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Installation

Duplex Water-Cooled
Hermetic CenTraVac With
CH530 Controller

Cooling Only
Direct Drive with CH530 Control Panel

X396406690100

CDHF-SVN01A-EN

Warnings and
Cautions

Warnings and Cautions


Notice that warnings and cautions
appear at appropriate intervals
throughout this manual. Warnings
are provided to alert installing
contractors to potential hazards that
could result in personal injury or

death, while cautions are designed


to alert personnel to conditions that
could result in equipment damage.
Your personal safety and the proper
operation of this machine depend
upon the strict observance of these
precautions.

NOTICE:
Warnings and Cautions appear at appropriate sections throughout this manual.
Read these carefully.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
CAUTION Indicates a situation that may result in equipment or property-damage-only accidents.

2002 American Standard Inc. All rights reserved.

CDHF-SVN01A-EN

Contents

Warnings and Cautions

General Information

Water Piping

25

Vent Line Piping

36

Insulation

42

Electrical Information

44

Trane Supplied Starter

45

Customer Supplied Starter

46

Line Power Supply

48

PFCC

49

PFCC and Unit Mounted Starters

50

Remote Starter

51

Starter to UCP Control Wiring

53

Control Circuit Wiring

54

System Control Wiring

56

Wiring Diagrams

CDHF-SVN01A-EN

59

General Information

About this Manual

Product Description Block

Original date of manual:

Trane 60 Hz. Model CDHF hermetic


CenTraVac units are defined by the
product definition and selection
system (PDS). Each unit is defined by
the product description block which
appears on the unit nameplate. An
explanation of the PDS product code
is provided in the unit operation and
maintenance literature.

This manual contains information


regarding installation of Models
CDHF 60 Hz and CDHG 50 Hz chillers
equipped with Tracer CH530
controller. Reference is made to the
CDHF. All installation procedures
described for the CDHF apply also to
the CDHG. By carefully reviewing the
information in this manual and
following the instructions given
along with the submittal package
provided for the unit will assure that
the chiller is installed correctly.

CDHF-SVN01A-EN

General Information

Commonly Used Acronyms

Warnings and Cautions

ASME = American Society of


Mechanical Engineers
ASHRAE = American Society of
Heating, Refrigerant and Air
Conditioning Engineers

Notice that WARNINGS and


CAUTIONS appear at appropriate
intervals throughout this manual.
WARNINGS are provided to alert
installing contractors to potential
hazards that could result in personal
injury or death, while CAUTIONS are
designed to alert personnel to
conditions that could result in
equipment damage.

BAS = Building Automation System


LBU = La Crosse Business Unit
CABS = Auxiliary Condenser TubeBundle Size
CDBS = Condenser Bundle Size
CDSZ = Condenser Shell Size
CWR = Chilled Water Reset
DTFL = Delta-T at Full Load (i.e., the
difference between entering and
leaving chilled water temperatures at
design load)
EVBS = Evaporator Bundle Size
EVSZ = Evaporator Shell Size
GPM = Gallons-per-Minute
HVAC = Heating, Ventilating, and Air
Conditioning
IE = Internally Enhanced Tubes
IPC = Interprocessor Communication
PFCC = Power Factor Correction
Capacitor
PSID = Pounds-per-Square-Inch
(differential pressure)
PSIG = Pounds-per-Square-Inch
(gauge pressure)
UCP = Chiller Control Panel
CH530 = Tracer CH530 Chiller
Controller

Your personal safety and the proper


installation of this machine depend
upon the strict observance of these
precautions.

Unit Nameplate
The CDHF unit nameplate is located
on the left side of the left hand unit
control panel (UCP). A typical unit
nameplate is illustrated in Figure 1.
The following information is
provided on the CDHF unit
nameplate.
- Unit model and size descriptor
- Unit serial number
- Unit electrical requirements
- Correct operating charge and type
of refrigerant.
- Unit test pressures and maximum
operating pressures
- Unit Installation and Operation and
Maintenance manuals
- Product description block (identifies
all unit components and unit
design sequence used to order
literature and make other inquiries
about the unit).

Metric Conversion
The following conversions apply for
tables and charts in this manual,
In. x 2.54 = cm
Ft. x 30.48 = cm.
Lb. x .453 = kg.

CDHF-SVN01A-EN

General Information

Figure 1 Information from a Typical CDHF Unit Nameplate


MODEL: CDHF2000 DATE OF MFG (DD/MM/YY): @TODAY05
MODEL NO:
CDHF2000KR0TA2802745B0A106B0A1CFFRR10W4C0010330001S
SERIAL NO:
S.O. NO: SAMPLE
RATED VOLTAGE: 4160 VOLTS 60 HZ 3 PH
VOLTAGE UTILIZATION RANGE: 3744-4576 VAC
LH CIRCUIT RH CIRCUIT
MINIMUM CIRCUIT AMPACITY: 96 AMPS 103 AMPS
MAXIMUM OVERCURRENT
PROTECTIVE DEVICE: 150 AMPS 175 AMPS
COMPRESSOR MOTOR
MAX
VOLTS-AC HZ PH RLA KW LRAY
LH CIRCUIT 4160 60 3 75 480 400
RH CIRCUIT 4160 60 3 82 523 473
VOLT HZ PH
OIL TANK HEATER (LH&RH): 115 60 1 750 WATTS
CONTROL CIRCUIT (LH&RH): 115 60 1 4000 VA MAX
CARBON TANK HEATER (LH&RH):115 60 1 1.7 RLA
PUMPOUT COMPRESSOR(LH&RH): 115 60/50 1 1.55 RLA
PURGE COMP MTR(LH&RH): 115/110 60/50 1 8RLA 34.6LRA
WHEN MOTOR CONTROLLER PROVIDED BY OTHERS
TRANE ENGINEERING SPEC. S6516-0513 APPLIES
REFRIGERANT SYSTEM
LH RH
FIELD CHARGED WITH:
1850 1850 LBS. OF R-123
ACTUALLY CHARGED WITH:
LBS. OF R-123
MAXIMUM WORKING PRESSURE: 15 15 PSIG HIGH SIDE
MAXIMUM WORKING PRESSURE: 15 15 PSIG LOW SIDE
FACTORY TEST PRESSURE:
HIGH SIDE 45 PSIG LOW SIDE 45 PSIG
FIELD LEAK TEST PRESSURE 8 PSIG MAX.
TESTED AT PSIG
MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING
U.S. PATENTS: 4232533 4686834 4689967 4715190
4751653 4800732 5031410 5056032 5058031 5355691
5434738 5537830 5553997 5563489 5600960 5675978
5836382 5848538 6065297 6098422 6250101
SERVICE LITERATURE
INSTALLATION MANUAL:
CDHF-SVN01A-EN
OPERATION/MAINTENANCE MANUAL: CDHF-SVU01A-EN
PRODUCT DESCRIPTION:
TVSQ
1
CTM1 75
CTM2
MODL CDHF
DSEQ R0
HRTZ 60
CPM1 512
CPD2 274
EVSZ 210D
EVTH 35
EFLD WATE
EVWC STD
EVPR 150
CDSZ 210D
CDBS 1900
CFLD WATE
CDWT MAR
CDPR 150
CDCO VICT
ORC2 1265
AGLT UL
WCNM BNMP
CNIF CH53
TRMM TRM4
EPRO YES
ASCL OUTS
APTY STD
SOPT 3RTD
GENR NO

PTON 1975
100
NTON 2000
CPD1 280
EVBS 1850
EVWT MAR
EVCO VICT
CDTM TECU
CDWP 1
CDWA LFRF
TEST CWSP
OPST YES
CDRP YES
SRT1 CXL

VTR1
MAC1
VOLT 4160
CPM2 588
EVTM TECU
EVWP 1
EVWA RRLR
CDTH 35
CDWC STD
ORC1 1265
TTOL SPCL
WPSR WFC
SPKG DOM
SRT2 CXL

165
6

VTR2
MAC2

165
6

CDHF-SVN01A-EN

General Information

Responsibilities of Installing
Contractors
For your convenience, a summary of
the contractor responsibilities
typically associated with the chiller
installation process is provided
below. Table 1 further categorizes
these responsibilities by
differentiating between Tranesupplied and field-supplied and field
installed components.
Refer to the Installation section of
this manual for more detailed
instructions.
Locate and maintain the loose
parts, i.e. isolators, bulb wells,
temperature sensors, flow sensors
or other factory-ordered field
installed options, for installation as
required. Loose parts are located in
the starter panel on units with
factory-installed unit-mounted
starters or in the motor terminal
box for units with remote-mounted
starters.
Install unit on a foundation with flat
support surfaces level within 1/16,
and of sufficient strength to
support concentrated loading.
Place manufacturer-supplied
isolation pad assemblies under
unit. (Use spring isolators for upper
floor installations).
Install unit per applicable Trane
installation manual.
Complete all water piping and
electrical connections.

CDHF-SVN01A-EN

Note: Field-piping must be arranged


and supported to avoid stress on the
equipment. It is strongly
recommended that the piping
contractor refrain from piping closer
than 3-0 minimum to the
equipment. This will allow for proper
fit-up upon arrival of the unit at the
jobsite. Any adjustment that is
necessary can be made to the piping
at that time.
Where specified, supply and install
valves in water piping upstream
and downstream of evaporator and
condenser water boxes to isolate
shells for maintenance, and to
balance/trim system.
Supply and install flow switches (or
equivalent devices) in both chilled
water and condenser water piping.
Interlock each switch with proper
pump starter to ensure unit can
only operate when water flow is
established.
Supply and install taps for
thermometers and pressure
gauges in water piping adjacent to
inlet and outlet connections of both
evaporator and condenser.
Supply and install drain valves on
each water box.
Supply and install vent cocks on
each water box.
Where specified, supply and install
strainers ahead of all pumps and
automatic modulating valves.
Supply and install pressure relief
piping from pressure-relief rupture
disc to atmosphere.

If necessary, supply sufficient


Refrigerant-HCFC-22 (maximum of
1 lb. per machine) and dry nitrogen
(8 psig per machine) for pressure
testing under manufacturers
supervision.
Start unit under supervision of a
qualified service technician.
Where specified, supply and
insulate evaporator and any other
portions of machine as required to
prevent sweating under normal
operating conditions.
Unit-Mounted Starters Only,
remove top of starter panel and cut
access area for line-side wiring;
front left quadrant of top provides
recommended access to starter
lugs.
Supply and install wire terminal
lugs to starter.
Unit-Mounted Starters Only,
Supply and install field wiring to
line-side lugs of starter.
Supply and install a Refrigerant
Monitor per ASHRAE 15
specifications. Reference the
compliance to ASHRAE Standard
15 as shown on the Model
CenTraVac Checksheet and
Request for Serviceman.
To obtain a copy of Model
CenTraVac Checksheet and Request
for Serviceman (Form 1-27.08-6)
order from your local Trane office.

General Information

Table 1 Installation Requirements


Type of
Trane-Supplied
Requirement
Trane-Installed
Rigging
Isolation
Electrical

A. Circuit breakers or
fusible disconnects
(optional)
B. Unit-mounted
starter (optional)
C. PFCCs (optional)

Water Piping

Rupture Disc
Insulation

A. Rupture disc assy


A. Insulation (Optional)

Trane-Supplied
Field-Installed

Field-Supplied
Field-Installed
A. Safety chains
B. Clevis connectors
C. Lifting beam
A. Isolation pads or spring isolators

A. Isolation pads or
spring isolators
A. Jumper bars
A. Circuit breakers or fusible
B. Temperature sensor
disconnects (optional)
(optional outdoor air) B. Remote-mounted starter
C. Flow switches (may
C. PFCCs (Remote-mounted
be field supplied)
starter option only)
D. Terminal lugs
E. Ground connection(s)
F. Jumper bars
G. BAS wiring (optional)
H. IPC wiring (remotemounted starters only
I. Control voltage wiring
(remote-mounted starters only)
J. Oil pump interlock wiring
(remote-mounted
starters only)
K. High condenser pressure
interlock wiring
(remote-mounted starters only).
L. Chilled water pump contactor
and wiring
M.Condenser water pump
contactor and wiring
N. Option relays and wiring
(See Table 14 & 16)
A. Flow switches (May
A. Thermometers
be field supplied)
B. Water flow pressure gauges
C. Isolation and balancing valves
water piping
D. Vents and drain valves
(1 each per class)
E. Pressure-relief valves
(for water boxes as required)
A. Vent line and flexible connector
A. Insulation

CDHF-SVN01A-EN

General Information

Unit Shipment
Each chiller ships from the factory as
a hermetically assembled package; it
is factory piped, wired and tested. All
openings are covered or plugged to
prevent contamination during
shipment and handling.
See Figure 2 for an illustration of a
typical unit and its components. As
soon as the unit arrives at the job
site, inspect it thoroughly for
damage and material shortages. In
addition:
1. Verify the chillers hermetic
integrity by checking the
evaporator pressure for an
indication of holding charge
pressure.
Note: Since there are two refrigerant
circuits end must be checked.

CDHF-SVN01A-EN

To prevent damaging moisture from


entering the unit and causing
corrosion, each chiller is pressurized
with dry nitrogen before shipment.
Note: The holding charge should
register approximately 5 psig (at sea
level) on the gauge. If the charge has
escaped, contact your local Trane
sales office for instructions.
2. Check the oil sump sight glasses
to verify that the sump was
factory-charged with 9 gallons of
oil. If no oil level is visible, contact
your local Trane sales office.
3. Compare the unit nameplate data
(including electrical characteristics)
with the corresponding ordering
and shipping information to verify
that the correct unit was shipped
to the job site.
If a thorough inspection of the
chiller reveals damage or material
shortages, be sure to file these
claims with the carrier
immediately. Specify the extent
and type of damage found, and
notify the appropriate Trane sales
representative. Do not install a
damaged unit without the sales
representatives approval!

Storage
If the chiller will be stored at the job
site for an extended period of time
before it is installed, exercise these
precautionary measures to protect
the unit from damage:
1. Do not remove the protective
coverings factory-installed on the
control panel and compressor
inlet vane actuator for shipment.
2. Store the chiller in a dry vibration
free and secure area. If factory
insulated, protect chiller from
prolonged exposure to sunlight.

CAUTION
To prevent damage to the factoryinstalled insulation, do not allow
excessive exposure to sunlight.
3. Periodically check the condenser
and evaporator pressure to verify
that the 5 psig dry nitrogen at 72F
ambient holding charge is still in
the chiller. If this charge escapes,
contact a qualified service
organization and the Trane sales
engineer that handled the order.
Note: The storage range for the
microcomputer-based devices in the
unit control panel is -40F to 158F
(-40C to 70C).

General Information

Figure 2 Typical CDHF Chiller

10

CDHF-SVN01A-EN

General Information

Recommended Unit
Clearances
Adequate clearance around and
above the chiller is required to allow
sufficient access for service and
maintenance operations.
Figure 3 illustrates the
recommended clearances for units
with and without options. Figure 4
shows tube bundle locations. Notice
that, in each instance, the minimum
vertical clearance above the chiller is
3-feet.
In addition, be sure to provide at
least 3-feet of working space in front
of the unit control panel to satisfy the
National Electrical Code, and/or local
codes.
Important! Do not install piping or
conduit above the compressor
motor assembly or behind the
suction elbow!
Note: Specific unit clearance
requirements are also indicated in
the submittal package provided for
your unit.

Operating Environment
Besides assuring that the site
selected for chiller installation
provides the necessary clearances,
consider the equipments operating
environment.
To assure that electrical components
operate properly, do not locate the
chiller in an area exposed to dust,
dirt, corrosive fumes, or excessive
heat and humidity. Note that the
maximum ambient temperature for
chiller operation is 95 to 100F (35 38 C).

CDHF-SVN01A-EN

CAUTION
Equipment Failure
CDHF operation at ambient
temperatures exceeding 100F
(38C) can fatigue the units rupture
disc, causing it to break at a reduced
refrigerant pressure (i.e., <15 psig).
Starter component damage can also
occur because of the panels inability
to dissipate heat adequately.
If any of these adverse operating
conditions are present, take
whatever action is necessary to
improve the equipment room
environment.

Foundation Requirements
Provide rigid, non-warping
mounting pads or a concrete
foundation as a mounting surface for
the chiller. Ensure that the base is of
sufficient strength and mass to
properly support the chiller at its full
operating weight (i.e., including
completed piping, and full operating
charges of refrigerant, oil and water).
For your convenience, a summary of
standard unit shipping and operating
weights is provided in Table 2.
Notice that the floor loading for all
sizes of chillers is 60 pounds per
square inch.
To assure proper unit operation, the
chiller must be level within 1/16
over its length and width when set
into place on the mounting surface.
Trane will not assume responsibility
for equipment problems resulting
from an improperly designed or
constructed foundation.

11

General Information

Figure 3 Clearance Requirements for Standard CDHF

Notes:
1. Per NEC Article 110 - Unit mounted starters from 0-600V require 42" clearance; 601-2500V require 48" clearance;
2501-9000V require 60" clearance.
2. Clearance 1 can be at either end of machine and is required for tube pull clearance
Clearance 2 is always at the opposite end of machine from Clearance1 and is required for service clearance
3. Clearance requirement for evaporator tube removal does not include water box. Add water box dimension to this
figure.

UCP Clearance Requirements for Standard CDHF


Shell
210 D
250 D
250 M
250 X

12

Width
130.875
142.625
142.625
142.625

Entire Width
184.875
196.625
196.625
196.625

Height
132.750
136.875
141.375
141.375

Length
258.000
258.000
312.000
360.000

Entire Length
606.000
606.000
714.000
810.000

CL1
Clearance 1
264.000
264.000
318.000
366.000

CL2
Clearance 2
84.000
84.000
84.000
84.000

CDHF-SVN01A-EN

General Information

Figure 4 Tube Bundle Locations for Model CDHF Units

Cooling Only and Free Cooling Units


EVSZ
CDSZ
A
B
210 D
210 D
4-5-7/16"
5"-3/8"
250 D
250 D
5-0-3/4"
5"-1/4
250 M
250 M
5-0-3/4"
5"-1/4
250 X
250 X
5-0-3/4"
5"-1/4

CDHF-SVN01A-EN

C
7-9/16"
6"-1/2
6"-1/2
6"-1/2

D
1-4-1/4"
1-7-1/4"
1-7-1/4"
1-7-1/4"

E
5-0-1/8"
5-8-3/4"
5-8-3/4"
5-8-3/4"

F
3-5-1/4"
3-10-5/8"
3-10-5/8"
3-10-5/8"

G
2-5"
2-4-1/8"
2-4-1/8"
2-4-1/8"

H
3-10-3/16"
3-11-5/8"
3-11-5/8"
3-11-5/8"

13

General Information

Table 2 Typical Shipping and Operating Weights


Operating Weight
TYPE
NTON
CPKW
EVSZ
CDSZ
(lbs)
(kg)
CDHF
1500-2000
957
210D
210D
80171
36366
CDHF
2100-2500
1228
250D
250D
93186
42269
CDHG
1250-1750
716
210D
210D
82349
37354
CDHG
2150
892
250D
250D
96964
43983
CDHF
3000
1340
250M
250M
106659
48381
CDHF
3500
1340
250X
250X
114445
51912
Notes:
Weights shown above are accurate within +/- 3% and are based on the following
Operating weights include refrigerant, oil charge and water
Shells are with largest bundles and TECU .028 wall tubes
Compressor weight with medium voltage motor and above CPKW
Starter weights not included
Waterboxes are 1 pass, 150 psig Non-Marine
For other configurations refer to submittal package

14

Shipping Weight
(lbs)
(kg)
68629
31130
79213
35931
70807
32118
82991
37645
89425
40563
95077
43127

CDHF-SVN01A-EN

General Information

Note: Immediately report any unit


damage incurred during handling or
installation at the job site to the
Trane sales office.

Rigging
Lifting is the recommended method
for moving chillers. Suggested lifting
arrangements for standard units are
illustrated in Figure 5.
Note that each of the cables used to
lift the unit must be capable of
supporting the entire weight of the
chiller. (See Table 2 for unit shipping
and operating weights.) Notice that
the lifting beam used to lift the unit
must be at least 23 feet long.
See Figure 5 and Table 2 for
guidance in selecting cable or sling
lengths.

WARNING!
Test Lift
Verify chiller remains horizontal.
To avoid serious injury and possible
equipment damage, lift the chiller
horizontally; use the lifting
arrangement and rigging shown in
Figure 5.

To lift the chiller properly, insert


clevis connections at the points
indicated in Figure 5; a 2-1/2
diameter lifting hole is provided at
each of these points. Next, attach the
lifting cables or slings.
Once the lifting cables are in place,
attach a safety cable or sling
between the first-stage casting of the
compressor and the lifting beam. To
do this, remove a retaining bolt from
the compressor first-stage casting
and replace it with an eyebolt, or
swivel clevis.
Note: There should not be tension
on this safety cable; it is used only to
prevent the unit from rolling during
the lift.
When the lift is completed, detach
the clevis connections and safety
chain, then remove the eyebolt that
was used to secure the safety chain
to the compressor, and reinstall the
retaining bolt in its place. If the chiller
cannot be moved using the
conventional rigging method just
described, consider these points.
1. If job site conditions require
rigging of the chiller at an angle
greater than 45 from horizontal
(end-to-end), dowel-pin the compressor and remove it from the
unit. Be sure to contact a qualified
service organization for specific
rigging instructions.

2. When lifting the chiller is either


impractical or undesirable, attach
cables or chains to the jacking
slots shown in Figure 5; then push
or pull the unit across a smooth
surface. Should the chiller be on a
shipping skid, it is not necessary to
remove the shipping skid from the
chiller before moving it into place.

CAUTION
To prevent possible equipment
damage, do not use a fork lift to
move the chiller!

CAUTION
Lifting the compressor/motor
assembly from the shells without
factory-installed doweling in the
compressor casting flanges may
result in misalignment of the
compressor castings.
3. Position isolator pads (or spring
isolators) beneath the chiller feet;
see Unit Isolation section for
instructions.
4. Once the isolators are in place,
lower the chiller; again, work from
end to end in small increments to
maintain stability.

CAUTION
Oil Loss
To prevent oil migration out of the
oil tank during lifting procedures,
remove the oil from the oil tank if
the unit will be lifted at any angle
greater than 15 from horizontal
end-to-end. If oil is allowed to run
out of the oil tank into other areas of
the chiller, it will be extremely
difficult to return the oil to the oil
tank even during operation.

CDHF-SVN01A-EN

15

General Information

Figure 5 Recommended Lifting Arrangements for CDHF


Y
X

LIFTING BEAM

A
Safety Chain

Safety
Chain

H
B
C

Jacking Points

TYPE
CDHF
CDHF
CDHG
CDHG
CDHF
CDHF

NTON
1500-2000
2100-2500
1250-1750
2150
3000
3500

EVSZ
210D
250D
210D
250D
250M
250X

CDSZ
210D
250D
210D
250D
250M
250X

X
143 in.
143 in.
143 in.
143 in.
172 in.
199 in.

Y
23 ft
23 ft
23 ft
23 ft
27.5 ft
31.5 ft

H
25.5 in
24.5 in
25.5 in
24.5 in
24.5 in
24.5 in

Notes:
1. Lifting chains (or cables) are not the same length between point A and B, or between points A and C. Adjust as
necessary for an even lift.
2. Lifting holes provided on chillers to attach chains are 2 1/2 inch in diameter.
3. Attach safety chain (or cable) as shown, and without tension. The safety chain is not used for lifting, but is there to
prevent the unit from rolling.
4. Do not fork-lift the unit.

16

CDHF-SVN01A-EN

General Information

Unit Isolation

Isolation Pads

To minimize sound and vibration


transmission through the building
structure - and to assure proper
weight distribution over the
mounting surface, always install
isolation pads or spring isolators
under the chiller feet.

When the unit is ready for final


placement, position isolation pads
under the chiller feet as shown in
Figure 7.

Note: Isolation pads (Figure 6) are


provided with each chiller unless
spring isolators are specified on the
sales order.
Note: The center support is
approximately is 1/2 inches shorter
(higher) than the end supports. After
unit leveling, shim the center isolator
pads. If spring isolators are used,
shim the isolators for the center
support. See Figure 7.
Specific isolator loading data is
provided in the unit submittal
package. If necessary, contact your
local Trane sales office for further
information.

Remember that the chiller must be


level within 1/16 over its length and
width after it is lowered onto the
isolation pads. In addition, all piping
connected to the chiller must be
properly isolated and supported so
that it does not place any stress on
the unit.

Spring Isolators
Spring isolators should be
considered whenever chiller
installation is planned for an upper
story location. Base isolator selection
and placement on the information
presented in Figures 8-10a. (Notice
that 3 types of spring isolators - each
with its own maximum loading
characteristics are used with CDHF
chillers).

Important! When determining


placement of isolation pads or spring
isolators, remember that the control
panel side of the unit is always
designated as the unit front.

Spring isolators typically ship


assembled and ready for installation.
To install and adjust the isolators
properly, follow the instructions
given.
Note: Do not adjust the isolators
until the chiller is piped and charged
with refrigerant and water.
1. Position the spring isolators under
the chiller as shown in Figures 8
and 9. Make sure that each isolator
is centered in relation to the tube
sheet.
Note: Spring isolators shipped with
the chiller are not identical! Be sure
to compare the data provided in the
unit submittal package and Figures 8
through 10a to determine proper
isolator placement.
2. Set the isolators on the sub-base;
shim as necessary to provide a
flat, level surface at the same
elevation for the end supports,
and approximately 1/2" higher for
the center support. Be sure to
support the full underside of the
isolator base plate; do not straddle
gaps or small shims.

Figure 6 Isolation Pad

5/16-3/8"
[8-10 mm]

CDHF-SVN01A-EN

17

General Information

Figure 7 Isolation Pad Placement - CDHF, CDHG

Important:
Center support is 1/2" (13mm) shorter than end supports. Requires 1/2" steel shim under pad for Center
Support at installation after leveling.
TYPE
CDHF
CDHF
CDHG
CDHG
CDHF
CDHF

NTON
1500-2000
2100-2500
1250-1750
2150
3000
3500

CPKW
957
1228
716
892
1340
1340

EVSZ
210D
250D
210D
250D
250M
250X

CDSZ
210D
250D
210D
250D
250M
250X

TYPE
NTON
CPKW
EVSZ
CDSZ
CDHF
1500-2000
957
210D
210D
CDHF
2100-2500
1228
250D
250D
CDHG
1250-1750
716
210D
210D
CDHG
2150
892
250D
250D
CDHF
3000
1340
250M
250M
CDHF
3500
1340
250X
250X
Notes:
Isolator pad loading is based on the following
Operating weights include refrigerant, oil charge and water
Shells are with largest bundles and TECU .028 wall tubes
Compressor weight with medium voltage motor and above CPKW
Starter weights not included
Waterboxes are 1 pass, 150 psig Non-Marine
For other configurations refer to submittal package
18

Isolation Pad Loading (lb)


Left Pad
Center Pad
Right Pad
25150
26718
28304
29292
31056
32838
25997
27446
28907
30680
32317
33967
33527
35546
37586
35975
38140
40330
Isolation Pad Loading (kg)
Left Pad
Center Pad
Right Pad
11408
12119
12839
13287
14087
14895
11792
12449
13112
13916
14659
15407
15208
16123
17049
16318
17300
18294

CDHF-SVN01A-EN

General Information

Figure 8 Spring Isolator Placement - CDHF, CDHG

TYPE
CDHF
CDHF
CDHG
CDHG
CDHF
CDHF

NTON
1500-2000
2100-2500
1250-1750
2150
3000
3500

CPKW
957
1228
716
892
1340
1340

EVSZ
210D
250D
210D
250D
250M
250X

CDSZ
210D
250D
210D
250D
250M
250X

LF
14120
13861
14432
14413
15865
17023

Estimated Spring Isolator Loading (lb)


MF
RF
LR
MR
14948
15785
11029
11770
14721
15591
15431
16334
15193
15960
11564
12253
15209
16012
16267
17108
16850
17845
17663
18696
18080
19148
18952
20060

Estimated Spring Isolator Loading (kg)


TYPE
NTON
CPKW
EVSZ
CDSZ
LF
MF
RF
LR
MR
CDHF
1500-2000
957
210D
210D
6405
6780
7160
5003
5339
CDHF
2100-2500
1228
250D
250D
6287
6678
7072
7000
7409
CDHG 1250-1750
716
210D
210D
6546
6892
7239
5246
5558
CDHG
2150
892
250D
250D
6538
6899
7263
7379
7760
CDHF
3000
1340
250M
250M
7196
7643
8095
8012
8480
CDHF
3500
1340
250X
250X
7722
8201
8686
8597
9099
Notes:
Vibration isolator loading is based on the following
Operating weights include refrigerant, oil charge and water
Shells are with largest bundles and TECU .028 wall tubes
Compressor weight with medium voltage motor and above CPKW
Starter weights not included
Waterboxes are 1 pass, 150 psig Non-Marine
For other configurations refer to submittal package

CDHF-SVN01A-EN

RR
12519
17247
12947
17955
19741
21182

RR
5679
7823
5873
8145
8954
9608

19

General Information
Figure 9 Chiller Foot/Isolator Orientation
Side View of Unit
Center tube sheet
support leg

End View of Unit


Outside edge of
tube sheet

End of tube
sheet

Center of
Isolator Spring
Note: The spring isolator must be centered in relation
to the tube sheet. Do not align the isolator with the
flat part of the chiller foot, because the tube sheet is
often off-center.

3. If required, bolt the isolators to the


floor through the slots provided,
or cement the pads.
Note: Fastening the isolators to the
floor is not necessary unless
specified.
4. If the chiller must be fastened to
the isolators, insert capscrews
through the chiller base and into
the holes tapped in the upper
housing of each isolator. However,
do not allow the screws to
protrude below the underside of
the isolator upper housing. An
alternative method of fastening
the chiller to the isolators is to
cement the neoprene pads.

20

Note: Place isolator near outside


edge of tube sheet as shown.

5. Set the chiller on the isolators;


refer to Rigging for lifting
instructions.
The weight of the chiller will force
the upper housing of each isolator
down, perhaps causing it to rest
on the isolators lower housing.
(Figure 10, 10a illustrates spring
isolator construction.)
6. Check the clearance (labeled X in
Figure 10, 10a ) on each isolator. If
this dimension is less than 1/4 on
any isolator, use a wrench to turn
the adjusting bolt one complete
revolution upward.
Note: When the load is applied to
the isolators (Step 5), the top plate
of each isolator moves down to
compress the springs until either:
a. The springs support the load; or
b. The top plate rests on the
bottom housing of the isolator.
1. If the springs are supporting
the load, screwing down on
the adjusting bolt (Step 7) will
immediately begin to raise
the chiller.

7. Turn the adjusting bolt on each of


the remaining isolators to obtain
the required minimum clearance
at X (Figure 10, 10a ) of 1/4.
8. Once the minimum required
clearance is obtained on each of
the isolators, level the chiller by
turning the adjusting bolt on each
of the isolators on the low side of
the unit. Be sure to work from one
isolator to the next. Remember
that the chiller must be level to
within 1/16: over its length and
width, and that clearance X of
each isolator must be at least 1/4
inch.

CDHF-SVN01A-EN

General Information

Figure 10 Typical Spring Isolator Types and Construction


Type CT-4 Spring Isolators

5/8" [16 mm]


9-1/4"
[235 mm]
C-C
foundation
bolts

7-1/2" [191 mm]


10-1/4"
[260 mm]

Adjusting Bolt
Adjust the isolator so
that the upper
housing clears the
lower housing by at
least 1/4 [6 mm]

6-1/2" [165 mm]


Free Height

Acoustical nonskid
neoprene pad (top
and bottom)

Isolator
Type
and Size
CT-4-25
CT-4-26
CT-4-27
CT-4-28
CT-4-31
CT-4-32

Maximum
Load
(lbs.)
1,800
2,400
3,000
3,600
4,400
5,200

Deflection
(Inches)
1.22
1.17
1.06
1.02
0.83
0.74

Spring
Color
Coding
Red
Purple
Orange
Green
Gray
White

Isolator
Type
and Size
CT-4-25
CT-4-26
CT-4-27
CT-4-28
CT-4-31
CT-4-32

Maximum
Load
(Kg)
816
1,089
1,361
1,633
1,996
2,359

Deflection
(mm)
31
30
27
26
21
19

Spring
Color
Coding
Red
Purple
Orange
Green
Gray
White

Isolator
Type
and Size
CT-7-25
CT-7-26
CT-7-27
CT-7-28
CT-7-31
CT-7-32

Maximum
Load
(lbs.)
3,150
4,200
5,250
6,300
7,700
9,100

Deflection
(Inches)
1.22
1.17
1.06
1.02
0.83
0.74

Spring
Color
Coding
Red
Purple
Orange
Green
Gray
White

Isolator
Type
and Size
CT-7-25
CT-7-26
CT7-27
CT-7-28
CT-7-31
CT-7-32

Maximum
Load
(Kg)
1,429
1,905
2,381
2,858
3,493
4,128

Deflection
(mm)
31
30
27
26
21
19

Spring
Color
Coding
Red
Purple
Orange
Green
Gray
White

Type CT-7 Spring Isolators

5/8"
[16 mm]
7-1/4"
[184 mm]

8-3/4" [222
mm] C-C
foundation
bolts

6-5/8" [168
mm] Free
Height

9-3/4"
[248 mm]
Adjust the isolator so that
the upper housing clears the
lower housing by at least
1/4 [6 mm]
5/8"
[16 mm]

Adjusting Bolt
Acoustical nonskid
neoprene pad (top
and bottom)

CDHF-SVN01A-EN

21

General Information

Figure 10A Typical Spring Isolator Types and Construction


CT-12 Spring Isolators
14-3/4" [375 mm]
7-3/8" [187 mm]
12-1/2"
[318 mm]
6-1/2"
[165 mm]

Isolator
Max
Type/Size Load lb (kg)
CT-12-25
5,400
CT-12-26
7,200
CT-12-27
9,000
CT-12-28
10,800
CT-12-31
13,200
CT-12-32
15,600

Deflection
Spring
inches (mm) Color Code
1.22
Red
1.17
Purple
1.06
Orange
1.02
Green
0.83
Gray
0.74
White

3-1/2"
[89 mm]
7"
[178
mm]

5/8"
[16 mm]
6-5/8"
[168 mm]
13-1/4" [337 mm]

(2) Adjusting Bolts

Adjust the isolator so that


the upper housing clears the
lower housing by at least
1/4 [6.4 mm]

8-1/8" [206
mm] Free
Height

5/8"
[16 mm]

22

Acoustical nonskid
neoprene pad (top
and bottom)

CDHF-SVN01A-EN

General Information

CT-16 and CT20


Spring Isolators

CDHF-SVN01A-EN

Isolator
Type/Size
CT 16-26
CT 16-27
CT 16-28
CT 16-31
CT 16-32

Max
Deflection
Spring
Load lb (kg) inches (mm) Color Code
9600 (4355)
1.17 (29.7)
Purple
12000 (5443)
1.06 (26.9)
Orange
14400 (6532)
1.02 (25.9)
Green
17600 (7983)
0.83 (21.1)
Gray
20800 (9435)
0.74 (18.8)
White

Isolator
Type/Size
CT 20-26
CT 20-27
CT 20-28
CT 20-31
CT 20-32

Max
Deflection
Spring
Load lb (kg) inches (mm) Color Code
12000 (5443)
1.17 (29.7)
Purple
15000 (6804)
1.06 (26.9)
Orange
18000 (8165)
1.02 (25.9)
Green
22000 (9979)
0.83 (21.1)
Gray
26000 (11794) 0.74 (18.8)
White

23

General Information

Unit Leveling
Follow the instructions outlined
below and illustrated in Figure 11 to
determined whether or not the
chiller is set level.
1. Measure an equal distance up
from each foot of the chiller
(identified as X in Figure 11) and
make a punch mark at each
measured distance.
2. Suspend a clear plastic tube along
the length of the chiller as shown
in Figure 11.

3. Fill the tube with water until the


level aligns with the punch mark at
one end of the chiller; then check
the water level at the opposite
mark.
If the water level does not align
with the punch mark, use fulllength shims to raise one end of
the chiller until the water level at
each end of the tube aligns with
the punch marks at both ends of
the chiller
4. Once the unit is level across its
length, repeat Steps 1 through 3 to
see if unit is level across the width.
5. If isolation pads have been used,
shim the center support.

Figure 11 Checking Unit Levelness


Raise chiller at one
end to align match
marks with water
level.

Measure and mark


an equal distance
up from each
chiller foot.

Clear Plastic Tube


(Fill tube with water to punch mark.)

24

CDHF-SVN01A-EN

Water Piping

Overview
Several water piping circuits must be
installed and connected to the chiller.
Note: Field piping must be arranged
and supported to avoid stress on the
equipment. It is strongly
recommended that the piping
contractor refrain from piping closer
than 3-0 minimum to the
equipment. This will allow for proper
fit-up upon arrival of the unit at the
job-site. Any adjustment that is
necessary can be made to the piping
at that time.
1. Pipe the evaporator into the chilled
water circuit.
2. Pipe the condenser into the
cooling tower water circuit. Piping
suggestions for each of the water
circuits listed above are outlined
later in this section. General
recommendations for the
installation of field-supplied piping
components (e.g., valves, flow
switches, etc.) common to most
chiller water circuits are listed
below.

Water Treatment
Since the use of untreated or
improperly treated water in a
CenTraVac may result in inefficient
operation and possible tube
damage, be sure to engage the
services of a qualified water
treatment specialist if needed. A
label with the following disclamatory
note is affixed to each CDHF unit:
Customer Note: The use of
improperly treated or untreated
water in this equipment may result
in scaling, erosion, corrosion, algae
or slime. The services of a qualified
water treatment specialists should
be engaged to determine what
treatment, if any, is advisable. The

CDHF-SVN01A-EN

Trane warranty specifically excludes


liability for corrosion, erosion, or
deterioration of Trane equipment,
Trane assumes no responsibilities
for the results of the use of untreated
or improperly treated water, or saline
or brackish water.

CAUTION
Water Treatment
Do not use untreated or improperly
treated water, or equipment
damage may occur.

Pressure Gauges
Locate pressure gauge taps in a
straight run of pipe. Place tap a
minimum of one pipe diameter
downstream of any elbow, orifice
etc. Example, for a 6 pipe, the tap
would be at least 6 from any elbow,
orifice, etc.

Valves

b) Relief valves are required by


ASME codes when the shell
waterside is ASME. Consult
guidelines or other applicable
codes to assure proper relief
valve installation.

CAUTION
Overpressurization
Failure to install pressure-relief
valves in the condenser and
evaporator water circuits may result
in shell damage due to hydrostatic
expansion.

Strainers
Install a strainer in the entering side
of each piping circuit to avoid
possible tube plugging in the chiller
with debris.

CAUTION
Tube Damage

1. Install field-supplied air vents and


drain valves on the water boxes.
Each water box is provided with a
3/4 NPTF vent and drain
connection.

Failure to install strainers in all water


piping entering the chiller can result
in tube plugging conditions that
damage unit components.

Plastic plugs are factory-installed in


both openings for shipment;
remove and discard these plugs as
you install the water box vents
and drain valves.
2. If necessary for the application,
install pressure-relief valves at the
drain connections on the
evaporator and condenser water
boxes. To do so, add a tee with the
relief valve attached to the drain
valve. To determine whether or
not pressure-relief valves are
needed for a specific application,
keep in mind that:

Use either flow switches or


differential pressure switches in
conjunction with the pump interlocks
to verify evaporator and condenser
water flows.

Flow-Sensing Devices

To assure adequate chiller


protection, wire the chilled-water
and condenser-water flow switches
in series with the appropriate water
pump interlock. Refer to the wiring
diagrams that shipped with the unit
for specific electrical connections.

a) Vessels with close-coupled


shutoff valves may cause high,
potentially damaging hydrostatic pressures as fluid
temperature rises; and,

25

Water Piping

Unless stated otherwise, all flowsensing devices must be


field-supplied. Be sure to follow the
manufacturers recommendations
for device selection and installation.
Also, review the general flow switch
installation guidelines listed below.
1. Mount the flow switch upright in a
horizontal section of pipe. Allow at
least 5 pipe diameters of straight,
horizontal run on each side of the
switch.
Avoid locations adjacent to
elbows, orifices and valves
whenever possible.
2. To assure that the flow switch
operates as designed, adjust the
length of the flow switch paddle to
compensate for the pipe diameter
and the height of the coupling tee
used to install the switch.

3. Install the flow switch using a


coupling that is large enough to
allow the insertion of a bushing
one pipe diameter larger than the
flow switch base (Figure 12). This
will prevent interference with the
flow switch paddle.
4. Verify that the direction-of-flow
arrow on the switch points in the
same direction as actual water
flow through the piping circuit.
5. Remove all air from the piping
circuit to prevent possible flow
switch fluttering.
6. Adjust the flow switch to open
when water flow is less than
normal.

Figure 12 Flow Switch Installation


Example Flow Switch

Pipe half coupling


1 Pipe size larger
bushing to avoid
paddle interference

5 pipe diameters

26

5 pipe diameters

CDHF-SVN01A-EN

Water Piping

Evaporator and Condenser


Water Piping
Figures 13 and 14 illustrate the
typical water piping arrangements
recommended for the evaporator
and condenser.
Note: It is strongly recommended
that the piping contractor refrain
from piping closer than 3-0
minimum to the equipment. This will
allow for proper fit-up upon arrival of
the unit at the job-site. Any
adjustment that is necessary can be
made to the piping at that time.
Water piping connection sizes are
identified in Tables 3 and 4.
Remember that entering and leaving
evaporator and condenser water
must be piped in accordance with
the nameplate entering and leaving
orientation.

IMPORTANT

For applications that include an


infinite source or multiple-use
cooling condenser water supply,
install a valve bypass leg
(optional) between the supply and
return pipes; see Figure 14. This
valve bypass allows the operator to
short-circuit water flow through the
cooling condenser when the supply
water temperature is too low.
Note: To prevent operating
problems, pressure differential
between condenser and evaporator
should not fall below 3 psid.
To accommodate lifting apparatus,
lifting holes are provided in the
stiffening ribs of each evaporator
water box to enable attachment of a
swivel clevis (field-supplied).
Condenser water boxes are provided
with welded nuts that allow
installation of the eyebolt included in
the units loose parts-box.

Water flows must be piped in


accordance with nameplate
designation.
Note: To assure that the evaporator
water piping is clear, check it after
the chilled water pump is operated
but before initial chiller start-up. If
any partial blockages exist, they can
be detected and removed to prevent
possible tube damage resulting from
evaporator freeze-up or erosion.

CDHF-SVN01A-EN

27

Water Piping

Figure 13 Typical Evaporator Water Piping Circuit

5S1

Notes:
1. Flow switch 5S1 (Item 7 in Legend of Components) should be installed in
the leaving leg of the chilled water circuit.
2. It is recommended to pipe 1 gauge between entering and leaving pipes. A
shutoff valve on each side of the gauge allows the operator to read either
entering or leaving water pressure.
Legend of Field-Supplied/Installed Components
1. Pressure Gauge
2. Thermometer(s) (If field supplied)
3. Union(s) or Flanged Connection(s)
4. 1/2" NPT Coupling(s)
5. Balancing Valve
6. Gate (Isolation) Valve(s) or Ball Valve(s)
7. Chiller Water Flow Switch (5S1)
8. Strainer
9. Evaporator Water Pump

28

CDHF-SVN01A-EN

Water Piping

Figure 14 Typical Condenser Water Piping Circuit

Notes:
1. Flow switch 5S2 (Item 7 in Legend of Components) should be installed in
the leaving leg of the chilled water circuit.
2. It is recommended to pipe 1 gauge between entering and leaving pipes.
3. Some type of field-supplied temperature control device may be required to
regulate the temperature of the heat-recovery condenser water circuit. For
application recommendations, see Trane Applied Manual, AM-FND-8, titled
Heat-Recovery Engineering Seminar.
4. Intalla bypass valve system to avoid circulating water through the auxiliary
shell when theunit is shut down.
Legend of Field-Supplied/Installed Components
1. Pressure Gauge
2. Thermometer(s) (If field supplied)
3. Union(s) or Flanged Connection(s)
4. 1/2" NPT Coupling(s)
5. Balancing Valve
6. Gate (Isolation) Valve(s) or Ball Valve(s)
7. Condenser Water Flow Switch
8. 3-Way Valve (Optional)
9. Condenser Water Pump
10. Strainer

CDHF-SVN01A-EN

29

Water Piping

Water Piping Connections


All CDHF units, A and later design
sequences, use grooved-pipe
connections. (See Table 5). These are
cut-groove end NSP (Victaulic-style)
pipe connection .
Flanged connections for 300 PSI
waterboxes use welded flanges.
Piping joined using grooved type
couplings, like all types of piping
systems, requires proper support to
carry the weight of pipes and
equipment.

Table 3 Evaporator Water Piping


Connection Sizes
CDHF and CDHG
Evaporator
Units
Shell
Connection
Size
Size
Size
Range
EVSZ
1 Pass
1250-2000
210D
16"
2100-2500
250D
16"
3000
250M
18"
3500
250X
18"

Table 4 CondenserWater Piping


Connection Sizes
CDHF and CDHG
Condenser
Units
Shell
Connection
Size
Size
Size
Range
CDSZ
1 Pass
1250-2000
210D
16"
2100-2500
250D
16"
3000
250M
20"
3500
250X
20"

Note:
EVSZ = Evaporator Shell Size;
D = Duplex

Note:
CDSZ = Condenser Shell Size;
D = Duplex

Table 5 Water Piping Connection Components


Water Box
Connection
Water Box Design Pressure
Unit Model
Type
150 psig
300 psig
CDHF or CDHG
Victaulic
Customer provided Customer provided
Victaulic Coupling
Victaulic Coupling
CDHF or CDHG
Flanged
Trane provided
Trane Provided
Victaulic-to-Flange
Welded on
Adapter
Flange
Figure 15 Typical Grooved Pipe Connection

The support methods used must


eliminate undue stresses on joints,
piping and other components; allow
movement where required, and
provide for any other special
requirements (i.e., drainage, etc.).

30

CDHF-SVN01A-EN

Water Piping

Grooved Pipe Coupling


A customer-supplied, standard
flexible grooved pipe coupling
(Victaulic Style 77 or equivalent)
should be used to complete the
Victaulic connection for both 150 and
300 psig water boxes. See Figures 15
and 16 . When a flexible coupling
such as this is installed at the water
box connections (Figure 16 ), other
flexible piping connectors (i.e.,
braided-steel, elastomeric arch, etc.)
are usually not required to attenuate
vibration and/or prevent stress on
the connections.

Refer to the coupling manufacturers


guidelines for specific information
concerning proper piping system
design and construction methods for
grooved water piping systems.
Note: Flexible coupling gaskets
require proper lubrication before
installation to provide a good seal.
Refer to the coupling manufacturers
guidelines for proper lubricant type
and application.

Figure 16 Customer Piping Alternatives for CDHF Water Box Connections

CDHF-SVN01A-EN

31

Water Piping

Flange-Connection Adapters
When flat-face flange connections
are specified, flange-to-groove
adapters are provided (Victaulic Style
741 for 150 psig systems), Figure 17.
The adapters are shipped bolted to
one of the chiller end-supports
(Figure 18). Adapter weights are
given in Table 6. The flange adapters
provide a direct, rigid connection of
flanged components to the groovedpipe chiller water box connections.
In this case, the use of flexible type
connectors (i.e., braided steel,
elastomeric arch, etc.) is
recommended to attenuate vibration
and/or prevent stress at the water
box connections.
Flange adapters are not provided for
units with 300 psig water boxes.
(These require welded flanges).

All flange-to-flange assembly bolts


must be provided by the installer.
Bolt sizes and number required are
given in Table 6. The four draw-bolts
needed for the 16-inch Style 741 (150
psig) adapters are provided. The
Style 741, 150 psig flange adapter
requires a smooth, hard surface for a
good seal.
Connection to other type flange
faces (i.e., raised serrated, rubber,
etc.) will require the use of a flange
washer between the faces. Refer to
the flange adapter manufacturers
guidelines for specific information.
Note: The flange-adapter gasket
must be placed with the color coded
lip on the pipe and the other lip
facing the mating flange.

CAUTION
Piping Connection Leaks
To provide effective seal, gasketcontact surfaces of adapter must be
free of gouges, undulations or
deformities.

Victaulic Gasket Installation


1. Check gasket and lubricate: Check
gasket supplied to be certain it is
suited for intended service. Code
identifies gasket grade. Apply a
thin coat of silicone lubricant to
gasket lips and outside of gasket.
2. Install Gasket: Place gasket over
pipe end, being sure gasket lip
does not overhang pipe end. See
Figure 17 for gasket configuration.
3. Join pipe ends: Align and bring
two pipe ends together and slide
gasket into position centered
between the grooves on each
pipe. No portion of the gasket
should extend into the groove on
either pipe.
4. Apply Vic-Flange. Open Vic-Flange
fully and place hinged flange
around the grooved pipe end with
the circular key section locating
into the groove.
5. Insert Bolt: Insert a standard bolt
through the mating holes of the
Vic-Flange to secure the flange
firmly in the groove.
6. Tighten Nuts: Tighten nuts
alternately and equally until
housing bolt pads are firmly
together -metal-to-metal.
Excessive nut tightening is not
necessary.
Note: Uneven tightening may cause
gasket to pinch.

Table 6 Installation Data for CDHF 150 PSIG Flange Adapters


Nom. Size
Assy Bolt Size
No. Assy
Bolt Pattern
Weights
(In/mm)
(In)*
Bolts Req.
Dia. (In/mm)
(lbs/kg)
16/400
1 x 4-1/2
16
21.25/540
90.0/40.8
18/457
1.13 x 4.75
16
22.75/578
100/45.4
20/508
1.13 x 5.25
20
25.00/635
120/54.4
*Bolt size for conventional flange-to-flange connection. Longer bolts are required when flange washer must be used.

32

CDHF-SVN01A-EN

Water Piping

Figure 17 Typical Victaulic Flange Gasket Configuration

Figure 18 Typical Shipping Location on Unit for Shipping Flange


LEG SUPPORT

SCREW

CDHF-SVN01A-EN

ADAPTER

33

Water Piping

Bolt-Tightening Sequence for


Water Piping Connections
A bolt-tightening sequence for
flanges with flat gaskets or O-rings is
described below and shown in
Figure 19. Remember that
improperly tightening flanges may
cause a leak!
Note: Before tightening any of the
bolts, align the flanges. Flange bolt
torque requirements are given in
Table 7.
Flanges with 4, 8 or 12 Bolts.
Tighten all bolts to a snug tightness,
following the appropriate numerical
sequence for the flange. Repeat this
sequence to apply the final torque to
each bolt.
Flanges with 16, 20 or 24 Bolts.
Following the appropriate numerical
sequence, tighten only the first half
of the total number of bolts to a snug
tightness. Next, sequentially tighten
the remaining half of the bolts in the
proper order.

Flanges with More than 24 Bolts.


Refer to Figure 19 and sequentially
tighten the first 12 bolts to a snug
tightness. Tighten the next 12
consecutively numbered bolts in
sequence, to the final torque.
Then, apply final torque to the first
12 bolts and the bolts not yet
tightened (i.e., unnumbered bolts in
Figure 19). Be sure to start with bolt
1 and move progressively around
the flange in a clockwise direction.
Evaporator Water Box Covers.
See Figure 19. Ensure that the water
box head rests tightly against the
gasket or tube sheet; then snugly
tighten the bolts in sequential order.
If excessive tube sheet crown
prevents the head from contacting
the tube sheet, tighten the bolts
located where the greatest gaps
occur. Be sure to use an equal
number of bolt turns from side to
side.
Then, apply final torque to each bolt
in sequential order. (Each bolt is
identified by number in Figure 19.)

Table 7 Flange Bolt Torque Recommendations for O-Ring and Flat-Gasket


Piping Connections (See Note).
Bolt Size
Gasket Type
(In)
O-Ring
Flat
3/8
25 (34)
12-18 (16-24)
1/2
70 (95)
33-50 (45-68)
5/8
150 (203)
70-90 (95-122)
3/4
250 (339)
105-155 (142-210)
Note: Torques provided in Ft./Lbs. (Newton/metres)

34

CDHF-SVN01A-EN

Water Piping

Figure 19 Bolt Tightening Sequences for Water Piping Flanges and


Water Boxes

Flanges with more than 24 bolts

Evaporator Water Box Covers

CDHF-SVN01A-EN

35

Vent Line Piping

Refrigerant Vent-Line Piping

Purge Discharge Vent Line

General Recommendations
Both the purge and rupture disc vent
lines must be routed to outside
atmosphere. Use only material
compatible with the refrigerant in
use. The use of PVC (not CPVC)
piping is acceptable if the pipe joint
is properly primed and if the
adhesive used has been tested for
refrigerant compatibility. Testing
conducted in Trane laboratories has
approved the use of the following
materials for PVC pipe construction.

On CDHF units, the purge discharge


lines are factory-piped downstream
of the rupture discs on the unit.
Since there are two separate
refrigerant circuits, there will be two
purges installed on each machine.
Each purge has its own discharge
line.

Primer - Hercules, Primer for PVC


#60-456;
Adhesive - Hercules, Clear PVC,
Medium Body, Medium Set, #60-020.
Consult with the manufacturers of
any field-provided components or
materials added to the refrigerantside of the machine for acceptable
material compatibility.
During vent line construction,
provide a drip leg on the line that is
of sufficient length to accommodate
a minimum of one gallon of liquid.
Provide a standard 1/4 FL x 1/4
NPT, capped refrigerant service valve
to facilitate liquid removal.
Accumulated liquid must be drained
from the drip leg into an evacuated
waste container once every six
months, at a minimum; and more
often if the purge operates
excessively.

36

Rupture Disc Vent Installation


All CenTraVac chillers are equipped
with carbon rupture discs. A crosssection of the rupture disc assembly
appears in Figure 20A along with an
illustration indicating the location of
the rupture disc on the suction
elbow. There are two rupture discs
on CDHF chillers, one per refrigerant
circuit. See Figure 20 for locations.
If refrigerant pressure within the
evaporator exceeds 15 psig, the
rupture disc breaks, shell pressure is
relieved as refrigerant escapes from
the chiller.

3. Rupture Disc Installation


Instructions. To prevent damage to
the rupture disc, use the following
installation procedure:
3.1 Install the bottom 2 bolts.
3.2 Install the rupture disc with
correct orientation (Ref. arrow
or vacuum support bar facing
inside) and a gasket on each
side. See Figure 20.
3.3 Install the top 2 bolts.
3.4 Center the disc and gaskets to
flange bore.
3.5 Hand tighten all bolts assuring
equal pressure
3.6 Use a Torque Wrench set to
240 In-Lb with a 9/16" socket.
3.7 Tighten bolts in a star pattern 1/
2 turn each.
3.8 Torque bolts in a star pattern to
240 In-Lbs. each.

When constructing the rupture disc


vent line, be sure to consult local
codes for applicable guidelines and
constraints.
Several general recommendations
for rupture disc vent line installation
are outlined below.
1. Verify that the vacuum support
side of the rupture disc is
positioned as shown in the cross
section view that appears in Figure
20.
Note: If the rupture disc was
removed for any reason, it must
be reinstalled as shown.
2. Do not apply threading torque to
the outside pipe assembly when
installing the connection pipe.

CDHF-SVN01A-EN

Vent Line Piping

4. Support the vent piping, use a


flexible connection to avoid
placing stress on the rupture disc.
(Stress can alter rupture pressure
and cause the disc to break
prematurely.)
The flexible connector used to
isolate the rupture disc from
excessive vent line vibration must be
compatible with the refrigerant in
use. Use a flexible, steel connector
such as the stainless-steel type MFP,
style HNE, flexible pump connector
(from Vibration Mounting and
Control, Inc.) or equivalent.

See Figure 20C for a recommended


relief piping arrangement.
Important! Vent pipe size must
conform to ANSI/ASHRAE Standard
15, which discusses vent pipe sizing.
Use Table 8 and then Figure 21 to
determine proper vent pipe size.
Note: To determine the total C
value for a specific unit, add the
appropriate C values for the
evaporator, condenser and
economizer. With this sum, refer to
Figure 21 to determine the vent line
pipe diameter needed to handle
flow.

5. If the two vent lines are piped


together, size the common line
appropriately to handle the total
flow. (See Note 2, Table 8).
6. Normally, where multiple chillers
are used, install a separate rupture
disc vent line for each unit.
7. Consult local regulations for any
special relief line requirements
and refer to CFC-GUIDE-2
published by The Trane Company.
8. The discharge of the vent line
outside should not be in the
general vicinity of any fresh air
intakes to the building. Any gas
venting from the vent line should
not be allowed to re-enter the
building.

Table 8 - C Value Used to Determine Rupture Disc Vent Line Size CDHF & CDHG
Evaporator
Condenser
Total
NTON
Shell
Shell
Rupture
C Value for Each Component for
C Value for
Compressor
Size
Size
Disc
Each Duplex Side
Each Duplex
Size
EVSZ
CDSZ
Diameter
Evaporator Condenser
Economizer
Side
1250-2000
210D
210D
3"
53.6
40.4
17.4
111.4
2100-2500
250D
250D
3"
59.1
43.9
17.4
120.4
3000
250M
250M
3"
72.2
53.8
19.5
145.5
3500
250X
250X
3"
83.3
62.0
19.5
164.8
Notes:
1. Use the Total C Value for Each Circuit to determine the vent line diameter needed to handle the flow, refer to
Figure 21.
2. If piping multiple rupture discs to a common vent line, first determine the total C value for each rupture disc, then
add all C values together and apply the result to the Vent Pipe Sizing Chart Figure 21.
3. EVSZ = Evaporator Shell Size
D = Duplex
4. CDSZ = Condenser Shell Size
D = Duplex

CDHF-SVN01A-EN

37

Vent Line Piping

Figure 20 - Illustrated Rupture Disc Location, Cross Section of Rupture Disc and Recommended Rupture Disc Relief
Piping

Rupture Disc
circled with
dashed lines

Figure 20A - (Continued)

38

CDHF-SVN01A-EN

Vent Line Piping

Figure 20B - (Continued)

CDHF-SVN01A-EN

39

Vent Line Piping

Figure 20C - (Continued)

40

CDHF-SVN01A-EN

Vent Line Piping

Figure 21 - Rupture Disc Vent Pipe Sizing

CDHF-SVN01A-EN

41

Insulation

Unit Insulation Requirements


Factory-installed insulation is
available as an option for all units.
Below is Table 9 showing unit
insulation requirements for CDHF
units.
In those instances where the chiller
is not factory-insulated, install
insulation over the areas shaded in
Figure 22. It may also be necessary
to insulate the compressor suction
cover if the unit is installed in an area
subject to high humidities. The
quantities of insulation required
based on unit size and insulation

thickness listed is determined at


normal design conditions which are:
- 85F Dry Bulb Ambient
Temperature
- 75% Relative Humidity
Note: If the unit is not factoryinsulated: Install insulation around
the evaporator bulbwells; and,
ensure that the bulbwells and
connections for the water box drains
and vents are still accessible after
insulation is applied.

CAUTION
If the factory-installed insulation will
be painted in the field, use only
water-based latex paints! Thinners
and solvents used in other types of
paints may cause seams in the
insulation to open as a result of
shrinkage.

CAUTION
To prevent damage to the factoryinstalled insulation, do not allow
excessive exposure to sunlight.

Important:
Units with a refrigerant pump do
not need insulation on the motor.
Do not insulate over unit wiring.
Raise the wiring harness and
insulate underneath. Do not insulate
over sensor modules.

Table 9 - CDHF Unit Insulation Requirements


EVSZ
3/4" Insulation
3/8" Insulation
(Note: 1)
(Note: 2)
(Note: 3)
210D
1270 Sq. Ft.
193 Sq. Ft.
250D
1308 Sq. Ft.
258 Sq. Ft.
250M
1410 Sq. Ft.
280 Sq. Ft.
250X
1500 Sq. Ft.
280 Sq. Ft.
Notes:
1. EVSZ = Evaporator Shell Size,
L = Long Shell, S = Short Shell,
D = Duplex
2. 3/4" sheet insulation is installed on the evaporator, evaporator waterboxes,
suction elbow and suction cover as indicated in Figure 22.
3. 3/8" sheet insulation is installed on all economizers. All liquid lines and
other pipes require the use of 1/2"-wall pipe insulation, or 3/8" sheet
insulation.

42

CDHF-SVN01A-EN

Figure 22 - Recommended Areas for Unit Insulation

CDHF-SVN01A-EN

43

Electrical
Information

About Wiring Drawings


The typical Duplex customer
connection diagrams shown at the
end of this manual are
representative of standard CDHF
units, and are provided only for
general reference. Because these
illustrations may not reflect the
actual wiring of your unit always
refer to the wiring diagrams that
shipped with the chiller for specific
electrical schematic and connection
information.
Note: Unit-mounted starters are
available as an option on CDHF
units.
While this option eliminates most
field-installed wiring requirements,
the electrical contractor must still
complete the electrical connection
for: (1) power supply wiring to the
starter, (2) other unit control options
present, and (3) any field-supplied
control devices.

General Requirements

WARNING!
To prevent injury or death due to
electrical shock or contact with
moving parts, lock supply power
and chiller disconnect switches open
using lockout tagout procedures.
As you review this manual, along
with the wiring instructions
presented in this section, keep in
mind that:

General

3. Compressor motor electrical data


including motor kw, voltage
utilization range, rated load amps
and locked rotor amps is listed on
the chiller nameplate.
4. All field-installed wiring should be
checked for proper terminations,
and for possible shorts or
grounds.

1. Typical field connection


requirements for remote-mounted
starters are shown in drawings at
end of the manual and
summarized in Table below.
2. All field-installed wiring must
conform to NEC guidelines, as
well as to any applicable state and
local codes. Be sure to satisfy
proper equipment grounding
requirements per NEC.

Typical Duplex Wiring


2309-4922C
2309-4902C
2309-4917B
2309-4924A
2309-4955A
2309-4956A
2309-4961A
2309-4941A
2309-4957A
2309-4957A
2309-4958A
2309-4958A

44

Schematic Legend
Unit Mounted Wye Delta Starter (Applicable to Circuit 1 & 2)
Purge (Applicable to Circuit 1 & 2)
Unit Controls Schematic (Page 1 & 2)
System Controls Schematic (Page 1 & 2)
Options Schematic (Page 1 & 2)
Connection Diagram LH Panel
Connection Diagram RH Panel
Connection Diagram - Trane Starter - Circuit 1
Page 1 of 2
Connection Diagram - Trane Starter - Circuit 1
Page 1 of 2
Connection Diagram - Customer Starter - Circuit 1
Connection Diagram - Customer Starter - Circuit 2

CDHF-SVN01A-EN

Electrical
Information

Trane Supplied
Remote Starter

Trane Supplied Starters Wiring


Standard Field Power wiring: Reference Field connection diagram 2309-4957
Note: All wiring to be in accordance with National Electrical Code and any local codes.
This information is applicable to the starter 1 for Compressor 1 as well as starter 2 for compressor 2. (For wire
estimation purposes please double the below list as there are two starters to be wired)

Table 10
Line Power wiring
(to Starter Panel)
3-Phase Line Voltage: Terminal Block

3-Phase Line Voltage: Circuit Breaker

To Starter Panel
Terminals
2X3-L1, L2, L3,
and GROUND

2Q1-L1,L2,L3,
and GROUND
Starters
T1 through T6 terminals

Starter to Motor Power Wiring


Remote Starter to
Chiller Motor Junction Box
Starter to UCP
To Starter
control wiring (120Vac)
Panel Terminals
120VAC Power Supply from starter to UCP 2X1-1-1,
2X1-2
2X1-20(Ground)
High Pressure Cutout interlock
2X1-4,
2X1-6
Oil Pump Interlock
2X1-7,
2X1-8
Low Voltage Circuits
To Starter
(less than 30VAC)
Panel Terminals
Standard Circuits
Inter Processor Communications (IPC)
2A1- J3-3 to 4,
Remote Mounted
or 2X1-12 to
13 if present
(do not ground
shield at starter )

CDHF-SVN01A-EN

All wiring to be in
accordance with
National Electrical
Code and any
local codes.
Motor
T1 through T6 terminals
From Unit Control
Panel Terminations
1X1-1,
1X1-12
1X1-18 (Ground)
1X1-4,
1X1-3
1A7-J2-4,
1A7-J2-2
From Unit Control
Panel Terminations

#8 gauge
minimum
40 amps circuit
14 ga.
14 ga.

1A1 J5 1-2
Shield ground at
1X1- 22(GND) only.

2 wire w/ ground
Comm link.

45

Electrical
Information

Customer Supplied
Remote Starter

Customer Supplied Starter


Standard Field Power wiring: Please refer to Trane Specification S6516-0513.
Note: All wiring to be in accordance with National Electrical Code and any local codes.
This information is applicable to the Starter 1 for Compressor 1 as well as Starter 2 for Compressor 2. (For wire
estimation purposes please double the below list as there are two starters to be wired)
Reference Field Connection Customer Supplied Starter diagram 2309-4958

Table 11
Line Power wiring
(to Starter Panel)
Starter by others
Power wiring:
3-Phase Power Supply to Starter
Starter to Motor Power Wiring
Remote Starter to
Chiller Motor Junction Box
Starter to UCP control wiring
(120VAC)
120VAC Power Supply from
starter to UCP

Power from UCP 1Q1


Interlock Relay signal
Start contactor signal
Oil Pump Interlock
Run Contactor signal
Transition Complete
Low Voltage Circuits
(less than 30VAC)
Standard Circuits
Current Transformers* (Required)
Potential Transformers* (Required)

Starter Panel
Terminals
See Starter by
others schematic

Starters

T1 through T6
terminals

All wiring to be in
accordance with
National Electrical
Code and any
local codes.
Motor
T1 through T6

terminals

To Starter

From Unit Control

Panel Terminals
See Starter by
others schematic
5X1-1,
5X1-2
5X1-20 (ground)
5X1-3
5X1-4
5X1-5
5X1-7,
5X1-8
5X1-10
5X1-14
To Starter
Panel Terminals

Panel Terminations
1X1-1,
1X1-12
1X1-18 (ground)
1X1-3, 1A23-J6-3
1A23-J10-1
1A23-J8-1
1A7-J2-4,
1A7-J2-2
1A23-J6-12
1A23-J12-2
From Unit Control
Panel Terminations

5CT4- wht, blk


5CT5- wht, blk
5CT6- wht, blk
5T17-236,237
5T18-238,239
5T19-240,241

1A23-J7-1,2
1A23-J7-3,4,
1A23-J7-5,6,
1A23 J5-1,2,
1A23 J5-3,4,
1A23 J5-5,6

#8 gauge minimum
40 amps circuit
14 ga.
14 ga.
14 ga.
14 ga.
14 ga.
14 ga.

Note: Phasing must


be maintained
Note: Phasing must
be maintained

*see Table 12 (CT* wire sizes)

46

CDHF-SVN01A-EN

Electrical
Information

Customer Supplied
Remote Starter

Table 12 - Current Transformer and Potential Transformer Wire sizing tables for Customer Supplied starter to Chiller
Unit Control Panel Starter module 1A23.
The maximum recommended wire length for secondary CT leads in a dual CT system are:
Wire
Maximum Wire Length Secondary CT Leads
AWG(mm2)
Feet
Meters
8(10)
1362.8
415.5
10(6)
856.9
261.2
12(4)
538.9
164.3
14(2.5)
338.9
103.3
16(1.5)
213.1
65.0
17(1)
169.1
51.5
18(0.75)
134.1
40.9
20(0.5)
84.3
25.7
Note: 1. Wire lengths are for copper conductors only.
2. Wire lengths are total one way distance that the CT can be from the Starter module.
The maximum recommended total wire length for PTs in a single PT system:
Wire Gauge
Max lead length(ft)
8
5339
10
3357
12
2112
14
1328
16
835
17
662
18
525
20
330
21
262
22
207

Max lead length (m)


1627
1023
643
404
254
201
160
100
79
63

The maximum recommended total wire length (to and from) for PT leads in a dual PT system are:
Max Wire
Max Wire
Max Wire
Max Wire
Wire
Length
Length
Length
Length
Gauge
Primary (ft)
Primary (m)
Secondary (ft)
Secondary (m)
8
3061
933
711
217
10
1924
586
447
136
12
1211
369
281
85
14
761
232
177
53
16
478
145
111
33
17
379
115
88
26
18
301
91
70
21
20
189
57
44
13
21
150
45
34
10
22
119
36
27
8
Note: These wire lengths are for copper conductors only
Note: The above lengths are maximum round trip wire lengths. The maximum distance the PT can be located from
the Starter module is 1/2 of the listed value.

CDHF-SVN01A-EN

47

Line Power Supply Wiring


To assure that power supply wiring
to the starter panels are properly
installed and connected, review and
follow the guidelines outlined below.
Typical equipment room layouts are
shown in Figures 25 and 26.

3-Phase Power Source


1. Verify that the starter nameplate
ratings are compatible with the
power supply characteristics - and
with the electrical data on the CDHF
nameplate.
2. If the starter enclosure must be cut
to provide electrical access, exercise
care to prevent debris from falling
inside the enclosure.

CAUTION
Debris inside the starter panel may
cause an electrical short that
seriously damages the starter
components.

Electrical
Information

Line Power
Wiring

3. Use copper wire to connect the 3phase power supply to the


remote-or-unit-mounted starter
panel.

6. As you install the power supply


conduit, make sure that its position
does not interfere with the
serviceability of any of the
components, nor with structural
members and equipment. Also,
assure that the conduit is long
enough to simplify any servicing that
may be necessary in the future (e.g.,
starter removal).

CAUTION
To avoid corrosion or overheating,
use only copper conductors for
terminal connections.
4. Size the power supply wiring in
accordance with NEC, using the RLA
value stamped on the chiller
nameplate and transformer load on
L1-and L2.
Note: All CDHF units are designed to
comply with NEC guidelines.
5. Make sure that the incoming
power wiring is properly phased;
each power supply conduit run to
the starter must carry the correct
leads to ensure equal phase
representation. See Figure 23.

Note: Use flexible conduit to


enhance serviceability and minimize
vibration transmission.

Circuit Breakers and Fusible


Disconnects
In compliance with NEC guidelines,
size the circuit breaker or fused
disconnect, the chiller nameplate
max. fuse size or max. circuit breaker
size marking.
Note: Right hand and left hand
circuits may have different RLAs.
See unit nameplate.

Figure 23 - Proper Phasing for Starter Power Supply Wiring

48

CDHF-SVN01A-EN

Electrical
Information

Optional PFCCs
Power factor correction capacitors
(PFCCs) are designed to provide
power factor correction for the
compressor motor. Available as an
option for unit-mounted starters, and
remote-mounted starter.

Note: Remember that the PFCC


nameplate voltage rating must be
greater than or equal to the
compressor voltage rating stamped
on the unit nameplate. See Table 13
to determine what is appropriate for
each compressor voltage
application.

PFCC

CAUTION
PFCCs must be wired into the
starter correctly! Misapplication of
these capacitors could result in a
loss of motor overload protection
and subsequent motor damage.
PFCCs are wired as shown in Figure
24 where the capacitor leads are run
through the overload transformer.

Table 13 - PFCC Design Voltage per Compressor Voltage Application


PFCC
Compressor Motor Voltage
Design Voltage
(See CDHF Nameplate)
240V/60 Hz
200V/60 Hz
208V/60 Hz
480V/60 Hz
380V/60 Hz
440V/60 Hz
460V/60 Hz
480V/60 Hz
600V/60 Hz
575V/60 Hz
600V/60 Hz
2400V/60 Hz
2300V/60 Hz
2400V/60 Hz
4160V/60 Hz
3300V/60 Hz
4000V/60 Hz
4160V/60 Hz

PFCC
Design Voltage
480V/50 Hz
440V/50 Hz
460V/50 Hz
480V/50 Hz
4160V/50 Hz

CDHF-SVN01A-EN

Compressor Motor Voltage


(See CDHF Nameplate)
380V/50 Hz

3300V/50 Hz

49

Electric
Information

PFCC and Unit


Mounted Starter

Figure 24 - PFCC Leads Routed thru Overload Current Transformer

Figure 25 - Typical Equipment Room Layout for CDHF with Unit-Mounted Starter

Notes:
1. Refer to the unit field connection diagram for approximate UCP knockout
locations.
CAUTION: To prevent damage to the UCPs components, do NOT route
control circuit conduit into the top of the UCP enclosure.
2. IPC circuit conduit must enter the left back portion of the UCP.
3. See Starter Submittal drawing for location of incoming wiring to the starter.

50

CDHF-SVN01A-EN

Electrical
Information

Remote Starter

Figure 26 - Typical Equipment Room Layout for CDHF with Remote-Mounted Starter

Notes:
1. Refer to the unit field connection for approximate UCP knockout locations.
CAUTION: To prevent damage to the UCPs components, do NOT route
control circuit conduit into the top of the UCP enclosure.
2. IPC circuit conduit must enter the left back portio nof the UCP.

CDHF-SVN01A-EN

51

Electrical
Information

Starter to Motor (RemoteMounted Starters)

Wire Terminal Lugs. Wire terminal


lugs must be field-supplied.

Reference Table 17-43 and 44.

1. Use field-provided crimp-type wire


terminal lugs properly sized for the
application.

Ground Wire Terminal Lugs.


Ground wire lugs are provided in the
motor terminal box, and in the
starter panel.
Terminal Clamps. Terminal clamps
are supplied with the motor
terminals to accommodate either
bus bars or standard motor terminal
wire lugs. Terminal clamps provide
additional surface area to minimize
the possibility of improper electrical
connections.

Note: Wire size ranges for the


starter-line and load-side wire lugs
are listed on the starter submittal
drawings supplied by the starter
manufacturer. Carefully review the
submitted wire lug sizes for
compatibility by the electrical
engineer or contractor.

Figure 27 - Terminal Stud, Clamp and Lug Assembly

Remote Starter

2. A terminal clamp with a 3/8 bolt


is provided on each motor
terminal stud; use the factorysupplied Belleville washers on the
wire lug connections.
Figure 27 illustrates the juncture
between a motor connection pad
and the wire terminal lug.
3. Tighten each bolt to 24 footpounds.
4. Install but do not connect the
power lead between the starter
and compressor motor.) These
connections will be completed
under supervision of a qualified
Trane service engineer after the
prestart inspection).
Bus Bars. Install bus bars between
the motor terminals when a lowvoltage across-the-line, primary
reactor/resistor or auto
transformer starter is used.
Be sure to jumper motor Terminal T1
to T6, T2 to T4, and T3 to T5.
Bus bars and extra nuts are available
as a Trane option.
Note: Bus bars are not needed in
medium or high-voltage applications
since only 3 terminals are used in the
motor and starter.

52

CDHF-SVN01A-EN

Electrical
Information

Starter to UCP
Control Wiring

Starter to UCP (RemoteMounted Starters Only)

Note: The polarity of the IPC wire


pair is critical for proper operation.

CAUTION

Electrical connections required


between the remote-mounted starter
and the chiller control panel (UCP)
are outlined in Table 10 or 11, as
applicable.

3. Separate low-voltage (less than


30V) wiring from the 115V wiring
by running each in its own
conduit.

Note: Install separate conduit


between the volt circuits; and the
UCP to the starter for the IPC circuit.

4. As you route the IPC circuit out of


the starter enclosure, make sure
that it is at least 6 from all wires
carrying a higher voltage.

When sizing and installing the


electrical conductors for these
circuits, follow these guidelines.

5. The IPC Shielded Twisted Pair


wiring should be grounded on one
end only at UCP end.

CAUTION

The other end should be unterminated and taped back on the


cable sheath to prevent any contact
between shield and ground.

Debris inside the starter panel may


cause an electrical short that
seriously damages the starter
components.
1. If the starter enclosure must be cut
to provide electrical access,
exercise care to prevent debris
from falling inside the enclosure.
2. Use only shielded twisted pair for
the IPC circuit between the starter
and the UCP on remote mounted
starters. Recommended wire is
Beldon Type 8760, 18 AWG for
runs up to 1000 feet.

CDHF-SVN01A-EN

6. Oil Pump Interlock - Both starters


must provide an interlock [N.O.]
contact with the chiller oil pump
connected to the UCP at Terminals
1A7-J2-4 and 1A7-J2-2 [14 ga] in
each control panel. The purpose of
this interlock is to power the oil
pump on the chiller in the event
that a starter failure, such as
welded contacts, keeps the chiller
motor running after the controller
interrupts the run signal.

To ensure that electrical noise does


not distort the signals carried by the
low-voltage wiring, including the
IPC, maintain at least 6 between
low-voltage (<30V) and 115V
circuits.

UCP Electrical Specifications


Following is a list of constraints for
the UCP in the control panel:
Note that the control panel is
designed to receive input from the
secondary of a power transformer in
the starter panel.
1. Nominal Voltage: 115 VAC, with
operating range of 98 to 132 VAC,
inclusive.
2. Maximum VA: 1725 VA (15-amp
fuse).
3. Power input wiring must be at
least 6 from low-voltage less than
30V wiring.
4. All signal inputs are low-voltage,
less than 30V.
5. UCP Storage Range: -40F to 158F
(-40C to 70C).

53

Electrical
Information

Control Circuit
Wiring

Left Hand Control Panel


Table 14 - UCP Control Wiring 120Vac
Standard
120 Vac Control Circuits:

Unit Control
Panel Terminations

Input or
Output Type

Chilled Water Flow Proving Input

1X1-5 to 1A6-J3-2

Binary Input

Condenser Water Flow Proving Input

1X1-6 to 1A6-J2-2

Binary Input

Chilled Water Pump Relay Output


Condenser Water Pump Relay Output
Optional
Control Circuits status outputs
Ice Making Relay Output

1A5-J2- 4 to 6
1A5-J2-1 to 3

Binary Output
Binary Output

Contacts
Normally Open,
closure with flow
Normally Open,
closure with flow
Normally Open
Normally Open

1A5-J2-10 to 12

Binary Output

Normally Open

* PROGRAMABLE OUTPUTS
defaults:
Chiller Non-Latching Alarm Relay Output 1A8-J2-1 to 3
Binary Output
Chiller Limit Mode Relay Output
1A8-J2-4 to 6
Binary Output
Chiller Latching Alarm Relay Output
1A8-J2-7 to 9
Binary Output
Chiller Running Relay Output
1A8-J2-10 to 12
Binary Output
Maximum Capacity Relay Output
1A9-J2-1 to 3
Binary Output
Chiller Head Relief Request Relay Output 1A9-J2-4 to 6
Binary Output
Circuit 2 Purge Alarm Relay Output
1A9-J2-7 to 9
Binary Output
Circuit 1 Purge Alarm Relay Output
1A9-J2-10 to 12
Binary Output
Alternates;
Circuit 1 Running
Circuit 2 Running
Chiller Alarm
Circuit 1 Alarm
Circuit 2 Alarm
Purge Alarm
* Defaults as Factory programed; Alternates can be selected at startup using service tool.

54

All wiring to be
in accordance with
National Electrical
Code and any
local codes.

Normally Open
Normally Open
Normally Open
Normally Open
Normally Open
Normally Open
Normally Open
Normally Open

CDHF-SVN01A-EN

Electrical
Information

Control Circuit
Wiring

Left Hand Control Panel


Table 15 - UCP Control Wiring less than 30 Vac
Standard
Low Voltage Circuits
Unit Control
(less than 30VAC)
Panel Terminations
External Auto Stop Input
1A13-J2-1 to 2

Input or
Output Type
Binary Input

Emergency Stop Input

1A13-J2-3 to 4

Binary Input

Circuit 1 External Lockout

1A25-J2-1 to 2

Binary Input

Circuit 2 External Lockout

1A25-J2-3 to 4

Binary Input

1A18-J2-1 to 2
1A18-J2-3 to 4
1A19-J2-1 to 2

Binary Input
Binary Input
Binary Input

Normally Open
Normally Open
Normally Open

1A15-J2-1 to 3 Left Panel

Analog Output

2-10 vdc

1A15-J2-4 to 6 Left Panel


1A16-J2-2 to 3
1A16-J2-5 to 6
1A17-J2-2 to 3
1A17-J2-5 to 6
IPC bus Connection
and sensor
1A14-J2-1(+) to 2(-)
1A14-J2-3(+) to 4(-)
Left Panel
1A14-J2-1(+) to 2(-)
1A14-J2-3(+) to 4(-)
Left Panel only

Analog Output
Analog Input
Analog Input
Analog Input
Analog Input
Communication
and sensor.
Communication
to Tracer

2-10 vdc
2-10 vdc, or 4-20 mA
2-10 vdc, or 4-20 mA
2-10 vdc, or 4-20 mA
2-10 vdc, or 4-20 mA

Optional
Low Voltage Circuits
External Base Loading Enable Input
External Hot Water Control Enable Input
External Ice Machine Control Enable Input
% RLA Compressor 1 Output
(Circuit 1 Left Panel 1A15 )
External Condenser Pressure Output
(Circuit 1 Left Panel 1A15 )
External Current Limit Setpoint Input
External Chilled Water Setpoint
External Base Load Setpoint Signal
Generic Refrigerant Monitor input
Outdoor Air Temperature sensor
Tracer Comm 4 Interface 1A14
[note Comm 4 requires two modules;
one is mounted in each panel]
Tracer Comm 5 Interface
[future, one Comm 5 module;
left panel only]

Closure required for


normal operation
Closure required for
normal operation
Closure required for
circuit lockout.
Closure required for
circuit lockout.

Communication
to Tracer

Right Hand Control Panel


Optional
Low Voltage Circuits [right panel]
% RLA Compressor 2 Output
(Circuit 2 Right Panel 1A15 )
External Condenser Pressure Output
(Circuit 2 Right Panel 1A15 )
Tracer Comm 4 Interface 1A14
[note Comm 4 requires two modules;
one is mounted in each panel]

CDHF-SVN01A-EN

1A15-J2-1 to 3
Right Panel
1A15-J2-4 to 6 Right Panel
1A14-J2-1(+) to 2(-)
1A14-J2-3(+) to 4(-)
Right Panel

Analog Output

2-10 vdc

Analog Output
Communication
to Tracer

2-10 vdc

55

System Control Circuit Wiring


Water Pump Interlock Circuits
and Flow Switch Input
Chilled Water Pump. Wire the
evaporator water pump contactor
(5K1) to a separate 120 volt single
phase power supply with 14 AWG,
600 volt copper wire, then connect
this circuit to 1A5-J2-6. Then use
1A5-J2-4 120 VAC output to allow the
UCP to control the evaporator water
pump, or wire the 5K1 contactor to
operate remotely and independently
of the UCP. (Left panel only.)
Chilled Water Proof of Flow
Wire the auxiliary contacts of the
evaporator water pump contactor
(5K1) in series with the flow switch
(5S1) installed in the evaporator
supply pipe. Use 14 AWG, 600-volt
copper wire.
Connect this circuit to UCP terminals
lX1-5 to 1A6-J3-2. (Left panel only.)
When installed properly, the chilled
water interlock circuit will only allow
compressor operation if the
evaporator pump is running and
providing at least the minimum
water flow required.

56

Electrical
Information

System Control
Wiring

Condenser Water Pump. Wire the


condenser water pump contactor
(5K2) to a separate 120-volt, singlephase power supply with 14 AWG,
600-volt copper wire; then connect
this circuit to UCP terminals 1A5-J23. Then use 1A5-J2-1 120 VAC output
to allow UCP to control the
condenser pump. (Left panel only.)

Temperature Sensor Circuits

Condenser Water Proof of Flow


Next, use 14 AWG, 600-volt copper
wire to connect the auxiliary contacts
of the condenser water pump
contactor (5K2) in series with the
flow switch (5S2) installed in the
condenser supply pipe.
Connect this circuit to UCP terminals
1X1-6 to 1A6-J2-2. (Left panel only.)
When installed properly, the
condenser water lock circuit will only
allow the compressor to operate if
the condenser pump is running and
providing at least the minimum
water flow required.

All temperature sensors are factoryinstalled except the optional outdoor


air temperature sensor. This sensor
is required for the outdoor air
temperature type of chilled water
reset. Follow the guidelines below to
locate and mount the outdoor air
temperature sensor. Mount the
sensor probe where needed,
however, mount the sensor module
in the UCP.
The outdoor temperature sensor
similar to the unit mounted
temperature sensors in that it
consists of the sensor probe and the
module. A four-wire IPC bus is
connected to the module for 24 vdc
power and the communications link.
We recommend mounting the
sensor module within the UCP and
the sensor two wire leads be
extended and routed to the outdoor
temperature sensor probe sensing
location. This assures the four wire
IPC bus protection and provides
access to the module for
configuration at start-up.

CDHF-SVN01A-EN

Electrical
Information

System Control
Wiring

The sensor probe lead wire between


the sensor probe and the module
can be separated by cutting the two
wire probe lead leaving equal
lengths of wire on each device; the
sensor probe and the sensor
module. Note this sensor and
module are matched and must
remain together or inaccuracy may
occur. These wires can then be
spliced to with two 14-18 AWG 600V
wires of sufficient length to reach the
desired outdoor location, maximum
length 1000 feet (305 meters). The
module four-wire bus must be
connected to the UCP four-wire bus
using the Trane approved
connectors provided.

Note: If shielded cable is used to


extend the sensor leads, be sure to
tape off the shield wire at the
junction box and ground it at the
UCP. If the added length is run in
conduit, do not run them in the same
conduit with other circuits carrying
30 or more volts.

CAUTION
MAINTAIN AT LEAST 6 INCHES
BETWEEN LOW-VOLTAGE (<30V)
AND HIGH VOLTAGE CIRCUITS.
Failure to do so could result in
electrical noise that may distort the
signals carried by the low-voltage
wiring, including the IPC.

The sensor will be configured (given


its identity and become functional) at
start-up when the serviceman
performs the start-up configuration.
It will not be operational until that
time.

CDHF-SVN01A-EN

57

Electrical
Information

System Control
Wiring

Optional Relay Circuits

Unit Start-Up

Forms Information

Optional Control and Output Circuits

Optional Tracer
Communication Interface

All phases of initial unit start-up must


be conducted under the supervision
of a qualified Trane local service
engineer. This includes pressure
testing, evacuation, electrical checks,
refrigerant charging, actual start-up
and operator instruction.

Samples of start-up and operating


forms along with other helpful forms
are found in the Operation
Maintenance manual which can be
obtained from the nearest Trane
office.

This control options allows the UCP


to exchange information such as
chiller status and operating set
points with a Tracer system.

Advance notification is required to


assure that initial start-up is
scheduled as close to the requested
date as possible.

Note: The circuit must be run in


separate conduit to prevent electrical
noise interference.

Starter Module Configuration

Install various optional wiring as


required by the owners
specifications.

Additional information about the


Tracer Comm option is published in
the installation manual and
operators guide that ships with the
Tracer.
See Table 15 for Tracer Connections.
Note: Comm 4 will require Tracer to
be connected to each panel for
individual circuit information.
(Comm 5 will require connections to
the left panel only when available.

58

The starter module configuration


settings will be checked (and
configured for Remote Starters)
during start-up commissioning. To
configurate starter modules, and
perform other starter checks, it is
recommended that the line voltage
three phase power be turned off and
secured (locked out), and then a
separate source control power (115
vac) be utilized to power up the
control circuits. To do this, remove
control coil circuit fuse, typically 2F4,
and then connect separate source
power cord to starter terminal block
1X1-5 (L1), 1X1-17 (L2), and Ground.
This needs to be done in each panel.
Use the as-built starter schematic
to assure correct fuse and terminals.
Verify correct fuse is removed,
control circuit connections are
correct, then apply the 115 vac
separate source power to service the
controls.

It is recommended that the


serviceman contact the local Trane
office to obtain the most recent
printing date of the form. The forms
in the operation and maintenance
manual are only current at the time
of printing of the manual.
After obtaining the most recent form,
complete all the information and
forward it to your local Trane office.

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The Trane Company


A business of American Standard Companies
www.trane.com
For more information contact your local district
office or e-mail us at comfort@trane.com

Literature Order Number

CVHF-SVN01A-EN

File Number

SV-RF-CTV-CVHF-SVN01A-EN-0902

Supersedes

CDHF-IN-1C

Stocking Location

La Crosse

Trane Company has a policy of continuous product and product data improvement and reserves the right to
change design and specifications without notice.
Only qualified technicians should perform the installation and servicing of equipment referred to in this
publication.