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Trane Cold Generator CGWR Series Installation, Operation And Maintenance Manual

Scroll liquid chillers 20 to 65 tons (60 hz) water-cooled and compressor chillers
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Installation, Operation,
and Maintenance
Cold Generator™ Scroll Liquid Chillers
Model CGWR and CCAR
20 to 65 Tons (60 Hz)
Water-Cooled and Compressor Chillers
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
September 2017
SAFETY WARNING
CG-SVX038A-EN

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Summary of Contents for Trane Cold Generator CGWR Series

  • Page 1 Installation, Operation, and Maintenance Cold Generator™ Scroll Liquid Chillers Model CGWR and CCAR 20 to 65 Tons (60 Hz) Water-Cooled and Compressor Chillers SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
  • Page 2 ALWAYS refer to the appropriate MSDS/SDS and compounds have the same potential impact to the OSHA/GHS (Global Harmonized System of environment. Trane advocates the responsible handling of Classification and Labelling of Chemicals) guidelines all refrigerants-including industry replacements for CFCs for information on allowable personal exposure...
  • Page 3 Copyright This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

  • Page 4: Table Of Contents

    Table of Contents Model Number Descriptions ....5 Unit Components ......6 General Data .

  • Page 5: Model Number Descriptions

    Model Number Descriptions Digit 1, 2, 3, 4 — Unit Type Digit 16 — Short Circuit Rating (SCCR) CGWR=Water-Cooled Chiller CCAR= Compressor Chiller Standard 5 kA Rating Optional 100 kA Rating Digit 5, 6, 7 — Unit Nominal Tonnage Digit 17 — Sound Attenuator 020 = 20 Nominal Tons No Sound Attenuation...

  • Page 6: Unit Components

    Unit Components Power Wiring Unit Nameplate Location Optional 15.4” Color Touchscreen (inside door) (Keypad w/ Display comes standard) Optional Disconnect Switch Location Evaporator Water Inlet (Vic) Evaporator Water Outlet (Vic) Condenser Water Rigging Bracket Outlet (FPT) Install Pockets Condenser Water Inlet (FPT) Removable Water Plate on Shell-and-...

  • Page 7: General Data

    General Data Table 1. General data for CGWR water-cooled chillers Unit Size Compressor Quantity each Nominal Tons tons 10/10 15/15 10/10, 20 12/12, 25 15/15, 30 Steps of Unloading 100-50 100-50 100-75-50-25 100-75-50-25 100-75-50-25 Compressor Sound Data 81.0 84.0 87.2 87.5 90.2 Compressor Sound Data with Sound...
  • Page 8 CCAR/CAUJ Combination Minimum Ambient Temperature Limit Refer to SS-APG014*-EN Application Guide – Pairing Trane CCAR Compressor Chillers (20 to 65 tons) with Trane CAUJ Air-Cooled Condensers (20 to 80 tons). In general, the minimum outdoor ambient temperature for operation of CCAR compressor chiller in combination with a CAUJ air cooled condenser is 40°F .

  • Page 9: Inspection Check List And Unit Identification

    • Notify the Trane sales representative and arrange for repair. Do not repair the unit, however, until damage is inspected by the carrier’s representative. After completing the inspection checklist, identify the unit with the unit nameplate, packing list and ordering information.

  • Page 10: Electrical Data

    Electrical Data Table 3. Electrical data — CGWR water cooled chillers & CCAR compressor chillers Unit Wiring Data Compressors Minimum Recommended Unit Circuit Maximum Dual Element Refrig. Nom. Control Size Rated Voltage Ampacity Fuse Size Fuse Size Circuits Tons (ea) (ea) 200-230/3/60 39/39...

  • Page 11: Dimensions And Weights

    Dimensions Refer to name plate on control box door (inside) for specific unit electrical data. The Trane application manual and/or project submittals These documents can be forwarded for specific jobs as contain dimensional data, application data, and electrical part of a job submittal package upon request.
  • Page 12 Dimensions and Weights Table 4. CGWR/CCAR 20 to 30 ton — in (mm) Dimension CGWR 20 CGWR30 CCAR 20 CCAR30 76.6 (1946) 77.5 (1969) 70.4 (1788) 70.4 (1788) 59.8 (1519) 59.8 (1519) 45.8 (1163)* 45.8 (1163)* 19.3 (490) 20.1 (511) 26.7 (678) 26.7 (678) 26.7 (678)
  • Page 13 Dimensions and Weights Figure 2. CGWR/CCAR 40 to 65 ton mechanical drawing (4 PLACES) CG-SVX038A-EN...
  • Page 14 Dimensions and Weights Table 5. CGWR/CCAR 40 to 65 ton — in (mm) Dimension CGWR40 CGWR50 CGWR65 CCAR40 CCAR50 CCAR65 83.8 (2128) 83.8 (2128) 83.8 (2128) 87.6 (2225) 87.6 (2225) 87.6 (2225) 59.8 (1519) 59.8 (1519) 59.8 (1519) 45.8 (1163)* 45.8 (1163)* 45.8 (1163)* 13.1 (333)
  • Page 15 Dimensions and Weights Weights Table 6. Weights Shipping Operating Unit Size 1116 1042 1252 1242 CGWR 1659 1577 1847 1833 2039 2005 CCAR 1265 1110 1304 1152 1484 1336 CG-SVX038A-EN...

  • Page 16: Installation

    32°F , vibration free, and • Optional Water Regulating Valve — Trane offers a fully secure area. Periodically check the pressure in each installed and integrated water regulating valve refrigerant circuit to verify that the refrigerant charge is designed to stabilize discharge pressure at all full and intact.
  • Page 17 Installation Rigging/Lifting Procedure A minimum clearance of 42 in (2067 mm) is required to other electrically grounded parts. A minimum clearance of 48 in (1220 mm) is required between two units opposite If the CGWR/CCAR is not moved using a forklift and the each other (front-to-front or back-to-back) or to other forklift pockets provided as part of the chiller's frame, then electrically live parts.
  • Page 18 Evaporator Nameplate 1. A qualified Trane technician must perform the task 2. Use technical support for any questions that may arise The evaporator nameplate is mounted on evaporator during the task under the insulation.

  • Page 19: Unit Piping

    Entering and leaving chilled and condenser water water treatment specialist be engaged to determine lines should have shutoff valves installed to isolate the what water treatment, if any, is required. Trane heat exchanger for service. See Figure 3, p. 21...
  • Page 20 Saturated discharge temperature must be maintained a pump that would trigger the flow switch to start the between 80°F and 128°F . Trane offers an optional factory chiller. The flow switch is meant to act as a safety installed water regulating valve that is controlled by the switch and not a start/stop mechanism.
  • Page 21 Unit Piping disc and seat type water regulating valves caused by excessive pressure drops through the valve. Under full load AHRI standard conditions, and with approximately 3 gpm/ton cooling water flow through the condenser, the temperature rise across the condenser will be approximately 10°F .
  • Page 22 Unit Piping Figure 4. Condenser piping schematic Optional Water Vibration Eliminator Regulating Temperature Gauge Valve Valve for Pressure Measurement Isolation Valve Condenser Out Pressure Gauge Bypass Valve Condenser In Isolation Valve Valve for Pressure Measurement Temperature Gauge Vibration Eliminator FACTORY INSTALLED UNIT CUSTOMER PIPING...
  • Page 23 Unit Piping Water Pressure Drop Curves Figure 5. Evaporator water pressure drop 20.00 20 TON 18.00 30 TON 16.00 50 TON 65 TON 14.00 12.00 40 TON 10.00 8.00 6.00 4.00 2.00 0.00 Flow, GPM Figure 6. Condenser water pressure drop 18.00 25.00 20 TON...
  • Page 24 Unit Piping Low Suction Temperature and Pressure Cutouts/ Percent Glycol Recommendations Table 9 shows the low suction temperature and pressure For some operating conditions this effect can be cutouts for different glycol levels. significant. Additional glycol beyond the recommendations will If additional glycol is used, then use the actual percent adversely affect unit performance.
  • Page 25 Note: If using a Trane CAUJ air-cooled condenser with a 5. A replaceable core liquid line filter drier must be Trane CCAR compressor chiller, please refer to the installed as close as possible to the compressor chiller.
  • Page 26 Unit Piping Final Leak Test • Double risers are generally unnecessary. The scroll compressors in Trane units unload to the extent that a single, properly sized riser can transport oil at any load WARNING condition. Hazard of Explosion! Table 10. Minimum discharge-line velocities for oil...

  • Page 27: Electrical Wiring

    Electrical Wiring Power and Control Wiring WARNING Unit Power Wiring Proper Field Wiring and Grounding Required! The installing contractor must connect appropriate power wiring (with fused disconnects) to the terminal block or Failure to follow code could result in death or serious non-fused, unit-mounted disconnect in the power section injury.
  • Page 28 Electrical Wiring Voltage Imbalance Research Model 45 Phase Sequence indicator or equivalent and follow this procedure. Excessive voltage imbalance between phases in a three- 1. Verify that all operating controls for the unit are in the phase system will cause motors to overheat and “Off”...
  • Page 29 Electrical Wiring CGWR Condenser Water Loss of Flow Protection NOTICE: The controller logic will sense a loss of flow through the Unexpected Chiller Start! condenser. No flow switches are necessary with the Failure to follow instructions could cause the chiller to standard unit controller configuration.
  • Page 30 Electrical Wiring ® communication via BACnet MSTP , Johnson N2, and ® , and this should be ordered with the chiller if ORKS required. An ethernet connection is also provided on each unit. While field changes can be made, please insure that the unit is ordered set up for required communications to insure that factory testing includes end user configuration.

  • Page 31: Unit Controller-Software Installation And Setup

    Connect the supplied NULL MODEM cable between your USB adapter or serial port to the chiller. A standard serial Trane chillers are programmed, set up, and tested prior to cable will not work. Start the MCS-CONNECT software and shipment. Sometimes after a unit arrives at the jobsite, the select LOCAL SERIAL.
  • Page 32 In the MCS-CONNECT software, select TRANSMIT SW. Locate the extracted hex file and select Transmit. Watch the chiller LCD screen. After the file is uploaded, the Trane MCS Digital Controller will verify that it’s a valid file and then erase the flash memory. Next, it will write the new hex to memory.

  • Page 33: Unit Startup Procedures

    To prevent compressor damage, do not operate the CG-ADF005*-EN (CGWR Installation Completion Check unit with discharge or liquid line service valves List and Request for Trane Service) or CG-ADF006*-EN closed. (CCAR Installation Completion Check List and Request for Trane Service), as appropriate, must be completed and •...
  • Page 34 Unit Startup Procedures Checking Operating Conditions 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. NOTICE: The system may not be properly charged although Evaporator/Condenser Damage! the sight glass is clear.

  • Page 35: Unit Shutdown

    Unit Shutdown Normal Unit Shutdown 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 Inhibit Level Evap Pump Off Delay Timer (0 to 30 Minutes) De-Energize Condenser Water Pump Relay (If Chiller Controls...

  • Page 36: Unit Restart

    7. Check the flow switch on the evaporator outlet piping for proper operation. 8. Stop the water pump(s). 9. Complete each step in Trane literature CGWR-ADF002*-EN (Start-up Check List for CGWR and CCAR Chillers). 10. Energize Crankcase Heaters (Must be energized 24 hours before startup).

  • Page 37: Maintenance

    Maintenance Scroll Compressor Functional Test WARNING Since the scroll compressor does not use discharge or Hazardous Service Procedures! suction valves, it is not necessary to perform a pump- Failure to follow all precautions in this manual and on down capability test, i.e. a test where the liquid line valve the tags, stickers, and labels could result in death or is closed and the compressor is pumped in a vacuum to serious injury....
  • Page 38 Maintenance Figure 7. Compressor operating map Compressor Operating Map Saturated Evaporating Temperature (°F) Compressor Operational Noises Note: Operation of the chiller with saturated suction temperatures below freezing will cause damage to the evaporator. If this occurs immediately stop the Because the scroll compressor is designed to machine, diagnose and correct the problem.
  • Page 39 Maintenance Inspect the entire system for unusual conditions. Use an operating log to record a weekly operating conditions history for the unit. A complete operating log is a valuable diagnostic tool for service personnel. Monthly Maintenance Once the unit has been operating for about 10 minutes and the system has stabilized, check operating conditions and complete the checkout procedures that follow.

  • Page 40: Electrical Schematics

    Electrical Schematics CGWR Water-Cooled Chillers CGWR Field Wiring Figure 8. Field wiring for 20 to 65 ton, R-410A CGWR water-cooled chillers Control Panel Representation PDB1 UNIT CONTROLLER DSW1 Optional: Disconnect (Factory Installed) 10 11 16 17 18 19 20 21 23 24 PANEL GROUND...
  • Page 41 Electrical Schematics CGWR Power/Control Wiring Refer to name plate on control box door (inside) for electrical data and wiring diagram. Figure 9. Power/control wiring schematic for 20 to 30 ton, R-410A CGWR water-cooled chillers (OPTIONAL) (OPTIONAL) Bellimo WRV Com NO Com NO Com NO Com NO...
  • Page 42 Electrical Schematics Figure 10. Power/control wiring schematic for 40 to 65 ton, R-410A CGWR water-cooled chillers YELLOW BLUE (OPTIONAL) (OPTIONAL) 120 VAC POWER IN Bellimo WRV #1 SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 SENSOR 7 SENSOR 8 SENSOR 1 S1 GND +5 S1 GND +5...
  • Page 43 Electrical Schematics Figure 11. Control panel layout for 20 to 30 ton, 208V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 44 Electrical Schematics Figure 12. Control panel layout for 20 to 30 ton, 460V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 45 Electrical Schematics Figure 13. Control panel layout for 20 to 30 ton, 575V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 46 Electrical Schematics Figure 14. Control panel layout for 40 to 65 ton, 208V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 47 Electrical Schematics Figure 15. Control panel layout for 40 to 65 ton, 460V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 48 Electrical Schematics Figure 16. Control panel layout for 40 to 65 ton, 575V, R-410A CGWR water-cooled chillers CG-SVX038A-EN...
  • Page 49 This point intended to operate a low ambient damper on a remote air-cooled condenser. out and start-up procedures have Wiring to be 2-wire shielded cable between outdoor unit and Trane been completed. indoor chiller. If installing with a Trane CAUJ air-cooled condenser, more specific field wiring instructions can be found in the operations and maintenance manual.
  • Page 50 AO. Wiring to be 2-wire shielded cable between outdoor unit and Trane indoor chiller. CAUTION If installing with a Trane CAUJ air-cooled condenser, more specific Do not energize the unit until check- field wiring instructions can be found in the operations and out and start-up procedures have maintenance manual.
  • Page 51 Electrical Schematics CCAR Power/Control Wiring Refer to name plate on control box door (inside) for electrical data and wiring diagram. Figure 19. Power/control wiring schematic for 20 to 30 ton, R-410A CCAR compressor chillers (OPTIONAL) Com NO Com NO Com NO Com NO Com NO Com NO...
  • Page 52 Electrical Schematics Figure 20. Power/control wiring schematic for 40 to 65 ton, R-410A CCAR compressor chillers YELLOW BLUE SENSOR 5 SENSOR 7 SENSOR 8 120 VAC POWER IN SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 6 SENSOR 1 SI GND +5SI GND +5 SI GND +5 SI GND +5 SI GND +5SI GND +5 +12 +12 +12 LINE NEUT GND SI GND +5...
  • Page 53 Electrical Schematics Figure 21. Power schematic, CAUJ condenser control circuit modification: fan cycling control by CCAR compressor chillers 1TB2-1 1TB3-4 1TB3-5 1TB3-6 1TB3-9 1TB3-10 C 1TB3-11 CG-SVX038A-EN...
  • Page 54 Connect 1TB2-1 to TBA 15 at Trane Chiller. Remove wire 64E. Connect 1TB3-5 to TBA 16 at Trane Chiller. This is the first fan on and last fan off. Remove wire 63A. Connect 1TB3-4 to TBA 17 at Trane Chiller. This is the second fan on and first fan off.
  • Page 55 Electrical Schematics Figure 23. Low ambient damper schematic wiring and connections diagrams — CAUJ condenser control circuit modification: low ambient damper control by CCAR compressor chillers Low Ambient Schematic Wiring Diagram P2-4 849A 2U83 (+) J2-4 P2-3 848A (-) J2-3 2TB34-9 2TB34-10 Low Ambient Connections Diagram...
  • Page 56 Electrical Schematics Figure 24. Instructions — CAUJ condenser control circuit modification:  low ambient damper control by CCAR compressor chillers Trane CAUJ Condenser Control Circuit Modification Ambient Damper Control by Trane CCAR Compressor Chiller FOR ONE DAMPER ASSEMBLY: Reference COMPLETE...
  • Page 57 Electrical Schematics Figure 25. Control panel layout for 20 to 30 ton, 208V, R-410A CCAR compressor chillers CG-SVX038A-EN...
  • Page 58 Electrical Schematics Figure 26. Control panel layout for 20 to 30 ton, 460V, R-410A CCAR compressor chillers CG-SVX038A-EN...
  • Page 59 Electrical Schematics Figure 27. Control panel layout for 20 to 30 ton, 575V, R-410A CCAR compressor chillers CG-SVX038A-EN...
  • Page 60 Electrical Schematics Figure 28. Control panel layout for 40 to 65 ton, 208V, R-410A CCAR compressor chillers CG-SVX038A-EN...
  • Page 61 Electrical Schematics Figure 29. Control panel layout for 40 to 65 ton, 460V, R-410A CCAR compressor chillers CG-SVX038A-EN...
  • Page 62 Electrical Schematics Figure 30. Control panel layout for 40 to 65 ton, 575V, R-410A CCAR compressor chillers CG-SVX038A-EN...

  • Page 63: Appendix

    Appendix Vendor Data Sheet MSC-CT300 Current Transducer Data Sheet The MCS-MAGNUM-N MCS-CT300 Dimensions: Height ........... 4.00” Width ............ 2.38” Depth ............ 1.56” Wire Hole ..........1.00” Amperage Rating........0-300A Accuracy ..........± 3 amps Sensor Output Voltage ......0-5vdc Supply Voltage........Induced Operating Temperature ......-40°F to +158°F (-40°C to +70°C) Storage Temperature ......-40°F to +158°F (-40°C to +70°C) Part # MCS-CT300...
  • Page 64 Appendix MSC-667F Pressure Transducer Data Sheet The MCS-MAGNUM-N MCS-667B-xx Speci c tions Pressure Range....0 to psi seale gauge Housing ......Stainless Steel Sealing Material ....Neoprene Electrical Connection ..P Operating Temperature ..- 0 F to 5 F - 0 C to 1 5 C Accuracy ......
  • Page 65 Appendix The MCS-T100 Specifications and Description The MCS-MAGNUM-N MCS-T100 Standard Temperature Range....Standard Temperature Accuracy ..Resistance Range ........Input Voltage......... 5vdc Sensor Resistance ......Dimensions ........Material ......... Stainless Steel Environmental rating..... Testing .......... 10,000 freeze/thaw thermal Part # Description Length...........
  • Page 66 (18) months from date of original shipment, hermetic motor/compressors, the nearest wholesaler whichever may first occur. Service Parts shall be so referred to herein shall be the nearest TRANE PARTS warranted for a period of ninety (90) days from date of CENTER. The replacement hermetic motor/compressor...
  • Page 68 Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results.

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