CG PRB018 E4

Options Guide
Air-cooled Liquid Chillers with Scroll

compressors
Models CGAM 020 to 170
August 2013
CG-PRB018-E4
CG-PRB018-E4
CG-PRB018-E4
Table of Contents
1.1. Aquastream 3G Air-cooled liquid chiller range ...................................................................7

1.2. CGAM Range .........................................................................................................................8
5.1.
Application ................................................................................................................... 12
5.2.
Description ................................................................................................................... 12
5.3.
Operation ..................................................................................................................... 13
5.4.
Benefits ........................................................................................................................ 13
5.5.
Incompatibilities........................................................................................................... 13
5.6.
More detail .................................................................................................................. 13
7.1. Ice making Digit 21 = C ........................................................................................................14
9.1. Lanced Aluminum Fins Digit 23 = A......................................................................................18
9.1.1.
Application ................................................................................................................... 18
9.1.2.
Description ................................................................................................................... 18
9.1.3.
Operation ..................................................................................................................... 18
9.1.4.
Benefits ........................................................................................................................ 18
9.1.5.
9.3. Non-lanced Aluminum Fins with Pre-coated Black Epoxy Digit 23 = E .............................19
9.3.1.
Application ................................................................................................................... 19
9.3.2.
Description ................................................................................................................... 19
9.3.3.
Operation ..................................................................................................................... 19
9.3.4.
Benefits ........................................................................................................................ 19
9.3.5.
Inconvenience .............................................................................................................. 19
9.3.6.
9.4. More detail..........................................................................................................................20
10.1. Partial Heat Recovery (PHR) Digit 24 = 2 .............................................................................21
10.1.1. Application....................................................................................................................... 21
10.1.2. Description ...................................................................................................................... 21
10.1.3. Operation ........................................................................................................................ 21
Water piping PHR .................................................................................................................... 22
10.1.3.1 How does Partial Heat Recovery ( PHR) work .............................................................. 22
10.1.4. Benefits............................................................................................................................ 23
10.1.5. Incompatibilities .............................................................................................................. 23
10.2. Total Heat Recovery Digit (THR) 24 = 3 ................................................................................24
10.2.1. Application....................................................................................................................... 24
10.2.2. Description ...................................................................................................................... 24
10.2.3. Operation ........................................................................................................................ 24
10.2.3.1. How does Total Heat Recovery (THR) work ................................................................ 25
10.2.4. Benefits............................................................................................................................ 27
11.1. Across the Line Starter/Direct on Line Digit 26= A ...............................................................28
11.2. Solid-state Soft Starter Digit 26 = B .....................................................................................28
11.2.1. Application....................................................................................................................... 28
11.2.2. Description ...................................................................................................................... 28
11.2.3. Operation ........................................................................................................................ 29
11.2.4. Benefits............................................................................................................................ 29
11.3. More detail..........................................................................................................................29
11.3. More detail..........................................................................................................................30
12.1. LonTalk LCI-C Interface with Modbus Interface Digit 31 = 1 ................................................31
CG-PRB018-E4
12.1.1. Application....................................................................................................................... 31
12.1.2. Description ...................................................................................................................... 31
12.1.3. Operation/Benefits .......................................................................................................... 31
12.2. LCI-C Card (LonTalk Communication Interface) Digit 31 = 2 .................................................33
12.2.1. Application....................................................................................................................... 33
12.2.2. Description ...................................................................................................................... 33
12.3 Time of Day Scheduling Digit 31 = 3.....................................................................................35
12.3.1. Application....................................................................................................................... 35
12.3.2. Description/Operation ..................................................................................................... 35
12.3.2.1. Scenarios ................................................................................................................... 35
12.3.3. Benefits............................................................................................................................ 36
12.4. BCI-C (BACnet Communication Interface) Digit 31 = 4 .........................................................37
12.4.1. Application....................................................................................................................... 37
12.4.2. Description ...................................................................................................................... 37
13.1. External Chilled Water and Demand Limit Setpoint with ....................................................38
4-20 mA Digit 32 = A .......................................................................................................................38
13.1.1. Application....................................................................................................................... 38
13.1.2. Description ...................................................................................................................... 38
13.1.3. Operation ........................................................................................................................ 38
13.1.4. Benefits............................................................................................................................ 38
13.2. External Chilled Water and Demand Limit Setpoint ............................................................39
2-10 VDC Digit 32 = B ......................................................................................................................39
13.2.1. Application....................................................................................................................... 39
13.2.2. Description ...................................................................................................................... 39
13.2.3. Operation ........................................................................................................................ 39
13.2.4. Benefits............................................................................................................................ 39
13.3. Second leaving water temperature setpoint Digit 32 = C ....................................................40
14.1.
Application ................................................................................................................... 41
14.2.
Description ................................................................................................................... 41
14.3.
Operation ..................................................................................................................... 41
14.3.1. Example ....................................................................................................................... 41
14.4.
Benefits ........................................................................................................................ 42
14.5.
15.1.
Application ................................................................................................................... 43
15.2.
Description ................................................................................................................... 43
15.3.
Operation ..................................................................................................................... 44
15.4.
Benefits ........................................................................................................................ 44
15.5.
16.1. Starter type for Pump Digit 35 = 1, 2, 3, 4 ...........................................................................46
16.1.1. Benefits of TeSys U........................................................................................................... 46
2.
Pump Insulation ..................................................................................................................46
17.1. Pump Flow Controlled by Balancing Valve Digit 36 = A .......................................................47
17.1.1. Application....................................................................................................................... 47
17.1.2. Description ...................................................................................................................... 47
17.1.3. Operation ........................................................................................................................ 47
17.1.4. Benefits............................................................................................................................ 47
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17.2. Pump Flow Controlled by Variable Speed Drive Digit 36 = B ...............................................48

17.2.1. Application....................................................................................................................... 48
17.2.2. Description ...................................................................................................................... 48
17.2.3. Operation ........................................................................................................................ 48
17.2.4. Benefits............................................................................................................................ 48
17.2.6. More detail ...................................................................................................................... 49
17.2.6.1. Pump flow adjustment by Variable Speed Drive......................................................... 49
17.2.6.2. Detailed example pay back time ................................................................................ 50
18.1.
Application ................................................................................................................... 52
18.2.
Description ................................................................................................................... 52
18.3.
Operation ..................................................................................................................... 53
18.4.
Benefits ........................................................................................................................ 53
18.5.
19.1. Elastomeric Isolators Digit 39 = 1 ........................................................................................54
19.1.1. Application....................................................................................................................... 54
19.1.2. Description ...................................................................................................................... 54
19.1.4. Incompatiblities ............................................................................................................... 54
19.2. Neoprene Pads Digit 39 = 4 .................................................................................................55
19.2.1. Application....................................................................................................................... 55
19.2.2. Description ...................................................................................................................... 55
19.2.4. Inconvenience .................................................................................................................. 55
20.1.
Application ................................................................................................................... 56
20.2.
Description ................................................................................................................... 56
20.3.
Operation ..................................................................................................................... 57
20.4.
Benefits ........................................................................................................................ 57
20.5.
20.6.
More detail .................................................................................................................. 57
21.1. Compact unit Digit 41 = 1 ....................................................................................................58
21.2. Super quiet unit Digit 41 = 3 ................................................................................................58
21.3. Super quiet with Night Noise setback Digit 41 = 4 ...............................................................58
21.4. Comprehensive acoustic package unit Digit 41 = 5 ..............................................................58
22.1 No Appearance option Digit 42 = X ......................................................................................59
22.2. Architectural Louvered Panels Digit 42 = A ..........................................................................59
22.2.1. Application....................................................................................................................... 59
22.2.2. Description ...................................................................................................................... 59
22.2.3. Operation ........................................................................................................................ 60
22.2.4. Benefits............................................................................................................................ 60
23.1. Digit 45= X ...........................................................................................................................61
23.2. Digit 45= 1 ...........................................................................................................................61
23.1.1. Application....................................................................................................................... 61
23.1.2. Description ...................................................................................................................... 61
23.1.3. Operation ........................................................................................................................ 62
23.1.4. Benefits............................................................................................................................ 62
23.1.6. Summary ......................................................................................................................... 62
24.1. Unit Containerization Package Digit 46 = A .........................................................................63
Annexe 1: Wilo pumps curves. ........................................................................................................64
DPL or IL50/120-1,5/2.................................................................................................................. 64
DPL or IL50/130-3/2 .................................................................................................................... 64
DPL or IL65/120-3/2 .................................................................................................................... 65
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DPL or IL65/130-4/2 .................................................................................................................... 65

DPL or IL65/140-5,5/2.................................................................................................................. 66
DPL or IL80/155(127)-7,5/2 ......................................................................................................... 66
DPL or IL80/150-11/2................................................................................................................... 67
DPL or IL40/160-4/2 .................................................................................................................... 67
DPL or IL40/160-5,5/2.................................................................................................................. 68
DPL or IL65/175(143)-7,5/2 ......................................................................................................... 68
DPL or IL80/160-11/2................................................................................................................... 69
DPL or IL80/170(165)-15/2 .......................................................................................................... 69
CG-PRB018-E4
1.
Range Overview
1.1.
Aquastream 3G Air-cooled liquid chiller range
Before explaining the different options and accessories available, lets first take a look at
the current range and review the definition of the Aquastream 3G Air-cooled liquid
chillers
Illustration 1. Range Overview
The Aquastream 3G Air-cooled liquid chillers family covers a capacity range between 50
kW and 450 kW, which includes Cooling only and Heat pump units. For the Cooling only
unit, it is called CGAM and the other unit is named CXAM. The units come in 3 families
which are Simplex (1 circuit), Duplex V (2 circuits) and Duplex W (2 circuits). S1, S2, V1,
V2, W1, W2, W3 and W4 are the cabinet depending on the units size and the units
sound level. If the units are in the same cabinet, its mean that they have the same
dimensions(length,width,height). Section with grey colour means there is no units for the
specific sizes and the chosen sound level.
CG-PRB018-E4
1.2.
CGAM Range
Illustration 2. CGAM range
CGAM range is Eurovent certified

Performances are available on website
www.eurovent-certification.com
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2.
Unit appearance
Unit appearance is different according to its acoustic level. There are 3 types of
acoustic level, Compact, Super Quiet or Super Quiet with Night Noise Setback
(fan operation on low speed, reducing sound level during the night) and
Comprehensive Acoustic Package. For each type, the unit will be provided with
different size of compressor, type of fan and compressor insulation. The difference of
unit appearance can be noticed easily by compressor insulation.
2.1. Compact
Compressors are not covered.
Illustration 3. Compressors
appearance for compact unit
2.2. Super quiet and SQ + NNSB

A black jacket covers the compressors.
Illustration 4. Black jackets cover the
compressor for Super quiet unit
2.3. Comprehensive acoustic package

The compressors are installed in a box
Illustration 5. Box is used to cover the
compressors for comprehensive acoustic
package
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3.
Compressor size
The table below shows the compressor size for each size of the unit.
1A
SLANT
V
# of Circuits
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1B
1C
Comp. Manifold CKT1

10
10
10
13
13
13
15 lc
15 lc
15
20
20
20
20
25
25
25
10
10
10
13
13
13
15 lc
15 lc
15
20
20
20
20
25
25
25
25
30
30
30
25
25
25
30
20
25
25
25
25
25
30
30
2A
2B
2C
Comp. Manifold CKT2
10
13
13
15 lc
20
20
25
25
30
30
10
10
13
15 lc
15
20
20
25
25
30
25
25
30
30
20
25
25
25
25
25
25
30
Size
020
023
026
030
035
039
045
050
040
046
052
060
070
080
090
100
110
120
140
150
160
170
CGAM/CXAM
Circuit 1 Circuit 2
0
0
0
0
0
0
0
0
0
3
0
3
0
3
0
3
0
3
0
3
0
3
0
3
0
3
0
3
9
1
1
8
9
7
7
8
Table 1. Compressor size in ton

Compressor staging pattern circuit 1
Compressor staging pattern circuit 2
A, AB = 0
A, AB, ABC = 1
B, BA, BAC = 8
A, AB, ABC (Not B) = 9
B, AB = 3
C, CB, CBA = 7
B, BA, BAC = 8
A, AB, ABC (Not B) = 9
Explication on how compressor staging is done

For the 2-compressor circuits:
If the compressors are equally sized, we can start with any of them first.
If not, we want to start the smaller compressor first.
Thus, for sizes up to 120 nominal tons, we always do A, AB for circuit 1 and B,
AB for circuit 2.
For the 3-compressor circuits:
For 140 and 170 ton units, the smallest compressor is the B compressor. 140
ton was not qualified to run compressor B alone. 170 ton was qualified to run
compressor B alone. Thus, they get different sequences.
On 150 & 160, we act similar to a duo, and do A, AB, ABC on circuit 1, and C,
CB, CBA on circuit 2.
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10
4.
Operating Map
Fan control
Min. outdoor air
temperature
Max. outdoor air
temperature
Min. leaving water
temperature
Max. leaving water
temperature
Low
ambient
-18C
Standard
ambient
+7C
High
ambient
+7C
Wide
ambient
-18C
+46C
+46C
+52C
+52C
-12C
-12C
-12C
-12C
+20C
+20C
+20C
+20C
Table 2. Cooling only units (CGAM)
Illustration 6. Operating map for cooling only
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11
5.
Freeze Protection(CH530) Digit 18 = 2
5.1.
Application
5.2.
-
When the unit is exposed to ambient temperature between 0C and -18C.

When the unit needs to be protected from freezing (no glygol in the water loop).
By electric heaters activation.
Description
Heaters on all cold parts.
Heaters used are heat mat and heating cables.
Freeze protection is integrated into the main power of the unit.
S type units
V type units
W type units
From May
2013
heater
heater
heater
Illustration 7. Pump package anti-freeze heater
An anti-freeze heater is installed in water pumps for pump freeze protection.

Pump package anti-freeze heater power
Buffer tank anti-freeze heater power
S type units = 530 W
S type units = 860 W
V type units = 530 W
V type units = 800 W
W type units = 1030 or 1150 W*
W type units = 800 or 1200 W*
* (depends on unit size,efficiency and sound level)
Buffer heaters are heat mat,
attached at the lower part as
the heated water can go
upwards by nature
convection
Illustration 8. Heaters of buffer tank
Note: The water piping between the chiller and the building has to be protected
against freezing by installing heating cable
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12
5.3.
-
5.4.
5.5.
5.6.
-
Operation
Freeze protection via the CH530 control turns on the heaters based on ambient
temperature.
Benefits
All the components are protected.
No additional or dedicated electrical connection when installing.
Incompatibilities
No incompatibility.
More detail
On the evaporator a blanket heater is installed at the bottom of the brazed plate
heat exchanger(BPHE).
Illustration 9.
Blanket heater
6.
Freeze Protection digit 18 = X
No heaters are provided but the anti freeze protection is possible with the pump
activation by CH530 control (pump ON from 2C down to negative ambient
temperature; pump OFF up to 5C) using external temperature sensor. This system
allows to reduce the price of the unit.
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13
7.
Evaporator Application Digit 21
-12C
5.5C
20C
Standard cooling
Low temperature processing
Ice making
Illustration 10. Range of evaporator application option
The illustration above shows the application that can be adapted for evaporator. In
standard, the evaporator is provided with standard cooling application which the
evaporator leaving temperature is in a range of 5.5C to 20C. Low temperature
processing with the range of leaving water temperature between -12C and 5.4C is an
option.
7.1.
Ice making Digit 21 = C
The other option for evaporator is ice making(ice building) with a wide range of leaving
water temperature between -12C and 20C. This option can be applied when the chiller
is used to make ice at night. The frozen water (ice) serves as thermal storage that can be
melted to produce cooling. 2 set points enable the customer to control the chiller for this
option. One set point used for the day time and the other one used during the night time.
At night, unit generates ice when utility rates are low (off-peak period) and uses ice for
cooling during the day when utility rates are high (on-peak period). During the night, the
chiller cools the mixture of glycol/water to a very low leaving water temperature (i.e. -7C)
which is then circulated through coils inside a tank containing water to create ice. During
the day, heat load is carried through the chilled water system to the ice storage tanks.
The ice melts and cools the glycol/water mixture (i.e. 5C), then is routed to the cooling
coils and cools the building. The chiller will start and run all available compressors (no
stagging). The chiller will load at its maximum rate. Softloading is not in effect in ice
making. The condenser control in ice making shall be the same as normal cooling.
Control on ice making
Ice Building Enable/Disable setting
This setting will Enable or Disable the ice building option. It can be set through
the DynaView or TechView. This setting does not start or stop ice building. The
Ice Building Command starts and stops ice building.
CG-PRB018-E4
14
Initiating Ice Building (Ice Building Command)

Ice Building can be initiated through the following means:
The external ice building command binary input (optional).

BAS ice building command (optional).
Front panel ice building command (set from DynaView or TechView).
If any one of these inputs command the chiller to make ice and the ice building feature
is enabled the chiller will attempt to make ice.
Benefits of ice making
Reduces or even replaces mechanical cooling durind the day

Reduces the electricity consumption cost
Avoid over sizing the chiller
More detail
The ice bank tank for ice making is manufactured by Calmac. Ice making can be used in
Air conditioning
Eliminates peak-hours load ( explained in paragraph above)
Limitation of power absorbed
During the day, the chiller used the ice to cool the building. Thus, the energy
used during the peak period is reduced.
Industrial application
Poultry
Fisheries
In process
Chemical process
Food process
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15
8.
Water Connection Digit 22
There are 3 ways which are suggested by Trane for water pipe connections (cold
water and HR hot water (if any) connections) .
8.1. Grooved pipe connection(standard) digit 22 = 1
This type of pipe has a grooved end.
This groove provides a gripping area for the coupling to engage around the full
pipe circumference.
Easy to connect the piping .
Illustration 11. Grooved pipe connection
Grooved area
8.2. Grooved pipe connection with flange adapter digit 22 = 2

This kind of pipe connection comes with a flange adapter which is used to convert
both water connections from grooved pipe to flanged PN 10 connections.
To connect the grooved pipe with the grooved flange adapter, a victaulic
coupling is used between them.
flange
Victaulic
coupling
Illustration 12. Grooved pipe with flange adapter
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16
8.3. Grooved pipe connection with coupling and pipe stub digit 22 = 3
Used when tube is welded.
Pipe stub
Weld
sleeve
Illustration 13. Grooved pipe and coupling
Victaulic coupling
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17
9.
Condenser Fin Materiel Digit 23
9.1.
Lanced Aluminum Fins Digit 23 = A
9.1.1. Application
-
When the chiller is installed in standard condition

Non polluted ambiance
Non corrosive ambiance
9.1.2. Description
-
Aluminum fin is a standard fin used on all air-chillers.

Also known as slit fins.
The slit is located between of two collar.
Slit
Illustration 14. Aluminum slit fin
9.1.3. Operation
-
The aluminum fins increase the capacity of heat exchange between the
refrigerant and the ambient air flow.
Slit increases the air turbulences.
It allows more heat transfers between the two fluids than non-lanced aluminum
fins.
9.1.4. Benefits
-
Increases the condenser and chiller performance.
9.1.5. Incompatibilities
-
Heat pump as it slows down defrost cycle
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18
9.3.
Non-lanced Aluminum Fins with Pre-coated Black Epoxy
Digit 23 = E
9.3.1. Application
-
When chiller is needed for coastal or salt mist environments.

When the aluminum fin is exposed to hard weather conditions(acid rain,
moisture,pollution, salt )
9.3.2. Description
-
Condenser black epoxy coated.

Edges treated.
Illustration 15. Black epoxy fin
9.3.3. Operation
-
Black epoxy slows down the corrosion process on the aluminum fins when the
unit is installed on sea side or in a polluted area.
9.3.4. Benefits
-
This option allows installation near the sea and avoids aluminum corrosion.
Trane coating also includes edges of the fins. If edges are not treated, then the
corrosion starts at this point and the coil would be quickly destroyed.
The black epoxy also provides a barrier protection at the fin collar to stop
galvanic corrosion action between the aluminum fins and the copper tubes.
9.3.5. Inconvenience
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19
Aluminum fin is painted with black epoxy, it is covered by 3 layers of

protection.Thus, this action will decrease slightly the capacity of heat transfer
( 2%) between the refrigerant and the ambient air.
Resin Polyurethane, color black

Resin Black Epoxy
Phosphochromate
Aluminum 0.12 mm thickness
-
9.4.
Lanced/slit aluminum fins.
More detail
For information, there are 192 fins per foot installed in the condenser.
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20
10.
Condenser Heat Recovery Digit 24
10.1. Partial Heat Recovery (PHR) Digit 24 = 2

10.1.1. Application
-
When a portion of rejected heat around 25% needs to be recovered.

Usually used to pre-heat hot water services
10.1.2. Description
-
Braze Plate Heat Exchanger (BPHE) for PHR is installed between the
downstream of the compressor and air cooled condenser.
Two BPHE Partial Heat Recovery for dual circuits.
An antifreeze protection is supplied by Trane to protect the heat exchangers in
area where negative temperature can occur.
A control algorithms is used for partial heat recovery when this feature is
installed.
The HR condensers and water lines are insulated to prevent heat loss.
Insulation is factory provided on the PHR BPHE
Partial heat
recovery BPHE
Illustration 16. Installation BPHE for partial heat recovery in V type

unit
10.1.3. Operation
-
The Braze Plate Heat Exchanger cools down the gas at the discharge of the
compressor and heats water.
The heat exchanger uses desuperheating effect of discharge gas.
Partial Heat Recovery can be executed either in cooling mode or heating mode
Illustration 17. Partial heat recovery

system
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21
PHR anti-freeze heater power

In duplex V and W, there are two PHR circuit which means the heater is installed in
each BPHE and water piping of PHR.
Unit type
Slant
Duplex V
Duplex W
BPHE PHR
100 W
100 W x 2
100 W x 2
Water piping PHR

60 W
60 W x 2
60 w x 2
Table 3. PHR anti-freeze heater power
10.1.3.1 How does Partial Heat Recovery ( PHR) work
Field supplied
Trane supplied
Hot water
to building
Cold
water
from city
network
Illustration 18. Water loop in partial heat recovery
The customer shall provide the water loop for partial heat recovery as shown in figure
18. The circulation pump provides constant water flow rate from the tank. The threeway valve adjusts the water flow of PHR heat exchanger based on the heat exchanger
leaving water temperature. As the leaving water temperature increases, the PHR
water flow rate increases. The main heater supply additional heat if needed. CH530
does not control the three-way valve.
For domestic hot water in lodging applications, a separate heat exchanger is needed
for potable water.
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22
PHR operating map

PHR LWT (C) = 45 - 70 C
Ambient temperature (C) = 10 52 C
Illustration 19. Cooling priority map (ambient temperature VS PHR LWT)
As shown in the figure above, the maximum delta Temperature between PHR EWT
and PHR LWT is 10C. This means, for example, for 45C of PHR LWT, the customer
can provide 35C for PHR EWT.
PHR is not compatible with low leaving water temperature options. For application with
ELWT below +5.5C, please contact sales support team.
With PHR option, there is no control on the CGAM air flow.
10.1.4. Benefits
-
Up to 25% heat recovered from the cooling/heating load.

Heat recovered can be used for pre-heat of boiler system or domestic water
(i.e. swimming pool,laundry facilities).
Energy saving.
For process which needs chilled water and hot waterat the same time.
In office blocks,during winter,computer rooms still need cooling while offices
need heating.
-
Total heat recovery.

Ice making
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23
10.2. Total Heat Recovery Digit (THR) 24 = 3

10.2.1. Application
-
When a large portion of rejected heat around 80% needs to be recovered.

When there must be a simultaneous need for chilled water and hot water unless
a larger hot water storage is available.
10.2.2. Description
-
Braze Plate Heat Exchanger (BPHE) for THR is installed between the
compressor and air cooled condenser.
An antifreeze protection is supplied by Trane to protect the heat exchangers
and water piping in area where negative temperature can occur.
3 way valve and liquid receiver are installed on THR circuit.
A control algorithms is used for total heat recovery when this feature is installed.
The HR condensers and water lines are insulated to prevent heat loss.
Insulation is factory provided.
3 way valve
condenser
Illustration 20. Installation of THR components in the unit
10.2.3. Operation
-
The Braze Plate Heat Exchanger cools down the gas at the discharge of the
compressor and heat water.
The heat exchanger uses desuperheating plus condensing effect of discharge
gas.
The 3 way valve factory installed is used to adjust the water flow of Total Heat
Recovery heat exchanger to provide as much heat capacity as possible without
causing defaults.
Liquid receiver is installed on the condenser to serve to accumulate the reserve
liquid refrigerant, to provide a storage for off-peak operation in order to have
always have enough refrigerant.
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24
Illustration 21. Total heat recovery system
THR anti-freeze heater power

THR is installed in duplex V and W unit only. In Duplex V unit, there are two circuits
of THR and for each circuit, a BPHE is installed. Meanwhile, in Duplex W, there is
only one BPHE installed for two circuits of THR. Every circuit is applied with heater for
anti-freeze protection.
Unit type
Slant
Duplex V
Duplew W
BPHE
100 W x 2
120 W
Water piping
60 W x 2
100 W x 2
Table 4. THR anti-freeze heater power
10.2.3.1. How does Total Heat Recovery (THR) work
Hot watet to
building
Field supplied
Trane supplied
Cold water
from city
network
Illustration 22. Water loop in total heat recovery
CG-PRB018-E4
25
Illustration 22 shows the THR water loop in application. The components in red dash
box are mounted in factory and in the blue dash are provided by customer. The main
heater supply additional heat if needed. The circulation pump provides constant water
flow rate from the tank. The 3 way valve is controlled by CH530 to adjust the water
flow of THR heat exchanger to provide as much heat capacity as possible without
causing defaults and to maintain optimal condensing parameters. THR is applied to
the cooling unit only. The chiller will always maintain the leaving chilled water
temperature according to its set point.
The goal of the water flow control is to provide suitable water flow rate in order to
recover as much heat capacity as possible from THR BPHE.
With THR option, on heat recovery mode, condenser air flow is controlled in order to
recover a maximum capacity in the plate heat exchanger. However, recovered
capacity depends on the compressors load and is also dependant of the air ambient
temperature. TOPSS selection give the HR capacity for chiller at full load.
Below 15C ambient temperature, HR capacity cannot be predicted due to non
controlled air flow variations.
THR operating map
THR LWT (C) = 30 - 55 C
Ambient temperature (C) = 7 - 52 C
THR Operation Map (Amb VS Evap LWT) (SI Units)

60
4,4 ; 52
6,7 ; 52
15,6 ; 52
50
4,4 ; 46
15,6 ; 44
6,7 ; 46
Amb T (C)
40
15,6 ; 42
7; 35
30
SE Unit OM
SE Unit Part Load
20
HE Unit OM
HE Unit Part Load
Rating Point
10
4.4 , 7
15.6 , 7
0
2
10
12
14
16
18
Evap LWT (C)
Illustration 23. THR operating map
The customer can get 30 55 C of THR LWT. The maximum delta Temperature
between THR EWT and THR LWT is 10C. This means, for example, for 45C of THR
LWT, the customer can provide 35C for THR EWT.
In the chart above, the minimum ELWT that can operate THR is 4.4 C and the
maximum is 15.6 C.
CG-PRB018-E4
26
10.2.4. Benefits
-
Up to 80 % of cooling capacity recovered.

Energy saving.
Heat recovered can be used for pre-heat of boiler system or domestic water
(i.e. swimming pool,laundry facilities).
Typically for hotel applications.
-
Partial Heat Recovery

Ice making
CG-PRB018-E4
27
11.
Starter Type Digit 26
Starters installed have an IP-54 gasketed enclosure. It is a protection index which is

able to protect the starters againts dust and water projection from all directions.
11.1. Across the Line Starter/Direct on Line Digit 26= A
This is the standard starter located in electrical panel of the unit.
contactors
Illustration 24. Circuit of direct on Line
11.2. Solid-state Soft Starter Digit 26 = B

11.2.1. Application
-
To reduce inrush current when the compressors start.
11.2.2. Description
-
Factory-installed , located in eletrical panel of the unit.
Illustration 25. Soft starter
CG-PRB018-E4
28
Illustration 26. Solid-state soft starter installed for W unit
11.2.3. Operation
-
In this circuit, the soft starter replaces the direct on line starter.
It controls the current flow which will generate the compressors to start
gradually.
11.2.4. Benefits
-
With the soft stater, the starting current drops down to 2.5 - 3 IN
(IN:nominal intensity).
The compressor can start smoothly as the starting current is reduced.
Smooth starting reduces motor and compressor wear.
Less stress on the power supply.
Reduce cable size.
-
Direct on Line.
11.3. More detail

-
There is a device called Silicon Controlled Rectifier(SCR) that soft starter

works with. The SCR is an electronic switch which allows current to flow
through it only when electronic signal is applied to its gate.
CG-PRB018-E4
29
11.3. More detail

Comparison between across line starter and soft starter
By installing soft starter in the circuit, it will reduce the starting current.There are 6
different sizes of compressor.
Compressor
size
Across Line
Starter (A)
Soft Starter
(A)
% current
reduction
10
13
15
20
25
30
142
158
160
215
260
320
85
95
96
129
156
192
40
40
40
40
40
40
Table 5. Inrush current
Compressor
size
Across Line
Starter (ms)
Soft Starter
(ms)
10
13
15
20
25
30
70
100
68
61
70
70
400
300
280
320
320
250
Table 6. Startup time (ms)
As shown in table 5,inrush current is reduced by installing soft starter to the electrical
circuit. Thus, the compressor will be started up with small quantity of current and it
improves the stability of the power supply. In table 6, it shows that the compressor
with soft starter will take more time to run than with across the line starter. It means
that the compressor starts progressively.
CG-PRB018-E4
30
12.
Remote Interface Digit 31
12.1. LonTalk LCI-C Interface with Modbus Interface Digit 31 = 1

12.1.1. Application
-
When the unit needs to interface with Modbus.
12.1.2. Description
-
Protocol Interface Controller( PIC) is a gateway for converting LonTalk

protocols to Modbus protocols.
Illustration 27. PIC
Illustration 28. PIC layout
12.1.3. Operation/Benefits
-
The layout shown above is the connectors to the PIC.( see table below).
Table 7. Connectors definition
CG-PRB018-E4
31
Wiring PIC with RS-232 and RS-485 Modbus BMS.
Illustration 29. Installation of Modbus RS-232
Illustration 30. Installation of Modbus RS-485
-
BCI-C.
CG-PRB018-E4
32
12.2. LCI-C Card (LonTalk Communication Interface) Digit 31 = 2

12.2.1. Application
-
When a communication interface between a Tracer CH530 controller and a

LonTalk network is needed.
When the chiller needs to communicate with building automation system(BAS).
12.2.2. Description
-
The LCI-C is factory installed with the chiller controller, located in the control
panel box.
Illustration 31. LCI-C card
-
The hardware of an LCI-C consists of a low-level intelligent device (LLID),

which is an electronic board that allows the Tracer CH530/531 controller to
communicate on a LonTalk network.
LCI-C shall be used to provide gateway functionality between the LonTalk
protocol and the IPC3 (Intra Processor Communication) protocol.
The LCI-C LLID and CH530 Main Processor shall collaborate to ensure that
data synchronization is maintained under reasonable failure modes, which
include:
Message loss or corruption between the BAS and the LCI-C LLID.
Message loss or corruption between the LCI-C LLID and the
CH530 Main Processor.
Temporary power loss/brownout conditions on the LCI-C LLID,
CH530 Main Processor, or both simultaneously.
CG-PRB018-E4
33
The LLID is designed to be mounted in an enclosure so that it is protected from

the environment. The chiller control panel box, where the other Tracer
CH530/531 LLIDs reside, provides a convenient place for the LCI-C.
Illustration 32. The installation of LCI-C card, LCI-C LLID and IPC3 communication bus ribbon cable
-
BCI-C
Time of day scheduling
CG-PRB018-E4
34
12.3 Time of Day Scheduling Digit 31 = 3

12.3.1. Application
-
Provides a means of scheduling the chiller operation on a daily basis.

When the user needs to set up events.
12.3.2. Description/Operation
-
The users can set the schedules up through Trane CH530 panel.
No need of building automation system (BAS).
The schedule shall consist of 10 events.
Each event shall have an enable and disable. An event shall store which days
of the week it is active.
Each event shall have a trigger time, which is the time (on the active days of the
week) that the event will occur.
12.3.2.1. Scenarios
Note: The following example is meant to demonstrate the flexibility of the local time of
day schedule and is notmeant to indicate the proper way to run a chiller. Events not
displayed are considered disabled.
I want the chilled water set to 7C during work hours (event 1) and then in
the evenings 9C (event 2). Saturday I want the chilled
water set to 8C from 10:00am to 2:00pm (event 3) and after that disabled
until Monday morning (event 4).
00 :00
02 :00
04 :00
06 :00
08 :00
10 :00
12 :00
14 :00
16 :00
18 :00
20 :00
22 :00
Monday
Tuesday Wednesday Thursday
Friday
Event 1
Event 1
Event 1
Event 1
Event 1
Saturday
Sunday
Event 3
Event 4
Event 2
Event 2
Event 2
Event 2
Event 2
Table 8. Events schedule
CG-PRB018-E4
35
12.3.3. Benefits
-
Allows the user to set up to ten events in a seven day time period.
Allows the customer to perform simple chiller scheduling without the need for a
building automation system.
This function gives a simple and reliable solution to control the chiller.
Energy saving as the user do not have to do daily set up.
-
Communication cards.
CG-PRB018-E4
36
12.4. BCI-C (BACnet Communication Interface) Digit 31 = 4

12.4.1. Application
-
When the unit needs to communicate with BACnet systems and devices.
12.4.2. Description
-
factory-installed in the chiller control panel.

There are three rotary switches on the front of the BCI-C device that are used to
define a three-digits address when the BCI-C is installed on a BACnet
communications network.
Illustration 33. BCI-C
Illustration 34. BCI-C layout
-
Used with CH530 main processor (MP) 2.00 and TechView 12.1 SP2 or higher.
-
LCI-C.
Time of day scheduling
CG-PRB018-E4
37
13.
External Chilled Water and Demand Limit Setpoint Digit 32
13.1. External Chilled Water and Demand Limit Setpoint with

4-20 mA Digit 32 = A
13.1.1. Application
-
When the chilled water setpoint needs to be set by sending an external signal.
When the number of compressors allowed to start needs to be limited in order
to control chiller power consumption by sending an external signal.
13.1.2. Description
-
CH530 accepts two 4-20 mA analog input suitable for customer connection to
set the unit external chilled water setpoint ( ECWS ) and the external demand
limit setpoint ( EDLS).
There is one input to reset the chilled water setpoint and one input to limit the
number of compressors allow to start.
13.1.3. Operation
-
External chilled water and demand limit setpoint set via the DynaView.
4-20 mA correspond to an external chilled water setpoint range with both
minimum and maximum external chilled water setpoint configurable.
4-20 mA correspond to an external demand limit setpoint range with a minimum

of 0% and a maximum of 100%.
If the power draw is exceeding set thresholds, this application can send a
demand limit request to the chiller.
For input signals beyond the 4-20mA range, the end of range value shall be
used. For example, if the customer inputs 21 mA, the external chilled water
setpoint and external demand limit setpoint shall limit itself to the corresponding
20 mA external chilled water setpoint/external demand limit setpoint.
13.1.4. Benefits
-
Provides external signals to set the chilled water setpoint and to limit the
number of compressor allowed to run.
Energy saving as the user do not need to set the application on site
CG-PRB018-E4
38
-
Analog input 2-10 VDC.

BCI-C.
13.2. External Chilled Water and Demand Limit Setpoint

2-10 VDC Digit 32 = B
13.2.1. Application
-
When the chilled water setpoint needs to be set by sending an external signal.
When the number of compressors allowed to start needs to be limited in order
to control chiller power consumption by sending an external signal.
13.2.2. Description
-
CH530 accepts two 2-10 VDC analog input suitable for customer connection to
set the unit external chilled water setpoint ( ECWS ) and the external demand
limit setpoint ( EDLS).
There is one input to reset the chilled water setpoint and one input to limit the
number of compressors allow to start.
13.2.3. Operation
-
External chilled water and demand limit setpoint set via the DynaView.
2-10 VDC correspond to an external chilled water setpoint range with both
minimum and maximum external chilled water setpoint configurable.
2-10 VDC correspond to an external demand limit setpoint range with a

minimum of 0% and a maximum of 100%.
If the power draw is exceeding set thresholds, this application can send a
demand limit request to the chiller.
For input signals beyond the 2-10 VDC range, the end of range value shall be
used. For example, if the customer inputs 11VDC, the external chilled water
setpoint and external demand limit setpoint shall limit itself to the corresponding
10 VDC external chilled water setpoint/external demand limit setpoint.
13.2.4. Benefits
CG-PRB018-E4
39
Provides external signals to set the chilled water setpoint and to limit the
number of compressor allowed to run.
Energy saving as the user do not need to set the application on site
-
Analog input 4-20 mA.

BCI-C.
Note : Both functions, the external chilled water setpoint (ECWS) and the
external demand limit setpoint (EDLS) can work at the same time.
13.3. Second leaving water temperature setpoint Digit 32 = C

This option is described in CGAM User Guide.
CG-PRB018-E4
40
14.
Percent Capacity digit 33 = 1
14.1. Application
-
To provide the customer generic BAS feedback about unit active capacity.
14.2. Description
-
A CH530 configuration option.
14.3. Operation
-
The CH530 provides an analog voltage output (2-10 VDC) to communicate

active unit capacity [%]. Current output (4-20 mA for example) is not available.
Output the number of compressors that are operating as an analog 2-10 VDC
signal.
If the unit has 2 compressors and it send an analog voltage of 2 VDC,no
compressor will be running. It means that the unit capacity is 0%. If the unit
receives 10 VDC, the unit capacity will be 100 % which means both
compressors will be running.
14.3.1. Example
Table 9. Number of compressors running depending on the voltage signal
Number of compressors
in the unit
2
4
6
Number of compressors allowed to run
2 Vdc
0
0
0
6 Vdc
1
2
3
10 Vdc
2
4
6
Unit Capacity vs Output signal

120
capacity %
100
80
60
40
20
0
0
10
12
output(VDC)
CG-PRB018-E4
41
14.4. Benefits
-
A customer without a communicating BAS interface will be able to get feedback

about the active unit capacity.
The information may be useful as a status indication or to perform load
shedding in high electrical demand scenarios.
14.5. Incompatibilities
-
No incompatibility.
CG-PRB018-E4
42
15.
Programmable Relays Digit 34 = A
15.1. Application
-
When certain events or states of the chiller need to be remotely controled.
15.2. Description
-
Use 4 output relays as shown in the field wiring diagram.

Factory installed, located in control panel.
Illustration 35. Relay output card
Illustration 36. Programmable output relays wiring diagram
CG-PRB018-E4
43
15.3. Operation
-
The relay will be energized when the event or state occurs.

Works with CH530.
CH530 (TechView) is used to install the Alarm and Status Relay Option
package and assign any of the above list of events or status to each of the four
relays provided.
Available outputs are Alarm-Latching, Alarm-Auto Reset, General Alarm,
Warning, Chiller Limit Mode, Compressor Running and Tracer Control.
The default assignments for the four available relays of the CGAM Alarm and
Status Package Option:
Relay
Relay 1 terminals J2-12,11,10:
Alarm and status

Compressor running
Latching alarm
Chiller limit
alarm
Table 11. Default assignments
Note : other events/states that can be assigned to the programmable relays can
be found in Installation Operation Maintenance
15.4. Benefits
-
Customers will be alerted if the events or states of the chiller occur.

Reduces maintenance works of the chiller
Customer can stop the chiller if the undesire events occur in order to
prevent the components from damages.
-
No incompatibilitiy.
CG-PRB018-E4
44
16.
Pump Type Digit 35 = 5, 6, 7, 8
Trane provides the same pump model to each unit according to unit size for high
efficiency and standard efficiency. WILO is the pump brand used by Trane for all units.
Unit Size
020
023
026
030
035
039
045
050
040
046
052
060
070
080
090
100
110
120
140
150
160
170
Single pump
Dual pump
Standard Head (Digit 35=5) High Head (Digit 35=6) Standard Head (Digit 35=7) High Head (Digit 35=8)
Wilo
Wilo
Wilo
Wilo
IPL50/120-1,5/2
IPL40/160-4/2
DPL50/120-1,5/2
DPL40/160-4/2
IPL50/120-1,5/2
IPL40/160-4/2
DPL50/120-1,5/2
DPL40/160-4/2
IPL50/120-1,5/3
IPL40/160-4/2
DPL50/120-1,5/3
DPL40/160-4/2
IPL50/120-1,5/4
IPL40/160-4/2
DPL50/120-1,5/4
DPL40/160-4/2
IPL50/120-1,5/5
IPL40/160-5,5/2
DPL50/120-1,5/5
DPL40/160-5,5/2
IPL50/130-3/2
IPL40/160-5,5/2
DPL50/130-3/2
DPL40/160-5,5/2
IPL50/130-3/3
IPL40/160-5,5/2
DPL50/130-3/2
DPL40/160-5,5/2
IPL50/130-3/2
IPL40/160-5,5/2
DPL50/130-3/2
DPL40/160-5,5/2
IPL65/120-3/2
IPL40/160-5,5/2
DPL65/120-3/2
DPL40/160-5,5/2
IPL65/130-4/2
IPL40/160-5,5/2
DPL65/130-4/2
DPL40/160-5,5/2
IPL65/130-4/2
IPL40/160-5,5/2
DPL65/130-4/3
DPL40/160-5,5/2
IPL65/130-4/2
IPL65/175(143)-7,5/2
DPL65/130-4/4
DPL65/175(143)-7,5/2
IPL65/140-5,5/2
IPL65/175(143)-7,5/2
DPL65/140-5,5/2
DPL65/175(143)-7,5/2
IPL65/140-5,5/2
IPL65/175(143)-7,5/2
DPL65/140-5,5/2
DPL65/175(143)-7,5/2
IPL65/140-5,5/2
IPL65/175(143)-7,5/2
DPL65/140-5,5/2
DPL65/175(143)-7,5/2
IPL65/140-5,5/2
IPL65/175(143)-7,5/2
DPL65/140-5,5/2
DPL65/175(143)-7,5/2
IPL80/155(127)-7,5/2
IPL65/175(143)-7,5/2
DPL80/155(127)-7,5/2
DPL65/175(143)-7,5/2
IPL80/155(127)-7,5/2
IL80/160-11/2
DPL80/155(127)-7,5/2
DL80/160-11/2
IL80/150-11/2
IL80/160-11/2
DL80/150-11/2
DL80/160-11/2
IL80/150-11/2
IL80/160-11/2
DL80/150-11/2
DL80/160-11/2
IL80/150-11/2
IL80/170(165)-15/2
DL80/150-11/2
DL80/170(165)-15/2
IL80/150-11/2
IL80/170(165)-15/2
DL80/150-11/2
DL80/170(165)-15/2
Table 12. Pump model for each unit size
To get more information on pump visit web site www.wilo.fr

When the unit is provided with two pumps, the pump needs to be interchanged
as only one pump is allowed to run at once. The control will alternate pump
operation each time the unit is allowed to start.
When the CGAM doesnt have the hydraulic module option, maximum water side working pressure is
10 bars (the safety valve is not provided).
With hydraulic module option, CGAM Slant & V models water side working pressure is
limited to 4 bars.
The safety valve limit this working pressure to 5 bars on CGAM W hydraulic module.
CG-PRB018-E4
45
16.1. Starter type for Pump Digit 35 = 1, 2, 3, 4

For pump protection, Trane uses TeSys U ( from Schneider Electric) which includes
contactor and overload protection. Each pump will be connected to one TeSys U.
Illustration 37. TeSys U for unit with single pump package
Illustration 38. TeSys U for unit with dual pump package
16.1.1. Benefits of TeSys U

-
Only one bloc with 2 functions, contactor and overload protection.

Reduces installation time in the electrical panel.
TeSys U has a different range of control for each unit type.(see table below)
Unit Size
Mini pump motor size
Maxi pump motor size
TeSys U range
CGAM Slant
CGAM V
1,5 kW
5,5 kW
3-12 A
2.2 kW
7.5 kW
4.5-18 A
5,5 kW
15 kW
8-32 A
080-090-100
110 to 170
Table 13. TeSys U range of control and pump power
2.
When the unit is provided with starters for dual pumps option, the pump needs
to be interchanged as only one pump is allowed to run at once. The control will
alternate pump operation each time the unit is allowed to start.
Pump Insulation
Pump insulation is factory provided.

Slant unit
V & W unit
Pump
insulation
Pump
insulation
Illustration 39. Insulation for pump and others
components in Slant unit
CG-PRB018-E4
Illustration 40. Insulation for pump and others

components in V and W unit.
46
17.
Pump Flow Control Digit 36
17.1. Pump Flow Controlled by Balancing Valve Digit 36 = A

17.1.1. Application
-
When the water flow has to be adjusted.

Used to adjust water flow and stop waterflow for servicing.
17.1.2. Description
-
Memory valve factory installed.

The water flow through the valve must be in the direction of the embossed
arrow on the body.
On site the service engineer set the postion of the valve to adjust the water
flow.
Memory valve
Illustration 41. Balancing valve

with memory valve
Illustration 42. Balancing valve

with memory valve
17.1.3. Operation
-
Balancing valve limits the flow.
17.1.4. Benefits
-
Low first cost.
-
Variable speed drive.

No pump package.
CG-PRB018-E4
47
17.2. Pump Flow Controlled by Variable Speed Drive Digit 36 = B

17.2.1. Application
-
When the water flow has to be adjusted by varying the speed of pump
Used to adjust water flow at a specified pressure drop and stop waterflow for
servicing.
Used to save energy on the pump consumption
17.2.2. Description
-
The inverter is factory installed in a separate box.

Also known as Variable Frequency Drive (VFD).
The speed input is controlled manually via the Variable Speed Drive (VSD).
The Run command is commanded by the CH530 controls.
Illustration 43. VSD box for V type unit
Illustration 44. VSD inverter
VSD box
17.2.3. Operation
-
Adjust the frequency of the power supply to the motor.

Pump control is most often performed by maintaining a pressure differential at a
selected point in the system.
The control point is selected to minimize overpressuring the system and to
ensure adequate flow at all critical loads.
17.2.4. Benefits
-
Controls the water flow.

Energy saving on the pump consumption.
Pay back time.
CG-PRB018-E4
48
-
Balancing valve.
No pump package.
17.2.6. More detail

17.2.6.1. Pump flow adjustment by Variable Speed Drive
Pump flow can be adjusted by 2 possibilities :
1) By adjusting the frequency of variable speed drive at site.
2) By sending to variable speed drive an external signal 2-10 V .
The frequency of variable speed drive will be corresponding to the
external signal.
External signal ( V )
2
10
Frequency (Hz)
30
50
Table 14. Pump frequency corresponds to external signal
Pump frequency vs External Signal

55
50
pump frequency (Hz)
45
40
35
30
25
20
15
10
5
0
0
10
12
External signal (V)
CG-PRB018-E4
49
17.2.6.2. Detailed example pay back time

This study is made to explain the difference between balancing valve option and
variable speed drive option. The study is carried out to estimate roughly how much we
can save by installing a variable speed drive vs the use of a balancing valve.
The function of variable speed drive is to vary the pumps motor frequency which
changes the pressure drop to the pump itself. For a pressure between 150 kPa and
250 kPa and a pressure decrease of 10 kPa, we have approximately 5% of reduction
in energy consumption
Example
A pump with reference number IPL40/160-5.5/2 has been chosen to carry out this
study. The starting pressure of the pump is about 175 kPa. We would like to reduce
the pressure to 155 kPa. Therefore, we have 20 kPa of diminution in pressure, which
means the energy consumption is saved about 10%.
Initial energy consumption = 5.5 kW
Saved energy = 10% * 5.5 = 0.5 kW
With variable speed drive, we can save 0.5 kW of energy consumption. For the
electricity consumption, we did an annual calculation.
Saving calculation :
Saving made over one year

=
Number of operating hours for one year
*
Energy saved (kW)
*
Electricity rate (kW/h)
Number of pumps operating hours for one year = 5000 h

Energy saved = 0.5 kW
Electricity rate = 0.15 /kWh
Saving made over one year thanks to variable speed drive = 5000 * 0.5 * 015
= 375
Comparison the price
Variable speed drive
= 570
Balancing valve
= 250
___________________________
= 320
CG-PRB018-E4
50
The difference price between variable speed drive and balancing valve is 320 .
However, the customer will get the pay back in one year with variable speed drive as
the customer will save 375 per year by using variable speed drive.
Another example
Number of pumps operating hours for one year = 2000 h
Energy saved = 0.5 kW
Electricity rate = 0.15 /h
Saving made over one year thanks to variable speed drive = 2000 * 0.5 * 015
= 150
Here, the customer will save 150 per year. The pay back time is around two years.
Conclusion
Most of the time pay back time is around one or two years.
CG-PRB018-E4
51
18.
Buffer Tank Digit 37 = 1
18.1. Application
-
Used to increase the chilled water circuit inertia.

Allows to meet the two minutes water loop circulation.
18.2. Description
-
It is factory-installed, located on the supply of water loop.

It is installed before the water pump so that water pump can circulate the
supplied water in buffer tank to the evaporator
Buffer tank
Water pump
Illustration 45. Hydraulic module water chart
For Simplex and Duplex V units, the buffer tank is mounted next to the chiller
while for Duplex W units, it is placed inside the unit. Water tank volume is given
in general data table of the selection guide.
Illustration 46. Buffer tank for

simplex unit
CG-PRB018-E4

duplex V unit

duplex W unit
52
Illustration 49. Installation

buffer -tank on Simplex

buffer tank on Duplex V

buffer tank on Duplex W
Tank water volume is given in general data tables of the selection guide.
18.3. Operation
-
Works only with pump package units.

With short water loops, the chilled water circuit inertia will be increased, thus it
reduces the compressors cycling.
18.4. Benefits
-
Ease of installation at the building site.

Increases the compressor life span.
Allows more accurate water temperature .
Saves energy as compared to hot gas bypass on the refrigerant circuit.
-
It is not available with chiller without hydraulic module.
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53
19.
Installation Accessories Digit 39
19.1. Elastomeric Isolators Digit 39 = 1

19.1.1. Application
-
Used to minimize the vibrations transmited to the building.
19.1.2. Description
-
They are installed under the condenser.

Shipped with the chiller.
Illustration 52. Isolators installed near the pump box
isolators
-
Eliminates vibration and noise transmission througout the building.
19.1.4. Incompatiblities
-
Neoprene pads.
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54
19.2. Neoprene Pads Digit 39 = 4

19.2.1. Application
-
Used to avoid direct contact of the chiller and the ground.
19.2.2. Description
-
They are installed under the chiller.

Shipped in the control panel.
Illustration 53. Neoprene pad
-
Avoid direct contact of the base frame with the ground.
19.2.4. Inconvenience
-
Neoprene pad do not filter vibrations.
-
Elastomeric isolators.
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55
20.
Water Strainer Digit 40 = A
20.1. Application
-
For a prevention of accumulation of the foreign particles in the restricted area

as the isolation valves and the brazed plate heat exchange.
20.2. Description
-
Factory-installed .
The strainer basket is in a lower position.
Mesh size = 1.6 mm.
Install on water inlet piping before the evaporator.
Illustration 54. Water strainer
Illustration 55. View of the water stariner
CG-PRB018-E4
56
20.3. Operation
-
Particules are retained in the filter.
direction of the water
filter
Illustration 56. Water strainer inside view
20.4. Benefits
-
Reduces chiller installation cost as it is factory-mounted.

Increases the life of heat exchanger and isolation valves.
Heat exchanger and isolation valves are protected.
Avoid the abrasive effect of flowing particles .
The customer do not have to dismount completely the strainer for cleaning or
changing the filter.
-
No incompatibility.
20.6. More detail

The isolation jacket for strainer is made in two parts. It means for the entire
isolation of strainer, the two parts of isolation jacket are attached by using
straps. Thus, during a maintenance work, when the filter of strainer needs to be
clean or changed, the client can easily removed the isolation jacket and reattaches it after the work is done.
The bond needs

to be cut off first
before removing
the isolation
jacket
Illustration 57. Isolation jacket for strainer.
CG-PRB018-E4
Illustration 58. Strap for attaching the two

parts of isolation jacket.
57
21.
Sound Attenuation Package Digit 41
All units are provided with the same type of fan.

21.1. Compact unit Digit 41 = 1
In this option, the compressor is not insulated (see page 9). The unit operates with the
speed of fans 920 RPM.
21.2. Super quiet unit Digit 41 = 3
The compressor is isolated with black jackets (see page 9). Black jackets give a first
attenuation level against compressor noise. With this option, the fan speed is
decreased to 700 RPM.
21.3. Super quiet with Night Noise setback Digit 41 = 4
The insulation of compressor is the same as in Super Quiet unit. The fans can rotate
at 700 RPM and when the unit is set into Night Noise setback at night, the fan speed is
decreased to 560 RPM. The unit can operate with the fan speed at 560 RPM with
38C of ambient temperature .
21.4. Comprehensive acoustic package unit Digit 41 = 5
Trane provides a compressor enclosure or box for compressors insulation (see page
9). The compressor enclosure give a highest level of sound attenuation. The unit is
provided with the same low noise fans as Super Quiet unit which means the fan speed
is 700 RPM.
CG-PRB018-E4
58
22.
Appearance Options Digit 42
22.1 No Appearance option Digit 42 = X

No louvered panel.
Illustration 59. Unit without architectural louvered panel
22.2. Architectural Louvered Panels Digit 42 = A

22.2.1. Application
-
When the unit needs to be installed in an open area.

When the unit needs to be protected (especially for the units components).
22.2.2. Description
-
The color is silver grey RAL 7001.

Factory-installed.
CGAM W
CGAM V
Illustration 60. Unit with architectural louvered panel
CG-PRB018-E4
59
22.2.3. Operation
-
Cover the complete condensing coil and service area of the unit.
22.2.4. Benefits
-
Easy integration on jobsite.

Ensure safety on sensitive site.
Protect the internal components of the unit from external element such as hail
stones and animals.
Prevent people to get injured.
Improve the esthetics of the units.
-
No incompatibility.
CG-PRB018-E4
60
23.
Phase Reversal Protection Digit 45
23.1. Digit 45= X

Each compressor needs to be protected from a phase reversal. The scroll compressor
in small CGAM sizes (020, 023, 026, 030, 040, 046, 052 and 060), dont have
integrated phase reversal protection modul, thus, in the electrical panel, a relay DPA
51 C M44 insures the phase reversal protection.
Illustration 62. Phase reversal protection modul
Scroll compressor sizes 15 to 30 tons (other unit sizes), have a motor phase reversal
protector, it is installed in every compressor terminal box.
Illustration 63. Phase reversal protection modul, installed in the compressor terminal box (motor protection)
23.2. Digit 45= 1

23.1.1. Application
-
A RM4 TR relay is used to control unit phase sequence and under/over voltage
protection.
23.1.2. Description
-
Factory installed, located in the control panel.

Only one relay for each unit.
CG-PRB018-E4
61
R Yellow LED: Indicates the relay state.

U Green LED: Indicates that the relay
power supply is on.
> U Red LED: Overvoltage fault.
< U Red LED: Under voltage fault.
P Red LED: Phase failure or phase
reversal.
Illustration 64. RM4 TR
Illustration 65. RM4 TR face layout
23.1.3. Operation
-
If any fault linked is detected, the compressor is stopped.

Overvoltage and undervoltage detection (RM4TR):
In normal operation, the relay is energized and LEDs U and R are lit.
If the average of the three voltages between phases fluctuates outside
the range to be monitored, the output relay is de-energized.
Overvoltage: the Red LED > U on
Under voltage: the Red LED < U on
23.1.4. Benefits
-
All motors are fully protected.

Relay RM4 TR provides a phase reversal protection and under/over
voltage protection
-
No incompatibility.
23.1.6. Summary
CG-PRB018-E4
62
24.
Shipping Package Digit 46
In standard, units are provided with wood skid, a treated wood located under the base
frame.
Illustration 66. Wood skid
24.1. Unit Containerization Package Digit 46 = A

In this option, units are always provided with wood skid installed under the chiller. In
addition, a pull key is installed at each corner of the base frame. The purpose of pull
keys is to unload easily the chiller from container without using directly a forklift to the
chiller.
Illustration 67. Pull key and wood skid

Illustration 68. Pull key at each corner
How unloading the chiller
Cables with hooks are attached to the pull keys

Use a forklift to pull the cables and then extract the chiller from the container.
Note : A yellow label will be affixed at the base frame to indicate that use
of forklift directly to unload the chiller is probihited.
CG-PRB018-E4
63
Annexe 1: Wilo pumps curves.

IPL and Il pump have the same curve as DPL and DL pump ranges working in
individual operation.
DPL or IL50/120-1,5/2
DPL or IL50/130-3/2
CG-PRB018-E4
64
DPL or IL65/120-3/2
DPL or IL65/130-4/2
CG-PRB018-E4
65
DPL or IL65/140-5,5/2
DPL or IL80/155(127)-7,5/2
CG-PRB018-E4
66
DPL or IL80/150-11/2
DPL or IL40/160-4/2
CG-PRB018-E4
67
DPL or IL40/160-5,5/2
DPL or IL65/175(143)-7,5/2
CG-PRB018-E4
68
DPL or IL80/160-11/2
DPL or IL80/170(165)-15/2
CG-PRB018-E4
69
25.
Acronyms
BPHE/BPHX
Brazed Plate Heat Exchanger
HR
Heat Recovery
ELWT
Evaporator Low Water Temperature
PHR
Partial Heat Recovery
PHR LWT
PHR Leaving Water Temperature
PHR EWT
PHR Entering Water Temperature
THR
Total Heat Recovery
THR LWT
THR Leaving Water Temperature
THR EWT
THR Entering Water Temperature
SCR
Silicon Controlled Rectifier
LCI-C
LonTalk Communication Interface
PIC
Protocol Interface Controller
BMS
Building Management System
BAS
Building Automation System
LLIDs
Low Level Intelligent Devices
IPC3
Intra Processor Communication
BCI-C
BACnet Communication Interface
MP
Main Processor
ECWS
External Chilled Water Setpoint
EDLS
External Demand Limit Setpoint
VFD
Variable Frequency Drive
VSD
Variable Speed Drive
CG-PRB018-E4
70
26.
Illustration List
Illustration 1. Range Overview ...............................................................................................................7

Illustration 2. CGAM range ....................................................................................................................8
Illustration 3. Compressors appearance for compact unit......................................................................9
Illustration 4. Black jackets cover the compressor for Super quiet unit ...................................................9
Illustration 5. Box is used to cover the compressors for comprehensive acoustic package ......................9
Illustration 6. Operating map for cooling only ...................................................................................... 11
Illustration 7. Pump package anti-freeze heater................................................................................... 12
Illustration 8. Heaters of buffer tank .................................................................................................... 12
Illustration 9. Blanket heater ............................................................................................................... 13
........................................................................................................................................................... 13
Illustration 10. Range of evaporator application option ....................................................................... 14
Illustration 11. Grooved pipe connection.............................................................................................. 16
Illustration 12. Grooved pipe with flange adapter ................................................................................ 16
Illustration 13. Grooved pipe and coupling ........................................................................................... 17
Illustration 14. Aluminum slit fin .......................................................................................................... 18
Illustration 15. Black epoxy fin ............................................................................................................. 19
Illustration 16. Installation BPHE for partial heat recovery in V type unit ............................................ 21
Illustration 17. Partial heat recovery system ........................................................................................ 21
Illustration 18. Water loop in partial heat recovery .............................................................................. 22
Illustration 19. Cooling priority map (ambient temperature VS PHR LWT) ............................................ 23
Illustration 20. Installation of THR components in the unit ................................................................... 24
Illustration 21. Total heat recovery system .......................................................................................... 25
Illustration 22. Water loop in total heat recovery ................................................................................. 25
Illustration 23. THR operating map ...................................................................................................... 26
Illustration 24. Circuit of direct on Line................................................................................................. 28
Illustration 25. Soft starter................................................................................................................... 28
Illustration 26. Solid-state soft starter installed for W unit ................................................................... 29
Illustration 27. PIC ............................................................................................................................... 31
Illustration 28. PIC layout .................................................................................................................... 31
Illustration 29. Installation of Modbus RS-232 ..................................................................................... 32
Illustration 30. Installation of Modbus RS-485 ..................................................................................... 32
Illustration 31. LCI-C card..................................................................................................................... 33
Illustration 32. The installation of LCI-C card, LCI-C LLID and IPC3 communication bus ribbon cable ..... 34
Illustration 33. BCI-C ............................................................................................................................ 37
Illustration 34. BCI-C layout ................................................................................................................. 37
Illustration 35. Relay output card......................................................................................................... 43
Illustration 36. Programmable output relays wiring diagram ............................................................... 43
Illustration 37. TeSys U for unit with single pump package ................................................................... 46
Illustration 38. TeSys U for unit with dual pump package ..................................................................... 46
Illustration 39. Insulation for pump and others components in Slant unit ............................................. 46
Illustration 40. Insulation for pump and others components in V and W unit. ....................................... 46
CG-PRB018-E4
71
Illustration 41. Balancing valve with memory valve.............................................................................. 47

Illustration 42. Balancing valve with memory valve.............................................................................. 47
Illustration 43. VSD box for V type unit ................................................................................................ 48
Illustration 44. VSD inverter ................................................................................................................. 48
Illustration 45. Hydraulic module water chart ...................................................................................... 52
Illustration 46. Buffer tank for simplex unit .......................................................................................... 52
Illustration 47. Buffer tank for duplex V unit ........................................................................................ 52
Illustration 48. Buffer tank for duplex W unit ....................................................................................... 52
Illustration 49. Installation buffer tank on Simplex ............................................................................... 53
Illustration 50. Installation buffer tank on Duplex V ............................................................................. 53
Illustration 51. Installation buffer tank on Duplex W ........................................................................... 53
Illustration 52. Isolators installed near the pump box ........................................................................... 54
Illustration 53. Neoprene pad .............................................................................................................. 55
Illustration 54. Water strainer ............................................................................................................. 56
Illustration 55. View of the water stariner............................................................................................ 56
Illustration 56. Water strainer inside view ......................................................................................... 57
Illustration 58. Strap for attaching the two parts of isolation jacket. .................................................... 57
Illustration 57. Isolation jacket for strainer. ......................................................................................... 57
Illustration 59. Unit without architectural louvered panel .................................................................... 59
Illustration 60. Unit with architectural louvered panel ......................................................................... 59
Illustration 62. Phase reversal protection modul .................................................................................. 61
Illustration 63. Phase reversal protection modul, installed in the compressor terminal box (motor
protection) .......................................................................................................................................... 61
Illustration 64. RM4 TR ........................................................................................................................ 62
Illustration 65. RM4 TR face layout ...................................................................................................... 62
Illustration 66. Wood skid .................................................................................................................... 63
Illustration 67. Pull key and wood skid ................................................................................................. 63
Illustration 68. Pull key at each corner ................................................................................................. 63
27.
Table List
Table 1. Compressor size in ton ........................................................................................................... 10

Table 2. Cooling only units (CGAM)...................................................................................................... 11
Table 3. PHR anti-freeze heater power ................................................................................................ 22
Table 4. THR anti-freeze heater power ................................................................................................ 25
Table 5. Inrush current ........................................................................................................................ 30
Table 6. Startup time (ms) ................................................................................................................... 30
Table 7. Connectors definition ............................................................................................................ 31
Table 8. Events schedule ..................................................................................................................... 35
Table 9. Number of compressors running depending on the voltage signal .......................................... 41
Table 11. Default assignments ............................................................................................................. 44
Table 12. Pump model for each unit size ............................................................................................. 45
Table 13. TeSys U range of control and pump power ........................................................................... 46
Table 14. Pump frequency corresponds to external signal ................................................................... 49
CG-PRB018-E4
72
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the
leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad
portfolio of advanced controls and HVAC systems, comprehensive building services, and parts.
For more information, visit www.Trane.com.
Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications
without notice.
2013 Trane All rights reserved
CG-PRB018-E4_0813 Supersedes CG-PRB018-E4 MAY 01, 2011
2011 Trane All rights reserved
CG-PRB018-E4
CG-PRB018-E4 MAI 01, 2011
73

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Options Guide

Air-cooled Liquid Chillers with Scroll

1.1. Aquastream 3G Air-cooled liquid chiller range ...................................................................7

17.2. Pump Flow Controlled by Variable Speed Drive Digit 36 = B ...............................................48

DPL or IL65/130-4/2 .................................................................................................................... 65

Aquastream 3G Air-cooled liquid chiller range

Illustration 1. Range Overview

Illustration 2. CGAM range

CGAM range is Eurovent certified

2.2. Super quiet and SQ + NNSB

2.3. Comprehensive acoustic package

Comp. Manifold CKT1

Comp. Manifold CKT2

Table 1. Compressor size in ton

Compressor staging pattern circuit 2

Explication on how compressor staging is done

Table 2. Cooling only units (CGAM)

Illustration 6. Operating map for cooling only

Freeze Protection(CH530) Digit 18 = 2

When the unit is exposed to ambient temperature between 0C and -18C.

An anti-freeze heater is installed in water pumps for pump freeze protection.

Illustration 8. Heaters of buffer tank

Freeze Protection digit 18 = X

Evaporator Application Digit 21

Low temperature processing

Illustration 10. Range of evaporator application option

Ice making Digit 21 = C

Initiating Ice Building (Ice Building Command)

The external ice building command binary input (optional).

Reduces or even replaces mechanical cooling durind the day

Water Connection Digit 22

Illustration 11. Grooved pipe connection

8.2. Grooved pipe connection with flange adapter digit 22 = 2

Illustration 12. Grooved pipe with flange adapter

Illustration 13. Grooved pipe and coupling

Condenser Fin Materiel Digit 23

Lanced Aluminum Fins Digit 23 = A

When the chiller is installed in standard condition

Aluminum fin is a standard fin used on all air-chillers.

Illustration 14. Aluminum slit fin

Increases the condenser and chiller performance.

Heat pump as it slows down defrost cycle

Non-lanced Aluminum Fins with Pre-coated Black Epoxy

When chiller is needed for coastal or salt mist environments.

Condenser black epoxy coated.

Illustration 15. Black epoxy fin

Aluminum fin is painted with black epoxy, it is covered by 3 layers of

Resin Polyurethane, color black

Lanced/slit aluminum fins.

Condenser Heat Recovery Digit 24

10.1. Partial Heat Recovery (PHR) Digit 24 = 2

When a portion of rejected heat around 25% needs to be recovered.

Illustration 16. Installation BPHE for partial heat recovery in V type

Illustration 17. Partial heat recovery

PHR anti-freeze heater power

Water piping PHR

Table 3. PHR anti-freeze heater power

10.1.3.1 How does Partial Heat Recovery ( PHR) work

PHR operating map

Ambient temperature (C) = 10 52 C

Illustration 19. Cooling priority map (ambient temperature VS PHR LWT)

Up to 25% heat recovered from the cooling/heating load.

Total heat recovery.