Ingersoll-Rand Trane CALMAC Ice Bank Manual

IB-SVX147C-EN
June 6, 2019
Ice Bank® Energy Storage
OPERATION & MAINTENANCE MANUAL
®

INTRODUCTION
cool a building, it is important for the operators and
maintenance personnel to understand the overall con-
cept, not just the monthly routine. Therefore, we have
started this manual with a brief overview of the technol-
ogy and its application.
Air-conditioning can account for over 40% of average
conditioning is needed to maintain comfortable tem-
peratures, the increased demand for electricity adds to
that already created by lighting, operating equipment,
computers and thousands of other uses. This requires
the utility to use additional, more costly generating
sources to handle its increased demand. Commercial
users, whose large air-conditioning loads contribute
to these added generating requirements are normally
assessed an additional charge based on their highest
on-peak demand for electricity.
demand charges during the air-conditioning season
but also can lower total energy usage as well. It uses a
standard packaged chiller to produce solid ice at night
needs are at a minimum and the utility’s generating
capacity is typically underutilized. The ice is built and
stored in modular Ice Bank® energy storage tanks to pro-
vide cooling to help meet the building’s air-conditioning
load requirement the following day.
Product Description and Normal Operation
The Ice Bank tank is a modular, insulated polyeth-
ylene tank containing a spiral-wound plastic tube
heat exchanger which is submerged in water. They are
available in various sizes. At night, a solution typically
75% water and 25% ethylene glycol, circulates through
a standard packaged air-conditioning chiller and the
tubing in the tank heat exchanger, extracting heat until
eventually almost all the water in the tank is frozen
solid. The ice is built uniformly throughout the tank by
Water does not become surrounded by ice during the
freezing process and can move freely as ice forms, pre-
venting stress or damage to the tank.
Flow diagrams for a Partial Storage system are shown
in Figures 2 and 3. The temperatures shown are typical
however, many other ranges are used.
Charge Cycle
Chiller
Ice Bank
Tank Temperature
Modulating Valve
Automatic Diverting Valve
Coil
25˚F (-3.9˚C) 31˚F (-0.56˚C)
25˚F
(11.1˚C)
31˚F
(1.1˚C)
Coil
52˚F (11.1˚C) 60˚F (15.6˚C)
60˚F (15.6˚C)
55˚F
(12.8˚C)
44˚F (6.7˚C)
75˚F
(23.9˚C)
44˚F
(6.7˚C)
52˚F (11.1˚C)
52˚F
(11.1˚C)
34˚F
(1.1˚C)
Discharge Cycle
Chiller
Ice Bank
Tank Temperature
Modulating Valve
Automatic Diverting Valve

In a standard installation, ice is made at night. The
water-glycol solution circulates through the chiller and
the Ice Bank® heat exchanger, bypassing the air handler
(-3.9ºC) and the water surrounding the heat exchanger
freezes.
During the day, the glycol solution is cooled by the
IceBank® tank from approximately 52ºF to 34ºF (11ºC to
1ºC). (See Figure 3). A temperature modulating valve is
used to maintain a blended supply temperature typically
-
it cools air ordinarily from 75ºF to 55ºF (24ºC to 13ºC).
chiller and is cooled to 52ºF (11.1ºC). In some systems,
the ice will handle the entire day time load (Full Storage)
and in others, the ice will help a smaller than full size
chiller meet the load (Partial Storage).
MAINTENANCE
Since there are no moving parts in our standard thermal
storage tanks, the list of maintenance items is short. The
items we do list are important and should be done at
regular intervals as indicated. The inspection port cover
must always be replaced.
Water Level
The water level in the tank will rise and fall 2.5 to 7.8
inches (63 to 195mm) (depending on Model No. of
tank) during the charge and discharge cycle. This change
Water expands approximately 9% when changing to ice
at 32ºF (0ºC); therefore, during the freezing process,
the level will rise. (More about this in later sections).
The water stays in the tank (it is NOT pumped through
the system) and the amount of water/ice in the tank
remains constant except for possibly a slight amount of
evaporation, which normally occurs in outdoor, very hot,
dry climates.
The water level should be just covering the top heat
exchanger tube, (which is 5/8" (16mm) diameter and
the bottom of the top HX tube. This measurement must
be done with no ice in the tank. The water level should
be checked every year except in hot, dry climates when
every three months is recommended.
Inventory Meter Calibration
During operation the only time to accurately check that
the the inventory meter probe level is correct is when
the tank is 100% charged. (See Ice Inventory Meter
Manual IB-153 for more information.)
Coolant Concentration
The coolant should be checked regularly in accordance
with the manufacturer’s recommendations. For eth-
a sample should be sent once a year to the manufac-
turer for analysis. Checking the coolant’s freeze point
is recommended twice a year using a refractometer or
The maximum freezing point for our system is normally
12ºF (-11.1ºC) (25%EG/H2O); however, some jobs
require lower freeze points because of particular oper-
ating conditions.
Storage Tank Water Treatment
Pour in the initial treatment of biocide into the tank
partially frozen year round, provide retreatment with
biocide as needed. However, if tanks are not kept frozen
the tanks should be checked for slime or odor season-
ally. At the end of the cooling season, you should fully
charge the tanks and leave them frozen until the start of
your next air-conditioning season. This will help to con-
trol biological growth. CALMAC® recommends a 20%
Tetrakis hydroxymethyl phosphonium sulfate solution
such as Aquacar PS20. All tank models require 16 oz. of
biocide solution per tank.
The CAS number is 555-66-30-8
In most systems, the termination of the charge cycle is
determined by the temperature of the coolant leaving
the storage tanks. Typically this temperature is in the
range of 27-28ºF (-2.7 to -2.2ºC). However, it is imper-
ative that the actual temperature be calculated for each
system using CALMAC Performance Data (IB-102).
This temperature is calculated by adding Coolant
Temperature Rise to the minimum Charging Coolant
Temperature. This temperature should be entered in the
and checked once every six months.

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June, 2019
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To find out more about Ice Bank® energy storage visit calmac.com or trane.com/energystorage
Ice Caps
important. Setting the temperature lower than what is
stated in the Performance Data can cause the water in
the expansion area above the heat exchanger to freeze.
It is important that this water does not freeze so that
ice during discharge. Therefore, twice a year the tank
should be checked for excessive ice-build-up above the
top heat exchanger tube. Ice thicker than 1" is an early
Tanks include a patented design which incorporates a
layer of insulation located just above the heat exchanger
to reduce the likelihood of Ice Caps. Inspection should
still be done twice a year and no ice should be seen
above the insulation layer.
Warranty Repairs
parts must be obtained in writing before any repairs are
attempted.
A purchase order must be entered through the local
CALMAC® representative for any possible warranty work
or replacement parts.
is determined that the failure is due to our workmanship
or material defect, a credit will be issued against the
customer’s purchase order.
Date Water Level
Above top of
tube w/no ice
Coolant
Freeze Temp.
Coolant
Analysis by
Mfr.
Water
Treatment
(Biocide)
Temperature
Ice Cap
Present
For example 1/4" (6mm) 12ºF (-11.1ºC) YesYes 28ºF (-2.2ºC) No