20Q0050_ RFQ attachments_II.pdf

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. 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.

CVHE, CVHF, and CVHG

Water-Cooled CenTraVac™ Chillers

With Tracer AdaptiView™ Control

Installation, Operation, and Maintenance

Models: CVHE, CVHF, CVHG X39641075100

CVHE-SVX02K-ENAugust 2016

Attachment 1

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

The three types of advisories are defined as follows:

WARNING

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

CAUTIONs Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

NOTICE: Indicates a situation that could result in equipment or property-damage only accidents.

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians

MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing).

ALWAYS refer to appropriate Material Safety Data

Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate MSDS/SDS and

OSHA/GHS (Global Harmonized System of

Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY

SWITCHING, DISCONNECTING, OR VOLTAGE

TESTING WITHOUT PROPER ELECTRICAL PPE AND

ARC FLASH CLOTHING. ENSURE ELECTRICAL

METERS AND EQUIPMENT ARE PROPERLY RATED

FOR INTENDED VOLTAGE.

© 2016 Ingersoll Rand All rights reserved CVHE-SVX02K-EN

Introduction 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.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

• Update to “Water Flow Detection Controller and Sensor,” p. 22 torque instruction

Factory Warranty Information

Compliance with the following is required to preserve the factory warranty:

All Unit Installations

Startup MUST be performed by Trane, or an authorized agent of Trane, to VALIDATE this WARRANTY. Contractor must provide a two-week startup notification to Trane (or an agent of Trane specifically authorized to perform startup).

Additional Requirements for Units Requiring

Disassembly

When a new fully assembled chiller is shipped and received from our Trane manufacturing location and, for any reason, it requires disassembly or partial disassembly—which could include but is not limited to the evaporator, condenser, control panel, compressor/motor, purge, factory-mounted starter or any other components originally attached to the fully assembled unit— compliance with the following is required to preserve the factory warranty:

• Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products, will perform or have direct on-site technical supervision of the disassembly and reassembly work.

• The installing contractor must notify Trane—or an agent of Trane specifically authorized to perform startup and warranty of Trane® products—two weeks in advance of the scheduled disassembly work to coordinate the disassembly and reassembly work.

• Start-up must be performed by Trane or an agent of Trane specifically authorized to perform startup and warranty of Trane® products.

Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products, will provide qualified personnel and standard hand tools to perform the disassembly work at a location specified by the contractor. Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane products, will perform or have direct on-site supervision of the disassembly and reassembly work. The contractor shall provide the rigging equipment such as chain falls, gantries, cranes, forklifts, etc. necessary for the disassembly and reassembly work and the required qualified personnel to operate the necessary rigging equipment.

WARNING

Refrigerant May Be Under Positive Pressure!

Failure to recover refrigerant to relieve pressure or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in an explosion which could result in death or serious injury or equipment damage. System contains oil and refrigerant and may be under positive pressure.

Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

NOTICE:

Do Not Use Non-Compatible Parts or Materials!

Use of non-compatible parts or materials could result in equipment damage. Only genuine Trane® replacement components with identical Trane part numbers should be used in Trane CenTraVac chillers. Trane assumes no responsibility for damages resulting from the use of non-compatible parts or materials.

CVHE-SVX02K-EN 3

Table of Contents Unit Model Number Description

Model Number Descriptions

Pre-Installation

ASHRAE Standard 15 Compliance

Unit Shipment

Installation Requirements and Contractor Re-sponsibilities

Storage Requirements

Unit Components

Unit Clearances and Weights

Recommended Unit Clearances

General Weights

Installation: Mechanical

Operating Environment

Foundation Requirements

Rigging

Standard Chiller Lift

Special Lift Requirements

Unit Isolation

Isolation Pads

Spring Isolators

Leveling the Unit

Installation: Water Piping

Overview

Water Treatment

Pressure Gauges

Valves—Drains and Vents

Strainers

Required Flow-Sensing Devices

Evaporator and Condenser Water Piping 23

Water Piping Connections

Waterbox Locations

Grooved Pipe Coupling

Flange-Connection Adapters

Victaulic Gasket Installation

Bolt-Tightening Sequence for Water Piping Connections

Flanges with 4, 8, or 12 Bolts

Flanges with 16, 20, or 24 Bolts

Flanges with More than 24 Bolts

Evaporator Waterbox Covers

Pressure Testing Waterside Piping

Vent Piping

Refrigerant Vent Line

General Requirements

Purge Discharge

Vent Line Materials

Vent Line Sizing

Vent Line Installation

Insulation

Unit Insulation Requirements

Insulation Thickness Requirements

Installation: Controls

UC800 Specifications

Wiring and Port Descriptions

Communication Interfaces

Rotary Switches

LED Description and Operation

Installing the Tracer AdaptiView Display . .41

Adjusting the Tracer AdaptiView Display Arm

Electrical Requirements

Installation Requirements

Electrical Requirements

Trane-Supplied Starter Wiring

Customer-Supplied Remote Starter Wiring 45

Current Transformer and Potential Transform-er Wire Sizing

Power Supply Wiring

Three-Phase Power

Circuit Breakers and Fused Disconnects . .47

Power Factor Correction Capacitors (Optional)

Interconnecting Wiring

Starter to Motor Wiring (Remote-Mounted Starters Only)

Ground Wire Terminal Lugs

Terminal Clamps

4 CVHE-SVX02K-EN

Table of Contents Wire Terminal Lugs

Bus Bars

Starter to Control Panel Wiring

10kV–13.8kV Medium Voltage Installation . 51

10kV–13.8kV Medium Voltage Motor . . . 51

Motor Terminal Box

Motor Supply Wiring

System Control Circuit Wiring (Field Wiring)

Water Pump Interlock Circuits and Flow Switch Input

Temperature Sensor Circuits

Optional Control and Output Circuits . . . 55

Optional Tracer Communication Interface 55

Unit Start-up/Commissioning

Starter Module Configuration

Schematic Wiring Drawings

Operating Principles

General Requirements

Cooling Cycle

Oil and Refrigerant Pump

Motor Cooling System

Tracer AdaptiView Display

Start-up and Shut-down

Sequence of Operation

Software Operation Overview Diagram . 60

Start-up Sequence of Operation—Wye-Delta

Power Up Diagram

Ice Machine Control

Free Cooling Cycle

Free Cooling (FRCL)

Hot Gas Bypass (HGBP)

Hot Water Control

Heat Recovery Cycle

Auxiliary Condensers

Control Panel Devices and Unit-Mounted De-vices

Unit Control Panel

User-Defined Language Support

Unit Start-up and Shut-down Procedures 67

Daily Unit Start-up

Seasonal Unit Start-up

Daily Unit Shut-down

Recommended Maintenance

Record Keeping Forms

Normal Operation

Recommended Compressor Oil Change . .71

Purge System

Leak Checking Based on Purge Pump Out Time

Long Term Unit Storage

Refrigerant Charge

Recommended System Maintenance . . .73

Waterbox Removal and Installation

Discussion

Procedure

Reassembly

Torque Requirements

Connection Devices Information

Forms and Check Sheets

CVHE-SVX02K-EN 5

6 CVHE-SVX02K-EN

Unit Model Number Description

The unit nameplate is located on the left side of the control panel. A typical unit nameplate is illustrated in Figure 1 and contains the following information:

• Unit model and size descriptor

• Unit electrical requirements

• Correct operating charge and refrigerant type

• Unit test pressures and maximum operating pressures

• Unit literature

Serial Number. The unit serial number provides the specific chiller identity. Always provide this serial number when calling for service or during parts identification.

Service Model Number. The service model represents the unit as built for service purposes. It identifies the selections of variable unit features required when ordering replacements parts or requesting service.

Note: Unit-mounted starters are identified by a separate number found on the starter.

Product Description Block. The CenTraVac™ models are defined and built using the Product Definition and Selection (PDS) system. This system describes the product offerings using a product coding block which is made up of feature categories and codes that identifies all characteristics of a unit.

Figure 1. Typical unit nameplate

CVHE-SVX02K-EN 7

Model Number Descriptions

Digit Description 1–3 Unit Type 4 Development Sequence

5–7 Nominal Tonnage 8 Unit Voltage 9 Unit Type

10–11 Design Sequence 12 Hot Gas Bypass 13 Starter Type 14 Control Enclosure 15 Compressor Motor Power (CPKW)

16–18 Compressor Impeller Cutback 19 Evaporator Shell Size 20 Evaporator Tube Bundle (nominal tons) 21 Evaporator Tubes 22 Evaporator waterbox 23 Condenser Shell Size 24 Condenser Tube Bundle (nominal tons) 25 Condenser Tubes 26 Condenser waterbox 27 Heat Recovery Condenser Shell Size 28 Heat Recovery Condenser Tube Bundle (nominal 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 Option-Insulation & Rupture Guard 36 Enhanced Protection 37 Generic BAS 38 Extended Operation 39 Tracer Communication 40 Condenser Refrigerant Control 41 Manufacturing Location 42 Special Options 43 Water Flow Control 44 Chilled Water Reset 45 Heat Recovery Temperature Sensors 46 Gas Powered Chiller 47 Compressor Motor Frame Size 48 Volute Discharge Angle 49 Operating Status 50 Industrial Chiller Package 51 Control Power Transformer 52 Motor & Terminal Board Config

Pre-Installation

ASHRAE Standard 15 Compliance

Trane recommends that indoor CenTraVac unit installations fully meet or exceed the guidelines of the current version of ASHRAE Standard 15, in addition to any applicable national, state, or local requirements. This typically includes:

• A refrigerant monitor or detector that is capable of monitoring and alarming within the acceptable exposure level of the refrigerant, and that can actuate mechanical ventilation.

• Audible and visual alarms, activated by the refrigerant monitor, inside the equipment room and outside of every entrance.

• The equipment room should be properly vented to the outdoors, using mechanical ventilation that can be activated by the refrigerant monitor.

• The purge discharge and the rupture disk must be properly piped to the outdoors.

• If required by local or other codes, a self-contained breathing apparatus should be available in close proximity to the equipment room.

Refer to the latest copy of ASHRAE Standard 15 for specific guidelines. Trane assumes no responsibility for any economic, health, or environmental issues that may result from an equipment room’s design or function.

Unit Shipment

Inspect unit while it is still on the truck for any shipping damage. The chiller ships shrink-wrapped in a 0.010-in.

(0.254 mm) recyclable film protective covering. Do not remove shrink-wrap for inspection! Inspect for damage to the shrink-wrap and determine if physical damage has occurred.

Each chiller ships from the factory as a hermetically assembled package; it is factory-assembled, -wired, and -tested. All openings except for the waterbox vent and drain holes are covered or plugged to prevent contamination during shipment and handling. Figure 2,

p. 11 shows an illustration of a typical unit and its components. As soon as the unit arrives at the job site, inspect it thoroughly for damage and material shortages.

In addition:

1. Verify the hermetic integrity of the unit by checking the chiller pressure for an indication of holding charge pressure.

2. To prevent damaging moisture from entering the unit and causing corrosion, each chiller is pressurized with 3 to 5 psig (20.7 to 34.5 kPaG) of dry nitrogen before shipment.

Note: The holding charge should register approximately 5 psig (34.5 kPaG) at 72°F (22.2°C). Place a gauge on the access valve provided (indicated by arrow and circle in the preceding figure) on the refrigerant pump discharge line to verify the holding charge. If the charge has escaped, contact your local Trane sales office for instructions.

3. The loose parts box and isolator pads ship on top of the control panel box.

4. Check the oil sump sight glasses to verify that the sump was factory-charged with 9 gallons (34.1 L) of oil. If no oil level is visible, contact your local Trane sales office.

Installation Requirements and

Contractor Responsibilities

A list of the contractor responsibilities typically associated with the unit installation process is provided.

Note: The chiller should remain within its protective shrink-wrap covering during storage.

WARNING

Combustible Material!

Failure to follow this instruction could result in death or serious injury or equipment damage. Shrink-wrap is a combustible material. Avoid open flames and hot sparks.

8 CVHE-SVX02K-EN

Type of Requirement

Trane Supplied Trane Installed

Trane Supplied Field Installed

Field Supplied Field Installed

Foundation • Meet foundation requirements

Rigging • Safety chains

• Clevis connectors

• Lifting beam

Disassembly/Reassembly (as required)

• Trane will perform or have direct on-site supervision of the disassembly and reassembly work (contact your local Trane office for pricing)

Isolation • Isolation pads or spring isolators

• Isolation pads or spring isolators

Electrical • Circuit breakers or fusible disconnects (optional)

• Unit mounted starter (optional)

• PFCCs (optional)

• Jumper bars

• Temperature sensor

(optional outdoor air)

• Flow switches (may be field supplied)

• Remote-mounted starter

(optional)

• Circuit breakers or fusible disconnects (optional)

• Electrical connections to unit mounted starter

(optional)

• Electrical connections to remote mounted starter

(optional)

• Wiring sizes per submittal and NEC

• PFCCs (remote mounted starter optional only)

• Terminal lugs

• Ground connection(s)

• Jumper bars

• BAS wiring (optional)

• IPC wiring (AFD and remote-mounted starters only)

• Control voltage wiring (AFD and remote-mounted starters only)

• Oil pump interlock wiring (AFD and remote mounted starters only)

• High condenser pressure interlock wiring (AFD and remote mounted starters only)

• Chilled water pump contactor and wiring including interlock

• Condenser water pump contactor and wiring including interlock

• Option relays and wiring

• Tracer SC communication wiring (optional)

Water piping • Flow sensing devices (may be field supplied)

• Taps for flow sensing devices

• Taps for thermometers and gauges

• Thermometers

• Strainers (as required)

• Water flow pressure gauges

• Isolation and balancing valves in water piping

• Vents and drain on waterbox valves (one each per pass)

• Pressure relief valves (for waterboxes as required)

Relief • Rupture disk assembly • RuptureGuard™ (optional)

• Vent line and flexible connector and vent line from rupture disk to atmosphere

Insulation • Insulation (optional) • Insulation

• Chiller feet insulation

Water Piping Connection Components

Flanged (optional)

• Welded on flange for

300 psig (2068.4 kPaG) waterboxes

Flanged (optional)

• Victaulic® to flange adapter for 150 psig (1034.2 kPaG) waterboxes

Victaulic

• Victaulic coupling for 150 psig (1034.2 kPaG) and

300 psig (2068.4 kPaG) waterboxes

• Fasteners for flanged-type connections (optional)

Other Materials • R-22 refrigerant (1 lb [0.45 kg] maximum per machine as needed to perform leak testing)

• Dry nitrogen (8 psig [55.2 kPaG] maximum per machine as needed)

CVHE-SVX02K-EN 9

Storage Requirements

“CenTraVac™ Installation Completion Check Sheet and Request for Trane Service” (CTV-ADF001*-EN; refer to “Forms and Check Sheets,” p. 79)

• To be completed by installing contractor prior to contacting Trane for start-up

Chiller start-up commissioning(a)

• Trane, or an agent of Trane specifically authorized to perform start-up of Trane® products

Post-commissioning transport of empty refrigerant containers for return or recycling

• Move empty refrigerant containers to an easily accessible point of loading

(a) Start-up must be performed by Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products. Contractor shall provide Trane (or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

Type of Requirement

Trane Supplied Trane Installed

Trane Supplied Field Installed

Field Supplied Field Installed

NOTICE:

Insulation Damage!

Do not expose unit to direct sunlight as it could result in damage to factory-installed insulation.

Less than 1 month 1–6 months Greater than 6 months

Location requirements:

• solid foundation

• vibration free

• dry

• temperature range -40°F to 158°F

(-40°C to 70°C)

Location requirements:

• solid foundation

• vibration free

• dry

• temperature range -40°F to 158°F

(-40°C to 70°C)

Location requirements:

• solid foundation

• vibration free

• dry

• temperature range -40°F to 158°F

(-40°C to 70°C)

• Do not remove any plastic coverings • Do not remove any plastic coverings • Do not remove any plastic coverings

• Do not charge the chiller with refrigerant

• If additional refrigerant is on site, follow manufactures storage requirements

• Do not charge the chiller with refrigerant

• If additional refrigerant is on site, follow manufactures storage requirements

• Do not charge the chiller with refrigerant

• If additional refrigerant is on site, follow manufactures storage requirements

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (20.7 to 34.5 kPaG)

• Notify the local Trane office if charge has escaped

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (20.7 to 34.5 kPaG)

• Notify the local Trane office if charge has escaped

• Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig (20.7 to 34.5 kPaG)

• Notify 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 verify no oil breakdown(a)

• Repeat yearly

• Replace oil if breakdown has occurred

• If no oil analysis program has been followed, replace oil prior to start up

• Every 6 months, start the oil pump and rotate compressor shaft about 450° to prevent potential bearing issues(a)

• Contact your local Trane office to perform this task

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

(a) If the chiller will be stored for more than 6 months after production, contact your local Trane service agency for required extended storage actions to minimize impact to the chiller and preserve the warranty.

10 CVHE-SVX02K-EN

Unit Components

Note: The control panel side of the unit is always designated as the front side of the unit.

Figure 2. Typical CVHF CenTraVac chiller

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

CVHE-SVX02K-EN 11

Unit Clearances and Weights

Recommended Unit Clearances

Adequate clearances around and above the chiller are required to allow sufficient access for service and maintenance operations. Specific unit clearance requirements are indicated in the submittal package provided for your unit.

• Do NOT install piping or conduit above the compressor motor assembly or behind the suction elbow of the unit.

• Minimum vertical clearance above the unit is 3 feet (92 cm).

• Use a housekeeping pad to provide better service clearances; refer to submittal for more information.

Per NEC Article 110: Unit mounted starters from 0–600V require a 42 inch (107 cm) clearance, 601–2500V require a 48 inch (122 cm) clearance, and 2501–9000V require a 60 inch (152 cm) clearance. Refer to NEC and local electrical codes for starter and control panel clearance requirements.

Figure 3. Clearance requirements

Optional unit mounted starter

Cooling condenser

Auxiliary condenser (optional)

Evaporator

Economizer

Motor

These dimensions 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.

18 in. (46 cm)

3 ft. (92 cm)

12 CVHE-SVX02K-EN

General Weights

The unit weight information provided in Table 2 should be used for general information purposes only. Trane does not recommend using this weight information for considerations relative to chiller handling. The large number of variances between chiller selections drives variances in chiller weights that are not recognized in this table. For specific weights for your chiller, refer to your submittal package.

The values in Table 2 representing chiller weights include the following:

• TECU 0.028-in. tube wall.

• 150 psig (1034.2 kPaG) non-marine waterboxes.

• Operating weights include the largest possible refrigerant charge.

• Chillers with starter weights include the weight of the heaviest possible starter.

• Heaviest possible bundle and heaviest possible motor combination for the application family chiller.

The values in Table 2 representing chiller weights do NOT include the following options:

• INDP (Industrial Control Panel) option—add 50 lb (23 kg)

• CPTR (Control Panel Transformer) option—add 130 lb (50 kg)

• SMP (Supplemental Motor Protection) option—add 500 lb (230 kg)

Table 1. Clearance requirements(a)

Evaporator Size Shell Combo A B C D E inch cm inch cm inch cm inch cm inch cm

032 Short/Long

Short/Short 45 114 141 358 321 815 34 86 53 134

Short/Long 77 195 219 556 431 1094 34 86 53 134

Long/Long 45 114 187 474 411 1043 34 86 53 134

050 Short/Long

Short/Short 45 114 141 358 321 815 40 101 62 157

Short/Long 78 198 219 556 431 1094 40 101 62 157

Long/Long 45 114 187 474 411 1043 40 101 62 157

080 Short/Long

Short/Short 53 134 141 358 329 835 36 91 76 193

Short/Long 85 215 219 556 439 1115 36 91 76 193

Long/Long 53 134 187 474 419 1064 36 91 76 193

142 Medium/Long/ Extended 210 Long

Medium Long 78 198 207 525 444 1127 44 111 92 233

Long/Long 58 147 187 474 424 1076 44 111 92 233

Extended/Long 58 147 209 530 469 1191 44 111 92 233

Long/Long 59 149 187 474 426 1082 47 119 102 259

250 Extended Extended/Long 63 160 209 530 475 1206 43 109 115 292

(a) All dimensions are approximate; refer to the unit submittal package for exact dimensions for your unit.

Table 2. Unit weights

Model NTON CPKW EVSZ CDSZ

Weight without Starter Weight with Starters Operating Shipping Operating Shipping lb kg lb kg lb kg lb kg

CVHE

(60 Hz)

230–320 287 032S 032S 14918 6767 13730 6228 17143 7776 15955 7237

230–320 287 032S 032L 15484 7023 14195 6439 17709 8033 16420 7448

230–320 287 032L 032L 16391 7435 14856 6739 18616 8444 17081 7748

230–320 287 050S 050S 19275 8743 17163 7785 21500 9752 19388 8794

230–320 287 050S 050L 20211 9168 17938 8137 22436 10177 20163 9146

230–320 287 050L 050L 21738 9860 18910 8577 23963 10869 21135 9587

360–500 453 050S 050S 20812 9440 18700 8482 23037 10449 20925 9491

360–500 453 050S 050L 21748 9865 19475 8834 23973 10874 21700 9843

360–500 453 050L 050L 23275 10557 20447 9275 25500 11567 22672 10284

360–500 453 050S 080S 23540 10678 20910 9485 25765 11687 23135 10494

360–500 453 050L 080L 26586 12059 23193 10520 28811 13068 25418 11529

360–500 453 080S 080S 28529 12941 25002 11341 30754 13950 27227 12350

360–500 453 080S 080L 30098 13652 26313 11935 32323 14661 28538 12945

360–500 453 080L 080L 32186 14599 27893 12652 34411 15609 30118 13661

CVHE-SVX02K-EN 13

CVHF

(60 Hz)

350–570 588 050S 050S 19319 8763 17207 7805 22260 10097 20148 9139

350–570 588 050S 050L 20255 9188 17982 8156 23196 10522 20923 9491

350–570 588 050L 050L 21682 9835 18954 8597 24623 11169 21895 9931

350–570 588 050S 080S 21997 9978 19417 8807 24938 11312 22358 10141

350–570 588 050L 080L 24993 11337 21700 9843 27934 12671 24641 11177

350–570 588 080S 080S 27010 12252 23483 10652 29951 13586 26424 11986

350–570 588 080S 080L 28579 12963 24794 11246 31520 14297 27735 12580

350–570 588 080L 080L 30667 13910 26374 11963 33608 15244 29315 13297

620–870 957 080S 080S 29594 13424 26068 11849 32484 14734 28957 13135

620–870 957 080S 080L 31163 14135 27378 12418 34053 15446 30268 13729

620–870 957 080L 080L 33251 15082 28958 13135 36141 16393 31848 14446

620–870 957 080L 142L 38501 17464 32413 14702 41391 18775 35303 16013

620–870 957 142M 142L 39419 17880 33487 15189 41734 18930 35646 16169

620–870 957 142L 142L 40660 18443 34310 15563 42309 19191 36377 16500

650–910 957 080S 080S 29385 13329 25858 11729 32275 14640 28748 13040

650–910 957 080S 080L 30954 14040 27169 12324 33844 15351 30059 13635

650–910 957 080L 080L 33042 14988 28749 13040 35932 16298 31639 14351

650–910 957 080L 142L 38292 17369 32204 14607 41182 18680 35094 15918

650–910 957 142M 142L 39210 17785 33278 15095 41525 18835 35437 16074

650–910 957 142L 142L 40451 18348 34101 15468 42100 19096 36168 16406

1070–1300 1228 080L 142L 40819 18515 34731 15754 43341 19659 36991 16779

1070–1300 1228 142M 142L 41511 18829 35579 16138 43150 19573 37218 16882

1070–1300 1228 142L 142L 42752 19392 36402 16512 44391 20135 38041 17255

1070–1300 1228 142E 142L 43986 19952 37292 16915 45625 20695 38931 17659

1070–1300 1228 142M 210L 46024 20876 38676 17543 47726 21648 40378 18315

1070–1300 1228 142L 210L 47403 21502 39591 17958 49105 22274 41293 18730

1070–1300 1228 142E 210L 48887 22175 40580 18407 50589 22947 42282 19179

1070–1300 1228 210L 210L 51651 23428 43440 19704 53290 24172 45079 20447

1070–1300 1228 250E 250L 60905 27626 50350 22838 62544 28369 51989 23582

1470 1340 210L 210L 54232 24599 46021 20875 55871 25343 47660 21618

1470–1720 1340 142L 210L 49984 22672 42172 19129 51686 23444 43874 19901

1470–1720 1340 142E 210L 51468 23345 43161 19578 53170 24118 44863 20350

1470–1720 1340 250E 250L 63486 28797 52931 24009 65125 29540 54570 24753

CVHE

(50 Hz)

190–270 242 032S 032S 14946 6779 13758 6241 16585 7523 15397 6984

190–270 242 032S 032L 15512 7036 14223 6451 17151 7780 15862 7195

190–270 242 032L 032L 16419 7448 14884 6751 18058 8191 16523 7495

190–270 242 050S 050S 19303 8756 17191 7798 20942 9499 18830 8541

190–270 242 050S 050L 20239 9180 17966 8149 21878 9924 19605 8893

190–270 242 050L 050L 21766 9873 18938 8590 23405 10616 20577 9334

300–420 379 050S 050S 20195 9160 18083 8202 21834 9904 19722 8946

300–420 379 050S 050L 21131 9585 18858 8554 22770 10328 20497 9297

300–420 379 050L 050L 22658 10277 19830 8995 24297 11021 21469 9738

300–420 379 080S 080S 27912 12661 24385 11061 29551 13404 26024 11804

300–420 379 080S 080L 29481 13372 25696 11656 31120 14116 27335 12399

300–420 379 080L 080L 31569 14319 27276 12372 33208 15063 28915 13116

Table 2. Unit weights (continued)

Model NTON CPKW EVSZ CDSZ

Weight without Starter Weight with Starters Operating Shipping Operating Shipping lb kg lb kg lb kg lb kg

14 CVHE-SVX02K-EN

CVHG

(50 Hz)

480–565 489 050S 050S 22009 9983 19897 9025 23648 10727 21536 9769

480–565 489 050S 050L 22945 10408 20672 9377 24584 11151 22311 10120

480–565 489 050L 050L 24372 11055 21644 9818 26011 11798 23283 10561

480–565 489 080S 080S 29726 13483 26199 11884 31365 14227 27838 12627

480–565 489 080S 080L 31295 14195 27510 12478 32934 14939 29149 13222

480–565 489 080L 080L 33383 15142 29090 13195 35022 15886 30729 13938

670–780 621 080S 080S 31037 14078 27510 12478 32676 14822 29149 13222

670–780 621 080S 080L 32606 14790 28821 13073 34245 15533 30460 13816

670–780 621 080L 080L 34694 15737 30401 13790 36333 16480 32040 14533

670–780 621 142M 142L 41176 18677 35244 15986 42815 19421 36883 16730

670–780 621 142L 142L 42417 19240 36067 16360 44056 19983 37706 17103

920–1100 892 142M 210L 46868 21259 39520 17926 48570 22031 41222 18698

920–1100 892 142L 210L 48247 21884 40435 18341 49949 22656 42137 19113

920–1100 892 142E 210L 49731 22558 41424 18790 51433 23330 43126 19562

920–1100 892 210L 210L 52495 23811 44284 20087 54134 24555 45923 20830

Table 2. Unit weights (continued)

Model NTON CPKW EVSZ CDSZ

Weight without Starter Weight with Starters Operating Shipping Operating Shipping lb kg lb kg lb kg lb kg

CVHE-SVX02K-EN 15

Installation: Mechanical

Operating Environment

Important:

• The standard chiller is designed for indoor use only and as such has NEMA Type 1 enclosures.

• For chillers in unheated equipment rooms, contact your local Trane service agency for methods to ensure that the oil temperature is maintained suitable for proper operation of the chiller.

To ensure that electrical components operate properly, do not locate the chiller in an area exposed to dust, dirt, corrosive fumes, or excessive heat and humidity. The maximum ambient temperature for chiller operation is 104°F (40°C).

Foundation Requirements

Chiller mounting surface must be:

• rigid non-warping mounting pads or a concrete foundation.

• able to support the chiller at its full operating weight (including completed piping, and full operating charges of refrigerant, oil and water.)

For proper unit operation, the chiller must be level within 1/16 in. (1.6 mm) over its length and width when set into place on the mounting surface. Table 2, p. 13 shows approximate weights for various chiller sizes and options.

Note: For specific weight information, refer to the unit submittal package.

Important: Trane will not assume responsibility for equipment problems resulting from an improperly designed or constructed foundation.

Rigging

Lifting is the recommended method for moving chillers.

Suggested lifting arrangements for standard units are described in “Standard Chiller Lift,” p. 16.

Note: The lifting beam used for Simplex units must be at least 16 feet (4.8768 meters) long.

Standard Chiller Lift

1. Insert clevis connections at the points indicated in Figure 4, p. 17. A 2 in. (50.8 mm) diameter lifting hole is provided at each of these points.

2. Attach the lifting chains or cables.

3. Once the lifting cables are in place, attach a safety chain or cable between the first-stage casing of the compressor and the lifting beam.

Important: There should not be tension on this safety cable; the cable is used only to prevent the unit from rolling during the lift.

4. Position isolator pads or spring isolators beneath the chiller feet (refer to “Unit Isolation,” p. 18 for instructions).

Note: Follow instructions provided by the spring isolator manufacturer, being careful to not damage isolator adjustment bolt.

5. Once the isolators are in place, lower the chiller— working from end to end—in small increments to maintain stability.

6. When lift is complete, detach the clevis connections and safety chain.

NOTICE:

Equipment Failure!

Unit operating at ambient temperatures exceeding 104°F (40°C) could fatigue the unit’s rupture disk, causing it to break at a reduced refrigerant pressure (<15 psig [<103.4 kPaG]). Starter component damage could also occur due to the panel’s inability to dissipate heat adequately. If any of these adverse operating conditions are present, take necessary action to improve the equipment room environment.

WARNING

Heavy Objects!

Failure to properly lift unit could result in death or serious injury, or equipment or property-only damage.

Do not use cables (chains or slings) except as shown in Figure 4, p. 17. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift.

WARNING

Improper Unit Lift!

Failure to properly lift unit could result in death or serious injury, or equipment or property-only damage.

Test lift unit approximately 24 inches (61 cm) to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level.

NOTICE:

Wiring Damage!

Damage to unit wiring could result in equipment failure. Care must be taken during rigging, assembly and disassembly to avoid damaging unit wiring.

16 CVHE-SVX02K-EN

Figure 4. Typical rigging arrangements for Simplex units

Safety chain or cable

Jack slots

16 feet (4.8768 meters) minimum effective length

Figure 4. Typical rigging arrangements for Simplex units (continued)

800 Short shells only— use rigging flange

Auxiliary option

Heat recovery option

CVHE-SVX02K-EN 17

Special Lift Requirements

If the chiller cannot be moved using a standard chiller lift, consider the following:

• When job site conditions require rigging of the chiller at an angle greater than 45° from horizontal (end-to-end), the unit may require removal of the compressor.

Contact Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products regarding the disassembly and reassembly work. For more information, refer to “Factory Warranty Information,” p. 3.

Note: Disassembly and reassembly work includes dowel-pinning the compressor and removing it from the unit. Contact Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products for specific rigging instructions. Do NOT attempt to rotate the chiller onto its side.

• When lifting the chiller is either impractical or undesirable, attach cables or chains to the jacking slots shown in Figure 4, p. 17; then push or pull the unit across a smooth surface. Should the chiller be on a shipping skid, it is not necessary to remove the skid from the chiller before moving it into place.

• If removal of the compressor or economizer assembly is necessary to move the chiller to the operating location, contact Trane. For more information, refer to “Factory Warranty Information,” p. 3.

Unit Isolation

To minimize sound and vibration transmission through the building structure, and to ensure proper weight distribution over the mounting surface, always install isolation pads or spring isolators under the chiller feet.

Note: Isolation pads (see Figure 5) are provided with each chiller unless spring isolators are specified on the sales order.

Specific isolator loading data is provided in the unit submittal package. If necessary, contact your local Trane sales office for further information.

Important: When determining placement of isolation pads or spring isolators, remember that the control panel side of the unit is always designated as the unit front.

Isolation Pads

When the unit is ready for final placement, position isolation pads (18-in. sides) end for end under the full length of the chiller leg. The pads measure 9 in. × 18 in.

(228.6 mm x 457.2 mm) and on some units there may be small gaps between pads. Pads are provided to cover entire foot. Place pad flush with the outside edge of the chiller foot and leave excess material under the chiller.

Remember that the chiller must be level within 1/16 in.

(1.6 mm) over its length and width after it is lowered onto the isolation pads. In addition, all piping connected to the chiller must be properly isolated and supported so that it does not place any stress on the unit.

Spring Isolators

Spring isolators should be considered whenever chiller installation is planned for an upper story location. Base isolator placement is shown in Figure 6.

NOTICE:

Oil Loss!

Failure to prevent oil migration out of the oil tank could result in equipment failure or property-only damage. To prevent oil migration out of the oil tank during lifting procedures, remove the oil from the oil tank if the unit will be lifted at any angle greater than 15° from horizontal end-to-end. If oil is allowed to run out of the oil tank into other areas of the chiller, it will be extremely difficult to return the oil to the oil tank even during operation.

NOTICE:

Equipment Damage!

Moving the chiller using a fork lift could result in equipment or property-only damage. Do not use a fork lift to move the chiller!

NOTICE:

Compressor Alignment!

Failure to preserve compressor alignment could result in equipment or property-only damage. Lifting the compressor/motor assembly from the shells without factory-installed doweling in the compressor casting flanges could result in misalignment of the compressor castings. Figure 5. Isolation pad and dimensions

9 in.

(228.6 mm)

18 in.

(457.2 mm)

3/8 in.

(9.5 mm)

18 CVHE-SVX02K-EN

Spring isolators typically ship assembled and ready for installation. To install and adjust the isolators properly, follow the instructions given.

Note: Do not adjust the isolators until the chiller is piped and charged with refrigerant and water.

1. Position the spring isolators under the chiller as shown in Figure 6. Ensure that each isolator is centered in relation to the tube sheet.

Note: Spring isolators shipped with the chiller may not be identical. Compare the data provided in the unit submittal package to determine proper isolator placement.

2. Set the isolators on the sub-base; shim as necessary to provide a flat, level surface at the same elevation for the end supports.

Important: Support the full underside of the isolator base plate; do NOT straddle gaps or small shims.

3. If required, bolt the isolators to the floor through the slots provided, or cement the pads.

Note: Fastening the isolators to the floor is not necessary unless specified.

4. If the chiller must be fastened to the isolators, insert capscrews through the chiller base and into holes drilled and tapped in the upper housing of each isolator.

Important: Do NOT allow the screws to protrude below the underside of the isolator upper housing, or interfere with the adjusting bolts. An alternative method of fastening the chiller to the isolators is to cement the neoprene pads.

5. Set the chiller on the isolators; refer to “Standard Chiller Lift,” p. 16. The weight of the chiller will force down the upper housing of each isolator, and could cause it to rest on the isolator’s lower housing (refer to Figure 7).

6. Check the clearance on each isolator. If this dimension is less than 1/4 in. (6.35 mm) on any isolator, use a wrench to turn the adjusting bolt one complete revolution upward.

Note: When the load is applied to the isolators (Step 5), the top plate of each isolator moves down to compress the springs until either the springs support the load or the top plate rests on the bottom housing of the isolator. If the springs are supporting the load, screwing down on the adjusting bolt (Step 7) will raise the chiller.

7. Turn the adjusting bolt on each of the remaining isolators to obtain the required minimum clearance of 1/4 in. (6.35 mm).

8. Once the minimum required clearance is obtained on each of the isolators, level the chiller by turning the adjusting bolt on each of the isolators on the low side of the unit. Work from one isolator to the next.

Important: The chiller must be level to within 1/16 in.

(1.6 mm) over its length and width, and the clearance of each isolator must be at least 1/ 4 in. (6.35 mm).

Figure 6. Isolation spring placement by shell size, evaporator and condenser length

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

Condenser

Evaporator left front left rear right front right rear

Condenser

Evaporator left center left front left rear right front right rear

Figure 7. Chiller foot and isolator orientation

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.

CVHE-SVX02K-EN 19

Leveling the Unit

The chiller must be set level within 1/16 in. (1.6 mm).

1. Measure and make a punch mark an equal distance up from the bottom of each foot of the chiller.

2. Suspend a clear plastic tube along the length of the chiller as shown in the following figure.

3. Fill the tube with water until the level aligns with the punch mark at one end of the chiller.

4. Check the water level at the opposite mark. If the water level does not align with the punch mark, use full length shims to raise one end of the chiller until the water level at each end of the tube aligns with the punch marks at both ends of the chiller.

5. Once the unit is level across its length, repeat Step 1 through Step 3 to level the unit across its width.

Note: Use of a laser level is an acceptable alternative method to level the unit.

Important: Immediately report any unit damage incurred during handling or installation at the job site to the Trane sales office.

Figure 8.

20 CVHE-SVX02K-EN

Installation: Water Piping

Overview

The following water piping circuits must be installed and connected to the chiller:

• Pipe the evaporator into the chilled water circuit.

• Pipe the condenser into the cooling tower water circuit.

• Optional: A heat-recovery condenser water circuit.

• Optional: An auxiliary condenser water circuit.

Note: Piping must be arranged and supported to avoid stress on the equipment. It is strongly recommended that the piping contractor does not run pipe closer than 3 feet (0.91 m) minimum to the equipment. This will allow for proper fit upon arrival of the unit at the job site. Any adjustment that is necessary can be made to the piping at that time. Expenses that result from a failure to follow this recommendation will not be paid by Trane.

Piping suggestions for each of the water circuits listed above are outlined in “Evaporator and Condenser Water Piping,” p. 23. General recommendations for the installation of field supplied piping components (e.g., valves, flow switches, etc.) common to most chiller water circuits are listed below.

Water Treatment

The use of untreated or improperly treated water in a CenTraVac may result in inefficient operation and possible tube damage.

Important: Trane strongly recommends using the services of a qualified water treatment specialist to determine necessary water treatment. A label with a customer disclaimer note is affixed to each unit.

Pressure Gauges

Locate pressure gauge taps in a straight length of pipe.

Place each tap a minimum of one pipe diameter downstream of any elbow, orifice, etc. For example, for a 6 in. (152.4 mm) pipe, the tap would be at least 6 in.

(152.4 mm) from any elbow, orifice, etc.

Valves—Drains and Vents

1. Install field-supplied air vents and drain valves on the waterboxes. Each waterbox is provided with a National Pipe Thread Female (NPTF) vent and drain connection;

depending on the waterbox types ordered, the openings may be 1/4 in. (6.35 mm), 1/2 in. (12.7 mm), or 3/4 in. (19.05 mm).

2. If necessary for the application, install pressure-relief valves at the drain connections on the evaporator and condenser waterboxes. To do so, add a tee with the relief valve attached to the drain valve.

To determine whether or not pressure relief valves are needed for a specific application, keep in mind that:

a. Vessels with close-coupled shutoff valves may cause high potentially damaging hydrostatic pressures as fluid temperature rises.

b. Relief valves are required by American Society of Mechanical Engineers (ASME) codes when the shell waterside is ASME. Follow ASME guidelines or other applicable codes to ensure proper relief valve installation.

Strainers

Install a strainer in the entering side of each piping circuit to avoid possible tube plugging in the chiller with debris.

Required Flow-Sensing Devices

Use flow paddle switches (see “Paddle Switches,” p. 22), differential pressure switches or ifm efector® flow detection controller and sensor (see “Water Flow

NOTICE:

Proper Water Treatment!

Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water. The use of untreated or improperly treated water in a CenTraVac could result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required.

NOTICE:

Waterbox Damage!

Failure to follow instructions could result in damage to the waterbox. Do not over-tighten or use excessive Teflon® pipe tape when installing valves, drains, plugs and vents on waterboxes.

NOTICE:

Over-pressurization!

Failure to install pressure-relief valves in the condenser and evaporator water circuits could result in waterbox damage due to hydrostatic expansion.

NOTICE:

Tube Damage!

Failure to install strainers in all water piping entering the chiller could result in tube plugging conditions that damage unit components.

CVHE-SVX02K-EN 21

Detection Controller and Sensor,” p. 22) in conjunction with the pump interlocks to verify evaporator and condenser water flows.

To ensure adequate chiller flow protection, wire the chiller water and condenser water proof of flow devices per the as-built schematics and submittal, and in accordance with associated notes.

Unless stated otherwise, all flow sensing devices must be field supplied. Be sure to follow the manufacturer’s recommendations for device selection and installation (see Figure 9).

Also, review the following general flow switch installation guidelines.

Paddle Switches

1. Mount the flow paddle switch upright in horizontal section of pipe. Allow at least five pipe diameters of straight, horizontal run on each side of the switch.

Whenever possible, avoid locations adjacent to elbows, orifices, and valves.

2. To ensure that the flow switch operates as designed, adjust the length of the flow switch paddle to compensate for the pipe diameter and the height of the coupling used to install the switch.

3. Install the flow switch using a coupling that is large enough to allow the insertion of a bushing one pipe diameter larger than the flow switch base as shown in Figure 9. This will prevent interference with the flow switch paddle.

4. Verify that the direction-of-flow arrow on the switch points in the same direction as actual water flow through the piping circuit.

5. Remove all air from the piping circuit to prevent possible flow switch “fluttering”.

6. Adjust the flow switch to open when water…