15685_Trane_Chiller_O&M_-_F_(1).pdf

PRODUCT SUBMITTAL FORM

Submittal No.

Project Title

P.O. No. PSR No.(s)

Project (Drawing) No.

Design Engineer(s)

Construction Contract Administrator

Prime Contractor Subcontractor

Transmitted herewith are the following documents submitted by the Contractor for GRU’s review and/or approval:

Reviewed or Approved by Date

Rejected or Disapproved by Date

Comments:

Date Received by CCA Date Forwarded to Designer

Date Returned to CCA Date Returned to Contractor

Contractor’s Certification:

1. Items submitted are in accordance with the requirements of the Work and contract documents.

Signed

2. Any product substitutions meet or exceed the quality level of the specified product and meet all other requirements of the Work and contract documents.

Signed

Project Data Project Title:

Project Number:

FSR Number:

Drawing Number:

Subcontractor Data Subcontractor/Supplier:

Spec / Package No:

Subcontract PO No.:

Submittal Number:

Submittal Title:

Spec Section & Paragraph:

Submittal Type:

Product Use / Application:

Date By

Received:

Contractor Approval

DESIGN/BUILDER'S APPROVAL

(see Contract Documents)

Action Legend

A. Submittal Approved: Proceed with affected work.

Send additional copies for final distribution

B. Submittal Approved as Noted: Proceed with work in accordance with notations. Revise and resubmit.

C. Submittal Returned for Revision: Do not proceed with affected work. Revise or complete and resubmit.

D. Submittal Not Approved: Submit compliance submittals responsive to Contract Documents.

E. Preliminary Submittal: Resubmit with additional information required for acceptance.

F. For Reference; No acceptance required: Send additional copies for final distribution.

G. Distribution Copy: Previous copies accepted.

Scheduled Completion Required Reviewers Review Complete Reviewed By Date Civil Engineer Architect Structural Engineer Mechanical Engineer Electrical Engineer Project Manager

Submittal Cover Sheet

Action:

Lead Reviewer Name:

Date:

Submittal Cover Form Page 1 of 1 September 20, 2006

Figure 1 . Typical Unit Nam eplate

Digit Descript ion

1-3 Unit Type

4 Developm ent Sequence

5-7 Nom inal Tonnage

8 Unit Voltage

9 Unit Type

10-11 Design Sequence

12 Hot Gas Bypass

13 Starter Type

14 Cont rol Enclosure

15 Com pressor Motor Power (CPKW)

16-18 Com pressor I m peller Cutback

19 Evaporator Shell Size

20 Evaporator Tube Bundle (Nom inal Tons)

21 Evaporator Tubes

22 Evaporator Waterbox

23 Condenser Shell Size

24 Condenser Tube Bundle (nom inal tons)

25 Condenser Tubes

26 Condenser Waterbox

27 Heat Recovery Condenser Shell Size

28 Heat Recovery Condenser Tube Bundle (nom inal tons)

29 Heat Recovery Tubes

30 Heat Recovery Condenser Waterbox

31 Auxiliary Condenser Size & waterbox

32 Auxiliary Condenser Tubes

33 Orifice Size

34 Orifice Size

35 Unit Opt ion- I nsulat ion & Rupture Guard

36 Enhanced Protect ion

37 Generic BAS

38 Extended Operat ion

39 Tracer Com m unicat ion

40 Condenser Refr igerant Cont rol

41 Manufactur ing Locat ion

42 Special Opt ions

43 Water Flow Control

44 Chilled Water Reset

45 Heat Recovery Tem perature Sensors

46 Gas Powered Chiller

47 Com pressor Motor Fram e Size

48 Volute Discharge Angle

49 Operat ing Status

50 I ndust r ial Chiller Package

51 Cont rol Power Transform er

52 Motor & Term inal Board Config

Type of Requirement

Trane Supplied Trane Installed

Trane Supplied Field Installed

Field Supplied Field Installed

Foundation ? Meet foundat ion requirements

Rigging ? Safety chains Clevis connectors Lifting beam

I solat ion ? I solat ion pads or spr ing isolators

? I solat ion pads or spr ing isolators

Elect r ical ? Circuit breakers or fusible disconnects (optional)

? Unit m ounted starter (optional)

? PFCCs (opt ional)

? Jum per bars ? Tem perature sensor

(optional outdoor air) ? Flow switches (m ay be field supplies) ? Rem ote m ounted starter

(optional)

? Circuit breakers or fusible disconnects (opt ional) ? Elect r ical connect ions to unit m ounted starter (opt ional) ? Elect r ical connect ions to rem ote mounted starter (optional) ? Wir ing sizes per subm it tal and NEC ? PFCCs ( rem ote m ounted starter opt ional only) ? Term inal lugs ? Ground connect ion(s) ? Jum per bars ? BAS wir ing (opt ional) ? I PC wir ing (AFD and rem ote m ounted starters only ? Cont rol voltage wir ing (AFD and rem ote m ounted starters only) ? Oil pum p inter lock wir ing (AFD and rem ote m ounted starters only) ? High condenser pressure inter lock wir ing (AFD and rem ote mounted starters only).

? Chilled water pum p contactor and wiring including interlock ? Condenser water pum p contactor and wir ing including interlock ? Opt ion relays and wir ing (See Table 12)

Water piping ? Flow switches (m ay be field supplied)

? Taps for therm om eters and gauges ? Therm om eters ? St rainers (as required) ? Water flow pressure gauges ? I solat ion and balancing valves in water piping ? Vents and drain on waterbox valves (1 each per pass) ? Pressure relief valves ( for waterboxes as required)

Relief ? Rupture disc assem bly ? Rupture guard (opt ional) ? Vent line and flexible connector and vent line from rupture disc to atmosphere

I nsulat ion ? I nsulat ion (opt ional) ? I nsulat ion

Water Piping Connection Components

Flanged ? Welded on flange for

300 psig waterboxes

Flanged ? Victaulic to flange adapter for 150 psig waterboxes

Victaulic ? Victaulic coupling for 150 and 300 psig waterboxes

Other Mater ials ? HCFC-22 refr igerant (1 lb. maximum per machine as needed) ? Dry nit rogen (8 psig m aximum per machine as needed)

Less than 1 m onth 1 ? 6 m onths Greater than 6 m onths

Location requirements:

? solid foundat ion ? vibrat ion free ? dry ? tem perature range -40° F to 158° F

(-40°C to 70°C)

Location requirements:

? solid foundat ion ? vibrat ion free ? dry ? tem perature range -40° F to 158° F

(-40°C to 70°C)

Location requirements:

? solid foundat ion ? vibrat ion free ? dry ? temperature range -40° F to 158° F

(-40°C to 70°C)

? Do not rem ove any plast ic coverings ? Do not rem ove any plast ic coverings ? Do not rem ove any plast ic cover ings

? Do not charge the chiller with refrigerant

? I f addit ional refr igerant is on site, follow manufactures storage requirements

? Do not charge the chiller with refrigerant

? I f addit ional refr igerant is on site, follow manufactures storage requirements

? Do not charge the chiller with refrigerant

? I f addit ional refr igerant is on site, follow manufactures storage requirements

? Verify dry nit rogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (21 to 34.5 kPa)

? Not ify the local Trane office if charge has escaped

? Verify dry nit rogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (21 to 34.5 kPa)

? Not ify the local Trane office if charge has escaped

? Verify dry nit rogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (21 to 34.5 kPa)

? Not ify the local Trane office if charge has escaped

? Do not operate purge unit ? Do not operate purge unit ? Do not operate purge unit

? Verify waterbox and tube bundles are clean and dry

? Verify waterbox and tube bundles are clean and dry

? Conduct an oil analysis and ver ify no oil breakdown

? Repeat year ly ? Replace oil if breakdown has occurred ? I f no oil analysis program has been followed, replace oil prior to start up

? Every 6 m onths start the oil pum p and rotate compressor shaft 450 degrees to prevent bearing issues

? Contact your local Trane office to preform this task

Note: Chillers stored 5 years or longer should be inspected every 5 years by a qualified service organization for leaks.

1. Suction Elbow

2. Compressor

3. Terminal Box

4. Control Panel

5. Condenser

6. Motor Housing

7. Economizer

8. Oil Tank Assembly

9. Purge

10. Evaporator

11. Display Panel

Evaporator Size Shell Com bo A B C D E

032 Short / Long Short / Short 44.25? 141? 320.25? 34? 53?

Short / Long 76.875? 218.875? 430.75? 34? 53?

Long/ Long 44.25? 186.25? 410.75? 34? 53?

050 Short / Long Short / Short 44.5? 141? 320.5? 39.125? 62?

Short / Long 77.125? 218.875? 431? 39.125? 62?

Long/ Long 44.5? 186.25? 411? 39.125? 62?

080 Short / Long Short / Short 52.25? 141? 328.25? 35.125? 75.75?

Short / Long 84.875? 218.875? 438.75? 35.125? 75.75?

Long/ Long 52.25? 186.25? 418.75? 35.125? 75.75?

142 Medium / Long/ Extended Medium Long 77.5? 206.5? 444? 43.875? 91.125?

Long/ Long 57.25? 186.25? 423.75? 43.875? 91.125?

Extended/ Long 57.25? 209? 469? 43.875? 91.125?

210 Long Long/ Long 59? 186.25? 425.5? 46.25? 101.375?

250 Extended Extended/ Long 62.375? 209? 474.125? 42.5? 114.125?

Optional unit mounted starter

Cooling condenser

Auxiliary condenser (optional)

Evaporator

Economizer

Motor

Per NEC article 110

C

BA

D

E

Right hand tube pull shown, apply tube pull clearance dimension to left end for left hand tube pull.

Per NEC article 110

Cond Size

CDSZ

Aux Condenser Size 80 Aux Condenser Size 130 Heat Recovery Condenser Free Cooling

Ship Weight in pounds

Operating Weight in pounds

Ship Weight in pounds

Operating Weight in pounds

Ship Weight in pounds

Operating Weight in pounds

Ship Weight in pounds

Operating Weight in pounds

032 Short 825 1057 960 1248 2119 2624 500 785

032 Long 825 1057 960 1248 2663 3263 500 785

050 Short 825 1057 960 1248 3170 4018 750 1290

050 Long 825 1057 960 1248 3985 4986 750 1290

080 Short 825 1057 960 1248 5340 6593 750 1360

080 Long 825 1057 960 1248 6683 8180 750 1360

142 Long 825 1057 960 1248 12180 14666 1400 2400

210 Long 825 1057 960 1248 16023 19299 1400 2400

16 feet mimimum effective lenght safety chain or cable

800 Short shells only -use rigging flange

Auxiliary opt ion Heat recovery opt ion side view of unit end view of unit outside edge of tube sheet center tube sheet support leg center of isolator spring

Note: the spring isolator must be centered in relation to the tube sheet. Do not align the isolator with the flat part of the chiller foot since the tube sheet is often off center

Note: the length of the isolator should be parallel to the leg.

032 S/S, S/L, L/L 050 S/S, S/L, L/L 080 S/S, S/L, L/L 142 M/L, L/L 210 L/L

142 E/L 250 E/L

CondenserCondenser

Evaporator

LF

LR

RF

RR

Condenser

Evaporator

LF

LR

RF

RR

LC

1 2

55 5

1. Balancing Valve

2. Gate (Isolation) Valve or Ball Valve

3. Thermometer (If field supplied)

4. Flanged Connection 1/2?

[13 mm] NPT Couplings

5. Drain, Vent, Anode

7. Chilled Water Flow Switch (5S1)

6. Strainer

9. Pump

10. Pressure Gauge Note: 1. Flow switch 5S1 (Item __in Legend of Components) may be installed in either the entering or leaving leg of the chilled water circuit.

2. It is recommended to pipe the gauge between entering and leaving pipes. A shutoff valve on each side of the gauge allows the operator to read either entering or leaving water pressure.

Figure 1 0 . Typical condenser w ater piping circuits

1. Balancing Valve

2. Gate (Isolation) Valve or Ball Valve

3. Thermometer (If field supplied)

4. Flanged Connection 1/2?

[13 mm] NPT Couplings

5. Drain, Vent, Anode

6. Strainer

7. Condenser Water Flow Switch

8. 3-Way Valve (Optional)

9. Condenser Water Pump

10. Pressure Gauge Note: 1. The Flow Switch 5S2 (Item __ in Legend of Components) may be installed in either the entering or leaving leg of the chilled water circuit.

2. It is recommended to pipe a single gauge between entering and leaving pipes.

3. Some type of field-supplied temperature control device may be required to regulate the temperature of the heat-recovery condenser water circuit. For application recommendations, see Trane Application Manual, ?AM- FND-8?, titled ?Heat-Recovery Engineering Seminar?.

4. Install a bypass valve system to avoid circulating water through the auxiliary shell when the unit is shut down.

5. On multiple pass condensers, entering condenser water must enter at the lowest nozzle.

4 45

2 1 outlet inlet

1 2

4 5

7 8

44 5 outlet inlet

EVSZ

Nominal Pipe Size (inch/mm)

1 Pass 2 Pass 3 Pass

I nch m m I nch m m I nch m m

032 8 219.1 6 168.3 5 141.3

050 10 273.0 8 219.1 6 168.3

080 12 323.9 10 273.0 8 219.1

142 16 406.4 12 323.9 10 273.0

210 16 406.4 14 355.6 12 323.9

250 16 406.4 14 355.6 12 323.9

Note: EVSZ = Evaporator Shell Size; S = Short Shell, L = Long Shell, E = Extended Shell

CDSZ

Nominal Pipe Size (inch/mm)

2 pass

I nch m m

032 6 168.3

050 8 219.1

080 10 273.0

142 12 323.9

210 14 355.6

250 14 355.6

Note: CDSZ =Condenser Shell Size; S = Short Shell, L = Long Shell, E = Extended Shell

Customer Piping Connection

Unit Model Unit Connect ion Type Victaulic? Flanged

CVHE and

CVHG

Flanged (Condenser 032-050 150 psig and 1035 kPa non-marine only)

Trane provided Victaulic-to-Flange

Adapter No Adapter Required

CVHE,

CVHF, and

CVHG

Victaulic (All others)

Customer provided Victaulic Coupling

Trane provided Victaulic-to-Flange

Adapter

Flanged Flanged Victaulic

Water Box

Welded Flange

Water Box

Flange Adaptor Trane Provided

Water Box

Style 77 Flexible Customer Provided

Customer

Nom inal Pipe Size Assembly Bolt Size* Num ber of Assembly

Bolts Required

Bolt Pat tern Diameter Weight

I nch mm I nch mm I nch mm Pounds kg

4 114.3 5/ 8 x 3 16 x 76 8 7.5 191 7.7 3.5

5 141.3 3/ 4 x 3-1 / 2 19 x 89 8 8.5 216 9.3 4.2

6 168.3 3/ 4 x 3-1/ 2 19 x 89 8 9.5 241 10.3 4.7

8 219.1 3/ 4 x 3-1 / 2 19 x 89 8 11.75 298 16.6 7.5

10 273.0 7/ 8 x 1/ 4 22 x 6 12 14.25 362 24.2 11.0

12 323.9 7/ 8 x 1 / 4 22 x 6 12 17 432 46.8 21.2

14 355.6 1 x 4-1 / 2 25 x 114 12 18.75 476 75 34.0

16 406.4 1 x 4-1 / 2 25 x 114 16 21.25 540 90 40.8

Note: Bolt size for conventional flange to flange connection. Longer bolts are required when flange washer must be used.

Nominal Pipe Size Assembly Bolt Size* Number of Assembly

Bolts Required

Bolt Pattern Diameter Weight Inch mm Inch mm Inch mm Pounds kg

4 114.3 3/4 x 3-3/4 19 x 95 8 7.88 200 15.3 6.9 5 141.3 3/4 x 4 19 x 102 8 9.25 235 17.7 8.0 6 168.3 3/4 x 4-1/2 19 x 114 12 10.63 270 23.4 10.6 8 219.1 3/4 x 4-3/4 19 x 121 12 13 330 34.3 15.6

10 273.0 1 x 5-1 /4 25 x 133 16 15.25 387 48.3 21.9 12 323.9 1-1 /8 x 5-3/4 29 x 146 16 17.75 451 70.5 32.0

Bolt Size Gasket Type

I nch mm O-Ring Flat

3/ 8? 9.5 25 (34) 12-18 (16-24)

1 / 2? 13 70 (95) 33-50 (45-68)

5/ 8? 16 150 (203) 70-90 (95-122)

3/ 4? 19 250 (339) 105-155 (142-210)

Note: Torques provided in Ft./Lbs. (Newton/metres) Bolt size is determined by the diameter of bolt shank.

4 bolt flange 8 bolt flange 12 bolt flange

16 bolt flange 20 bolt flange 24 bolt flange bolt rupture disc suction connection gasketoutside pipe assembly cap Note: Pipe conection is 3? NPT alternate purge discharge vent line outside wall support this pipe flexible steel connection drip leg (length as required for easy access)

1/4? FL x 1/4? NPT drain valve rupture disc assembly

Evaporator Size

(EVSZ)

(3)

Condenser Size

(CDSZ)

(4)

?C? Values for Unit Components

Total C value Short H.R.

Condenser

Long H.R.

Condenser

Auxiliary Condenser

With Free Cooling

032 Short 032 Short 49.97

18.87 25.19 15.28 4.16032 Short 032 Long 56.29

032 Long 032 Long 65.08

050 Short 050 Short 64.05

23.56 31.45 15.28 6.16050 Short 050 Long 71.94

050 Long 050 Long 83.02

080 Short 080 Short 86.28

29.06 38.80 15.28 5.87080 Short 080 Long 96.02

080 Long 080 Long 111.29

142 Extended 142 Long 142.20

N/A*

Design

Special

15.28

Design

Special

142M 142 Long 126.37 50.50

7.10 142 Long 142 Long 136.76

210 Long 210 Long 149.28 56.72

250 Extended 250 Long 173.33 62.12

Note: Rupture disc diameter is 3 inches (76 mm) Note: 1. To determine the total ?C? value for a specific unit, add the appropriate ??C? values for the evaporator, standard condenser and economizer. If the unit is equipped with any options (e.g., heat recovery, free cooling or an auxiliary condenser, add the applicable ?C? values to this total. With this new sum, refer to Figure 18 to determine the vent line pipe diameter.

Pipe size as a Function of ?C? Value and Length of Run

Note: This chart, provided as a reference, is based on ASHRAE Standard 15-2007. Vent line size is typically dictated by state or local code which may be different from ASHRAE Standard 15-2007 requirements.

10 100 1000

L = Pipe Length (Equivalent Feet) (Feet x .348 = Meters)

"C

V a lu e

Pipe Size (I.D.)

friction factor

6 NPS

(6.065) f=0.0149

4 NPS

(4.026) f=0.0163

3 NPS

(3.068) f=0.0173

5 NPS

(5.048) f=0.0155

L= .214d 5 (P2 0 - P2

2) -f C2

R d *ln(P0 / P2)

6 - f

P0= (0.5-15) + P2

P2= 14.7 psia f= Moody Friction Factor in fully turbulent flow

ANSI/ASHRAE Standard 15-2007

EVSZ

(Note 1)

Standard Unit Free Cooling

3/4? (19 mm) Insulation (Note 1)

(Square Feet)

3/8? (9.5 mm) Insulation (Note 2)

(Square Feet)

3/4? (19 mm) Insulation (Note 1)

(Square Feet)

3/8? (9.5 mm) Insulation (Note 2)

(Square Feet)

032 Short 337 52 347 74

032 Long 365 52 377 74

050 Short 385 63 398 72

050 Long 420 63 436 72

080 Short 505 84 515 97

080 Long 553 84 566 97

142 Medium 555 98 555 133

142 Long 578 98 578 133

142 Extended 603 104 629 133

210 Long 700 98 710 133

Notes:

1. 3/4? (19 mm) sheet insulation is installed on the evaporator, evaporator water boxes, compressor motor, suction elbow and suction cover.

2. 3/8? (9.5 mm0 sheet insulation is installed on all economizers. All liquid lines and other pipes require the use of 1/2? (13 mm) pipe insulation or 3/8? (9.5 mm0 sheet insulation. Copper oil eductor tube lines require pipe insulation.

3. Refrigerant Pump equipped units are NOT insulated on the motor or refrigerant drain lines.

Note 1. Bulbwells, drain and vent connections must be accessible after insulating

Note 2. Evaporators with ASME nameplates must have insulation cut out around the nameplate. Do not glue insulation to the nameplate.

Note 3. All units with evaporator marine waterboxes wrap waterbox shell insulation with strapping and secure strapping with seal.

Note 4. Apply two inch wide black tape on overlap joints.

Where possible apply three inch wide strip of.38 think insulation over butt joint seams.

Note 5. Insulate all economizer supports.

line to eductor filter drier and eductor lines line from Evap control panel support suction connection see note 1 & 3 suction elbow suction coverpipe (free cooling only) pipe evaporator see note 1 see note 1 & 3 eductor line pipe evaporator

Storage

Tem perature: -40° F to 185° F ( -40° C to 85° C)

Relat ive hum idity: Between 5% to 95% (non-condensing)

Operating

Tem perature: -40° F to 158° F ( -40° C to 70° C)

Hum idity: Between 5% to 95% (non-condensing)

Power: 19?30 Vac (24 Vac nom inal) 50?60 Hz 12 VA

Mount ing weight (enclosure) : Mount ing surface m ust support xx lb. ( x.xx kg)

Mount ing weight (controller) : Mount ing surface m ust support xx lb. ( x.xx kg)

Environm ental rat ing (enclosure) : NEMA 1

2 3 4 5

Front View

Bottom View

LED UC8 0 0 Status

Marquee LED

Powered. If the Marquee LED is green solid, the UC800 is powered and no problems exist.

Low power or malfunction. If the Marquee LED is red solid, the UC800 is powered, but there are problems present.

Alarm. The Marquee LED blinks Red when an alarm exists.

LINK, MBUS, IMC

The TX LED blinks green at the data transfer rate when the UC800 transfers data to other devices on the link.

The Rx LED blinks yellow at the data transfer rate when the UC800 receives data from other devices on the link.

Ethernet Link The LINK LED is solid green if the Ethernet link is connected and communicating.

The ACT LED blinks yellow at the data transfer rate when data flow is active on the link.

Service The Service LED is solid green when pressed. For qualified service technicians only. Do not use.

Marquee LED

1X2 1S1 1K1 1T41T21K 2 1T3

1T6 1T71T5

1A4 1A91A6 1A81A7 1A261A5

OR

1A11

1A12 1A23

1A21A1 1T1

1X1

Q

Q

Q

Q

Q

Q

F

1A20 1A211A19

OR

1A25

1A241A181A171A13 1A14 1A15 1A161A22

X19091218-01

OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL

OPTIONAL

OPTIONAL OPTIONAL OPTIONAL OPTIONAL

V M

A X

V M

A X

V M

A X

V M

A X

30V MAX 30V MAX

V T

O

V

V

T O

V

V T

O

V

V

T O

V

30V TO 115V30V TO 115V

30V TO 115V 30V TO 115V

30V TO 115V30V TO 115V

30V MAX 30V TO 115V

30 Volt Maxim um 30-115 Volt Maxim um

4A

4B

1A

1B 1C

Power supply wiring to starter panel

Starter panel terminals

3-Phase Line Voltage: Terminal Block (2TB3 or 2X3)

2X3-L1, L2, L3, and

GROUND

3-Phase Line Voltage: Circuit Breaker

2Q1-L1, L2, L3, and

GROUND

Starter to m otor pow er w ir ing Starters

Remote Starter to Chiller Motor Junction Box

T1 through T6

Starter to control panel 120VAC control wiring

Starter Panel Terminals

Unit Control Panel Terminations

120VAC Power Supply (from starter to control panel)

2X1-1-1, 2X1-2 2X1-20(Ground)

1X1-1, 1X1-12 1X1-18 (Ground)

1X1-1, 1X1-12 1X1-18 (Ground)

High Pressure Cutout to Starter 2X1-4 1X1-4 14 ga.

1Q1 Circuit Breaker to Starter 2X1-6 1X1-3 14 ga.

Oil Pum p I nter lock 2X1-7, 2X1-8 1A7-J2-4, 1A7-J2-2 14 ga.

Low Voltage Circuits less than 30VAC

Starter Panel Terminals

Unit Control Panel Terminations

Standard Circuits

Inter Processor Communications (IPC) Remote Mounted

2A1- J3-3 to 4, or 2X1-12 to 13 if present (do not ground shield at starter)

1A1-J5-1-2, 3-4

Shield ground at

1X1- 22 (GND) only.

2 wire with ground

Comm link.

Note: All wiring to be in accordance with National Electrical Code and any local codes.

Power supply wiring to starter panel

Starter panel terminals

Starter by others 3-phase power wiring

See starter by others schematic

Starter to m otor pow er w ir ing Starters Motor

Remote starter to chiller motor junction box

T1 through T6 term inals T1 through T6 terminals

Starter to control panel 120VAC control wiring

Starter Panel Terminals

Unit Control Panel Terminations

120VAC Power Supply (from starter to control panel)

See starter by others schematic 5X1-1, 5X1-2, 5X1-20 (ground)

1X1-1, 1X1-12, 1X1-18 (ground)

#8 gauge minimum 40 amps circuit

Power from cont rol panel 1Q1 5X1-3 1X1-3, 1A23-J6-3 14 ga.

I nter lock relay signal 5X1-4 1A23-J10-1 14 ga.

Start contactor signal 5X1-5 1A23-J8-1 14 ga.

Oil pum p inter lock 5X1-7, 5X1-8 1A7-J2-4, 1A7-J2-2 14 ga.

Run contactor signal 5X1-10 1A23-J6-12 14 ga.

Transit ion com plete 5X1-14 1A23-J12-2 14 ga.

Low Voltage Circuits less than 30VAC

Starter Panel Terminals

Unit Control Panel Terminations

Standard Circuits

Current Transformers* (see table next page) (Required)

5CT4- white, black 5CT5- white, black 5CT6- white, black

1A23-J7-1,2 1A23-J7-3,4, 1A23-J7-5,6, Note: Phasing must be maintained

Potent ial Transform ers (Required) 5T17-236,237 5T18-238,239 5T19-240,241

1A23 ?J5-1,2, 1A23 ?J5-3,4, 1A23 ?J5-5,6

Note: Phasing must be maintained

Note: All wiring to be in accordance with National Electrical Code and any local codes.

Note: Starter by others specification available from your local Trane sales office.

W ire AW G ( m m 2 ) Maxim um w ire length secondary CT leads

Feet Meters

8 (10) 1362.8 415.5

10 (6) 856.9 261.2

12 (4) 538.9 164.3

14 (2.5) 338.9 103.3

16 (1.5) 213.1 65.0

17 (1) 169.1 51.5

18 (0.75) 134.1 40.9

20 (0.5) 84.3 25.7

Note: 1. Wire length is for copper conductors only.

2. Wire length is total one-way distance that the CT can be from the starter module.

W ire Gauge Maxim um lead length

Feet Meters

8 5339 1627

10 3357 1023

12 2112 643

14 1328 404

16 835 254

17 662 201

18 525 160

20 330 100

21 262 79

22 207 63

Note: 1. Wire length is for copper conductors only.

2. The above length is maximum round trip wire length. The maximum distance the PT can be located from the starter module is half of the listed value.

W ire Gauge Max w ire length prim ary Max w ire length secondary

Feet Meters Feet Meters

8 3061 933 711 217

10 1924 586 447 136

12 1211 369 281 85

14 761 232 177 53

16 478 145 111 33

17 379 115 88 26

18 301 91 70 21

20 189 57 44 13

21 150 45 34 10

22 119 36 27 8

Note: 1. Wire length is for copper conductors only.

2. The above length is maximum round trip wire length. The maximum distance the PT can be located from the starter module is half of the listed value.

L3

G

L2 L1 L3

G

L2 L1

L3 L2 L1 G L3 L2 L1 G L3 L2 L1 G motor fuses enclosed 3-phase capacitor unit fused disconnect or suitable breaker power circuit current transformer motor starter contactor motor fuses enclosed 3-phase capacitor unit fused disconnect or suitable breaker power circuit current transformer motor starter contactor

1. line side power conduits

2. unit-mounted starter

3. unit control panel

1. line side power conduits

2. remote-mounted starter

3. unit control panel

4. IPC circuit conduit less than 30V Note: must enter the low voltage Class 2 portion of the unit control panel (1000 feet max)

5. motor terminal box

6. 115V control conduit Note: must enter the higher than 30 Vdc

Class 1 portion of the until control panel

7. lead power wiring Note: refer to the unit field connection diagram for approximate unit control panel knock out locations

Note: to prevent damage to the unit control panel components, do not route control conduit into the top of the box

Figure 2 9 . Term inal stud, clam p and lug assem bly

1. Belleville washer

2. terminal lugs

3. terminal clamp

4. motor terminal stud

5. 3/8? bolt

Standard Control Circuits: Unit Control Panel Control Wiring

(120 VAC)

Unit Control

Term inat ions I nput or Output Type Contacts

Chilled Water Flow Proving Input

1X1-5 to 1A6-J3-2 Binary I nput Norm ally Open, closure with flow

Condenser Water Flow Proving Input

1X1-6 to 1A6-J2-2 Binary I nput Norm ally Open, closure with flow

Chilled Water Pump Relay Output

1A5-J2- 4 to 6 Binary Output Norm ally Open

Condenser Water Pump Relay Output

1A5-J2-1 to 3 Binary Output Norm ally Open

Optional Control Circuits (120 VAC)

Note: Defaults are factory programmed, alternates can be selected at startup using the service tool.

Alarm Relay MAR (Non- Latching) Output

1A8-J2-1 to 3 Binary Output Norm ally Open

Limit Warning Relay Output

1A8-J2-4 to 6 Binary Output Norm ally Open

Alarm Relay MMR (Latching) Output

1A8-J2-7 to 9 Binary Output Norm ally Open

Compressor Running Relay Output

1A8-J2-10 to 12 Binary Output Norm ally Open

Maximum Capacity Relay Output

1A9-J2-1 to 3 Binary Output Norm ally Open

Head Relief Request Relay Output

1A9-J2-4 to 6 Binary Output Norm ally Open

Purge Alarm Relay Output

1A9-J2-7 to 9 Binary Output Norm ally Open

I ce Making Relay Output 1A5-J2-10 to 12 Binary Output Normally Open

Free Cooling Relay Output

1A11-J2-4 to 6 Binary Output Normally Open

Standard Low Voltage Circuits (less than

30VAC)

Unit Control Panel

Term inat ions I nput or Output Type Contacts

External Auto Stop I nput 1A13-J2-1 to 2 Binary I nput Closure required for normal operation

Em ergency Stop I nput 1A13-J2-1 to 2 Binary I nput Closure required for normal operation

Optional Low Voltage Circuits

External Base Loading Enable Input

1A18-J2-1 to 2 Binary I nput Normally Open

External Hot Water Control Enable Input

1A18-J2-3 to 4 Binary I nput Normally Open

External Ice Machine Control Enable Input

1A19-J2-1 to 2 Binary I nput Normally Open

External Free Cooling Input Enable Input

1A20-J2-1 to 2 Binary I nput Normally Open

% RLA Compressor Output

1A15-J2-1 to 3 Analog Output 2-10 vdc

External Condenser Pressure Output

1A15-J2-4 to 6 Analog Output 2-10 vdc

External Current Limit Setpoint Input

1A16-J2-2 to 3 Analog I nput 2-10 vdc, or 4-20 mA

External Current Limit Setpoint Input

1A16-J2-5 to 6 Analog I nput 2-10 vdc, or 4-20 mA

External Current Limit Setpoint Input

1A17-J2-2 to 3 Analog I nput 2-10 vdc, or 4-20 mA

Generic Refrigerant Monitor input

1A17-J2-5 to 6 Analog I nput 2-10 vdc, or 4-20 mA

Outdoor Air Temperature sensor

IPC bus Connection and sensor

Communication and sensor

Note: Tracer Comm Interface or LonTalk

1A14-J2-1(+) to 2(-) 1A14-J2-3(+) to 4(-)

Communication to Tracer or LonTalk

(as ordered, see sales order)

Note: All wiring to be in accordance with National Electrical Codes and any local codes

Field W ir ing Layout Draw ing Draw ing Num ber Maximum

Acceleration Time (seconds)

Unit Mounted Wye-Delta Star ter (USTR) 2311-0404 27

Unit Mounted Solid-State Starter (USI D) 2311-0412 15

Unit Mounted Across- the-Line (UXL) 2311-0452 6

Unit Mounted Adapt ive Frequency Drive (UAFD) 2311-0453 & 2311-0454

Unit Mounted Auto Transformer Start (UATR) 2311-0426 11

Unit Mounted Prim ary Transformer (UPI R) 2311-0439 11

Remote Wye-Delta Starter (RSTR) 2311-0402 27

Remote Mounted Solid-State Starter (FSI D, WSI D) 2311-410 15

Remote Across- the-Line Starter (RXL) 2311-0448 6

Remote Prim ary Reactor Starter (RPI R) 2311-0435 11

Remote Auto Transformer Starter (RATR 2311-0422 11

Customer Supplied Wye-Delta Starter (CSTR) 2311-0457 27

Customer Supplied Primary Reactor or Auto Transformer Starter (CATR, CPIR)

2311-0479 11

Customer Supplied Across- the-Line Starter (CXL) 2311-0493 6

Customer Supplied Solid-State Starter (CSOL) 2311-0461 20

Purge Schem at ic 2311-0510

Unit Cont rols Schemat ic 2311-0505

System Controls Schemat ic 2311-0508

Opt ional Cont rol Schemat ic 2311-0511

Connection Diagrams

Standard Connect ion Diagram Panel with Opt ions 2311-0526

Field Connect ion Trane Starter (LV) 2311-0551

Field Connect ion Trane Starter (MV) 2311-0555

Customer Supplied Starter (LV) 2311-0559

Customer Supplied Starter (MV) 2311-0562

Trane Supplied AFD 2311-0565

Unit Wir ing 2311-0549

Note: These are typical drawings only. Refer to specific as-built schematics for actual unit drawings which represent the unit wiring as shipped.

Note: Contact your local Trane representative for all other schematics, wiring diagrams and/or connection diagrams not listed.

condenser high side economizer evaporator 2

P1

P3

P2

P4

P re ss u re

P S

I) low side economizer condenser economizer evaporator

P1

P1P2

P3

P re ss u re

P S

I)

1. motor coolant return to condenser (2.125 OD) 11. liquid refr igerant to pump (1.625 OD)

2. oil tank vent to evaporator 12. econom izer

3. oil separator and tank vent m anifold 13. oil supply to bearings ( .625 OD)

4. tank vent line 14. purge

5. condenser 15. com pressor

6. high pressure condenser gas to drive oil reclaim eductors (.375 OD)

16. liquid refrigerant motor coolant supply

(1.125 OD)

7. oil return to tank 17.liquid refrigerant to economizer

8. oil tank 18. liquid refr igerant to evaporator

9. oil cooler within economizer (.625 OD coiled tubing) 19. evaporator

10. oil reclaim from evaporator (2nd eductor) ( .25 OD) 20. oil reclaim from suct ion cover (1st eductor) ( .25 OD) compressor lubrication system compressor lubrication sy motor cooling system oil reclaim system1

9 10

Operat ing Character ist ic Norm al Reading

Approxim ate Evaporator Pressure 6 to 9 PSI A / -9 to -6 PSI G

Approximate Condenser Pressure (see notes 1 & 2) 17 to 27 PSIA / 2 to 12 PSIG (standard condenser)

Oil Sum p Tem perature Unit not running 140° F to 176° F (60° C to 80° C)

Oil Sum p Tem perature Unit running 95° F to 162° F (35° C to 72° C)

Oil Sum p Tem perature Different ial Oil Pressure 18 to 22 psid

Note 1. Condenser pressure is dependent on condenser water temperature, and should equal the saturation pressure of HCFC-123 at a temperature above that of leaving condenser water at full load.

Note 2. Normal pressure readings for ASME condenser exceed 12 PSIG.

Note 3. Oil tank pressure -9 to -6 psig HG Discharge oil pressure 7 to 15 PSIG

Daily Every 3 m onths Every 6 m onths Annual

Check the chiller?s evaporator and condenser pressures, oil tank pressure, differential oil pressure and discharge oil pressure. Compare the readings with the values provided in the above.

Check the oil level in the chiller oil sump using the two sight glasses provided in the oil sump head. When the unit is operating, the oil level should be visible in the lower sight glass

Complete logs on a daily basis

Clean all water strainers in the water piping system

Lubricate the vane control linkage bearings, ball joints, and pivot points. See Lubrication Procedure

Lubricate vane operator tang o-rings. See Lubrication Procedure

Lubricate the oil filter shutoff valve o-rings. See Step 7 in Oil Filter Replacement Procedure

Drain contents of the rupture disc and purge discharge ventline drip-leg into an evacuated waste container. Do this more often if the purge is operated excessively.

Apply oil to any exposed metal parts to prevent rust.

Shut down the chiller once each year to check the items listed on the Annual Inspection Checklist.

Perform the annual maintenance procedures referred to in the maintenance section of the purge manual

Use an ice water bath to verify that the accuracy of the evaporator refrigerant temperature sensor (4R10) is still within tolerance (+ or - 2.0° at 32°F (1° at 0°C)). If the evaporator refrigerant temperature displayed on the control panel read-out is outside this 4-degree tolerance range, replace the sensor. If the sensor is exposed to temperature extremes outside its normal operating range (0°F to 90°F) (-18°C to 32°C), check its accuracy at six-month intervals.

Inspect the condenser tubes for fouling; clean if necessary.

Submit a sample of the compressor oil to a Trane qualified laboratory for comprehensive analysis.

Measure the compressor motor winding resistance to ground; a qualified service technician should conduct this check to ensure that the findings are properly interpreted. Contact a qualified service organization to leak-test the chiller; this procedure is especially important if the system requires frequent purging.

Every 3 years use a nondestructive tube test to inspect the condenser and evaporator tubes.

Note: It may be desirable to perform tube tests on these components at more frequent intervals, depending upon chiller application. This is especially true of critical process equipment.

Contact a qualified service organization to determine when to conduct a complete examination of the unit to discern the condition of the compressor and internal components.

Note: (a) Chronic air leaks, which can cause acidic conditions in the compressor oil and result in premature bearing wear; and, (b) Evaporator or condenser water tube leaks. Water mixed with the compressor oil can result in bearing pitting, corrosion, or excessive wear.

Top View Run Change Filter

Drain pipe connections circulator pump cleaning solution shutoff valves

Chiller tons (per circuit)

P u rg e m in u te s/ d a y large leak small leaks typical operation

Figure 4 2 . W aterbox r igging and lift ing - condenser and evaproator connections

Table 1 7 . CenTraVac Torque

Bot l Size I nch ( m m ) Gasket type O- r ing ft - lbs ( Nm ) Flat ft - lbs ( Nm )

3/ 8? (9.5) 25 (34) 12-18 (16-24)

1/ 2? (13) 70 (95) 33-50 (45-68)

5/ 8? (16) 150 (203) 70-90 (95-122)

3/ 4? (19) 250 (339) 105-155 (142-210)

Table 1 8 . CenTraVac W aterbox w eights

Fabricated Non-marine waterbox, welded flat plate

Non-m arine cast waterbox Fabricated Non-m arine waterbox welded dome

Marine style waterbox cover

Shell Size

Descr ipt ion Weight lbs (Kg)

Lifting Connection

Weight lbs (Kg)

Lifting Connection

Weight lbs (Kg)

Lifting Connection

Weight lbs (Kg)

Lifting Connection

Evaporator, 150 psi 265 (120) 3/ 4 - 10 NA NA NA NA 176 (80) 1/ 2 - 13

Evaporator, 300 psi

Condenser, 150 psi NA NA 176 (80) 1/ 2 - 13 NA NA 176 (80) 1/ 2 - 13

Condenser, 300 psi 265 (120) 3/ 4 - 10 NA NA NA NA 221 (100) 1/ 2 - 13

Evaporator, 150 psi 397 (180) 3/ 4 - 10 397 (180) Lift ing Fixture NA NA 265 (120) 1/ 2 - 13

Evaporator, 300 psi 353 (160) 3/ 4 - 10 NA NA NA NA 265 (120) 1/ 2 - 13

Condenser, 150 psi 265 (120) 1/ 2 - 13 265 (120) 1/ 2 - 13 NA NA 265 (120) 1/ 2 - 13

Condenser, 300 psi 551 (250) 3/ 4 - 10 NA NA NA NA 441 (200) 1/ 2 - 13

Evaporator, 150 psi 662 (300) 3/ 4 - 10 662 (300) Lift ing Fixture NA NA 441 (200) 3/ 4 - 10

Evaporator, 300 psi 882 (400) 3/ 4 - 10 NA NA NA NA 551 (250) 3/ 4 - 10

Condenser, 150 psi 551 (250) 3/ 4 - 10 551 (250) 3/ 4 - 10 NA NA 441 (200) 1/ 2 - 13

Condenser, 300 psi 882 (400) 3/ 4 - 10 NA NA NA NA 882 (400) 3/ 4 - 10

Evaporator, 150 psi 882 (400) 3/ 4 - 10 NA NA NA NA 662 ( 300) 3/ 4 - 10

Evaporator, 300 psi 1323 (600) 3/ 4 - 10 NA NA NA NA 882 (400) 3/ 4 - 10

Condenser, 150 psi 1543 (700) 3/ 4 - 10 NA NA 441 (200) 3/ 4 - 10 1323 (600) 3/ 4 - 10

Condenser, 300 psi 1985 (900) 3/ 4 - 10 NA NA NA NA 1764 (800) 3/ 4 - 10

Evaporator, 150 psi 1544 (700) 3/ 4 - 10 NA NA NA NA 1323 (600) 3/ 4 - 10

Evaporator, 300 psi 2205 (1000) 3/ 4 - 10 NA NA NA NA 1764 (800) 3/ 4 - 10

Condenser, 150 psi 2205 (1000) 3/ 4 - 10 NA NA 662 (300) 3/ 4 - 10 1764 (800) 3/ 4 - 10

Condenser, 300 psi 2867 (1300) 3/ 4 - 10 NA NA NA NA 2426 (1100) 3/ 4 - 10

Evaporator, 150 psi 1985 (900) 3/ 4 - 10 NA NA NA NA 1544 (700) 3/ 4 - 10

Evaporator, 300 psi 3087 (1400) 3/ 4 - 10 NA NA NA NA 2205 (1000) 3/ 4 - 10

Condenser, 150 psi 2867 (1300) 3/ 4 - 10 NA NA 662 (300) 3/ 4 - 10 2205 (1000) 3/ 4 - 10

Condenser, 300 psi 3528 (1600) 3/ 4 - 10 NA NA NA NA 3087 (1400) 3/ 4 - 10

Note: Refer to product block indentifier on the model number plate which identifies the evaporator and condenser shell sizes and the rated pressure. The designators are as follows:

Evaporator Size = EVSZ Condenser Size = CDSZ Evaporator Pressure = EVPR Condenser Pressure = CDPR Weights shown are maximum for waterbox size. Verify the waterbox from the latest published literature.

Unit Produt Part Num ber Order I nform at ion

CTV Safety Hoist Ring 3/ 4-10 RNG01884 Contact Trane Part Departm ent

CTV Safety Hoist Ring 1/ 2-13 RNG01885 Contact Trane Part Departm ent

CTV Evap Lift ing Fixture BAR00400 Contact Trane Part Departm ent

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