Trane Ice Bank User manual

Ice Bank®Energy Storage
Installation and Operation Manual
August 2020 IB-SVX186B-EN
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.

© 2020 Trane IB-SVX186B-EN
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.
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.
CAUTIONsIndicates 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.
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
and HCFCs such as saturated or unsaturated HFCs and
HCFCs.
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 according to local rules. For
the USA, 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.
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 Safety Data Sheets
(SDS) and OSHA guidelines for proper PPE.
• When working with or around hazardous chemicals,
ALWAYSrefer tothe appropriateSDSandOSHA/GHS
(Global Harmonized System of Classification and
Labeling 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.

WARNING
Follow EHS Policies!
Failure to follow instructions below could result in
death or serious injury.
• All Trane personnel must follow the company’s
Environmental, Health and Safety (EHS) policies
when performing work such as hot work, electrical,
fall protection, lockout/tagout, refrigerant handling,
etc. Where local regulations are more stringent than
these policies, those regulations supersede these
policies.
• Non-Trane personnel should always follow local
regulations.
Introduction
IB-SVX186B-EN 3
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
Updated for Trane Technologies.

4IB-SVX186B-EN
Introduction
This technical guide is written to provide a complete and
comprehensive procedure for the installation of Ice Bank®
Energy Storage tanks. It is not the intent of this guide to
exclude sound and proven methods of installation by
contractors who have, through experience, developed an
efficient method of installation expertise.
All work must be performed in accordance with LOCAL,
STATE and NATIONAL codes. After reading this manual, if
any questions arise, please call your local representative
or CALMAC® Applications Engineering Department at
[phone] or e-mail [email protected].
1. GENERAL
a. Module Description. The storage module
consists of a plastic tank full of water (ice in the charged
state) in which a specially designed heat exchanger is
immersed. The heat exchanger consists of a coiled mat of
plastic tubes, which are spaced evenly throughout the
entire volume of water. The unique spiral counterflow
configuration allows ice to build up evenly throughout the
tank without tank damage. An empty space is provided
above the heat exchanger for expansion of water during
freezing.
b. Model Types. The tank model numbers are
appended with suffixes to specify different configurations.
The complete model number can be found on the rating
plate located on the tank cover adjacent to the
connections.
c. Damage in Transit. Upon receipt of the shipment
of this equipment, inspect all tanks and packages for
external damage. If external damage is noted, mark the
number of damaged items and the nature of the damage
on the delivering carrier’s waybill and request the services
of an inspector.
Since all materials are sold FOB factory, it is the
responsibility of the consignee to file claims with the
delivering carrier for equipment received in damaged
condition. Normally, claims for any and all damages
should be filed with the freight company within five
working days of the receipt of shipment.
2. SITE LAYOUT
a. Floor Loading. When filled with water the tanks
are quite heavy. Consequently the structure supporting
the tanks must be capable of bearing this weight. Refer to
Table 1 for the filled weight of each tank model and
required floor loading strength. The plastic bottom of the
tank must be level (¼ inch /6 mm) over the tank diameter
and supported over its entire area. For all “C” Model tanks
(See Section Step ii) the adjoining tanks must be on a
continuous level surface.
b. Partial Burial. Partially burying the tanks in the
ground is permissible as long as one foot of the tank
protrudes above ground level. The tanks must be installed
on a concrete pad which is level and completely supports
the bottom of the tank. (See Specifications for Partially
Buried Ice Bank® tanks, #CS-3).
c. Full Burial. Tanks sitting on a concrete pad may be
placed in a pit. A layer of sand then wood chips or top soil
may cover the tanks. (See the Installation Manual for
Totally Buried Ice Bank Ice Storage Tanks, #IB-152 for more
information).
Table 1. Weight, loading strength and overhead clearances
Tank
Model
Number
Shipping
Weight-
Lbs. (kg)
Filled Weight-
Lbs. (Kg)
Floor
Loading-
Lbs./Sq..Ft.
(Kg/m2)
Overhead
Clearance-
inches
(cm)
Fork Lift
Slots
Required
Coolantgals.
(liters)
Pure Glycol
Added to
HX-
(Sec IV.D)
gals. (liters)
Required
Biocideoz.
(ml)
1045A 580 (265) 4380 (1986) 147 (718) 24 (61) Yes 40 (152) 13 (49) 16 (475)
1082A 1025 (465) 8455 (3835) 283 (1382) 24 (61) Yes 78 (295) 26 (98) 16 (475)
1098A 1225 (555) 10,100 (4580) 234 (1142) 24 (61) Yes 90 (341) 30 (114) 16 (475)
1105A 1275 (580) 10,760 (4880) 360 (1758) 36 (91.5) Yes 99 (375) 33 (125) 16 (475)
1190A 1950 (885) 16,765 (7605) 388 (1894) 36 (91.5) Yes 148 (560) 50 (189) 16 (475)
1045C 620 (280) 4505 (2045) 151 (737) 24 (61) Yes 47 (178) 16 (61) 16 (475)
1082C 1065 (485) 8580 (3890) 286 (1396) 24 (61) No 86 (326) 29 (110) 16 (475)
1098C 1275 (580) 10,235 (4645) 237 (1157) 24 (61) No 99 (375) 33 (125) 16 (475)
1105C 1315 (595) 10,760 (4880) 363 (1772) 36 (91.5) No 107 (405) 36 (136) 16 (475)
1190C 2000 (910) 16,900 (7665) 391 (1909) 36 (91.5) No 157 (594) 52 (197) 16 (475)
1220C 2625 (1190) 23,000 (10,433) 531 (2593) 36 (91.5) No 210 (795) 70 (265) 16 (475)
1320C 4000 (1814) 34,000 (15,420) 391 (1909) 36 (91.5) No 315 (1192) 105 (397) 2x16 (2x475)
1500C 6000 (2721) 50,600 (22,950) 391 (1909) 36 (91.5) No 470 (1179) 155 (587) 3x16 (4x475)
d. Outdoors. Tanks are suitable for outdoor
installation. They must be set on a surface that meets the
specifications outlined in Section II. A. Settling or erosion
of the surface may cause the tanks to shift. It is normal for
the tank covers to show minor distortions when exposed

Introduction
IB-SVX186B-EN 5
to the sunlight. These minor distortions will not affect the
operation of the tank.
e. Roofs. Tanks can be installed on roofs however
they may need to be spaced apart so that maximum
structural loading is not exceeded. Follow the instructions
of a structural engineer regarding the distribution of the
tank floor loading.
f. Service Access. Refer to Table 1 for the required
overhead clearances for each model tank. No service
access is required around the sides of the tank beyond
what is needed for proper headering.
3. TANK INSTALLATION
a. Insulation. All tank models are insulated at the
factory and are shipped with integral insulated bases
installed.
b. Moving the Tanks. The tanks are heavy even
when empty and two people, with help of a forklift or
crane, are generally required to move them. All standard
rigging procedures and safety rules for lifting heavy
objects should be followed at all times even if not
detailed in this manual.
i. “A” Model Tanks. All have forklift slots
incorporated into their bases to facilitate moving the
tanks. Forklifts must have forks or extensions at least 72
inches (1830 mm) in length. Forklift operators must take
care not to ram the tanks with their forks when picking the
tanks up. This type of handling could puncture or
otherwise damage the tanks.
When using a crane to move an “A” Model tank into
position put two 30 foot (9 m) long, 3-inch (75 mm) wide
“choker” straps — each 180º apart — around the
midsection of the tanks. As the crane starts to lift, the
straps will slide up about a foot (300 mm), tighten around
the tank, grip and then hold the tank. The tank can then be
maneuvered into position.
ii. “C” Model Tanks. These tanks consist of one,
two or three individual modules which have main headers
built into the cover. Models 1320C and 1500C tanks must
be rigged into position with a crane and a special rigging
bar available from CALMAC®. (A standard spreader bar
can be used on the Model 1190C and 1220C). When moved,
they must be lifted as a single unit. Each module is
equipped with 2 hoist rings. Normally, one rigging bar is
shipped with each job. Lifting hooks are provided and
packaged separately.
Insert the provided clevis pins through the
appropriate holes in the rigging bar, capturing the hooks
between the steel channels (Figure 2, Figure 3 and
Table 2). Lock the clevis pins in place by inserting a cotter
pin. Lifting cables should be attached to the rigging bar as
shown in Figure 2 and Figure 3 in accordance with Table 2.
The rigging bar should be placed on top of the ice
tank unit and the lifting hooks secured to the tank hoist
rings.
If either the Model 1320C or Model 1500C Ice Bank
units must be temporarily set down, prior to its final
placement, it should be placed on a clean, flat and
reasonably level surface.
Note: Keeping the tanks level and preventing them from
swinging will assist in maintaining the required
uniform spacing between tanks.
4. PLUMBING PROCEDURES
a. General. There is no preferred inlet or outlet
header connection to the tank.
Flange manufacturers recommend that the 4 inch
flange bolts with washers be torqued to no more than 60
ft. lbs (81.4 Nm) and standard tightening pattern be used to
prevent leaks or damage to the flanges.
i. “A” Model Tanks. The connections on Model
‘A’ tanks are 2" flanges.
Note: The standard polyethylene heat exchanger is
limited to 90 Psi (620 kPa) internal pressure.
(Special orders to 125 Psi/862 kPa.) If system
pressures exceed these limits, a heat exchanger
must be used to isolate the storage tanks from the
higher pressure. A pressure relief valve must also
be installed in the system to assure that pressure
does not exceed 90 Psi (620 kPa) for standard heat
exchangers and 125 Psi (862 kPa) for special order
heat exchangers.
Table 2. Lifting pin destinations
Model Pin # for Tanks
Pin # for lifting
cable
1320 1,2,3,4 7,9
1500 1,2,3,4,5,6 8,10
ii. “C” Model Tanks. External pipes must be
located in such a way that the internal header pipes are not
pulled from their normal, at rest position. Using flange
bolts to pull tank flanges to system piping may cause
internal damage.
Models 1320C and 1500C have 4 inch flange
connections. Model 1190C tanks can be bolted directly to
each other at the 4 inch flange connection. See Figure 3
and Figure 4. However, do not connect more than three
Model 1190C tanks directly to each other without an
intermediate flexible connection that will allow 3/4 inch to
1 inch (20 to 25mm) of axial motion.
b. Flushing. All field constructed piping systems
should be flushed thoroughly, before filling with the
coolant, to remove weld slag, flux, debris etc. from the
piping. It is a good practice at this time to valve off all heat
exchange devices that are not protected by a strainer so
that small passages do not become plugged. The Ice
Bank® tanks should also be valved off. It i s a good practi ce
to carefully monitor the amount of water needed to initially
fill the system for flushing. This may be useful for
determining the volume of coolant required to fill the
system. Remember to add the Ice Bank heat exchanger,

Introduction
6IB-SVX186B-EN
and any other piping volumes that were isolated from the
system in the total system volume. Once the system has
been thoroughly cleaned, the system should be totally
drained of water.
Figure 1. Clevis and Cotter pins
Figure 2. Model 1500C
Figure 3. Model 1320C

Figure 4. Assembly options for “C” model tanks
Introduction
IB-SVX186B-EN 7
c. Hydrostatic Testing. Hydrostatic tests are
normally done on all piping systems. If a hydrostatic test
is specified before coolant is put in the system, the tanks
should not be part of this test and should be valved off.
This is because if pure water is pumped into the heat
exchanger it cannot be removed. After the successful
completion of the test, drain the system and add premixed
glycol to the system as described in Section IV.D.2.
If the specifications call for a complete hydrostatic
pressure test of the entire system, including tank heat
exchangers, completely fill system with glycol/water
solution and remove air. Then increase air pressure in the
expansion tank up to the hydrostatic test pressure
(maximum 150 Psi/1034 kPa). After 30 minutes close
off all valves on each tank and let sit for the
prescribed period of time. Monitor system pressure
as tank valves are sequentially opened.
Liquid level and/or pressure switches in the expansion
tank are recommended to alert operators of a shortage of
liquid in the system. Since these systems contain a
valuable heat transfer solution, steps should be taken to
prevent the loss of the liquid. The tank farm as a whole
should be capable of isolation by valves. A twostep alarm,
triggered by either low liquid level in the expansion tank or
low pressure at the high point of the building, should be
installed. The first level of alarm is to alert the operator of
routine requirements for the system’s fluid. The second
level would be for extremely low level/pressure indicating
a major leak and should close automatic valves to isolate
the tanks and other parts of the system
Make-up systems using city water are not
recommended because adding water alone will
dilute the coolant. If an automatic coolant make-up
system is required, CALMAC® GMS liquid pressurization
system, which adds premixed solution is recommended.
Indoor installations should have floor drains in
accordance with local codes.
d. Recommended Filling Sequence.
i. Add Water to Tank. After the tanks are in final
position and plumbed, CALMAC® recommends that tanks
be initially filled with water to approximately 90% of final
fill height, or about 6 tubes below the top HX tube. At this
time the Biocide should be added to the water. See section
IV.D.4. After the tank heat exchangers are filled with
coolant, the water level would be brought to the final
correct height, just covering the top heat exchanger (HX)
tube, except for Model 1220, which is filled to the bottom
of the top HX tube. Partially or fully buried tanks
should be filled with water as soon as practically
possible to prevent tank flotation, should the burial
pit accumulate with water.

Introduction
8IB-SVX186B-EN
ii. Add Heat Transfer Fluid Solution to Heat
Exchanger. The system should be filled with a glycol/
water mixture with a freezing point of about 12ºF (-11ºC)—
approximately three parts water to one part ethylene
glycol. Refer to Table 1 for amount of coolant required for
each tank model. Houghton Chemical Wintrex, Dow SR-1
or equivalent are recommended; automotive anti-freeze is
not recommended because it contains additives which
reduce the life of internal surfaces.
Figure 5. Recesses in the header insulation facilitate the assembly of connecting hardware
If the tank heat exchangers have been filled with water,
perhaps due to a hydrostatic test or system flush (Section
IV.C.), an adjustment must be made to the concentration
and/or quantity of coolant added to the remaining system.
Pure glycol can be added to the system to account for the
water left in the tank heat exchangers. The required
quantity can be found in Table 1, (Pure glycol added to
water in HX, Gals. (liters). The remaining system volume
would then be filled with coolant at the normal
concentration. (e.g. Adding 50 gals./189 liters) of
concentrated glycol to the 148 gals./560 liters of water in an
1190 HX would result in 198 gals./750 liters) of solution
volume at 25.3% glycol concentration).
Alternatively, the concentration of all the coolant to be
added to the system can be increased. This procedure may
be simpler when coolant is ordered premixed, in bulk. The
needed concentration can be calculated approximately
from the following:
C = Concentration of added coolant
Vs = System volume, not including tank HX’s
CR = Final concentration needed by system
VIB = Volume of tank HX’s
(Required coolant, Gals. (liters) from Table 1)
C = C
R S +V IB
V S
In all large systems there should be a minimum two inch
(50 mm) fill connection on the suction side of the pump.
The premixed glycol solution should be pumped into this
connection. Before starting the filling pump, high points of
the system should have the vents open.
Note: Unlike when filling with water, these vent locations
must be manned at all times during the filling
process so that the heat transfer fluid is not
inadvertently spilled.
When the coolant reaches the vent, manually close the
vent and stop the fill pump. Care must be taken not to over
pressurize the system (maximum 90 psi/620 kPa at the tank
inlet for standard tanks and 125 psi/862 kPa for special
order tanks).
The system pump can now be turned on for a few
minutes, preferably at low speed or valved back to half
flow. Most air will quickly move to the high points. With the
system pump off, the vents can be opened and the fill
pump can be started again. After repeating this a few times
and when most of the air is eliminated, open the valves
and run the system pump at full flow. At this point the
system’s air eliminator should be able to remove the final
amounts of air. When all of the air is out, run the fill pump
until the system’s expansion tank is at the proper level and
the system is at its proper working pressure (usually 5 psi
35 kPa at the high point of the building).
Keep circulating coolant through the system at the
design pressure. Make sure the system pressure doesn’t
drop. If it does, there is a leak in the system.

Introduction
IB-SVX186B-EN 9
Use a refractometer or equivalent to test the solution’s
glycol concentration after the system has been filled and
circulated for 24 hours. If the solution’s glycol
concentration is less than 25% or above 12°F (-11.1°C),
draw off a sufficient amount of mixture and add pure
glycol to achieve a 25% concentration.
iii. Finish Adding More Water to Tank. At this
time, after heat transfer fluid has been added to the heat
exchanger, finish filling the tank with water to a height just
covering the top heat exchanger (HX) tube, except for
Model 1220, which is filled to the bottom of the top HX
tube. For water level instructions in MIXAIR tanks, see
Installation Manual for MIXAIR Ice Bank® tanks #IB- 158.)
iv. Add Water Treatment. Pour in the initial
treatment of biocide into the tank water upon
filling, into the inspection port. This will help to control
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
Note: The cover must always be in place whenever the
tank is in operation in order to prevent floating of
the heat exchanger. You are now ready to freeze the
tank(s)!
e. Insulation. All piping must be insulated to prevent
condensate dripping as well as exposure to sunlight (to
prevent ultra-violet degradation). Since these liquid lines
run cooler than most chilled water systems the thickness
of the insulation may need to be slightly greater than
normal to avoid condensation.
5. RECOMMENDED OPERATING TEMPERATURES
The storage system will operate most efficiently if the
chiller controls are set to terminate charging at the highest
return temperature that will charge the tanks in the
available hours. In most cases, with a 6ºF (-14.4°C)
temperature difference across the chiller, the average
leaving chilled coolant temperature will be approximately
25ºF (-3.9°C) with a 31ºF (-0.6°C) return. Most commonly,
if the chiller unit is set to turn off when the coolant
temperature leaving the tank reaches 28ºF (-2.2°C)
(See project engineers specification for exact
temperature.) the tanks will be completely charged.
If the chiller is allowed to run at lower conditions than
required the free water above the heat exchanger may
freeze causing an “ice cap”. This ice cap will in turn cause
a shortage of water during discharge, thereby impairing
the discharge performance and wasting energy.
6. REPAIRS AND MAINTENANCE
Note: The cover must always be in place whenever the
tank contains ice in order to prevent floating of the
heat exchanger.
a. Routine Maintenance.
i. Annually. The water/ice level in the tanks
should be checked at least once a year. (Check Ice Bank®
Ice Storage Operation and Maintenance Manual #IB-
SVX147*-EN for complete details). When the tanks are
100% frozen, usually first thing in the morning, there
should be approximately 4 to 7 inches (10 to 15 cm) of
water above the submerged insulation depending on the
tank model. The water level should be within ½ inch (1.27
cm) of the bottom of the tank covers. Add water if this is not
the case. (If the tanks are not fully frozen, adding water
may cause the tanks to overflow when fully charged, which
will not hurt the tanks however, it may cause flooding of
the area).
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.
If the tank is equipped with an inventory meter sensor,
altering the water level may require re-calibration of the
meter. Refer to “Ice Inventory Meter Installation and
Operation Manual”, #IB-153.
The coolant should be checked annually for proper
corrosion and freeze protection. This service should be
available from the glycol manufacturer.
ii. Tank Water Treatment. Generally, if tanks are
kept at least partially frozen year round, provide
retreatment with biocide as needed. However, if tanks are
not kept frozen year round, retreatment may be required
more often and the tanks should be checked for slime or
odor seasonally.
b. Warranty Repairs. Authorization for in-warranty
field repairs must be obtained in writing from CALMAC®
before any repairs are attempted.
Note: To find out more about Ice Bank®energy storage
visit calmac.com or trane.com/energystorage

©2020 Trane
Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without
notice. We are committed to using environmentally conscious print practices.
Trane - by Trane Technologies (NYSE: TT), a global climate innovator - creates comfortable, energy
efficient indoor environments for commercial and residential applications. For more information,
please visit trane.com or tranetechnologies.com.
IB-SVX186B-EN 07 Aug 2020
Supersedes IB-SVX186A-EN (Jun 2019)