB018-E4


- Analog input 2-10 VDC.

- BCI-C.

13.2. External Chilled Water and Demand Limit Setpoint 2-10 VDC Digit 32 = B

13.2.1. Application

- When the chilled water setpoint needs to be set by sending an external signal.

- When the number of compressors allowed to start needs to be limited in order

to control chiller power consumption by sending an external signal.

13.2.2. Description

- CH530 accepts two 2-10 VDC analog input suitable for customer connection to

set the unit external chilled water setpoint ( ECWS ) and the external demand

limit setpoint ( EDLS).

- There is one input to reset the chilled water setpoint and one input to limit the

number of compressors allow to start.

13.2.3. Operation

- External chilled water and demand limit setpoint set via the DynaView.

- 2-10 VDC correspond to an external chilled water setpoint range with both

minimum and maximum external chilled water setpoint configurable.

- 2-10 VDC correspond to an external demand limit setpoint range with a

minimum of 0% and a maximum of 100%.

- If the power draw is exceeding set thresholds, this application can send a

demand limit request to the chiller.

- For input signals beyond the 2-10 VDC range, the end of range value shall be

used. For example, if the customer inputs 11VDC, the external chilled water

setpoint and external demand limit setpoint shall limit itself to the corresponding

10 VDC external chilled water setpoint/external demand limit setpoint.

13.2.4. Benefits

40

CG-PRB018-E4

- Provides external signals to set the chilled water setpoint and to limit the

number of compressor allowed to run.

- Energy saving as the user do not need to set the application on site


- Analog input 4-20 mA.

- BCI-C.

Note : Both functions, the external chilled water setpoint (ECWS) and the

external demand limit setpoint (EDLS) can work at the same time.

13.3. Second leaving water temperature setpoint Digit 32 = C

This option is described in CGAM User Guide.

41

CG-PRB018-E4

14. Percent Capacity digit 33 = 1

14.1. Application

- To provide the customer generic BAS feedback about unit active capacity.

14.2. Description

- A CH530 configuration option.

14.3. Operation

- The CH530 provides an analog voltage output (2-10 VDC) to communicate

active unit capacity [%]. Current output (4-20 mA for example) is not available.

- Output the number of compressors that are operating as an analog 2-10 VDC

signal.

- If the unit has 2 compressors and it send an analog voltage of 2 VDC,no

compressor will be running. It means that the unit capacity is 0%. If the unit

receives 10 VDC, the unit capacity will be 100 % which means both

compressors will be running.

14.3.1. Example

Table 9. Number of compressors running depending on the voltage signal

Number of compressors in the unit

Number of compressors allowed to run

2 Vdc 6 Vdc 10 Vdc

2 0 1 2

4 0 2 4

6 0 3 6

0

20

40

60

80

100

120

0 2 4 6 8 10 12

cap

acit

y %

output(VDC)

Unit Capacity vs Output signal

42

CG-PRB018-E4

14.4. Benefits

- A customer without a communicating BAS interface will be able to get feedback

about the active unit capacity.

- The information may be useful as a status indication or to perform load

shedding in high electrical demand scenarios.



43

CG-PRB018-E4

15. Programmable Relays Digit 34 = A

15.1. Application

- When certain events or states of the chiller need to be remotely controled.

15.2. Description

- Use 4 output relays as shown in the field wiring diagram.

- Factory installed, located in control panel.

Illustration 35. Relay output card

Illustration 36. Programmable output relays wiring diagram

44

CG-PRB018-E4

15.3. Operation

- The relay will be energized when the event or state occurs.

- Works with CH530.

- CH530 (TechView) is used to install the Alarm and Status Relay Option

package and assign any of the above list of events or status to each of the four

relays provided.

- Available outputs are Alarm-Latching, Alarm-Auto Reset, General Alarm,

Warning, Chiller Limit Mode, Compressor Running and Tracer Control.

- The default assignments for the four available relays of the CGAM Alarm and

Status Package Option:

Table 11. Default assignments

Note : other events/states that can be assigned to the programmable relays can

be found in Installation Operation Maintenance

15.4. Benefits

- Customers will be alerted if the events or states of the chiller occur.

- Reduces maintenance works of the chiller

Customer can stop the chiller if the undesire events occur in order to

prevent the components from damages.


- No incompatibilitiy.

Relay Alarm and status

Relay 1 terminals J2-12,11,10: Compressor running

Relay 2 terminals J2-9,8,7: Latching alarm

Relay 3 terminals J2-6,5,4: Chiller limit

Relay 4 terminals J2-3,2,1: alarm

45

CG-PRB018-E4

16. Pump Type Digit 35 = 5, 6, 7, 8

Trane provides the same pump model to each unit according to unit size for high

efficiency and standard efficiency. WILO is the pump brand used by Trane for all units.

Table 12. Pump model for each unit size

- To get more information on pump visit web site www.wilo.fr

- When the unit is provided with two pumps, the pump needs to be interchanged

as only one pump is allowed to run at once. The control will alternate pump

operation each time the unit is allowed to start.

When the CGAM doesn’t have the hydraulic module option, maximum water side working pressure is 10 bars (the safety valve is not provided).

With hydraulic module option, CGAM Slant & V models water side working pressure is limited to 4 bars.

The safety valve limit this working pressure to 5 bars on CGAM W hydraulic module.

Unit Size

Standard Head (Digit 35=5) High Head (Digit 35=6) Standard Head (Digit 35=7) High Head (Digit 35=8)

Wilo Wilo Wilo Wilo

020 IPL50/120-1,5/2 IPL40/160-4/2 DPL50/120-1,5/2 DPL40/160-4/2

023 IPL50/120-1,5/2 IPL40/160-4/2 DPL50/120-1,5/2 DPL40/160-4/2

026 IPL50/120-1,5/3 IPL40/160-4/2 DPL50/120-1,5/3 DPL40/160-4/2

030 IPL50/120-1,5/4 IPL40/160-4/2 DPL50/120-1,5/4 DPL40/160-4/2

035 IPL50/120-1,5/5 IPL40/160-5,5/2 DPL50/120-1,5/5 DPL40/160-5,5/2

039 IPL50/130-3/2 IPL40/160-5,5/2 DPL50/130-3/2 DPL40/160-5,5/2

045 IPL50/130-3/3 IPL40/160-5,5/2 DPL50/130-3/2 DPL40/160-5,5/2

050 IPL50/130-3/2 IPL40/160-5,5/2 DPL50/130-3/2 DPL40/160-5,5/2

040 IPL65/120-3/2 IPL40/160-5,5/2 DPL65/120-3/2 DPL40/160-5,5/2

046 IPL65/130-4/2 IPL40/160-5,5/2 DPL65/130-4/2 DPL40/160-5,5/2

052 IPL65/130-4/2 IPL40/160-5,5/2 DPL65/130-4/3 DPL40/160-5,5/2

060 IPL65/130-4/2 IPL65/175(143)-7,5/2 DPL65/130-4/4 DPL65/175(143)-7,5/2

070 IPL65/140-5,5/2 IPL65/175(143)-7,5/2 DPL65/140-5,5/2 DPL65/175(143)-7,5/2

080 IPL65/140-5,5/2 IPL65/175(143)-7,5/2 DPL65/140-5,5/2 DPL65/175(143)-7,5/2

090 IPL65/140-5,5/2 IPL65/175(143)-7,5/2 DPL65/140-5,5/2 DPL65/175(143)-7,5/2

100 IPL65/140-5,5/2 IPL65/175(143)-7,5/2 DPL65/140-5,5/2 DPL65/175(143)-7,5/2

110 IPL80/155(127)-7,5/2 IPL65/175(143)-7,5/2 DPL80/155(127)-7,5/2 DPL65/175(143)-7,5/2

120 IPL80/155(127)-7,5/2 IL80/160-11/2 DPL80/155(127)-7,5/2 DL80/160-11/2

140 IL80/150-11/2 IL80/160-11/2 DL80/150-11/2 DL80/160-11/2

150 IL80/150-11/2 IL80/160-11/2 DL80/150-11/2 DL80/160-11/2

160 IL80/150-11/2 IL80/170(165)-15/2 DL80/150-11/2 DL80/170(165)-15/2

170 IL80/150-11/2 IL80/170(165)-15/2 DL80/150-11/2 DL80/170(165)-15/2

Single pump Dual pump

http://www.wilo.fr/

46

CG-PRB018-E4

16.1. Starter type for Pump Digit 35 = 1, 2, 3, 4

For pump protection, Trane uses TeSys U ( from Schneider Electric) which includes

contactor and overload protection. Each pump will be connected to one TeSys U.

16.1.1. Benefits of TeSys U

- Only one bloc with 2 functions, contactor and overload protection.

- Reduces installation time in the electrical panel.

TeSys U has a different range of control for each unit type.(see table below)

Unit Size Mini pump motor size Maxi pump motor size TeSys U range

CGAM Slant 1,5 kW 5,5 kW 3-12 A

CGAM V 2.2 kW 7.5 kW 4.5-18 A

080-090-100

110 to 170 5,5 kW 15 kW 8-32 A

Table 13. TeSys U range of control and pump power

- When the unit is provided with starters for dual pumps option, the pump needs

to be interchanged as only one pump is allowed to run at once. The control will

alternate pump operation each time the unit is allowed to start.

2. Pump Insulation

Pump insulation is factory provided.

Slant unit V & W unit

Illustration 38. TeSys U for unit with dual pump package Illustration 37. TeSys U for unit with single pump package

Illustration 39. Insulation for pump and others components in Slant unit

Pump

insulation

Illustration 40. Insulation for pump and others components in V and W unit.

Pump

insulation

47

CG-PRB018-E4

17. Pump Flow Control Digit 36

17.1. Pump Flow Controlled by Balancing Valve Digit 36 = A

17.1.1. Application

- When the water flow has to be adjusted.

- Used to adjust water flow and stop waterflow for servicing.

17.1.2. Description

- Memory valve factory installed.

- The water flow through the valve must be in the direction of the embossed

arrow on the body.

- On site the service engineer set the postion of the valve to adjust the water

flow.

17.1.3. Operation

- Balancing valve limits the flow.

17.1.4. Benefits

- Low first cost.


- Variable speed drive.

- No pump package.

Illustration 41. Balancing valve with memory valve Illustration 42. Balancing valve

with memory valve

Memory valve

48

CG-PRB018-E4

17.2. Pump Flow Controlled by Variable Speed Drive Digit 36 = B

17.2.1. Application

- When the water flow has to be adjusted by varying the speed of pump

- Used to adjust water flow at a specified pressure drop and stop waterflow for

servicing.

- Used to save energy on the pump consumption

17.2.2. Description

- The inverter is factory installed in a separate box.

- Also known as Variable Frequency Drive (VFD).

- The speed input is controlled manually via the Variable Speed Drive (VSD).

- The Run command is commanded by the CH530 controls.

17.2.3. Operation

- Adjust the frequency of the power supply to the motor.

- Pump control is most often performed by maintaining a pressure differential at a

selected point in the system.

- The control point is selected to minimize overpressuring the system and to

ensure adequate flow at all critical loads.

17.2.4. Benefits

- Controls the water flow.

- Energy saving on the pump consumption.

- Pay back time.

Illustration 43. VSD box for V type unit Illustration 44. VSD inverter

VSD box

49

CG-PRB018-E4


- Balancing valve.

- No pump package.

17.2.6. More detail

17.2.6.1. Pump flow adjustment by Variable Speed Drive

Pump flow can be adjusted by 2 possibilities :

1) By adjusting the frequency of variable speed drive at site.

2) By sending to variable speed drive an external signal 2-10 V .

The frequency of variable speed drive will be corresponding to the

external signal.

Table 14. Pump frequency corresponds to external signal

0

5

10

15

20

25

30

35

40

45

50

55

0 2 4 6 8 10 12

pu

mp

fre

qu

ency

(Hz)

External signal (V)

Pump frequency vs External Signal

External signal ( V ) Frequency (Hz)

2 30

10 50

50

CG-PRB018-E4

17.2.6.2. Detailed example pay back time

This study is made to explain the difference between balancing valve option and

variable speed drive option. The study is carried out to estimate roughly how much we

can save by installing a variable speed drive vs the use of a balancing valve.

The function of variable speed drive is to vary the pump’s motor frequency which

changes the pressure drop to the pump itself. For a pressure between 150 kPa and

250 kPa and a pressure decrease of 10 kPa, we have approximately 5% of reduction

in energy consumption

Example

A pump with reference number IPL40/160-5.5/2 has been chosen to carry out this

study. The starting pressure of the pump is about 175 kPa. We would like to reduce

the pressure to 155 kPa. Therefore, we have 20 kPa of diminution in pressure, which

means the energy consumption is saved about 10%.

Initial energy consumption = 5.5 kW

Saved energy = 10% * 5.5 = 0.5 kW

With variable speed drive, we can save 0.5 kW of energy consumption. For the

electricity consumption, we did an annual calculation.

Saving calculation :

Number of pump’s operating hours for one year = 5000 h

Energy saved = 0.5 kW

Electricity rate = 0.15 €/kWh

Saving made over one year thanks to variable speed drive = 5000 * 0.5 * 015

= 375 €

Comparison the price

Variable speed drive = 570 €

Balancing valve = 250 €

___________________________

= 320 €

Saving made over one year

=

Number of operating hours for one year

*

Energy saved (kW)

*

Electricity rate (kW/h)

51

CG-PRB018-E4

The difference price between variable speed drive and balancing valve is 320 €.

However, the customer will get the pay back in one year with variable speed drive as

the customer will save 375 € per year by using variable speed drive.

Another example

Number of pump’s operating hours for one year = 2000 h

Energy saved = 0.5 kW

Electricity rate = 0.15 €/h

Saving made over one year thanks to variable speed drive = 2000 * 0.5 * 015

= 150 €

Here, the customer will save 150 € per year. The pay back time is around two years.

Conclusion

Most of the time pay back time is around one or two years.

52

CG-PRB018-E4

18. Buffer Tank Digit 37 = 1

18.1. Application

- Used to increase the chilled water circuit inertia.

- Allows to meet the two minutes water loop circulation.

18.2. Description

- It is factory-installed, located on the supply of water loop.

- It is installed before the water pump so that water pump can circulate the

supplied water in buffer tank to the evaporator

- For Simplex and Duplex V units, the buffer tank is mounted next to the chiller

while for Duplex W units, it is placed inside the unit. Water tank volume is given

in general data table of the selection guide.

Illustration 46. Buffer tank for simplex unit

Illustration 47. Buffer tank for duplex V unit Illustration 48. Buffer tank for

duplex W unit

Illustration 45. Hydraulic module water chart

Buffer tank Water pump

53

CG-PRB018-E4

-

-

- Tank water volume is given in general data tables of the selection guide.

18.3. Operation

- Works only with pump package units.

- With short water loops, the chilled water circuit inertia will be increased, thus it

reduces the compressor’s cycling.

18.4. Benefits

- Ease of installation at the building site.

- Increases the compressor life span.

- Allows more accurate water temperature .

- Saves energy as compared to hot gas bypass on the refrigerant circuit.


- It is not available with chiller without hydraulic module.

Illustration 49. Installation buffer tank on Simplex

Illustration 50. Installation buffer tank on Duplex V

Illustration 51. Installation buffer tank on Duplex W

54

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19. Installation Accessories Digit 39

19.1. Elastomeric Isolators Digit 39 = 1

19.1.1. Application

- Used to minimize the vibrations transmited to the building.

19.1.2. Description

- They are installed under the condenser.

- Shipped with the chiller.

Illustration 52. Isolators installed near the pump box


- Eliminates vibration and noise transmission througout the building.

19.1.4. Incompatiblities

- Neoprene pads.

isolators

55

CG-PRB018-E4

19.2. Neoprene Pads Digit 39 = 4

19.2.1. Application

- Used to avoid direct contact of the chiller and the ground.

19.2.2. Description

- They are installed under the chiller.

- Shipped in the control panel.

Illustration 53. Neoprene pad


- Avoid direct contact of the base frame with the ground.

19.2.4. Inconvenience

- Neoprene pad do not filter vibrations.


- Elastomeric isolators.

56

CG-PRB018-E4

20. Water Strainer Digit 40 = A

20.1. Application

- For a prevention of accumulation of the foreign particles in the restricted area

as the isolation valves and the brazed plate heat exchange.

20.2. Description

- Factory-installed .

- The strainer basket is in a lower position.

- Mesh size = 1.6 mm.

- Install on water inlet piping before the evaporator.

Illustration 54. Water strainer

Illustration 55. View of the water stariner

57

CG-PRB018-E4

20.3. Operation

- Particules are retained in the filter.

direction of the water

20.4. Benefits

- Reduces chiller installation cost as it is factory-mounted.

- Increases the life of heat exchanger and isolation valves.

- Heat exchanger and isolation valves are protected.

- Avoid the abrasive effect of flowing particles .

- The customer do not have to dismount completely the strainer for cleaning or

changing the filter.



20.6. More detail

The isolation jacket for strainer is made in two parts. It means for the entire

isolation of strainer, the two parts of isolation jacket are attached by using

straps. Thus, during a maintenance work, when the filter of strainer needs to be

clean or changed, the client can easily removed the isolation jacket and re-

attaches it after the work is done.

Illustration 56. Water strainer – inside view

filter

Illustration 57. Isolation jacket for strainer.

The bond needs

to be cut off first

before removing

the isolation

jacket

Illustration 58. Strap for attaching the two parts of isolation jacket.

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CG-PRB018-E4

21. Sound Attenuation Package Digit 41

All units are provided with the same type of fan.

21.1. Compact unit Digit 41 = 1

In this option, the compressor is not insulated (see page 9). The unit operates with the

speed of fans 920 RPM.

21.2. Super quiet unit Digit 41 = 3

The compressor is isolated with black jackets (see page 9). Black jackets give a first

attenuation level against compressor noise. With this option, the fan speed is

decreased to 700 RPM.

21.3. Super quiet with Night Noise setback Digit 41 = 4

The insulation of compressor is the same as in Super Quiet unit. The fans can rotate

at 700 RPM and when the unit is set into Night Noise setback at night, the fan speed is

decreased to 560 RPM. The unit can operate with the fan speed at 560 RPM with

38°C of ambient temperature .

21.4. Comprehensive acoustic package unit Digit 41 = 5

Trane provides a compressor enclosure or box for compressor’s insulation (see page

9). The compressor enclosure give a highest level of sound attenuation. The unit is

provided with the same low noise fans as Super Quiet unit which means the fan speed

is 700 RPM.

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22. Appearance Options Digit 42

22.1 No Appearance option Digit 42 = X

No louvered panel.

Illustration 59. Unit without architectural louvered panel

22.2. Architectural Louvered Panels Digit 42 = A

22.2.1. Application

- When the unit needs to be installed in an open area.

- When the unit needs to be protected (especially for the unit’s components).

22.2.2. Description

- The color is silver grey RAL 7001.

- Factory-installed.

CGAM W CGAM V

Illustration 60. Unit with architectural louvered panel

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CG-PRB018-E4

22.2.3. Operation

- Cover the complete condensing coil and service area of the unit.

22.2.4. Benefits

- Easy integration on jobsite.

- Ensure safety on sensitive site.

- Protect the internal components of the unit from external element such as hail

stones and animals.

- Prevent people to get injured.

- Improve the esthetics of the units.



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23. Phase Reversal Protection Digit 45

23.1. Digit 45= X

Each compressor needs to be protected from a phase reversal. The scroll compressor

in small CGAM sizes (020, 023, 026, 030, 040, 046, 052 and 060), don’t have

integrated phase reversal protection modul, thus, in the electrical panel, a relay DPA

51 C M44 insures the phase reversal protection.

Scroll compressor sizes 15 to 30 tons (other unit sizes), have a motor phase reversal

protector, it is installed in every compressor terminal box.

23.2. Digit 45= 1

23.1.1. Application

- A RM4 TR relay is used to control unit phase sequence and under/over voltage

protection.

23.1.2. Description

- Factory installed, located in the control panel.

- Only one relay for each unit.

Illustration 63. Phase reversal protection modul, installed in the compressor terminal box (motor protection)

Illustration 62. Phase reversal protection modul

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CG-PRB018-E4

23.1.3. Operation

- If any fault linked is detected, the compressor is stopped.

- Overvoltage and undervoltage detection (RM4TR):

In normal operation, the relay is energized and LEDs U and R are lit. If the average of the three voltages between phases fluctuates outside the range to be monitored, the output relay is de-energized.

Overvoltage: the Red LED “> U” on

Under voltage: the Red LED “< U” on

23.1.4. Benefits

- All motors are fully protected.

Relay RM4 TR provides a phase reversal protection and under/over

voltage protection



23.1.6. Summary

R Yellow LED: Indicates the relay state.

U Green LED: Indicates that the relay power supply is on. > U Red LED: Overvoltage fault.

< U Red LED: Under voltage fault. P Red LED: Phase failure or phase

reversal.

Illustration 64. RM4 TR Illustration 65. RM4 TR face layout

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CG-PRB018-E4

24. Shipping Package Digit 46

In standard, units are provided with wood skid, a treated wood located under the base

frame.

24.1. Unit Containerization Package Digit 46 = A

In this option, units are always provided with wood skid installed under the chiller. In

addition, a pull key is installed at each corner of the base frame. The purpose of pull

keys is to unload easily the chiller from container without using directly a forklift to the

chiller.

How unloading the chiller

Cables with hooks are attached to the pull keys

Use a forklift to pull the cables and then extract the chiller from the container.

Note : A yellow label will be affixed at the base frame to indicate that use

of forklift directly to unload the chiller is probihited.

Illustration 66. Wood skid

Illustration 67. Pull key and wood skid Illustration 68. Pull key at each corner

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CG-PRB018-E4

Annexe 1: Wilo pumps curves.

IPL and Il pump have the same curve as DPL and DL pump ranges working in

individual operation.

DPL or IL50/120-1,5/2

DPL or IL50/130-3/2

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CG-PRB018-E4

DPL or IL65/120-3/2

DPL or IL65/130-4/2

66

CG-PRB018-E4

DPL or IL65/140-5,5/2

DPL or IL80/155(127)-7,5/2

67

CG-PRB018-E4

DPL or IL80/150-11/2

DPL or IL40/160-4/2

68

CG-PRB018-E4

DPL or IL40/160-5,5/2

DPL or IL65/175(143)-7,5/2

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CG-PRB018-E4

DPL or IL80/160-11/2

DPL or IL80/170(165)-15/2

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CG-PRB018-E4

25. Acronyms

BPHE/BPHX Brazed Plate Heat Exchanger

HR Heat Recovery

ELWT Evaporator Low Water Temperature

PHR Partial Heat Recovery

PHR LWT PHR Leaving Water Temperature

PHR EWT PHR Entering Water Temperature

THR Total Heat Recovery

THR LWT THR Leaving Water Temperature

THR EWT THR Entering Water Temperature

SCR Silicon Controlled Rectifier

LCI-C LonTalk Communication Interface

PIC Protocol Interface Controller

BMS Building Management System

BAS Building Automation System

LLIDs Low Level Intelligent Devices

IPC3 Intra Processor Communication

BCI-C BACnet Communication Interface

MP Main Processor

ECWS External Chilled Water Setpoint

EDLS External Demand Limit Setpoint

VFD Variable Frequency Drive

VSD Variable Speed Drive

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CG-PRB018-E4

26. Illustration List

Illustration 1. Range Overview ...............................................................................................................7

Illustration 2. CGAM range ....................................................................................................................8

Illustration 3. Compressor’s appearance for compact unit......................................................................9

Illustration 4. Black jackets cover the compressor for Super quiet unit ...................................................9

Illustration 5. Box is used to cover the compressors for comprehensive acoustic package ......................9

Illustration 6. Operating map for cooling only ...................................................................................... 11

Illustration 7. Pump package anti-freeze heater................................................................................... 12

Illustration 8. Heaters of buffer tank .................................................................................................... 12

Illustration 9. Blanket heater ............................................................................................................... 13

........................................................................................................................................................... 13

Illustration 10. Range of evaporator application option ....................................................................... 14

Illustration 11. Grooved pipe connection.............................................................................................. 16

Illustration 12. Grooved pipe with flange adapter ................................................................................ 16

Illustration 13. Grooved pipe and coupling ........................................................................................... 17

Illustration 14. Aluminum slit fin .......................................................................................................... 18

Illustration 15. Black epoxy fin ............................................................................................................. 19

Illustration 16. Installation BPHE for partial heat recovery in V type unit ............................................ 21

Illustration 17. Partial heat recovery system ........................................................................................ 21

Illustration 18. Water loop in partial heat recovery .............................................................................. 22

Illustration 19. Cooling priority map (ambient temperature VS PHR LWT) ............................................ 23

Illustration 20. Installation of THR components in the unit ................................................................... 24

Illustration 21. Total heat recovery system .......................................................................................... 25

Illustration 22. Water loop in total heat recovery ................................................................................. 25

Illustration 23. THR operating map ...................................................................................................... 26

Illustration 24. Circuit of direct on Line................................................................................................. 28

Illustration 25. Soft starter................................................................................................................... 28

Illustration 26. Solid-state soft starter installed for W unit ................................................................... 29

Illustration 27. PIC ............................................................................................................................... 31

Illustration 28. PIC layout .................................................................................................................... 31

Illustration 29. Installation of Modbus RS-232 ..................................................................................... 32

Illustration 30. Installation of Modbus RS-485 ..................................................................................... 32

Illustration 31. LCI-C card ..................................................................................................................... 33

Illustration 32. The installation of LCI-C card, LCI-C LLID and IPC3 communication bus ribbon cable ..... 34

Illustration 33. BCI-C ............................................................................................................................ 37

Illustration 34. BCI-C layout ................................................................................................................. 37

Illustration 35. Relay output card ......................................................................................................... 43

Illustration 36. Programmable output relays wiring diagram ............................................................... 43

Illustration 37. TeSys U for unit with single pump package ................................................................... 46

Illustration 38. TeSys U for unit with dual pump package ..................................................................... 46

Illustration 39. Insulation for pump and others components in Slant unit ............................................. 46

Illustration 40. Insulation for pump and others components in V and W unit. ....................................... 46

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CG-PRB018-E4

Illustration 41. Balancing valve with memory valve.............................................................................. 47

Illustration 42. Balancing valve with memory valve.............................................................................. 47

Illustration 43. VSD box for V type unit ................................................................................................ 48

Illustration 44. VSD inverter ................................................................................................................. 48

Illustration 45. Hydraulic module water chart ...................................................................................... 52

Illustration 46. Buffer tank for simplex unit .......................................................................................... 52

Illustration 47. Buffer tank for duplex V unit ........................................................................................ 52

Illustration 48. Buffer tank for duplex W unit ....................................................................................... 52

Illustration 49. Installation buffer tank on Simplex ............................................................................... 53

Illustration 50. Installation buffer tank on Duplex V ............................................................................. 53

Illustration 51. Installation buffer tank on Duplex W ........................................................................... 53

Illustration 52. Isolators installed near the pump box ........................................................................... 54

Illustration 53. Neoprene pad .............................................................................................................. 55

Illustration 54. Water strainer ............................................................................................................. 56

Illustration 55. View of the water stariner ............................................................................................ 56

Illustration 56. Water strainer – inside view ......................................................................................... 57

Illustration 58. Strap for attaching the two parts of isolation jacket. .................................................... 57

Illustration 57. Isolation jacket for strainer. ......................................................................................... 57

Illustration 59. Unit without architectural louvered panel .................................................................... 59

Illustration 60. Unit with architectural louvered panel ......................................................................... 59

Illustration 62. Phase reversal protection modul .................................................................................. 61

Illustration 63. Phase reversal protection modul, installed in the compressor terminal box (motor

protection) .......................................................................................................................................... 61

Illustration 64. RM4 TR ........................................................................................................................ 62

Illustration 65. RM4 TR face layout ...................................................................................................... 62

Illustration 66. Wood skid .................................................................................................................... 63

Illustration 67. Pull key and wood skid ................................................................................................. 63

Illustration 68. Pull key at each corner ................................................................................................. 63

27. Table List

Table 1. Compressor size in ton ........................................................................................................... 10

Table 2. Cooling only units (CGAM)...................................................................................................... 11

Table 3. PHR anti-freeze heater power ................................................................................................ 22

Table 4. THR anti-freeze heater power ................................................................................................ 25

Table 5. Inrush current ........................................................................................................................ 30

Table 6. Startup time (ms) ................................................................................................................... 30

Table 7. Connectors’ definition ............................................................................................................ 31

Table 8. Events schedule ..................................................................................................................... 35

Table 9. Number of compressors running depending on the voltage signal .......................................... 41

Table 11. Default assignments ............................................................................................................. 44

Table 12. Pump model for each unit size ............................................................................................. 45

Table 13. TeSys U range of control and pump power ........................................................................... 46

Table 14. Pump frequency corresponds to external signal ................................................................... 49

73

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Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the

leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad

portfolio of advanced controls and HVAC systems, comprehensive building services, and parts.

For more information, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications

without notice.

© 2013 Trane All rights reserved

CG-PRB018-E4_0813 Supersedes CG-PRB018-E4 MAY 01, 2011

© 2011 Trane All rights reserved

CG-PRB018-E4 MAI 01, 2011

Options Guide - Trane...1 CG-PRB018-E4 compressors August 2013 CG-PRB018-E4 Air-cooled Liquid...

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