Trane CGWH 115 Owner's manual

Installation
Operation
Maintenance
CGWH-SVX01D-E4
CGWH Packaged Water-cooled liquid chiller
CCUH Condenserless liquid chiller
Sizes 115 - 120 - 125 - 225 - 230 - 235 - 240 - 250
To be used with the user guide of CH530 scroll chiller controls

© Trane 2013 CGWH-SVX01D-E4
General information
Foreword
These instructions are given as
a guide to good practice in the
installation, start-up, operation, and
maintenance by the user, of Trane
CGWH/CCUH chillers. They do not
contain full service procedures
necessary for the continued
successful operation of this
equipment. The services of a
qualified technician should be
employed through the medium of a
maintenance contract with a reputable
service company. Read this manual
thoroughly before unit start-up.
Units are assembled, pressure tested,
dehydrated, charged and run tested
before shipment.
Warnings and cautions
Warnings and Cautions appear at
appropriate sections throughout this
manual. Your personal safety and
the proper operation of this machine
require that you follow them
carefully. The constructor assumes
no liability for installations or
servicing performed by unqualified
personnel.
WARNING! : Indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION! : Indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be used
to alert against unsafe practices or
for equipment or property-damage-
only accidents.
Safety recommendations
To avoid death, injury, equipment
or property damage, the following
recommendations should be
observed during maintenance and
service visits:
1. The maximum allowable pressures
for system leak testing on low and
high pressure side are given in the
chapter “Installation”. Always provide
a pressure regulator.
2. Disconnect the main power supply
before any servicing on the unit.
3. Service work on the refrigeration
system and the electrical system
should be carried out only by
qualified and experienced personnel.
Reception
On arrival, inspect the unit before
signing the delivery note.
Reception in France only:
In case of visible damage:
The consignee (or the site
representative) must specify any
damage on the delivery note,
legibly sign and date the delivery
note, and the truck driver must
countersign it. The consignee (or the
site representative) must notify Trane
Epinal Operations - Claims team and
send a copy of the delivery note.
The customer (or the site
representative) should send a
registered letter to the last carrier
within 3 days of delivery.
Note: for deliveries in France, even
concealed damage must be looked
for at delivery and immediately
treated as visible damage.
Reception in all countries except
France:
In case of concealed damage: The
consignee (or the site representative)
must send a registered letter to the
last carrier within 7 days of delivery,
claiming for the described damage.
A copy of this letter must be sent
to Trane Epinal Operations - Claims
team.

CGWH-SVX01D-E4
General information
3
Warranty
Warranty is based on the general
terms and conditions of the
manufacturer. The warranty is void if
the equipment is repaired or modified
without the written approval of the
manufacturer, if the operating limits
are exceeded or if the control system
or the electrical wiring is modified.
Damage due to misuse, lack of
maintenance or failure to comply
with the manufacturer’s instructions
or recommendations is not covered
by the warranty obligation. If the user
does not conform to the rules of this
manual, it may entail cancellation
of warranty and liabilities by the
manufacturer.
Refrigerant
The refrigerant provided by
the manufacturer meets all the
requirements of our units. When using
recycled or reprocessed refrigerant,
it is advisable to ensure its quality is
equivalent to that of a new refrigerant.
For this, it is necessary to have a
precise analysis made by a specialized
laboratory. If this condition is not
respected, the manufacturer warranty
could be cancelled.
Environmental Protection /
Compliance with F-Gas
regulation
This equipment contains a fluorinated
gas covered by the Kyoto Protocol [or
an ozone depleting substance covered
by Montreal Protocol].The type and
quantity of refrigerant per circuit is
indicated on the product nameplate.
The Global Warming Potential of the
refrigerant implemented in Trane
Air Conditioning and Refrigeration
Equipment is presented in the table by
type of refrigerant.
Refrigerant type GWP (1) value
R407C 1 653
The operator (contractor or end
user) must check local environmental
regulations impacting installation,
operation and disposal of the
equipment; in particular need to
recover environmentally harmful
substances (refrigerant, oil, antifreeze
agents, etc.) Do not vent into
the atmosphere any refrigerant.
The handling of refrigerant shall
be fulfilled by a qualified service
engineer.
With regards to the refrigerant charge
contained in this chiller, the F-gas
regulation requires 2 inspections,
including leak detection, per year
in the EU. Contact your local Trane
Service team.
(1) GWP = global warming potential
(2) Covered by Montreal Protocol
Maintenance contract
It is strongly recommended that
you sign a maintenance contract
with your local Service Agency.
This contract provides regular
maintenance of your installation
by a specialist in our equipment.
Regular maintenance ensures
that any malfunction is detected
and corrected in good time and
minimizes the possibility that serious
damage will occur. Finally, regular
maintenance ensures the maximum
operating life of your equipment.
We would remind you that failure
to respect these installation and
maintenance instructions may result
in immediate cancellation of the
warranty.
Training
To assist you in obtaining the best
use of it and maintaining it in perfect
operating condition over a long
period of time, the manufacturer
has at your disposal a refrigeration
and air conditioning service school.
The principal aim of this is to give
operators and technicians a better
knowledge of the equipment they are
using, or that is under their charge.
Emphasis is particularly given to
the importance of periodic checks
on the unit operating parameters as
well as on preventive maintenance,
which reduces the cost of owning the
unit by avoiding serious and costly
breakdown.

4CGWH-SVX01D-E4
Contents
General Information 2
Installation
Unit nameplate 5
Installation instructions 5
Handling 5
Minimum water volume 6
Refrigerant lines CCUH 7
Refrigerant line connections - CCUH and remote condenser 8
Winter freeze protection 10
Water treatment 11
Compressor sequencing 11
Interconnection between CCUH and remote condenser 12
Electrical connections 12
General data 14
General start-up
Preparation 16
Start-up 16
Operation
Control and Unit Operation 21
Weekly start up and week-end shutdown 21
Seasonal shutdown and start-up 21
Maintenance
Maintenance instructions 22
Installation checklist 23
Troubleshooting guide 25

CGWH-SVX01D-E4 5
Installation
Unit nameplate
The unit nameplate gives the
complete model reference numbers.
The unit power rating is shown, and
power supplies should not deviate by
more than 5 % from the rated power.
Compressor motor amperage is
shown in box I.MAX.
The customer’s electrical installation
must be able to withstand this
current.
Installation instructions
Foundations
No special foundations are required,
provided the supporting surface is
flat and level, and can withstand the
weight of the unit.
Isolation rubber pads
They are supplied as standard with
the machine, and should be placed
between the supporting floor and
the unit to isolate the unit from the
ground (4 pads for the sizes 115 to
125 and 6 pads for the sized 225
to 250). To reduce vibration, Trane
recommends the use of neoprene
pads (not included) but does not
allow the use of spring isolators.
Water drain hole
Install a drain hole wide enough to
drain away water from the unit in the
event of shut-down or repair.
Clearance
Respect recommended clearance
around the unit to allow maintenance
operation to take place without
obstruction. Submittals are available
on request from your local Trane
Sales Office.
Handling
A specific lifting method is
recommended as follows:
1. 4 lifting points are built into the
unit.
2. Slings and spreader bar to be
provided by rigger and attached
to the 4 lifting points.
3. Minimum rated lifting capacity
(vertical) of each sling and
spreader bar shall be no less
than the tabulated unit shipping
weight.
CAUTION!
The plates welded at the end of the
bases must not be used for handling.
Use the ones at 237 mm from the
ends.
Figure 1 - Handling
Table 1 - Dimensions of recommended slings and swing-bar :
Unit size 115 120 125 225 230 235 240 250
A (mm) 1400 1400 1400 1400 1400 1400 1400 1400
B (mm) 1900 1900 1900 1900 1900 1900 1900 1900
Weight (kg) CGWH 412 444 476 668 702 739 803 873
Weight (kg) CCUH 389 416 443 626 655 679 757 815

CGWH-SVX01D-E46
Before making any connections,
make sure the labeling for entering
and leaving water corresponds to
the submittals.
Install water circulation pump
upstream of the evaporator,
insuring that the evaporator is
under positive pressure.
Tables for water connections
diameter are shown on the certified
submittals.
These drawings are available on
request from your Trane Sales
Office.
Installation
1. Pressure gauges: show entering and
leaving water pressure (2 pressure
ports are available inside of the unit -
see item 1 in Figure 2)
2. Balancing valve: adjusts water flow.
3. Air purge: allows to remove the air
from the water circuit during fill up.
4. Stop valves: isolate chillers and water
circuiting pump during maintenance
operations.
5. Thermometers: indicate chilled water
entering and leaving temperatures
(not mandatory).
6. Expansion compensators: avoid
mechanical stress between chiller
and piping installation.
7. Stop valve located on the outlet
connection: used to measure the
water pressure inlet or outlet of
evaporator.
8. Strainer: avoid getting heat
exchangers dirty. All installation must
be equipped with efficient strainer
in order that only clean water enters
into exchanger. If there is no strainer,
reserve will be formulated by the
Trane technician at the start-up of the
unit. The strainer used must be able
to stop all particles with a diameter
greater than 1.6 mm.
9. Draining and charging: used to drain
and charge the plate heat exchanger.
10. Charging valve
Figure 2
10
Minimum water volume
Why is the water volume an
important parameter?
The water volume is an important
parameter because it allows a
stable chilled water temperature
and avoids short cycle operation of
the compressors.
Parameters which influence the
water temperature stability
• Water loop volume.
• Load fluctuation.
• Number of capacity steps.
• Compressors rotation.
• Dead band (adjusted by control
CH530).
• Minimum time between 2 starts
of a compressor.
Minimum water volume for a
comfort application
For comfort application we can
allow water temperature fluctuation
at part load.
The parameter to take into account
is the minimum operating time of
the compressor. In order to avoid
any lubrication problem, scroll
compressor must run for at least
2 minutes (120 seconds) before it
stops.

7CGWH-SVX01D-E4
Installation
Refrigerant lines CCUH
Calculating and fixing the capacity
of refrigerant lines is necessary
to assure the oil return to the
compressor, avoid refrigerant phase
changes and limit pressure drop.
Liquid lines
Calculate capacity of liquid line, as
per the following criteria.
1. Maximum load operating
conditions.
2. To avoid any evaporation risk:
- Consider the vertical risers
- Maximum pressure drop must
not exceed 1 to 2°C
3. Liquid circulation speed in a 0.5
to 2m/s range.
Insulation of refrigerant lines
Insulate refrigerant lines from
building itself to avoid transmission
to building structure of vibrations
normally caused by pipework. Also
avoid bypassing the unit’s damping
system by fixing the refrigerant
lines or the electrical ducts very
rigidly.
Vibrations may propagate into
building structure through rigidly
fixed refrigerant lines.
Pressure tests. Leak detection
During operations, take the
following precaution:
1. Neither oxygen nor acethylene
should be used instead of
refrigerant and nitrogen to
detect leaks, otherwise a violent
explosion may occur.
2. Always use valves and
manometers to check the test
pressure in system. Excessive
pressure may either cause
pipes to rupture, damage unit,
or cause an explosion, causing
possible physical injury.
Carry out liquid line and hot gas
pressure tests in accordance
with current standards.
CAUTION!
Do not go more than 0.7 bar above
the high pressure switch setpoint.
Introduce enough refrigerant into
circuit for 85 to 100 kPa pressure,
pump-injecting dry nitrogen, and
raise pressure to 100 kPa. Search
possible leaks using detector. This
operation should be carried out
great care throughout the system.
If leaks are detected, reduce system
pressure, and repair defective
component. Repeat test process, to
check that the repair can withstand
rated pressure.
NOTE:
CCUH is delivered with a nitrogen
holding charge and isolating valves.
The minimum volume can be
determined by using the following
formula : Volume = Cooling capacity
x Time x highest capacity step (%) /
Specific heat / Dead band.
Minimum operating time
= 120 seconds.
Specific heat = 4.18 kj / kg.
Average deadband = 3°C (or 2°C)
Note: To estimate the biggest step,
it is usually more reliable to make
a selection at lower condensing
temperature where efficiency is
higher and compressor steps bigger.
It is also essential to take into
account the brine specific heat, in
case of the use of glycol.
Table 2 - CGWH
Unit size 115 120 125 225 230 235 240 250
Cooling Capacity (kW) 51 64 77 91 103 116 127 155
Biggest step (%) 50 60 50 42 38 34 30 25
Biggest step (kW) 26 38 39 38 39 39 38 39
Minimum water
loop for comfort (l) 244 368 368 365 375 377 365 371
This table is estimated with
- Condenser : Water 30°/35°C
- Evaporator : Water 12°/7°C
- Dead Band of 3°C
Table 3 - CCUH
Unit size 115 120 125 225 230 235 240 250
Cooling Capacity (kW) 51 64 77 90 102 115 127 153
Biggest step (%) 50 60 50 42 38 34 30 25
Biggest step (kW) 26 38 38 38 39 39 38 38
Minimum water
loop for comfort (l) 244 367 367 363 371 374 365 366
This table is estimated with
- Condensing temp : 45°C with sub cooling 5°C
- Evaporator : Water 12°/7°C
- Dead Band of 3°C
Note: CCUH is only one component of a complete installation. It includes its own high pressure protection set at
29.5 bars.
The party in charge of the supply of the condenser and of its refrigerant piping is responsible of implementing all
the required protections to comply with the PED requirements for the design pressure of the condenser installed.
Please refer to the document PROD-SVX01_-xx delivered with this chiller to check all the mandatory conformity
requirements of the Pressure Equipment and Machinery directives for this installation.

CGWH-SVX01D-E48
Installation
Refrigerant line connections -
CCUH + remote condenser
Piping
Maximum distances and refrigerant
line diameters between units
must be checked according to
the configuration and system
operating conditions (Chilled water
temperature and subcooling).
Tables 4-8 provide the maximum
acceptable height according
to subcooling available and
recommended diameters for
discharge liquid lines when a CCUH
condenserless chillers is connected
to a remote condenser.
CAUTION! CCUH is only a
component of a complete
installation. It includes its own
high pressure protection set at
23 bar. The party in charge of the
supply of the condenser and of its
refrigerant piping is responsible for
implementing all required protections
to comply with PED requirements for
the design pressure of the condenser
installed. Refer to the document
PROD-SVX01_-XX delivered
with this chiller to check all the
mandatory conformity requirements
of the Pressure Equipment and
Machinery directives for this
installation.
Figure 3 - Installation configuration - CCUH and remote condenser at the same level
1: Discharge line
2: Liquid line
3: Remote condenser
4: CCUH
Figure 4 - Installation configuration - CCUH below remote condenser
1: Discharge line
2: Liquid line
3: Remote condenser
4: CCUH

9CGWH-SVX01D-E4
Installation
The minimum required subcooling
at the remote condenser level when
installed below is defined in the
following table.
Example : If the remote condenser
is 10m below the CCUH and the
condensing temperature is 50°C,
the refrigerant subcooling leaving
the remote condenser shall not be
below 4°C. To increase the amount of
subcooling, more refrigerant charge
is required.
For refrigerant piping longer than
50 m (distance of the condensing
unit to the evaporator), a pressure
relief valve on each circuit is
Table 5 - Required discharge line diameter CCUH circuit 1 (for vertical risers)
Leaving chilled water temperature (°C)
Unit size -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14
115 7/8” 1”1/8
120 7/8” 1”1/8 1”3/8
125 7/8” 1”1/8 1”3/8
225 7/8” 1”1/8
230 7/8” 1”1/8 1”3/8
235 7/8” 1”1/8 1”3/8
240 7/8” 1”1/8 1”3/8
250 7/8” 1”1/8 1”3/8
Table 6 - Required discharge line diameter CCUH circuit 2 (for vertical risers)
Leaving chilled water temperature (°C)
Unit size -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14
225 7/8” 1”1/8
230 7/8” 1”1/8
235 7/8” 1”1/8
240 7/8” 1”1/8 1”3/8
250 7/8” 1”1/8 1”3/8
Table 7 - Required discharge line diameter CCUH circuit 1 (either vertical or horizontal)
Leaving chilled water temperature (°C)
Unit size -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14
115 5/8” 7/8”
120 5/8” 7/8” 1”1/8
125 5/8” 7/8” 1”1/8
225 5/8” 7/8”
230 5/8” 7/8” 1”1/8
235 5/8” 7/8” 1”1/8
240 5/8” 7/8” 1”1/8
250 5/8” 7/8” 1”1/8
Table 8 - Required discharge line diameter CCUH circuit 2 (either vertical or horizontal)
Leaving chilled water temperature (°C)
Unit size -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14
225 5/8” 7/8”
230 5/8” 7/8”
235 5/8” 7/8”
240 5/8” 7/8” 1”1/8
250 5/8” 7/8” 1”1/8
Table 4 - Maximum elevation (H) of CCUH above remote condenser
Condensing dew temperature °C
Subcooling °C 20°C 35°C 50°C 65°C
4°C 4 m 6 m 8 m 10 m
6°C 8 m 12 m 16 m 20 m
8°C 12 m 17 m 23 m 30 m
10°C 16 m 23 m 30 m 40 m
12°C 20 m 28 m 38 m 49 m
necessary. It has to be located on the
suction side.

CGWH-SVX01D-E410
Winter freeze protection
During negative ambient air
temperature chilled water piping
must be fully insulated. Ensure that
all safeties are taken to prevent frost
damage during negative ambient air
temperature. The following systems
can be used:
• Electrical heater mounted on all
water piping exposed to negative
temperatures.
• Start chilled water pump
during negative ambient air
temperature.
• Add ethylene glycol in the chilled
water.
• Drain water-circuit, however be
aware of corrosion process when
drained.
CAUTION: There is a risk of
freezeup of the evaporator
circuit due to internal refrigerant
migration if the condenser circuit
is maintained at a low temperature
(below 0°C) for a long period during
the cold season.
If necessary, provide isolation
valves on the condenser water
circuit (CGWH). CCUH is protected
against refrigeration migration by a
liquid solenoid valve.
Recommended ethylene and
propylene glycol percentage are
indicated in the General Start-up
section.
Loading concentrated glycol in the
water loop at the suction side of the
pump is prohibited. It can severely
damage the mechanical seal of the
pump and consequently generate
potential water leaks.
Installation
Figure 5 - Freezing point versus ethylene glycol percentage
0
-1 0
-2 0
-3 0
-4 0
-5 0
0102030405
06
0
3
2
1
1. Liquid
2. Freezing without burst effect
3. Freezing with burst effect