Trane Cold Generator CICD Series Installation, Operation And Maintenance Manual
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Trane Cold Generator CICD Series Installation, Operation And Maintenance Manual

Trane Cold Generator CICD Series Installation, Operation And Maintenance Manual

Compact chiller 30 to 75 tons (60 hz), r-410a
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Installation, Operation,
and Maintenance
Cold Generator™ Compact Chiller Series
Model CICD
30 to 75 Tons (60 Hz)
R-410A
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.
June 2019
SAFETY WARNING
CG-SVX044B-EN

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  • Page 1 Installation, Operation, and Maintenance Cold Generator™ Compact Chiller Series Model CICD 30 to 75 Tons (60 Hz) R-410A 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 Unit Start-Up Procedures ....5 ....35 Pre-Start .

  • Page 5: Model Number Descriptions

    Model Number Descriptions Digits 1 to 4— Model Motorized Chilled Water Isolating 400 Amp Valve 600 Amp CICD= Compact Indoor Chiller 800 Amp Digit 20 — Condenser Heat Digits 5 to 7 — Nominal Capacity 1200 Amp Exchanger Type 030 = 30 Nominal Tons Digit 29 —...
  • Page 6 Model Number Descriptions Digit 37 — Water Side Pressure Digit 44 — Shipping Options 150 psi Framed Crate with Plastic Wrap 300 psi (Non-Shrink) Fully Enclosed Crate Digit 38 — Water Strainer(s) Digit 45 — Warranty None Chilled Water Flow Wye Strainer Standard Warranty Chilled Water Wye Strainer with Digit 46 —...

  • Page 7: General Information

    General Information Unit Description ™ Model CICD Cold Generator Compact Series water- cooled chillers are designed for installation on a prepared surface in a suitable, weatherproof location above freezing (32°F). Each unit consists of one or two independent refrigerant circuits, two scroll compressors, a single or dual circuited brazed plate evaporator, a single or dual circuited brazed plate or shell-and-tube condenser and control box with integral control panel—all mounted on a...
  • Page 8 General Information Unit Components Figure 1. Unit components Keypad or Touchscreen Controller Display Locking Door Detachable Water OFF/AUTO Switch, Header Frame RUN Light, ALARM Light Easily Accessible Condenser for Easy Cleaning Brazed Plate or Shell and Tube Condenser Single or Dual Refrigeration Circuit(s) Manual or Motorized...

  • Page 9: Pre-Installation

    • Notify the Trane sales representative and arrange for repair. However, do not repair the unit 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 2. Electrical data Compressor Wiring # of Minimum Refrigerant Nominal Circuit Fuse Recommended Dual Size Rated Voltage Circuits Tons (each) (each) Ampacity Size Element Fuse Size 200-230/60/3 460/60/3 1 or 2 15/15 575/60/3 200-230/60/3 460/60/3 1 or 2 20/20 575/60/3 200-230/60/3...

  • Page 11: Dimensions And Weights

    Dimensions and Weights Dimensions Figure 2. CICD unit dimensions, brazed plate condenser CG-SVX044B-EN...
  • Page 12 Dimensions and Weights Figure 3. CICD unit array dimensions, brazed plate condenser CG-SVX044B-EN...
  • Page 13 Dimensions and Weights Figure 4. CICD unit dimensions, shell and tube condenser POWER WIRE ENTRY CONTROL PANEL SHELL and TUBE CONDENSER 1 3/8" 45" 8 3/4" 7/8" BRAZED PLATE 29 3/4" EVAPORATOR 2x 29 3/4" 31 1/2" 3/4" 59 7/8" Footprint 60 5/8"...
  • Page 14 Dimensions and Weights Figure 5. CICD unit array dimensions, shell and tube condenser CG-SVX044B-EN...
  • Page 15 Dimensions and Weights Figure 6. CICD unit dimensions, remote condenser POWER WIRE ENTRY CONTROL PANEL BRAZED PLATE EVAPORATOR 1 3/8" 45" 8 3/4" 4 3/4" 7/8" 31 1/2" 29 3/4" 7/8" Footprint 3/4" 59 7/8" 60" Customer connections 6" S/40 pipe 76"...
  • Page 16 Dimensions and Weights Figure 7. CICD unit array dimensions, remote condenser CG-SVX044B-EN...

  • Page 17: Clearances

    Dimensions and Weights Clearances • Two units facing each other or other live parts require a clearance of 48 inch. Notes: • 36 inch clearance is recommended above the chiller. • Clearance of 42 inch is required in front of chiller to •...
  • Page 18 Dimensions and Weights Figure 9. Clearance — CICD array chiller application (all condenser options) 24" Recommended 3/4" Min. 3/4" Min. 36" 36" Recommended Recommended 42" Figure 10. Clearance needed to remove chiller from array— CICD array chiller application (all condenser options) 24"...
  • Page 19 Dimensions and Weights Figure 11. Single point power distribution panel dimensions CG-SVX044B-EN...

  • Page 20: Weights

    Dimensions and Weights Weights Table 3. CICD unit weights Shipping Weight Operating Weight Brazed Plate Shell-and-Tube Remote Brazed Plate Shell-and-Tube Remote Condenser Condenser Condenser Condenser Condenser Condenser Size 1495 1760 1205 1720 2025 1320 1775 1970 1420 2040 2265 1027 1550 1795 1970...

  • Page 21: Installation Mechanical

    Supply and install condenser water control valve(s). Noise Considerations See also Trane publication RLC-PRB021-EN, available from Trane Sales Offices, for additional technical Locate the unit away from sound-sensitive areas. If assistance. Provisions must be made for the control of necessary, install isolators under the unit. Install vibration condenser water that results in stable saturated isolators in all piping and use flexible electrical conduit.

  • Page 22: Clearances

    Installation Mechanical Clearances Figure 12. CICD rigging, fork lift pockets Provide adequate space around each unit for unrestricted Spreader Bar access for installation and maintenance. Unit dimensions are given in the Dimensions and Weights chapter. It is Lifting Straps critical that adequate space is provided for service and maintenance of evaporator, condenser and compressor.

  • Page 23: Access Restrictions

    Installation Mechanical Forklifting Procedure Access Restrictions Important: All CICD units are designed to pass through a standard 36 Step 1 through Step 4 must be followed to lift unit using a inch doorway. See outline drawings for other important dimensions. forklift.

  • Page 24: Minimum Water Volume For A Process Application

    Installation Mechanical Flow Sensing Devices Typically, a three-minute water loop circulation time is sufficient to prevent short water loop issues. Therefore, as a guideline, ensure the volume of water in the chilled water NOTICE loop is greater than or equal to three times the evaporator flow rate.
  • Page 25 Figure 4, p. 25. Special applications may deviate from ensure the evaporator is full of water and void of air these numbers as directed by Trane engineering. at all times. Operation below these volumes will cause unacceptable system control problems and the potential for evaporator •...
  • Page 26 Installation Mechanical Figure 14. Condenser pressure drop Brazed Plate Condenser Flow vs Pressure Drop 60.00 25.00 50.00 20.00 40.00 15.00 30.00 10.00 20.00 5.00 10.00 0.00 0.00 0.00 50.00 100.00 150.00 200.00 250.00 300.00 350.00 Flowrate (gpm) CICD030 CICD045 CICD055 CICD065 CICD075 Figure 15.
  • Page 27 Operation of chiller without screen in place will void water treatment, if any, is required. Trane assumes no warranty. Chemical treatment of the chilled water loop is responsibility for equipment failures which result from...
  • Page 28 Saturated discharge temperature must be maintained Waterborne Debris! between 80°F and 145°F. Trane offers an optional factory To prevent condenser damage, pipe strainers must be installed water regulating valve that is controlled by unit installed in the water supplies to protect components controller.
  • Page 29 Installation Mechanical the range of 3 gpm per ton. Minimum inlet condenser water temperature is 65°F. Condenser piping must be in accordance with all local and national codes. Condenser piping components generally function identically to those in the evaporator piping system. In addition, cooling tower systems may include a manual or automatic bypass valve that can alter water flow rate to maintain condensing pressure.

  • Page 30: Installation Electrical

    Installation Electrical Checking the Power Supply WARNING Electrical power to the unit must meet stringent Proper Field Wiring and Grounding requirements for the unit to operate properly. Total voltage Required! supply and voltage imbalance between phases should be within the tolerances listed in this manual. Failure to follow code could result in death or serious injury.

  • Page 31: Equipment Grounding

    Installation Electrical increase in winding temperature that will decrease This direction may be reversed by interchanging any two compressor motor life. of the line wires. The possibility of interchanging the wiring makes a phase sequence indicator necessary to Equipment Grounding quickly determine the proper phase rotation.

  • Page 32: Control Power Supply

    Installation Electrical Control Power Supply Condenser Water Loss of Flow Protection The CICD controller logic will sense a loss of flow through A fused, panel-mounted control power transformer is the condenser. No condenser water flow switches are standard. Replacement fuse information is listed on the necessary with the standard standalone CICD controller “Fuse Schedule”...

  • Page 33: Controls Interface

    Controls Interface Unit Controller — General Important: All configuration changes need to be done by factory representatives to ensure proper operation of the unit within design The CICD controller is a rugged microprocessor-based parameters. See CG-SVX030*-EN controller designed for the hostile environment of the controller manual for sequence of HVAC/R industry.
  • Page 34 Controls Interface want to analyze. This will pop up a screen that shows provided. Save the zipped folder to the computer’s operating conditions just prior to the trip allowing the user desktop. Right click folder and select EXTRACT ALL. This to determine if the fault was caused by a sudden or gradual will create another folder by the same name on the change.

  • Page 35: Unit Start-Up Procedures

    Unit Start-Up Procedures Prior to calling for start-up services or commissioning, CICD Compact Chiller Installation Completion Check List NOTICE and Request for Trane Service, CG-ADF003*-EN, must be Equipment Damage! completed and submitted. Once that has been completed • To prevent overheating at connections and under-...

  • Page 36: Checking Operating Conditions

    Unit Start-Up Procedures Checking Operating Conditions Important: The system may not be properly charged NOTICE although the sight glass is clear. Also consider superheat, sub-cooling and Evaporator/Condenser Damage! operating pressure. Water (fluid) flow must be established in evaporator • Once oil level, amp draw and operating pressures have and condenser before adding refrigerant, removing stabilized, measure system suction superheat.

  • Page 37: Shut Down

    Shut Down Normal Unit Shutdown Figure 18. Normal unit shutdown Extended Shutdown Procedure If the system is taken out of operation for long periods of time, use this procedure to prepare the system for shutdown. 1. Test condenser and high side piping for refrigerant leakage.

  • Page 38: Unit Restart

    Shut Down Unit Restart Unit Restart After Extended Shutdown Use this procedure to prepare the system for restart after an extended shutdown. NOTICE Compressor Failure! To protect compressors from premature failure the unit must be powered and crankcase heaters energized at least 24 hours BEFORE compressors are started.

  • Page 39: Maintenance

    Maintenance Monthly Maintenance WARNING Ensure the unit has been operating for about 10 minutes Hazardous Service Procedures! and the system has stabilized, check operating conditions and complete the checkout procedures that follow. Failure to follow all precautions in this manual and on the tags, stickers, and labels could result in death or •...

  • Page 40: Heat Exchanger Maintenance

    Maintenance Oil Level • 15°F to 39°F LWT: 60 to 103 psig While the compressor is running, the oil level may be Compressor Operational Noises below the sight glass but still visible through the sight At low ambient startup: When the compressor starts up glass.
  • Page 41 Maintenance overall operating costs. Following is a general description among others, and are commonly applied at of the system setup, the CIP procedure, and the various concentrations between 1 and 5 volume percent. cleaning fluids. Formic Acid Cleaning in Place (CIP) Procedure Formic acid alone is unable to remove iron oxide why it's used as a mixture with citric acid or HCl.

  • Page 42: Wiring

    Wiring Figure 19. CICD wiring schematic CG-SVX044B-EN...
  • Page 43 Wiring Figure 20. CICD wiring schematic (continued) CG-SVX044B-EN...
  • Page 44 Wiring Figure 21. Field wiring — CICD single unit, single circuit CG-SVX044B-EN...
  • Page 45 Wiring Figure 22. Field wiring — CICD single unit, dual circuit CG-SVX044B-EN...
  • Page 46 Wiring Figure 23. Field wiring — CICD array with master/slave controller, single circuit modules CG-SVX044B-EN...
  • Page 47 Wiring Figure 24. Field wiring — CICD array with master/slave controller, dual circuit modules CG-SVX044B-EN...
  • Page 48 Wiring Figure 25. Field wiring — CICD array with supervisory controller, single circuit modules CG-SVX044B-EN...
  • Page 49 Wiring Figure 26. Field wiring — CICD array with supervisory controller, dual circuit modules CG-SVX044B-EN...
  • Page 50 Wiring Figure 27. Field wiring — CICD array control panel Ethernet Cables From Ethernet Cable From Power Cord From Each Chiller Module Wireless Router Wireless Router (Field Provided) (Factory Provided) (Factory Provided) 16 Port Ethernet Switch PANEL GROUND REQUIRED 115 VAC Black Circuit Breaker Shield...

  • Page 51: Warranty

    Appendix A Warranty • Products on which payment to NAPPS is or has been in default. I. LIMITED PRODUCT WARRANTY & SERVICE POLICY • Products which have defects or damage which result from improper installation, wiring, electrical Napps Technology Corporation (NAPPS) warrants for a imbalance characteristics or maintenance (including, period of twelve (12) months from date of original without limitation, defects or damages caused by...
  • Page 52 Appendix A covered by this warranty. Evaporator failure due to fluid freezing that is the result of low fluid flow or inadequate fluid freeze protection, for applications with leaving fluid temperatures below 40° F, is not covered by this warranty THE WARRANTY PROVIDED ABOVE IS THE ONLY WARRANTY MADE BY NAPPS WITH RESPECT TO ITS PRODUCTS OR ANY PARTS THEREFORE AND IS MADE...

  • Page 53: Piping System Flushing Procedure

    Appendix B Piping System Flushing Water Treatment Requirements Procedure Supply water for both the chilled water and condenser Prior to connecting the chiller to the condenser and chilled water circuits shall be analyzed and treated by a water loop, the piping loops shall be flushed with a professional water treatment specialist who is familiar detergent and hot water (110-130°F) mixture to remove with the operating conditions and materials of...
  • Page 56 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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