Product Catalog. Cold Generator Compact Chiller Series Model CICA 20, 30 and 50Tons (60 Hz) R-410A CG-PRC028D-EN. June 2017

Transcription

1 Product Catalog Cold Generator Compact Chiller Series Model CICA 20, 30 and 50Tons (60 Hz) R-410A June 2017 CG-PRC028D-EN

2 Introduction Trane Cold Generator Compact model CICA water-cooled chillers were designed with flexibility, expandability and serviceability in mind. These high efficiency chillers provide quiet, reliable operation and are built to withstand demanding continuous duty cycles. Each chiller meets or exceeds ASHRAE energy efficiency standard that went into effect January 1, At the heart of the CICA product line is the highly efficient scroll compressor. Additionally the CICA utilizes brazed plate evaporators, brazed plate condensers, and state of the art electronic expansion valves for increased reliability. CICA compact water-cooled chillers can be easily combined to meet higher capacity demands and are easy to install in most building layouts.this makes them the ideal choice for retrofit or new building designs where reliability, high efficiency, flexibility, and expandability are critical Ingersoll Rand CG-PRC028D-EN

3 Introduction Copyright This document and the information in it are the property oftrane, 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 Revision History All trademarks referenced in this document are the trademarks of their respective owners. Updated certification information in Mechanical Specifications. Updated AHRI logo on back cover. CG-PRC028D-EN 3

4 Table of Contents Introduction...2 Features and Benefits...5 Application Consideration...9 Model Number Descriptions...12 General Data...13 Performance Data...14 Controls...15 Electrical...20 Electrical Connections...21 Dimensions and Weights...24 Mechanical Specifications...27 Appendix A Piping System Flushing Procedure CG-PRC028D-EN

5 Features and Benefits Standard Features Trane Cold Generator Compact Series model CICA water cooled chillers are complete, factoryassembled units designed for a wide range of ton capacity comfort and process cooling applications, but also have the ability to be piped into a multistage array of up to ten (10) chillers for much larger capacities. All CICA chillers meet or exceed ASHRAE energy efficiency requirements effective 1/1/2015. All CICA chillers are AHRI performance certified under AHRI Standard 550/590(I-P)-2011 and ETL safety compliant under ANSI/UL1995, CAN/CSA C , 4 th edition. Factory-assembled CICA chillers are pressure tested, dehydrated and charged with operating charge of POE compressor oil and 410A refrigerant before shipment. Every CICA chiller is run tested over a range of full and part load conditions before shipment, minimizing startup delay. A data log is retained at the factory for each unit shipped. Every CICA chiller s dimensions, including the detachable water header section and all standard or optional valving, are 30 wide X 72 tall X 60 deep. All CICA chillers have a single refrigeration circuit with (2) scroll compressors arranged in a tandem configuration for higher part load efficiencies and electronic expansion valve for increased reliability. The refrigerant circuit on all CICA chillers has (4) service ports, including one charging port located between the expansion device and the evaporator inlet. The standard hot gas injection feature is suction pressure actuated and is provided to stabilize the suction pressure/temperature in the evaporator during transient conditions which avoids potential nuisance safety trips. Core temperature sensors are installed in every CICA evaporator as a redundant low water temperature safety. CICA chillers have manual isolation valves andvictaulic couplings making it easy to isolate the heat exchangers. UL-listed brazed-plate evaporators have inlet and outlet pressure transducers that report water differential pressure to the unit controller which can be read from the keypad display for flow proving and system balancing. UL-listed brazed-plate condensers have inlet and outlet pressure gauge service ports for manually measuring the water differential pressure. Every CICA chiller has a detachable water header section consisting of left-hand or right-hand evaporator and condenser customer connections. Customer connections are Victaulic and arrive ready for immediate connection to the customer supply/return lines and, if applicable, to other adjacent CICA chillers. All cold refrigerant and water surfaces are insulated with closed-cell flexible insulation. All CICA power distribution and control components are located in (1) two-level control cabinet with operator keypad/display, non-fused disconnect, alarm light, run light and off/auto switch mounted on the exterior of the control cabinet door. The CICA unit controller is a microprocessor based controller capable of performing all of the operational, safety, data retention, communication and fault related functions of the chiller while providing compressor management through lead/lag logic. BACnet /IP and Modbus TCP/IP (or RTU) capability are the standard protocols for building automation and control network communication if needed. CICA chillers come with a complete unit parts warranty (excluding refrigerant) for one (1) year from startup or 18 months from shipment, whichever occurs first. CG-PRC028D-EN 5

6 Features and Benefits Factory-Installed Options The integral condenser water regulating valve option is available to stabilize and maintain the refrigerant condensing pressure within the operating limits of the CICA chiller.the valve would replace one of the manual isolating valves that come standard on every chiller and would also be used to isolate the condenser from the cooling water circuit when needed. A fused disconnect with through-the-door operator is available on most CICA models and would replace the standard non-fused disconnect. A 100kA SCCR electrical rating, if needed, could replace the standard 5kA SCCR electrical rating on all CICA chillers by use of current-limiting fuses. Sound attenuation enclosures are exterior panels designed to completely enclose the compressor section of the CICA chiller. Compressor blankets are used to dampen the sound produced by the compressors and can be used alone or in combination with the sound attenuation enclosures. The factory-installed phase/power monitor is designed to protect the chiller from premature failure and damage due to common voltage faults such as voltage unbalance, over/under voltage, phase loss, reversal, incorrect sequencing and rapid short cycling. BACnet MS/TP, Johnson N2 and LonTalk protocols for building automation and control network communication are available for the CICA unit controller. A controller expansion board can be installed if advanced peripheral control is needed. 6 CG-PRC028D-EN

7 Features and Benefits Factory-Provided/Field-Installed Options Wye-strainers with removable stainless steel 20-mesh screen, epoxy paint, tapped NPT blowdown connection and inlet/outlet pressure gauge taps are available in sizes ranging from 2-8. Wye-strainers with a minimum of 20-mesh are required to be field-installed before the customer connections to the chiller s evaporator and condenser inlets. An evaporator flow-proving device is required for all CICA applications. A paddle style liquid flow switch is available with a NEMAType 4X enclosure for field-installation. When opting to connect more than (1) CICA chiller together to form a larger capacity, multistage chiller array, the factory-provided/field-installed array controller can control up to (10) CICA chillers. The array controller package also includes: The entering and leaving chilled water temperature sensors and temperature wells to be field-installed in the array s common supply and return chilled water lines (factory-provided/ field-installed) All couplings and fittings needed to connect adjacent chillers (factory-provided/fieldinstalled) CICA header pipe size optimization for its position in the chiller array (factory-installed) Wireless router for wireless access to each individual chiller and the array control panel (factory-provided/field-installed, Ethernet cable field-provided) For critical cooling applications, the N+1 option allows for a dormant backup chiller to be available in a multiple CICA chiller array. If an active CICA chiller fails, the N+1 logic will open the chilled and condenser water valves and enable the backup chiller while closing the chilled and condenser water valves and disabling the failed chiller.the N+1 option package includes: The array controller package (factory-provided/field-installed) (1) backup CICA chiller to be connected to the N number of CICA chillers needed to satisfy the design cooling load (factory-provided/field-installed) Array controller N+1 logic programming (factory-installed) Motorized valves on all CICA chillers evaporator and condenser outlets (factory-installed) Neoprene isolator pads can be provided for all (6) load bearing points on the CICA chillers. The wheel kit, containing (4) swiveling casters, is easily installed to predrilled holes in the base of each CICA chiller and allows the chiller to be easily maneuvered and rolled into position across smooth surfaces. The rigging bracket kit includes four (4) steel rigging brackets with 1-5/8 lifting holes designed for chiller s weight and easily mounted to predrilled holes on chiller frame. Hardware is included. The forklift pocket kit include four (4) steel forklift pockets designed for the chiller s weight and easily mounted to predrilled holes on chiller frame. Hardware included. Ice build logic can be factory programmed into the CICA unit controller for use with a fieldprovided and installed dry contact closure device in ice storage applications. Available for single chiller application only. Condenser water temperature sensors allow measurement and monitoring of the condenser entering and leaving water temperatures. Ambient temperature sensor allows for measuring and monitoring of ambient temperature. CG-PRC028D-EN 7

8 Features and Benefits Other Features and Benefits Flexibility & Expandability Serviceability Single Source Responsibility Trane Cold Generator CICA compact series scroll chillers were specifically scaled to fit through a standard 36 doorway and to fit onto a standard elevator, ensuring fast and easy delivery and installation. Because the CICA compact series can be applied as an individual chiller or applied as a high capacity multi-stage, multi-chiller array by using the optional array controller package, the CICA chillers can be configured to meet capacity needs ranging from 20 tons to 500 tons. For atypical mechanical room configurations sometimes encountered with retrofit and renovation applications, CICA chiller arrays are not required to be installed side-by-side. If limited on space or dealing with a challenging layout,trane will design custom pipe sizes to suit the unique needs of your facility s chiller array layout. The array controller option allows the CICA chiller to be an ideal solution for facilities with growing occupancy and structural expansion plans because chillers can be added as capacity needs increase. The CICA compact chiller was designed in such a manner that the compressors, evaporator, condenser, refrigerant specialties and water pipe components can all be easily serviced or removed. When installed in an array, these components can all be easily serviced or removed from any one chiller in the array while the other chillers in the array continue to operate. Standard, integral valving makes it possible to isolate the CICA heat exchangers for routine maintenance. Once isolated, both heat exchangers have inlet and outlet Victaulic connections readily accessible to allow for backflushing and cleaning without having to remove the exchanger. If a heat exchanger must be removed and replaced, all necessary work can be performed at the back of the chiller without having to remove other unrelated parts. If needed, an entire CICA chiller can be removed from an array of chillers by using the integral valving,victaulic connections and the detachable water header section. Because the detachable water header section was designed with its own support frame, the water header section can be left in place to feed adjacent chillers allowing them to continue operating. In an array application, if the array controller fails or if communication is lost between the individual CICA chillers and the array controller, the individual chillers can be switched to standalone mode and continue operating on their own to control the chilled leaving water temperature within the control zone of a pre-set default setpoint. The CICA controller stores operational and diagnostic information that can be accessed locally using the chiller keypad/display or the PC connection inside the chiller control panel. This information can also be accessed from a remote location using an Ethernet or other type interface. Single source responsibility allows the customer to source all building comfort systems through their localtrane Sales Office. 8 CG-PRC028D-EN

9 Application Consideration Unit Location Trane CICA compact chillers are designed for indoor installations only that remain above 32 F and below 125 F at all times. Locate the chiller away from sound-sensitive areas on a level foundation or flooring strong enough to support 150 percent of the operating weight and large enough to keep with service clearances. Also, the chiller foundation or flooring must be rigid enough to minimize vibration transmission. Please see General Data, p. 13 for compressor sound data and Appendix A Piping System Flushing Procedure, p. 31 for unit operating weights and clearances to ensure the chiller will work for your application. If necessary, options are available for sound attenuation and vibration reduction. Water Circuit Requirements BecauseTrane CICA compact chillers are equipped with brazed plate evaporators and condensers, it is imperative the water/fluid circuits to be used with these chillers are designed and installed following sound engineering practices and procedures as well as any applicable local and industry standards with the utmost attention being focused on filtration and water quality. Prior to connecting a CICA chiller into a newly installed or existing water piping system, it is required to flush the system with a detergent and hot water mixture to remove previously accumulated dirt and other organics. In old piping systems with heavy encrustation of inorganic materials, a water treatment specialist should be consulted for proper passivation and/or removal of these contaminants. For more specifics on the flushing procedure and for the type of strainers to be used during the procedure, please see Appendix A Piping System Flushing Procedure, p. 31. Filtration - Particulate fouling is caused by suspended solids (foulants) such as mud, silt, sand or other particles in the heat transfer medium.the best way to avoid particulate fouling is to keep all system water clean and with open loop system water, maintain proper bleed rates and make up water. Strainers with a 20-mesh screen (or screen with 0.5 mm sized openings or less) are required to be installed before the inlet of the heat exchangers. Wye strainers are available as a factoryprovided, field-installed option. If an application is highly susceptible to foulant contamination, additional filtration methods should be investigated. Water quality Poor water quality can cause another type of fouling called scaling. Scaling is caused by inorganic salts in the water circuit of the heat exchangers. Scaling increases pressure drop and reduces heat transfer efficiency. The likelihood of scaling increases with increased temperature, concentration and ph. In addition to scaling, poor water quality can cause other issues like biological growths and corrosion. Therefore, water quality and water quality control needs to be an application consideration. Please review the water quality requirements for use with the brazed plate heat exchangers on the CICA compact chiller. For more specifics on the water treatment requirements, please see Appendix A Piping System Flushing Procedure, p. 31. Table 1. Water property limits Water Property Concentration Limits Alkalinity (HCO - 3 ) ppm Sulfate (SO 2-4 ) Less than 70 ppm HCO - 3 / SO 2-4 Greater than 1.0 Electrical Conductivity μs/cm ph Ammonia (NH 3) Less than 2 ppm Chlorides (Cl - ) Less than 300 ppm Free Chlorine (Cl 2) Less than 1 ppm Hydrogen Sulfide (H 2S) Less than 0.05 ppm CG-PRC028D-EN 9

10 Application Consideration Table 1. Water property limits (continued) Water Property Evaporator Fluid Temperatures and Flow Requirements Standard evaporator leaving water temperature range for the CICA chiller is 42 F - 60 F. For evaporator loops containing the appropriate amount of glycol, the chilled water leaving temperature range can be shifted to 15 F - 60 F. The evaporator minimum and maximum flow rates are listed in General Data, p. 13. In general, the listed flow rate ranges will develop temperature differentials across the evaporator between 7 F - 20 F. If your application conditions are unconventional or do not fit these requirements, please contact your localtrane representative to determine if the CICA chiller is the correct chiller for your needs. For all CICA chiller applications, the flow to the evaporator must be proven using a chilled water flow-proving device. A factory-provided flow-proving device is available as a field-installed option. Chilled Water System Volume As a minimum, a 3-minute loop time is required for the evaporator chilled water system. For your specific application, you can calculate the required chilled water system volume by multiplying the design evaporator flow rate in GPM by 3 minutes. Depending on the system, a tank with baffles for mixing may need to be installed into the loop to meet the required volume. Condenser Fluid Temperatures and Flow Requirements Standard condenser entering water temperature range for the CICA chiller is 65 F F. The condenser leaving water temperature (LWT) maximum is 130 F, and the condenser LWT minimum is 77 F. When the condenser LWT is lower than 77 F, the refrigerant condensing temperature can drop below 80 F and fall outside of the CICA compressors operating envelope. For these applications, provisions must be made to control the condenser water that results in a stable refrigerant condensing temperature/pressure that remains above 80 F (235 psig) throughout all steady state, part load and transient operating conditions.the integral factory-installed condenser water regulating valve option is perfect for these applications and is highly recommended. The condenser minimum and maximum flow rates are listed in General Data, p. 13. In general, the listed flow rate ranges will develop temperature differentials across the condenser between 5 F - 30 F. If your application conditions are unconventional or do not fit these requirements, please contact your localtrane representative to determine if the CICA chiller is the correct chiller for your needs. Variable Flow Applications Concentration Limits Free (aggressive) Carbon Dioxide (CO2) Less than 5 ppm Total Hardness ( dh) Nitrate (NO 3) Less than 100 ppm Iron (Fe) Less than 0.2 ppm Aluminum (Al) Less than 0.2 ppm Manganese (Mn) Less than 0.1 ppm CICA compact chillers can be applied in variable flow applications where the flow is varied and controlled by others. The flow being delivered to the chiller must not go outside the stated minimum and maximum flow rates in General Data, p. 13. Also, the chilled water system volume should be calculated using the highest evaporator flow rate to be delivered to the chiller, and the rate of change in flow rate must not exceed 10% of design flow GPM per minute. 10 CG-PRC028D-EN

11 Application Consideration Multiple Chiller Applications Anytime more than one CICA chiller is piped together (to form an array of chillers) for higher capacity and/or redundant chiller applications, a field-installed array controller package will be provided from the factory.the array controller included in the package can control up to (10) CICA chillers. The number of chillers that can be physically piped together to form an array and share a common header is limited to approximately 250 total tons. In general, if the total tonnage is 250 tons or less, one common evaporator supply/return line and one common condenser supply/return line can be used. If the total tonnage needed is greater than 250 tons, the flow from these common lines can be split between two arrays of chillers. Figure 1 shows examples of acceptable and unacceptable array piping configurations. For help with determining the most effective array configuration for your application, please contact your localtrane sales representative. Figure 1. Chiller configuration examples The header system on an array of chillers has optimized chilled and condenser water pipe sizes suited for the flow rates specific to each chiller s location in the array.this means that the header pipes will not all be the same size, but will graduate down from larger to smaller to keep velocities up at each chiller. The customer would tie into the array's header system at the end of the array with the largest piping. All left-hand or all right-hand customer connections must be specified. See Figure 6, p. 25 for CICA array dimension details. To provide power to an array of chillers, power must be connected to each individual chiller. Depending on the size of the application, an alternative method for powering an array may be available. Please contact your localtrane sales representative for more information. CG-PRC028D-EN 11

12 Model Number Descriptions Digits 1-3 Unit Type CIC = Compact indoor chiller Digit 4 Model A = Model A Brazed plate evaporator Brazed plate condenser Digits 5-7 Nominal Tons 020 = 20 nominal tons 030 = 30 nominal tons 050 = 50 nominal tons Digit 8 Unit Voltage A = 208/60/3 B = 230/60/3 F = 460/60/3 G = 575/60/3 Digits 9, 10 Design Sequence ** = Factory Assigned Digit 11 Agency Listing E = ETL/ETL-C listed to meet US and Canadian safety standards Digit 12 Remote Interface (Digital Comm) 0 = None 2 = LonTalk 4 = BACnet MS/TP 5 = BACnet IP 6 = Modbus 8 = Johnson N2 Digit 13 Water Piping Package Evaporator Entering 0 = None without piping package 1 = 2-inch chilled water piping 2 = 2.5-inch chilled water piping 3 = 3-inch chilled water piping 4 = 4-inch chilled water piping 5 = 5-inch chilled water piping Digit 14 Water Piping Package Evaporator Leaving 0 = None without piping package 1 = 2-inch chilled water piping 2 = 2.5-inch chilled water piping 3 = 3-inch chilled water piping 4 = 4-inch chilled water piping 5 = 5-inch chilled water piping Digit 15 Water Piping Package Condenser Entering 0 = None without piping package 1 = 2-inch chilled water piping 2 = 2.5-inch chilled water piping 3 = 3-inch chilled water piping 4 = 4-inch chilled water piping 5 = 5-inch chilled water piping Digit 16 Water Piping Package Condenser Leaving 0 = None without piping package 1 = 2-inch chilled water piping 2 = 2.5-inch chilled water piping 3 = 3-inch chilled water piping 4 = 4-inch chilled water piping 5 = 5-inch chilled water piping Digit 17 Motorized Control Valves 0 = None manual balancing isolating valves only 1 = Integral discharge pressure control condenser water regulating valve 2 = Motorized chilled water isolating valve 3 = Both chilled water and condenser water control valves Digit 18 Evaporator Temperature Range 0 = Standard cooling 42 to 60 F (5.6 to 15.6 C) 1 = Standard cooling/ice-making 20 to 60 F (-6.7 to 15.6 C) Digit 19 Power Connection D = Standard non-fused disconnect switch F = 100kA SCWR fused disconnect switch Digit 20 Sound Attenuator 0 = No sound attenuation 3 = Compressor sound blankets 4 = Factory sound enclosure cabinet 5 = Both sound enclosure cabinet and compressor blankets Digit 21 Power Monitor 0 = None 1 = With power monitor Digit 22 Neoprene Isolators 0 = None 1 = Neoprene isolators (ship loose) Digit 23 Evaporator Fluid Type 0 = Water 2 = Ethylene glycol 3 = Propylene glycol 4 = Methanol Digit 24 Condenser Fluid Type 0 = Water 2 = Ethylene glycol 3 = Propylene glycol Digit 25 Special Options 0 = None 1 = With special option(s) 12 CG-PRC028D-EN

13 General Data Table 2. General data Size Compressor Quantity Nominal 60 Hz tons 10/10 15/15 25/25 Compressor Sound Data (a) dba Compressor Sound Data with Sound Blankets Only (b) dba Evaporator Water Storage gal Minimum Flow gpm Maximum Flow gpm Condenser Water Storage gal Minimum Flow gpm Maximum Flow gpm General Unit Refrigerant R-410A R-410A R-410A Number of Independent Refrigerant Circuits Refrigerant Charge per Circuit lbs Oil Type Trane OIL00080 Trane OIL00080 Trane OIL00080 Oil Charge per Compressor oz 112/ / /228 (a) Compressor manufacturer sound power is given at rated compressor AHRI conditions measured in free space for tandem compressor sets. (b) Manufacturer data taken at compressor AHRI conditions measured in free space for tandem compressor sets using compressor blanket option. CG-PRC028D-EN 13

14 Performance Data Table 3. CICA performance data Unit Size % Load Tons kw % Load EER IPLV EER Notes: 1. Rated in accordance with AHRI Standard 550/590, based on TOPSS version 180: evaporator leaving temperature of 44 F and 2.4 gpm/ton, condenser entering temperature of 85 F and 3 gpm/ton with condenser relief at part loads, evaporator fouling of oF.ft2.h/Btu and condenser fouling of oF.ft2.h/Btu 2. Consult Trane representative for additional performance information 3. EER - Energy Efficiency Ratio (Btu/w.h) 14 CG-PRC028D-EN

15 Controls TheTrane Cold Generator CICA compact series scroll chiller control panel is designed to save space and provide one convenient area for all necessary field-wiring.the control panel consists of two levels which separate the power and control components. The power distribution section is located on the fixed back panel and contains the input power ground lug and non-fused disconnect switch for customer connection, power distribution block, across-the-line contactors, current transformers and control circuit power transformer with primary and secondary fuses. The controls section is located on the hinged interior panel and contains the unit controller, display with keypad (control panel door), power monitor (optional), electronic expansion valve driver, service friendly terminal strips to facilitate circuit diagnosis and a field connection terminal strip. Microprocessor-Based Controller The unit controller is a durable microprocessor-based controller designed to be the primary manager of the CICA compact chiller.the controller is capable of performing all operational, data retention and communication functions for the chiller while providing lead/lag logic to equalize run time on the individual compressors. When necessary, it will perform appropriate evasive actions in the event a sensor input returns a reading that is out of range based on setpoints. The data retention capabilities of the unit controller include storage of up to 1,008 packets of information that can be graphically presented based on an adjustable, set time interval. The controller also maintains a fault history including the date and time of day for each fault (up to the last 99 occurrences). If a fault results in a compressor lockout, 120 seconds of history prior to the lockout is saved.the history leading up to the lockout gives the technician a clear picture of what the chiller was experiencing just before the failure and is very helpful for diagnosing the causes. CG-PRC028D-EN 15

16 Controls Operator Interface The unit controller can be accessed using the keypad-display screen and uses a clear language format for easy interpretation by the user.the keypad-display is mounted to the front of the control panel door along with the non-fused disconnect switch actuator, off/auto switch, run indicator light and alarm indicator light. All information needed to run the chiller is available and can be changed and viewed using the keypad-display screen; however, a laptop or PC is invaluable for ease of use, for viewing dynamic on-line display screens, for better graphing capability and for downloading data files. A free PC/ laptop software package called MCS-Connect is available for download at Once installed, the unit controller can be accessed from the PC or laptop by using (1) of the (4) different ports located inside the control panel: 1. RS-485 network access through RS-232 serial port located on backside of keypad-display 2. RS-485 network access port located on backside of keypad-display 3. RS-485 network access port located on corner of unit controller 4. Ethernet port located on corner of unit controller Note: If only one of the RS-485 network accesses is already being used (#1-#3) for BMS communication or for an array controller, the Ethernet port would be the only port that can be used for PC or laptop access. Building Communications When thetrane Cold Generator CICA chiller is used in conjunction with a building management system such astracer, the chiller can be monitored and given input from a remote location. The chiller can be set up to fit into the overall building control strategy by using remote run/stop input, remote demand limit reset and/or remote chilled water reset functions. As standard, the unit controller Ethernet port is always ready to talk BACnet IP and ModbusTCP/ IP (Modbus RTU uses the RS485 network port). BACnet MS/TP, Johnson N2 and LonTalk are optional protocols that can be factory-installed.the unit controller can facilitate the following BMS communications: Remote Off/Auto signal (input from BMS) Demand Limit Reset signal (input from BMS) Chilled WaterTemperature Reset signal (input from BMS) Customer Alarm relay (view only) Chiller Run Indication (view only) 16 CG-PRC028D-EN

17 Controls System Protection Entering Chilled WaterTemperature (view only) Leaving Chilled WaterTemperature (view only) Chilled Water Flow Switch input (view only) Condenser Pump relay (view only) Chilled Water Pump relay (view only) A complete safety lockout system with alarms protects the CICA compact chiller operation to avoid compressor and evaporator failures.the unit controller directly senses pressures, temperatures, amperage, motor faults, etc. All control variables that govern the operation of the chiller are evaluated every second for exact control and protection. The following is an abbreviated list of safeties that are incorporated into the standard chiller algorithm control. For a complete list, please refer to the more detailed controls manual, CG-SVX030*-EN. No Flow Protection To protect the chiller from no water flow to the evaporator, the chiller is enabled to run only if the required flow proving device indicates there is flow present. If the chiller is active and flow is lost; the chiller will lock out, and an alarm is generated. Low Suction Pressure To protect the compressors and evaporator, if the refrigerant suction pressure drops below the set point value for a specified period of time, a safety trip occurs.this safety is bypassed when the compressor is in a Pump Down state. Unsafe Suction Pressure To protect the compressors and evaporator, if the refrigerant suction pressure drops below the set point value for a specified period of time, the chiller will immediately lock out, and an alarm is generated. Freeze Protection To protect the evaporator from low water temperatures, the chilled water temperature is monitored inside the core of the evaporator and leaving the evaporator. If theses temperatures fall below their set point temperatures for the set period of time, the entire system will lock out and an alarm is generated. Hot Gas Injection Working in conjunction with the low suction pressure and freeze protection safeties to avoid nuisance safety trips, the hot gas injection valve is opened when the suction pressure goes below the lower set point value and allows hot discharge gas to be injected directly before the inlet to the evaporator. The valve will stay open until the suction pressure rises safely above the upper set point level. High & Low Discharge Pressure, High & Low Superheat, High & Low Compressor Amps The compressors will be locked out if any one of these control variables rises above the upper set point value or falls below the lower set point value for the set amount of time for each, and an alarm is generated. Compressor Motor Protection Module The compressors on the CICA050 are equipped with an extra layer of protection.the pre-installed motor protection module, in the compressor terminal box, provides for an extra layer of protection against motor overheating and overloading, as well as phase loss/reversal. Should one of these parameters be incorrect, the motor module relay will lock out (open) and the red LED on the module will blink.the unit controller will indicate the lockout, and an alarm is generated. Optional Phase/Power Monitor The factory-installed phase/power monitor continuously monitors the incoming power supply to the chiller, before it reaches the compressors, for low voltage, phase rotation reversal, loss of phase and phase imbalance. Should one of these parameters be incorrect, the phase/power monitor relay will lock out (de-energize) and the fault LED on the monitor will blink.the unit controller will indicate the lockout, and an alarm is generated. As an additional layer of system protection, mechanical high and low pressure switches are used in conjunction with the refrigerant circuit high and low pressure transducers and unit controller. CG-PRC028D-EN 17

18 Controls Standard Peripheral Control Features The following peripheral control features and program logic come standard on all CICA compact chillers. Designated terminals on the field connection terminal strip in the control panel are provided for field connection of: Remote Off/Auto (dry contact closure from a remote device - input) Standard Capacity Control Optional Capacity Control Required Flow Proving Device (dry contact closure from a remote device - input) Remote Alarm (dry contact closure to a remote device - output) Chilled Water Pump Enable (dry contact closure for 1 chilled water pump - output) Condenser Water Pump Enable (dry contact closure for 1 condenser water pump - output) Standard capacity control on the CICA compact chillers is accomplished by staging the scroll compressors on and off. The unit controller will maintain a set point leaving chilled water temperature within a control zone using proportional, integral derivative (PID) logic. If the leaving chilled water temperature starts to decrease and falls below the set point, the unit controller will turn one compressor off. A further reduction in temperature will result in the second compressor being turned off. The reverse is true as the leaving chilled water temperature increases. Lead/lag logic is used to even the run time on the individual compressors. Chilled water temperature reset can be accomplished in two ways. In buildings with a building management system, the CICA unit controller allows the BMS to communicate an offset to the chilled water temperature set point. If a BMS is not being used, the unit controller can accept a fieldprovided 0 to 5 VDC analog input signal. As the input voltage varies away from center (2.5V), the chilled water temperature set point will be offset proportionally. Note:This control logic is factoryinstalled and must be denoted at the time of ordering. Demand limiting is a form of capacity control that limits the number of capacity steps the chiller is allowed to operate. It can be accomplished in the same two ways as the chilled water temperature reset: through BMS or field-provided 0 to 5 VDC input signal. Note: This control logic is factoryinstalled and must be denoted at the time of ordering. 18 CG-PRC028D-EN

19 Controls Array Control The optional array controller package offers yet another form of capacity control.this option allows up to 10 CICA compact chillers to be controlled and operated like a single, much higher capacity, multistage chiller. With this option, capacity modulation and equalization of compressor run time is shifted to the array controller. The array controller uses the same standard capacity control logic as an individual CICA unit controller but with more stages of capacity.there are other similarities and some differences in CICA array control when compared to individual CICA unit control. The list below briefly summarizes the comparison of the two: The factory-provided, field-installed CICA array control panel uses the same microprocessorbased controller and keypad-display as an individual CICA unit control panel. Power (115VAC) must be provided to a 2A circuit breaker inside the array control panel to power the array control circuit.the array control panel also contains a field connection terminal strip and door-mounted off/auto switch, run indicator light and alarm indicator light. The array controller is accessed in the same manner as the unit controller, through the keypaddisplay or PC/laptop. Note: If only one of the RS-485 network accesses is already being used (#1- #3) for BMS communication, the Ethernet port would be the only port that can be used for PC or laptop access; or vice versa, if the Ethernet port is already being used (#4) for BMS communication, one of the RS-485 network access ports would be the only means for PC or laptop access. The array controller can facilitate the same standard and optional BMS protocols and communications for an array as with a single chiller application. In addition, the array controller can also communicate the optional array condenser entering and leaving water temperatures for viewing by the BMS (if applicable). System protection is still provided by the individual unit controllers with the addition of the following being monitored and recorded by the array controller: Chiller Array Fault Low/No array chilled water flow Chiller Array Fault Low array chilled LWT Chiller Unit Fault Displays chiller unit number for unit where fault occurred The same peripheral control features can be controlled by the array controller for an array of CICA chillers as with an individual unit application, but with a few extras: Required Chilled Water Pump Enable and optional 2nd Chilled Water Pump Enable (dry contact closures for 2 chilled water pumps - output) Condenser Water Pump Enable (dry contact closures for 2 condenser water pumps - output) Array On/Off Status (dry contact closure for remote device output) If communication between the individual CICA chiller unit controllers and the array controller is lost or the array controller fails for whatever reason, the individual CICA chillers can be shifted into manual mode to operate independent from the array controller and will maintain a manual mode chilled LWT set point. CG-PRC028D-EN 19

20 Electrical Table 4. Electrical data Size Rated Voltage Qty Compressor Control Unit Wiring # Refrigerant Nominal Circuits Tons RLA (each) LRA (each) kw Minimum Circuit Ampacity Max Fuse Size Recommended Dual Element Fuse Size /60/ /60/ / /60/ /60/ /60/ / /60/ /60/ /60/ / /60/ Notes: 1. Use copper conductors only. 2. Local codes may take precedence. 3. Voltage Utilization Range: ± 10% of rated voltage. Rated voltage (use range): /60/3 ( ), 460/60/3 ( ), 575/60/3 ( ). 20 CG-PRC028D-EN

21 Electrical Connections Figure 2. Field wiring CICA unit control panel, single chiller application Representation - Front Panel Representation - Back Panel PANEL GROUND Unit Controller Voltage 115v DSW1 TBA OPTIONAL: Condenser Pump #1-125 VAC Max WARNING Hazardous voltage! Disconnect all electrical power including remote disconnects before servicing unit. Follow proper lockout/ tagout procedures to ensure power cannot be inadvertently energized. Failure to do so can cause death or serious injury. CAUTION Use copper conductors only! Unit terminals are not designed to accept other type conductors. Failure to use copper conductors may cause equipment damage. CAUTION Do not energize the unit until checkout and start-up procedures have been completed. REQUIRED: Chilled Water Pump #1-125 VAC Max OPTIONAL: Remote Alarm VAC Max REQUIRED: Flow Switch/Flow-Proving Device - Input from Dry 3 Contact Closure Only OPTIONAL: Remote Off/Auto - Input from Dry Contact Closure Only Notes: 1. All customer control-circuit wiring must have a minimum rating of 150V. 2. All field wiring must be in accordance with National Electric Code and State & Local requirements. 3. (Required) Factory supplied or approved alternate field installed flow proving device connection. CG-PRC028D-EN 21

22 Electrical Connections Figure 3. Field wiring CICA unit control panel, array application Representation - Front Panel Representation - Back Panel RELAY M-1 RELAY M-2 RELAY M-3 RELAY M-4 RELAY M-5 RELAY M-6 RELAY M-7 RELAY M-8 RELAY M-9 RELAY M-10 Ethernet Cable to 16 Port Ethernet Switch in Array Control Panel PANEL GROUND Unit Controller Voltage 115v DSW1 TX RS-485 ETHERNET TBA First Chiller in Array To TX RS-485 on Next Chiller in Array 7 _ + TERMINATION TX485 JP4 _ GND TX RS Middle Chiller(s) in Array, if Applicable OPTIONAL: Remote Alarm VAC Max OPTIONAL: Remote Off/Auto - Input from Dry Contact Closure Only 6 7 Last Chiller in Array 7 TERMINATION TX485 JP4 To TX RS-485 on Next Chiller in Array _ + _ GND TX RS TERMINATION TX485 JP4 _ GND TX RS _ + _ + _ From Array From TX RS-485 on From TX RS-485 on Controller MCS I/O Previous Chiller in Array Previous Chiller in Array WARNING Hazardous voltage! Disconnect all electrical power including remote disconnects before servicing unit. Follow proper lockout/ tagout procedures to ensure power cannot be inadvertently energized. Failure to do so can cause death or serious injury. CAUTION Use copper conductors only! Unit terminals are not designed to accept other type conductors. Failure to use copper conductors may cause equipment damage. Notes: 1. All customer control-circuit wiring must have a minimum rating of 150V. 2. All field wiring must be in accordance with National Electric Code and State & Local requirements. 3. All field provided RS-485 network cable must be 24 GA, shielded, 2-conductor with drain wire (Belden 9841 or equivalent). 4. All field provided ethernet cables must be Cat 5 or higher ethernet straight (patch) cables. 5. Only the first chiller in array is connected from TX RS-485 port to the Array Controller MCS I/O port in the Array Control Panel. 6. Consecutive chillers in array are daisy-chained through TX RS-485 ports. 7. Ensure all TX RS-485 Berg Termination Jumpers are removed EXCEPT on the last chiller in the array. CAUTION Do not energize the unit until checkout and start-up procedures have been completed. 22 CG-PRC028D-EN

23 RELAY M-1 Yellow Electrical Connections Figure 4. Field wiring CICA array control panel Ethernet Cables From Each Chiller Module (Field Provided) Ethernet Cable From Wireless Router (Factory Provided) Power Cord From Wireless Router (Factory Provided) 16 Port Ethernet Switch PANEL GROUND REQUIRED: Evap EWT REQUIRED: Evap LWT OPTIONAL: Cond EWT OPTIONAL: Cond LWT OPTIONAL: Ambient Temp Black Shield White Black Shield White Black Shield White Black Shield White Black Shield White OPTIONAL: Shield CHW Reset 0-5VDC Analog Signal REQUIRED: ROUTE RS-485 NETWORK CABLE TO "TX RS-485" ON CONTROLLER OF FIRST CHILLER IN ARRAY SENSOR 1SENSOR 2SENSOR 3 SENSOR 4SENSOR 5 SENSOR 6 Array Controller 115V RELAY M-2 RELAY M-3 RELAY M-4 RELAY M-5 RELAY M-6 RELAY M-7 RELAY M-8 RELAY M-9 RELAY M ETHERNET OPTIONAL: MCS I/OTX RS-485 Array On/Off Status VAC Max MCS I/O GND _ REQUIRED: -+ Flow Switch/Flow-Proving Device - + Input from Dry Contact Closure Only Circuit Breaker VAC Neutral OPTIONAL: Remote Alarm VAC Max REQUIRED: Chill Water Pump #1-125 VAC Max OPTIONAL: Chill Water Pump #2-125 VAC Max OPTIONAL: Condenser Pump #1-125 VAC Max OPTIONAL: Condenser Pump #2-125 VAC Max OPTIONAL: Remote OFF/Auto - Input from Dry Contact Closure Only WARNING Hazardous voltage! Disconnect all electrical power including remote disconnects before servicing unit. Follow proper lockout/ 2. tagout procedures to ensure power cannot be inadvertently energized. requirements. Failure to do so cause death or serious injury. CAUTION 4. Use copper conductors only! Unit terminals are not designed to accept other type conductors. Failure to use copper conductors may cause equipment damage. CAUTION Do not energize t he unit until checkout and start-up procedures have been completed. NOTES: 1. All field provided control-circuit wiring must have a minimum rating of 150V. All field wiring must be in acco rdance with NEC, State & Local 3. All field provided ethernet cables must be Cat 5 or higher ethernet straight (patch) cables. All field provided RS-485 network cable must be 24 GA, shielded, 2- conductor with drain wire (Belden 9841 or equivalent) CG-PRC028D-EN 23

24 Dimensions and Weights Dimensions Figure 5. CICA unit dimensions 2X 3" 2X 3" 2X " 2X 4" " 2X 24" " 6X 3 4 " 60" 72" Qty 4 - "A" Vic Cust Connections (if Left Config is ordered) "B" " Evap In " Cond Out 32" Cond In " 5" Evap Out NOTE: Header pipes will be sealed and capped on opposite end from customer connections. In some views, parts may be hidden for clarity. 30" Qty 4 - "A" Vic Cust Connections (if Right Config is ordered) "B" 24 CG-PRC028D-EN

25 CG-PRC028D-EN " Typ 30" Typ 2X 3" Typ " Typ 5 2X 3 " Typ "C" 6n X 3 4" 4X "B" Qty 4 - "A" Vic Customer Connections (if Right Config is ordered) "W" NOTE: Right Configuration shown, so left end of headers are capped and sealed. In some views, parts may be hidden for clarity. 4X "B" Qty 4 - "A" Vic Customer Connections (if Left Config is ordered) 4" Typ "C" 32" Cond In " Cond Out Evap Out 5" 1 Evap In 14 2 " 60" " 72" Figure " Typ 3" Typ Dimensions and Weights CICA array dimensions 25

26 Dimensions and Weights Clearances Notes: Clearance of 42 is required in front of chiller to other ground parts. Two units facing each other or other live parts require a clearance of clearance is recommended above the chiller. Clearances remain the same when more than one chiller is present. Figure 7. Clearance CICA 20, ton 36" 36" 36" 42" Weights Table 5. CICA unit weights Shipping Weight Operating Weight Size lbs kg lbs kg CG-PRC028D-EN

27 Mechanical Specifications General Trane Cold Generator Compact Model CICA water-cooled chillers are designed with high efficiency, reliability, serviceability and expandability in mind. CICA chillers can be applied as standalone chillers or in an array of up to ten (10) chillers controlled by an array controller to form a single high capacity multistage package chiller. The header pipe section is detachable and has optimized chilled and condenser water pipe size suited for the flow rates specific to the chiller s location in the array. Each CICA chiller is pressure tested, dehydrated, charged with refrigerant R-410A and POE oil, and run tested at full and part load conditions. Completed chillers are then top coated with industrial two-part epoxy direct-to-metal paint prior to shipment. Standalone chillers only require field connection of chilled and condenser water piping, chilled and condenser water wye strainer, and power and control wiring to the control panel terminal block / strip. CICA chillers installed in an array require additional coupling of water piping between chillers and mounting and wiring of array controller panel. Chilled and condenser water inlet and outlet connections are Victaulic for ease of installation and service. Chilled water flow proving device, and chilled and condenser water 20 mesh wye strainer are required and must be field installed. Certified AHRI Performance Agency Listing Compressor Motor Evaporator Trane water-cooled chillers are rated within the scope of the Air-Conditioning, Heating & Refrigeration Institute (AHRI) Certification Program and display the AHRI Certified mark as a visual confirmation of conformance to the certification sections of AHRI Standard 550/590 (I-P) and ANSI/AHRI Standard 551/591 (SI). The applications in this catalog specifically excluded from the AHRI certification program are: Custom Units Condenserless Chillers Evaporatively-cooled chillers Units with evaporators or condensers that use fluid other than fresh water except units containing freeze protection fluids in the condenser or in the evaporator with a leaving chilled fluid temperature above 32 F [0 C] are certified when rated per the Standard with water. Each CICA chiller is ETL Listed to U. S. and Canadian safety standards Fully hermetic direct drive scroll compressors are mounted on vibration isolators. Lubrication system with oil level sight glass is arranged to ensure adequate lubrication during starting, stopping and normal operation. Motor is suction gas cooled, runs at a constant speed of 3600 rpms, has motor protection and is designed for across-the-line start. Brazed plate evaporator is UL Listed for US & Canada. Refrigerant side has maximum design/ abnormal pressure rating (PS) of 609 psi (42 bar) atts of 437 F (225 C). Water side has maximum design/abnormal pressure rating (PS) of 392 psi (27 bar) atts of 437 F (225 C). Evaporators have one (1) refrigerant circuit and one (1) chilled water circuit. Evaporator is insulated with 0.5 inch (12.7 mm) thick closed-cell flexible insulation with a K value of 0.26 BTU/ (hr-ft.- F) and is furnished with core, inlet and outlet water temperature sensors. CG-PRC028D-EN 27