SAFETY WARNINGOnly qualified personnel should install and service the equipment.The installation, starting up, and servicingof heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge andtraining. Improperly installed, adjusted or altered equipment by an unqualified person could result in death orserious injury. When working on the equipment, observe all precautions in the literature and on the tags,stickers, and labels that are attached to the equipment.

Cold Generator™ Compact Chiller Series

Model CICA

20, 30 and 50Tons (60 Hz)R-410A

Installation, Operation,

and Maintenance

CG-SVX028A-ENNovember 2015

Introduction

Read this manual thoroughly before operating or servicingthis unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual asrequired.Your personal safety and the proper operation ofthis machine depend upon the strict observance of theseprecautions.

Important Environmental Concerns

Scientific research has shown that certain man-madechemicals can affect the earth’s naturally occurringstratospheric ozone layer when released to theatmosphere. In particular, several of the identifiedchemicals that may affect the ozone layer are refrigerantsthat contain Chlorine, Fluorine and Carbon (CFCs) andthose containing Hydrogen, Chlorine, Fluorine andCarbon (HCFCs). Not all refrigerants containing thesecompounds have the same potential impact to theenvironment.Trane advocates the responsible handling ofall refrigerants-including industry replacements for CFCssuch as HCFCs and HFCs.

Important Responsible RefrigerantPractices

Trane believes that responsible refrigerant practices areimportant to the environment, our customers, and the airconditioning industry. All technicians who handlerefrigerants must be certified.The Federal Clean Air Act(Section 608) sets forth the requirements for handling,reclaiming, recovering and recycling of certainrefrigerants and the equipment that is used in theseservice procedures. In addition, some states ormunicipalities may have additional requirements thatmust also be adhered to for responsible management ofrefrigerants. Know the applicable laws and follow them.

The three types of advisories are defined as follows:

WARNINGIndicates a potentially hazardoussituation which, if not avoided, couldresult in death or serious injury.

CAUTIONsIndicates a potentially hazardoussituation which, if not avoided, couldresult in minor or moderate injury. Itcould also be used to alert againstunsafe practices.

NOTICE Indicates a situation that could result inequipment or property-damage onlyaccidents.

WARNING

Proper Field Wiring and GroundingRequired!

Failure to follow code could result in death or seriousinjury. All field wiring MUST be performed by qualifiedpersonnel. Improperly installed and grounded fieldwiring poses FIRE and ELECTROCUTION hazards.Toavoid these hazards, you MUST follow requirements forfield wiring installation and grounding as described inNEC and your local/state electrical codes.

WARNING

Personal Protective Equipment (PPE)Required!

Failure to wear proper PPE for the job being undertakencould result in death or serious injury.Technicians, inorder to protect themselves from potential electrical,mechanical, and chemical hazards, MUST follow pre-cautions in this manual and on the tags, stickers, andlabels, as well as the instructions below:

• Before installing/servicing this unit, technicians

MUST put on all PPE required for the work being

undertaken (Examples; cut resistant gloves/sleeves,

butyl gloves, safety glasses, hard hat/bump cap, fall

protection, electrical PPE and arc flash clothing).

ALWAYS refer to appropriate Material Safety Data

Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA

guidelines for proper PPE.

• When working with or around hazardous chemicals,

ALWAYS refer to the appropriate MSDS/SDS and

OSHA/GHS (Global Harmonized System of Classifi-

cation and Labelling of Chemicals) guidelines for

information on allowable personal exposure levels,

proper respiratory protection and handling instruc-

tions.

• If there is a risk of energized electrical contact, arc, or

flash, technicians MUST put on all PPE in accordance

with OSHA, NFPA 70E, or other country-specific

requirements for arc flash protection, PRIOR to ser-

vicing the unit. NEVER PERFORM ANY SWITCHING,

DISCONNECTING, OR VOLTAGETESTING WITHOUT

PROPER ELECTRICAL PPE AND ARC FLASH CLOTH-

ING. ENSURE ELECTRICAL METERS AND EQUIP-

MENT ARE PROPERLY RATED FOR INTENDED

VOLTAGE.

© 2015Trane All rights reserved CG-SVX028A-EN

Introduction

Copyright

This document and the information in it are the property ofTrane, and may not be used or reproduced in whole or inpart without written permission.Trane reserves the rightto revise this publication at any time, and to make changesto its content without obligation to notify any person ofsuch revision or change.

Trademarks

All trademarks referenced in this document are thetrademarks of their respective owners.

WARNING

Refrigerant under High Pressure!

Failure to follow instructions below could result in anexplosion which could result in death or serious injuryor equipment damage. System contains oil andrefrigerant under high pressure. Recover refrigerant torelieve pressure before opening the system. See unitnameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, orrefrigerant additives.

CG-SVX028A-EN 3

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings, Cautions, and Notices . . . . . . . . 2

Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . 4

Model Number Descriptions . . . . . . . . . . . . . . 5

General Information . . . . . . . . . . . . . . . . . . . . . 6

Unit Description . . . . . . . . . . . . . . . . . . . . . . . 6

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Unit Components . . . . . . . . . . . . . . . . . . . . . . 7

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Dimensions and Weights . . . . . . . . . . . . . . . . 11

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . 11

Service Clearances . . . . . . . . . . . . . . . . . . . . 12

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation Mechanical . . . . . . . . . . . . . . . . . . 13

General Installation Information . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Noise Considerations . . . . . . . . . . . . . . . . . 13

Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Access Restrictions . . . . . . . . . . . . . . . . . . . 15

Compressor Mounting . . . . . . . . . . . . . . . . 15

Direct Mounting . . . . . . . . . . . . . . . . . . . . . . 15

Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . 15

Compressor Nameplate . . . . . . . . . . . . . . . 15

Evaporator Nameplate . . . . . . . . . . . . . . . . 16

Condenser Nameplate . . . . . . . . . . . . . . . . . 16

Unit Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation Electrical . . . . . . . . . . . . . . . . . . . . 21

General Recommendations . . . . . . . . . . . . 21

Equipment Grounding . . . . . . . . . . . . . . . . . 22

Unit Power Wiring . . . . . . . . . . . . . . . . . . . . 22

Control Power Supply . . . . . . . . . . . . . . . . . 22

External Contacts and Peripherals . . . . . . 23

Controls Interface . . . . . . . . . . . . . . . . . . . . . . . .24

Unit Controller — General . . . . . . . . . . . . . .24

Unit ControllerSoftware Installation and Setup . . . . . . . . .24

Unit Start-Up Procedures . . . . . . . . . . . . . . . . .26

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Sequence of Operation . . . . . . . . . . . . . . . . .26

Checking Operating Conditions . . . . . . . . . .27

System Superheat . . . . . . . . . . . . . . . . . . . . .27

System Sub-cooling . . . . . . . . . . . . . . . . . . .27

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Normal Unit Shutdown . . . . . . . . . . . . . . . . .28

Extended Shutdown Procedure . . . . . . . . . .28

Unit Restart . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Periodic Maintenance . . . . . . . . . . . . . . . . . .29

Compressor Maintenance . . . . . . . . . . . . . .29

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Appendix AWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Appendix BVendor Data Sheets . . . . . . . . . . . . . . . . . . . . . .38

MCS-CT300 Current Sensor Data Sheet . . .39

MCS-667 Pressure Transducer Data Sheet 40

MCS-T100 Temperature Sensor DataSheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Piping System Flushing Procedure . . . . . . .42

Water Treatment Requirements . . . . . . . . .42

4 CG-SVX028A-EN

CG-SVX028A-EN 5

Model Number Descriptions

Digits 1-4 — UnitTypeCIC = Compact indoor chiller

Digit 4 — ModelA = Model A

Brazed Plate Evaporator andBrazed Plate Condenser

Digits 5-7 — NominalTons020 = 20 nominal tons030 = 30 nominal tons050 = 50 nominal tons

Digit 8 — Unit VoltageA = 208/60/3B = 230/60/3F = 460/60/3G = 575/60/3

Digits 9, 10 — Design Sequence** = Factory Assigned

Digit 11— Agency ListingE = ETL/ETL-C listed to meet US and

Canadian safety standards

Digit 12— Remote Interface(Digital Comm)

0 = None2 = LonTalk®

4 = BACnet® MS/TP5 = BACnet IP6 = Modbus™8 = Johnson N2

Digit 13— Water Piping PackageEvaporator Entering

0 = None — without piping package1 = 2-inch chilled water piping2 = 2.5-inch chilled water piping3 = 3-inch chilled water piping4 = 4-inch chilled water piping5 = 5-inch chilled water piping

Digit 14— Water Piping PackageEvaporator Leaving

0 = None — without piping package1 = 2-inch chilled water piping2 = 2.5-inch chilled water piping3 = 3-inch chilled water piping4 = 4-inch chilled water piping5 = 5-inch chilled water piping

Digit 15— Water Piping PackageCondenser Entering

0 = None — without piping package1 = 2-inch chilled water piping2 = 2.5-inch chilled water piping3 = 3-inch chilled water piping4 = 4-inch chilled water piping5 = 5-inch chilled water piping

Digit 16— Water Piping PackageCondenser Leaving

0 = None — without piping package1 = 2-inch chilled water piping2 = 2.5-inch chilled water piping3 = 3-inch chilled water piping4 = 4-inch chilled water piping5 = 5-inch chilled water piping

Digit 17 — Motorized ControlValves

0 = None — manual balancingisolating valves only

1 = Integral discharge pressurecontrol condenser waterregulating valve

2 = Motorized chilled waterisolating valve

3 = Both chilled water andcondenser water control valves

Digit 18 — EvaporatorTemperature Range

0 = Standard cooling42 to 60°F (5.6 to 15.6°C)

1 = Standard cooling/ice-making20 to 60°F (-6.7 to 15.6°C)

Digit 19 — Power ConnectionD = Non-fused disconnect switchF = 100kA SCWR fused disconnect

Switch

Digit 20 — Sound Attenuator0 = No sound attenuation3 = Compressor sound blankets4 = Factory sound enclosure cabinet5 = Both sound enclosure cabinet

and compressor blankets

Digit 21 — Power Monitor0 = None1 = With power monitor

Digit 22 — Neoprene Isolators0 = None1 = Neoprene isolators (ship loose)

Digit 23 — Evaporator FluidType

0 = Water2 = Ethylene glycol3 = Propylene glycol4 = Methanol

Digit 24 — Condenser FluidType

0 = Water2 = Ethylene glycol3 = Propylene glycol

Digit 25 — Special Options0 = None1 = With special option(s)

General Information

Unit Description

Model CICA Cold Generator™ Compact Series water-cooled chillers are designed for installation on a preparedsurface in a suitable, weatherproof location above freezing(32°F). Each unit consists of a manifolded scrollcompressor set piped in parallel, a brazed plateevaporator, a brazed plate condenser and control box withintegral control panel—all mounted on a common frame.

Each unit is a completely assembled package that isfactory-piped,wired, leak-tested,dehydrated, chargedandrun-tested for proper control operation before shipment.Water inlet and outlet openings are covered beforeshipment. CICA units are shipped with an operatingcharge of refrigerant and oil.

General Data

Table 1. General data

Size 20 30 50

Compressor

Quantity 2 2 2

Nominal Tons @ 60 Hz tons 10/10 15/15 25/25

Compressor Sound Data(a) dbA 78 81 89

Compressor Sound Data with Sound Attenuator(b) dbA 72 75 85

Evaporator

Water Storage gal 2.4 3.2 4.5

Minimum Flow gpm 30 45 70

Maximum Flow gpm 68 102 170

Condenser

Water Storage gal 3.3 5.6 10.1

Minimum Flow gpm 40 60 100

Maximum Flow gpm 68 102 170

General Unit

Refrigerant R-410A R-410A R-410A

Number of Independent Refrigerant Circuits 1 1 1

Refrigerant Charge per Circuit lbs 21 26 44

Oil Type Trane OIL00080 Trane OIL00080 Trane OIL00080

Oil Charge per Compressor oz 112/112 122/122 228/228

(a) Compressor manufacturer sound power is given at rated compressor AHRI conditions measured in free space for tandem compressor sets.

(b) Manufacturer data taken at compressor AHRI conditions measured in free space for tandem compressor sets using com-pressor blanket option.

6 CG-SVX028A-EN

General Information

Unit Components

Figure 1. Unit components - front

Power WiringLocation

Unit Nameplate(Inside Door) Unit Controller

Keypad & Display

Locking Door

Off/Auto Switch, RunLight, Alarm Light

OptionalCondenser WaterRegulating Valve(Manual Valve is standard)

EvaporatorManual Balancing/Isolation Valve

EvaporatorWater Outlet

EvaporatorWater Inlet

CondenserWater Outlet

CondenserWater Inlet

OptionalElectronic ON/OFFEvaporator Valve

With LowFlowLogic(Manual valve

is standard)

Non-FusedDisconnect

Brazed PlateEvaporator

CG-SVX028A-EN 7

General Information

Figure 2. Unit components - back

Brazed PlateEvaporator

Brazed PlateCondenser

CompressorNameplate

EXV withIntegral Sight Glass

Filter Drier(Replaceable

Core on 50T Only)

SuctionLine

DischargeLine

Hot GasInjectionSolenoid Valve

EvaporatorWater Outlet

EvaporatorWater Inlet

CondenserWater Outlet

CondenserWater Inlet

Condenser ManualBalancing/Isolation

Valve

8 CG-SVX028A-EN

CG-SVX028A-EN 9

Pre-Installation

To protect against loss due to damage incurred in transit,complete the following checklist upon receipt of the unit.A more in depth list is included with the packing listadhered to the side of the shipping crate.

• Inspect the individual pieces of the shipment beforeaccepting the unit. Check for obvious damage to theunit or packing material.

• Inspect the unit for concealed damage as soon aspossible after delivery and before it is stored.Concealed damage must be reported within 15 days.

• If concealed damage is discovered, stop unpacking theshipment. Do not remove damaged material from thereceiving location.Take photos of the damage, ifpossible.The owner must provide reasonableevidence that the damage did not occur after delivery.

• Notify the carrier’s terminal of the damageimmediately, by phone and by mail. Request animmediate, joint inspection of the damage with thecarrier and the consignee.

• Notify theTrane sales representative and arrange forrepair. However, do not repair the unit until damage isinspected by the carrier’s representative.

After completing the inspection checklist, identify the unitwith the unit nameplate, packing list and orderinginformation.The unit nameplate is mounted inside thecontrol box.

See “Model Number Descriptions,” p. 5 for additional datathat can be found on the nameplate.

Check all items against the shipping list.Verify that it is thecorrect unit and that it is properly equipped. If optionalneoprene or spring isolators (or other ship-loose items)are ordered, they are secured in place on the shipping skidor inside the unit control box.

This Installation, Operation and Maintenance manual, theControls IOM, checklists and other pertinent documentscan also be found in the unit control box. Be sure to readall of this literature before installing and operating the unit.

10 CG-SVX028A-EN

Electrical Data

Table 2. Electrical data

Compressor Control Unit Wiring

Size Rated Voltage Qty

# Refrigerant

CircuitsNominal

TonsRLA

(each)LRA

(each) kW

Minimum Circuit

Ampacity

Max Fuse Size

Recommended Dual Element Fuse

Size

20 200-230/60/3

2 1 10/10

39 267 0.21 88 125 100

460/60/3 19 142 0.21 42 60 50

575/60/3 15 103 0.21 35 50 40

30 200-230/60/3

2 1 15/15

48 351 0.21 108 150 125

460/60/3 25 197 0.21 56 80 60

575/60/3 22 135 0.21 50 70 60

50 200-230/60/3

2 1 25/25

82 560 0.21 185 250 225

460/60/3 40 260 0.21 89 125 100

575/60/3 29 210 0.21 65 90 70

Notes:

1. Use copper conductors only. 2. Local codes may take precedence. 3. Voltage Utilization Range: ± 10% of rated voltage. Rated voltage (use range): 200-230/60/3 (180-253), 460/60/3 (414-506), 575/60/3 (517-632).

Dimensions and Weights

Unit DimensionsFigure 3. Dimensional drawing

30"

"B"

"B"

Qty

4 -

"A" V

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(if R

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Con

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141 2

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231 2

"C

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Out

32"

Con

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6X

3 4"

2X

3" 2

X 24

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2X

3"

2X

381 2

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X 4"

6

5 8"

16

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NO

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Head

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and

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CG-SVX028A-EN 11

Dimensions and Weights

Service Clearances

Notes:

• Clearance of 42” is required in front of chiller to otherground parts.

• Two units facing each other or other live parts requirea clearance of 48”.

• Allow 42” clearance above the chiller.

• Clearances remain the same when more than onechiller is present.

Weights

Figure 4. Service clearances

36"

36" 36"

42"

Table 3. Unit weights — single compact chiller

Shipping Weight Operating Weight

Size lbs kg lbs kg

20 1570 712 1501 681

30 1670 758 1641 744

50 2190 993 2223 1008

12 CG-SVX028A-EN

Installation Mechanical

General Installation Information

• Please read and take heed of the water piping systemflushing procedure and water treatment requirementsfound in “Appendix C,” p. 42 that are necessary toprepare and maintain an efficient and healthy chillersystem that utilizes brazed plate heat exchangers.

• Valvesinthewater piping upstream and downstream ofthe evaporator and condenser are installed on eachCICA chiller to isolate the heat exchangers formaintenance and to balance/trim the system.

• Supply and install condenser water control valve(s).See alsoTrane publication RLC-PRB021-EN, availablefromTrane Sales Offices, for additional technicalassistance. Provisions must be made for the control ofcondenser water that results in stable saturatedcondensing temperature between 80°F and 128°Fthrough all steady state, part load and transientoperating conditions.Trane recommends the optionalfactory-installed integral water regulating valvecontrolled by the unit controller.

• Supply and install flow switch or other approved flowproving device in the chilled water piping. Interlock thisswitch with the controller to ensure that the unit canonly operate when water flow is established. Seewiring diagram for connection point. A switch may beordered with the unit if desired. It will be shipped loosefor field installation.

• When appropriate and needed, supply and install drainvalves and vent cocks in the water system piping.Evaporator and condenser drain valves and vent cocksare factory-installed on all CICA chillers.

• Where specified, supply and install strainers ahead ofall pumps and control valves.

Note: CICA chillers are supplied with cleanable, factory-selectedY-strainers to be installed in the field byothers for protection of the brazed plate heatexchangers.

• Supply and install suitable refrigerant pressure reliefpiping to the atmosphere if required. Follow ANSI/ASHRAE 15-2010 guidelines, relief manufacturer’sguidelines, and industry standards when working withrelief valving, fusible plugs and/or piping.

• Start the unit under supervision of a qualified servicetechnician.

• Where specified, supply and insulate the chilled waterpiping as required, to prevent sweating under normaloperating conditions.Trane provides factoryinsulation on evaporator and related components.

Storage

Noise Considerations

Locate the unit away from sound-sensitive areas. Ifnecessary, install isolators under the unit. Install vibrationisolators in all piping and use flexible electrical conduit.Consult an acoustical engineer for critical applications.

Foundation

A base or foundation is recommended for mostinstallations. Provide a level surface strong enough tosupport the unit. Seechapter“Dimensions and Weights,”p. 11-12 for dimensions and weights. A flexible (isolated)concrete foundation or footings at each loading point willreduce transmission of vibration. Install anchor bolts in theconcrete to secure the unit.

Note: Use only anchor bolts that are flush with the top ofthe foundation, not a drive in stud type. Anexample of an acceptable anchor bolt is Red Head– Multi-Set II Drop In ShellType. Using a flush typeanchor bolt will make removal of a unit easier ifrequired.

If the floor is warped, uneven or in poor condition, makenecessary repairs before positioning the unit. Once theunit is inplace, it shouldbe level within 1/8 inch side-to-side(width) and 1/8 inch front-to-back (depth).

NOTICE:

Store Units Above Freezing!

Store these units in a protected area above freezing(32°F) only. Do not store outdoors with a protectivecovering such as a plastic shroud.This can result inexcessive water condensation that could damagecontrols and other components.

CG-SVX028A-EN 13

Installation Mechanical

Clearances

Provide adequate space around each unit for unrestrictedaccess for installation and maintenance. Unit dimensionsare given in “Dimensions and Weights,” p. 11-12. It iscritical that adequate space is provided for service andmaintenance of evaporator, condenser and compressor.A minimum of 42 inches above the unit is recommendedfor effective compressor service. A minimum clearance of3 ft.-6 inches is required to open the control panel door.

Important: In all cases, local codes will takeprecedenceover these recommendations.

Ventilation

Provisions must be made to remove heat generated byunit operation from the equipment room. Ventilation mustbe adequate to maintain an ambient temperature lowerthan 125°F.

Drainage

Locate the unit near a large capacity drain for drain-downduring shutdown or repair.

Handling

CICA units are shipped stretch-wrapped and bolted to ashipping skid unless special packaging is arranged.

The skidded unit can be moved by using a fork truck ofsuitable capacity. See “Dimensions andWeights,” p. 11-12for unit weights.

When moving the unit, the lifting forks must be positionedunder the shipping skid as wide as possible. Lift the unitand move it to the desired location.

Once the unit is at the installation location, remove thestretch wrap. Inspect the unit for damage and report ifdamage is found.

Optional“ship loose” items may be inside the control box,attached to the skid or shipped separately depending onoptions selected.

Forklifting Procedure

Important:

• Optional forklift pockets are required when lifting theunit with a forklift.

• Step 1 through Step 4 must be followed to lift unitusing a forklift.

Steps to be taken when forklift is used:

1. Remove the stretch wrap from the unit as describedpreviously, leaving the unit mounted to the skid.

2. Remove the bolts that secure the unit to the shippingskid.

3. Using a forklift, raise the unit enough to slightly clearthe skid, making sure the unit is level when lifting.

4. If the unit is level, lift the unit off of the skid and placein the installation location.

Figure 5. CICA rigging, fork lift pockets

Qty 4Rigging Bracketswith 1-5/8” Lifting Holes

Qty 4Lifting Pockets

34”Spreader

Bar

76-1/4”with

Rigging Brackets

25” min

12” min

14 CG-SVX028A-EN

Installation Mechanical

Rigging Procedure

Notes:

• See Figure 5 for reference.

• Do not use forklift to move or lift unit unless optionalfork lift pockets are installed and used. See “ForkliftingProcedure,” p. 14 for information.

• Do not lift unit from above unless optional riggingbrackets are installed and used.

Optional field installed Rigging Kit consists of four liftingeyes with mounting hardware.

Important:

• Optional forklift packets are required when lifting theunit with a forklift.

• Step 1 through Step 8 must be followed to hoist CICAunit.

Steps to be taken when rigging the unit for

hoisting:

1. Remove the stretch wrap from the unit as describedabove, leaving the unit mounted to the skid.

2. Install lifting eyes with the hardware included in the“Rigging Kit”. See Figure 5.

3. Install clevis connectors or equivalent in the 1-5/8 inchlifting holes provided on each of the lifting lugs.

4. Attach certified lifting chains (cables) to these points.Each chain (cable) alone must be strong enough to liftthe unit.

5. Attach chains (or cables) to a lifting beam. Position thechains (cables) so that they do not contact the unit

piping or the unit control panel. Use a suitablespreader bar to ensure proper weight distribution.

6. Remove the bolts that secure the unit to the shippingskid.

7. Raise the unit just off the skid to make sure that the unitis level when lifted. Adjust chain (cable) lengths asrequired.

8. Lift the unit off of the skid and place in the installationlocation.

Access Restrictions

All CICA units are designed to pass through a standard 36inch doorway. See outline drawings for other importantdimensions.

Compressor Mounting

All compressors are rigidly bolted with compressorisolation mounts to thesame compressor mounting frame(rails). No additional isolation or leveling is required.Inspect prior to start up to insure bolts are present andtight, and that no shipping damage has occurred.

Direct Mounting

The unit can be installed directly on an isolated, rigidmounting surface as long as the surface is level and will

support the weight of the unit.A mounting hole is providedat each of the unit mounting locations. See “Foundation,”p. 13 for more details. Provide a means of securelyanchoring the unit to the mounting surface. Level the unitcarefully.

Unit Leveling

Before tightening the mounting bolts, level the unit. Checkunit level front-to-back (depth) by using a level, or byplacing a level on the top surface of the unit frame. Unitshould be level within 1/8 inch front-to-back (depth). Placethe level on the unit frame and check side to side level.Adjust to within 1/8 inch of level side-to-side. Use shims asrequired to properly level the unit.

Compressor Nameplate

The nameplate for the hermetic scroll compressor ismounted on the compressor housing, near the motorterminal junction box.

WARNING

Heavy Objects!

Failure to follow instructions below or properly lift unitcould result in unit dropping and possibly crushingoperator/technician which could result in death orserious injury, and equipment or property-only damage.Ensure that all the lifting equipment used is properlyrated for the weight of the unit being lifted. Each of thecables (chains or slings), hooks, and shackles used tolift the unit must be capable of supporting the entireweight of the unit. Lifting cables (chains or slings) maynot be of the same length. Adjust as necessary for evenunit lift.

WARNING

Improper Unit Lift!

Failure to properly lift unit could result in unit droppingand possibly crushing operator/technician which couldresult in death or serious injury, and equipment orproperty-only damage.Test lift unit approximately 24inches to verify proper center of gravity lift point.Toavoid dropping of unit, reposition lifting point if unit isnot level.

NOTICE:

Equipment Damage!

To prevent damage, position the lifting beam andchains (cables) so that they do not contact unit pipingor control panel.

CG-SVX028A-EN 15

Installation Mechanical

Evaporator Nameplate

The evaporator nameplate is located on the evaporatorunder the insulation above the mounting bracket.To viewthe evaporator nameplate, remove the insulation over thearea if covered and spread the insulation.The serialnumber information is also on record at the factory.

Condenser Nameplate

The condenser nameplate is located on the condenserabove the mounting bracket. The serial numberinformation is also on record at the factory.

Unit Piping

See “Piping System Flushing Procedure,” p. 42 forinformation on piping system flushing procedure, andwater treatment requirements.

Exchanger Water Pressures

If field installed gauges are used, provide shutoff valves inthe line(s) to the gauge(s) to isolate thegaugeswhennot inuse.

Flow Sensing Devices

Chilled water flow switch, or other factory approved flowproving device is mandatory; field installation bycontractor is required. Flow switch is to be installed andmaintained per manufacturer’s recommendations andinterconnected to the control panel as described on thewiring diagram.To provide additional chiller protection,install and wire the flow switch in series with chilled waterpump interlock for the chilled water circuits. See “RequiredChilledWater Flow Switch,” p. 23. Specific connection andschematic wiring diagrams ship with the unit inside thecontrol box and in this IOM notebook.

Water Piping Recommendations

All water piping must be cleaned and flushed according to“Piping System Flushing Procedure,” p. 42 prior tocirculating any water through unit.

Make sure water piping connections to the evaporator andcondenser are isolated, and confirm that all piping to unitis supported independently to prevent any load beingtransferred to the unit. Use unions, flanges or grooved locktype fittings to facilitate service procedures. Use a pipesealant such asTeflon® tape on all threaded waterconnections. Use vibration eliminators to preventtransmitting vibrations through the water lines. Constructand install piping in accordance with all local, state andnational codes.

Supply and insulate the chilled water piping as required, toprevent sweating and minimize heat gain under normaloperating conditions. Chilled water piping must rise abovethe chiller to insure the evaporator is full of water and voidof air at all times. Install thermometers in the lines tomonitor evaporator entering and leaving watertemperatures.

CICA chillers have manual balancing ball-valves in theentering water lines.They may be used to establish abalanced water flow. Both the entering and leaving waterlines have valves that can be used to shutoff/isolate theevaporator and condenser for service.

Water Flow Rates

Establish balanced water flow through both theevaporator and condenser. Flow rates should fall betweenthe minimum and maximum values given in General DataTable 1, p. 6. Flow rates above or below these values cancause equipment damage or improper unit operation.Theevaporator water pressure drop is measured using thefactory-installed pressure transducers and can be readfrom the unit controller's keypad/display.The condenserwater pressure drop can be read manually using thefactory-installed condenser inlet and outlet pressuregauge service ports. Readings should approximate thoseshown by the pressure drop charts for the individualchillers (Figure 6, p. 17 and Figure 7, p. 17).

Note: Pressuredrop isanapproximationand is to be usedas a tool to estimate flow rate and as an aid towaterside system piping design. If an accuratemeasurement of flow rate is required, an accurateflow meter must be installed in the system.

NOTICE:

Vessel Damage!

To prevent pressure vessel damage, do not exceed unitnameplate water-side pressures.

NOTICE:

Unexpected Chiller Start!

An external source (EMS, time clock or any othermeans) should not be allowed to bring on a pump thatwould trigger the flow switch to start the chiller.Theflow switch is meant to act as a safety switch and not astart/stop mechanism. Failure to follow instructionscould cause the chiller to start unexpectedly whichcould result in equipment or property damage.

NOTICE:

Equipment Damage!

To prevent equipment damage, you MUST followinstructions below:

• Bypass unit when using a flushing agent.

• Chilled water piping must rise above the chiller to

insure the evaporator is full of water and void of air at

all times.

• Do not over tighten connections.

16 CG-SVX028A-EN

Installation Mechanical

Chilled Water System Volume

Minimum system volume requirements are indicated inFigure 4, p. 17. Special applications may deviate fromthese numbers as directed byTrane engineering.Operation below these volumes will cause unacceptablesystem control problems and the potential for evaporatorfailure.

Pressure Drop Curves

Table 4. Minimum required system volumes

Unit Size (tons) Volume (gal)

20 144

30 216

50 360

Figure 6. Evaporator pressure drop

Figure 7. Condenser pressure drop

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

0

2

4

6

8

10

12

14

16

18

0 20 40 60 80 100 120 140 160

CICA Evaporator Flow vs Pressure Drop

Flowrate, GPM

Pres

sure

Dro

p, P

SI

Pres

sure

Dro

p, F

T H

2O20 T

on

30 To

n

50 To

n

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

0

2

4

6

8

10

12

14

16

18

20

0 20 40 60 80 100 120 140 160 180 200

CICA Condenser Flow vs Pressure Drop

Flowrate, GPM

Pres

sure

Dro

p, P

SI

Pres

sure

Dro

p, F

T H

2O

20 T

on

30 To

n

50 To

n

CG-SVX028A-EN 17

Installation Mechanical

WaterTreatment

Using untreated or improperly treated water in these unitsmay result in inefficient operation and possible heatexchanger damage. Consult a qualified water treatmentspecialist to determine if treatment is needed. See“Appendix C,” p. 42 for water treatment requirements.

Evaporator & Water Piping

CICA chillers are equipped with brazed plate evaporatorsmade of stamped stainless steel plates, furnace brazedtogether with copper based joints. Because of the smallcomplex geometry of the flow passages, it is imperativecustomers takeallprecautions to insure these evaporatorsare not fouled by large particles or mineral deposits.Chillers are shipped with a factory-provided, 20-meshevaporator inlet wye strainer that must be field installed.The screen may be removed for cleaning. Operation ofchiller without screen in place will void warranty. Chemicaltreatment of the chilled water loop is required and must beperformed by a qualified water treatment specialist.

Chilled water inlets and outlets are grooved-type with thelocations provided in “Dimensions andWeights,” p. 11-12.Under full-load standard AHRI conditions, the chilledwater temperature rise should be approximately 10°F,producing a flow rate in the range of 2.4 gpm/ton.Minimum outlet water is 42°F without freeze inhibitor.

Chilled water piping must be in accordance with all local,state and national codes.

NOTICE:

Proper WaterTreatment!

The use of untreated or improperly treated water couldresult in scaling, erosion, corrosion, algae or slime. It isrecommended that the services of a qualified watertreatment specialist be engaged to determine whatwater treatment, if any, is required.Trane assumes noresponsibility for equipment failures which result fromuntreated or improperly treated water, or saline orbrackish water.

NOTICE:

Water Born Debris!

To prevent evaporator or condenser damage, pipestrainers must be installed in the water supplies toprotect components from waterborne debris.Trane isnot responsible for equipment-only-damage caused bywater born debris. Failure to install the shipped-loosesuppliedY-strainers or screens will void the warrantyon the brazed plate evaporator and condenser.

18 CG-SVX028A-EN

Installation Mechanical

Condenser & Condenser Piping

CICA units are equipped with brazed plate condensersmade of stamped stainless steel plates, furnace brazedtogether with copper based joints. Because of the smallcomplex geometry of the flow passages, it is imperativecustomers take all precautions to insure these condensersare not fouled by large particles or mineral deposits.Chillers are shipped with a factory-provided, 20-mesh

condenser inlet wye strainer that must be field installed.The screen may be removed for cleaning. Operation ofchiller without screen in place will void warranty. A closed-loop system and chemical treatment is highlyrecommended for the condenser water loop whenbrazedplate condensers are used. A closed-loop system protectsthe quality of the process fluid and reduces systemmaintenance. It is recommended the chemical treatmentbe performed by a qualified water treatment specialist.

CICA units are available with factory installed waterregulating valve.The optional water regulating valvemaintains condensing pressure and temperature bythrottling water flow leaving the condenser in response tocondensing pressure. It also facilitates condensingpressure stability at full-load, part-load, and transientconditions. Saturated condensing temperature must bemaintained between 80°F and 128°F.

Figure 8. Chilled water piping

Table 5. Chilled water piping components

Item Description Item Description1 Bypass Valve A Isolator Unit for initial water loop cleaning

2 Isolation Valves B(a) Arrangement for Measuring Differential Pressure

3 Vibration Eliminators FS(b) Water Flow Switch

4 Evaporator Heat Exchanger Pi Pressure Gauge

5 Inlet & Outlet Chilled Water Lines T1 Evaporator Outlet Temperature Sensor

6 Valves for Pressure Measurement T2 Evaporator Inlet Temperature Sensor

7(c) Strainer with 20 Mesh Screen T3 Evaporator Core Temperature Sensor

8 Evaporator Manual Air Vent Valve w/ Plug T4 Chiller Inlet Temperature Gauge

9 Evaporator Manual Ball Valve T5 Chiller Outlet Temperature Gauge

10 Evaporator Manual Ball Valve (Motorized On/Off Valve, optional) P1 Evaporator Outlet Pressure Sensor

11 Evaporator Manual Drain Valve with Plug P2 Evaporator Inlet Pressure Sensor

(a) Must account for water head difference when calculating total unit pressure differential.(b) Chilled water flow-proving device is required.(c) Strainer is factory supplied and field installed.

FS

Pi B

T5

T4

A

CUSTOMER PIPINGUNIT

3 2

6

1

26

74

8

5

3

T1

T3

T2 5

P1

P29

10

11

NOTICE:

Waterborne Debris!

To prevent evaporator or condenser damage, pipestrainers must be installed in the water supplies toprotect components from waterborne debris.Trane isnot responsible for equipment-only-damage caused bywater born debris. Failure to install the shipped-loosesuppliedY-strainers or screens will void the warrantyon the brazed plate evaporator and condenser.

CG-SVX028A-EN 19

Installation Mechanical

Coolingtower systems may include a manualor automaticbypass valve that can alter water flow rate to maintaincondensing pressure. Well (city) water condensingsystems should include a pressure reducing valve andwater regulating valve. A pressure reducing valve shouldbe installed to reduce water pressure entering thecondenser.This is required only if water pressure exceedsnameplate maximums.This is also necessary to preventdamage to the disc and seat of the water regulating valvethatcanbe caused by excessive pressure drop through thevalve.

Condenser water inlets and outlets are grooved- type withthe locations provided in “Dimensions andWeights,” p. 11-12. Under full-load standard AHRI conditions, thecondenser water temperature rise should beapproximately 10° F, producing a flow rate in the range of3 gpm/ton. Minimum inlet condenser water temperature is65°F.

Condenser piping must be in accordance with all local,state and national codes.

Figure 9. Condenser water piping

Table 6. Condenser water piping components

Item Description Item Description1 Bypass Valve 9 Condenser Manual Ball Valve (Water Regulating Valve, Optional)

2 Isolation Valves 10 Condenser Manual Ball Valve

3 Vibration Eliminators 11 Condenser Manual Drain Valve w/ plug

4 Condenser Heat Exchanger A Isolator Unit for initial water loop cleaning

5 Inlet & Outlet Water Lines B(a) Arrangement for Measuring Differential Pressure

6 Valves for Pressure Measurement Pi Pressure Gauge

7(b) Strainer with 20 Mesh Screen T6 Condenser Leaving Water Temperature Gauge

8 Condenser Manual Air Vent Valve w/ Plug T7 Condenser Entering Water Temperature Gauge

(a) Must account for water head difference when calculating total unit pressure differential.(b) Strainer is factory supplied and field installed.

Pi B

T7

T6

A

CUSTOMER PIPINGUNIT

3 2

6

1

264

5

359

1111

10 7

8

20 CG-SVX028A-EN

Installation Electrical

General Recommendations

The wiring procedures, as described in this portion of themanual, must be accomplished to obtain proper operationof the unit.

All wiring must comply with National Electrical Code(NEC) and state and local requirements. Outside theUnited States, the national and/or local electricalrequirements of other countries shall apply.The installermust provide properly sized system interconnecting andpower supply wiring with appropriate fused disconnectswitches.Type and locations of disconnects must complywith all applicable codes.

Minimum circuit ampacity, recommended fuse sizes andother unit electrical data are provided on the unitnameplate.

Checking the Power Supply

Electrical power to the unit must meet stringentrequirements for the unit to operate properly.Total voltagesupply and voltage imbalance between phases should bewithin the tolerances discussed below.

Total Supply Voltage

Measure each leg of the supply voltage at the line voltagedisconnect switches. For units with a nameplate voltage of208/230 volt, the readings must fall within the range of 180-253 volts. For units with a nameplate voltage of 460 volts,the readings must fall within the range of 414-506 volts. Ifvoltage on any leg does not fall within tolerance, notify thepower company and request correction of this situationbefore connecting to or operating the unit. Inadequatevoltage to the unit will shorten the life of relay contacts andcompressor motors.

Voltage Imbalance Between Phases

Excessive voltage imbalance between phases in a three-phase system will cause motors to overheat andeventually fail. Maximum allowable imbalance is 2percent. Voltage imbalance is defined as 100 times themaximum deviation of the three voltages (three phases)subtracted from the average (without regard to sign),divided by the average voltage.

Example:

If the three voltages measured at the line voltage fuseddisconnect are 221 volts, 230 volts and 227 volts, theaverage would be:

The percentage of imbalance is then:

In the preceding example, 221 is used because it is thefarthest from the average.The 2.2 percent imbalance thatexists exceeds maximum allowable imbalance by 0.2percent.This much imbalance between phases can equalas much as 20 percent current imbalance with a resulting

WARNING

Proper Field Wiring and GroundingRequired!

Failure to follow code could result in death or seriousinjury. All field wiring MUST be performed by qualifiedpersonnel. Improperly installed and grounded fieldwiring poses FIRE and ELECTROCUTION hazards.Toavoid these hazards, you MUST follow requirements forfield wiring installation and grounding as described inNEC and your local/state electrical codes.

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and onthe tags, stickers, and labels could result in death orserious injury.Technicians, in order to protect themselves frompotential electrical, mechanical, and chemical hazards,MUST follow precautions in this manual and on thetags, stickers, and labels, as well as the followinginstructions: Unless specified otherwise, disconnect allelectrical power including remote disconnect anddischarge all energy storing devices such as capacitorsbefore servicing. Follow proper lockout/tagoutprocedures to ensure the power can not beinadvertently energized. When necessary to work withlive electrical components, have a qualified licensedelectrician or other individual who has been trained inhandling live electrical components perform thesetasks.

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result inequipment damage as unit terminals are not designedto accept other types of conductors.

WARNING

Live Electrical Components!

Failure to follow all electrical safety precautions whenexposed to live electrical components could result indeath or serious injury. When necessary to work withlive electrical components, have a qualified licensedelectrician or other individual who has been properlytrained in handling live electrical components performthese tasks.

221 + 230 + 227 = 226 volts

3

100 (226 - 221) = 2.2%

226

CG-SVX028A-EN 21

Installation Electrical

increase in winding temperature that will decreasecompressor motor life.

Equipment Grounding

Provide proper grounding at the connection pointprovided in the unit control panel.

Unit Power Wiring

The installing contractor must connect appropriate powerwiring (with fused disconnects) to the unit-mounted, non-fused disconnect in the power section of the unit controlpanel. Electrical schematics and component locationdrawings are also mounted on the inside of the controlpanel door.

The unit power fused disconnect switch should be locatedin the general area of the unit, to comply with NEC or localcodes. Some codes require line-of-sight disconnectlocations.The unit mounted non-fused disconnect can beused as an emergency shutdown device.

Scroll Compressor Electrical Phasing

It is critical that proper rotation of the scroll compressorsbe established before the machine is started. Proper motorrotation requires confirmation of the electrical phasesequence of the power supply.The motor is internallyconnected for clockwise rotation with the inlet powersupply phased “ABC” or “L1, L2, L3”.

The order in which the three voltage waveforms of a three-phase system succeed one another is called phasesequence or phase rotation. When rotation is clockwise,phase sequence is usually called “ABC” and whencounterclockwise, “CBA”.

This direction may be reversed by interchanging any twoof the line wires.The possibility of interchanging the

wiring makes a phase sequence indicator necessary toquickly determine the proper phase rotation.

Setting the Proper Electrical PhaseSequence

Proper compressor motor electrical phasing can be quicklydetermined and, if necessary, corrected before starting theunit. Use a quality instrument, such as an AssociatedResearch Model 45 Phase Sequence indicator orequivalent and follow this procedure:

1. Verify that all operating controls for the unit are in the“Off” position.

2. Turn power to CICA unit “Off” using supply powerdisconnect to the unit.Verify that power to CICA unitis “Off” and that there is no voltage on “Line” orentering side of the CICA panel mounted unitdisconnect.

3. Connect the phase sequence indicator leads to the“Load” or leaving side of the CICA unit panel mounteddisconnect as follows:

4. Turn power to CICA unit “On” using the supply powerdisconnect to the unit

5. Read the phase sequence displayed on the indicator.The “ABC” LED on the face of the phase indicator willglow if phase sequence is ABC.

6. If the “CBA” indicator glows instead, turn power toCICA unit “Off” using the supply power disconnect tothe unit, then verify that the power to the CICA unit is“Off” and that there is no voltage on the “Line” side ofthe CICA panel mounted unit disconnect. Reverse twowires on the “Line” or entering side of the CICA panelmounted disconnect switch.Turn power to CICA unit“On” and recheck phase sequence (Step 5 above).

7. If phase sequence is correct, turn power to CICA unit“Off” using the supply power disconnect to the unit.Verify that power to the CICA unit is “Off” and thatthere is no voltage on “Line” or entering side of theCICA panel mounted unit disconnect. Remove thephase indicator and restore power to the CICA unit.

Control Power Supply

A fused, panel-mounted control power transformer isstandard. Replacement fuse information is listed on the“Fuse Schedule” decal located adjacent to the transformerinside the control box.

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result inequipment damage as unit terminals are not designedto accept other types of conductors.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing couldresult in death or serious injury. Disconnect all electricpower, including remote disconnects before servicing.Follow proper lockout/tagout procedures to ensure thepower can not be inadvertently energized.

NOTICE:

Compressor Damage!

Operating compressors in reverse rotation will causedamage or failure of the compressor.

Phase Sequence Lead Terminal ID

Black (Phase A) L1

Red (Phase B) L2

Yellow (Phase C) L3

22 CG-SVX028A-EN

Installation Electrical

External Contacts and Peripherals

The following peripheral control features and programlogic come standard on all CICA compact chillers.Designated terminals on the field connection terminalstrip in the control panel are provided for field connectionof each. Consult the field wiring diagram and wiringschematic diagram provided in this manual for theconnection points.The wiring schematic diagram is alsoattached to the inside of the control panel door.

Required Chilled Water Flow Switch

The CICA controller has a required input that accepts acontact closure from a proof-of-flow device such as a flowswitch or other factory approved flow proving device.When this input does not prove flow within a fixed timerelative to transition from enabled to run modes of thechiller, or if the flow is lost while the chiller is in the runningmode of operation, the chiller will be prohibited fromrunning.The installer must provide and install this flowproving device. Failure to provide this flow proving devicevoids unit warranty.

Condenser Water Loss of Flow Protection

The CICA controller logic will sense a loss of flow throughthe condenser. No condenser water flow switches arenecessary with the standard standalone CICA controllerconfiguration.

Pump Control

CICA units have one dry contact relay to start a condenserpump.These chillers also have one dry contact relay tostart a chilled water pump.These features are standard butnot required.

Remote Off/Auto

The CICA controller has an input that accepts a contactclosure from a remote device such as a toggle switch thatcan enable or disable the chiller to run. It would be wiredin series with the Off/Auto switch located on the controlpanel door.This feature is standard but not required.

Remote Alarm

CICA units have one dry contact relay to indicate with aremote light or bell or other device that at least onecompressor in the unit has been locked out for whatever

reason and needs attention.This feature is standard butnot required.

WARNING

Unexpected Chiller Start!

An external source (EMS, time clock or any othermeans) should not be allowed to bring on a pump thatwould trigger the flow switch to start the chiller.Theflow switch is meant to act as a safety switch and not astart/stop mechanism. Failure to follow instructionscould cause the chiller to start unexpectedly whichcould result in equipment or property damage.

CG-SVX028A-EN 23

Controls Interface

Unit Controller — General

The CICA controller is a rugged microprocessor-basedcontroller designed for the hostile environment of theHVAC/R industry. It is designed to be the primary managerof the CICA product.

The controller provides flexibility with setpoints andcontrol options that can be selected prior tocommissioning a system or when the unit is live andfunctioning. Unit display presents pressure, temperatureand alarm information with history in a clear and simplelanguage format, informing the user of the chiller status.See wiring diagram in the wiring section of this manual(“Wiring,” p. 32) and attached to the inside of the controlpanel door.

A password is required to access chiller setpoints. Usepassword code 2112 to access many of these features. Afactory code may be required to allow access to criticalareas, and can only be entered by a factory representative.

An RS-485 port is provided for communication with othermanufacturers’ systems.

Additionally, a built-in RS-485 to RS-232 converter allowscommunication over the RS-485 network via the RS-232port.

Other features include the integration of BACnet IP® andMODBUS® into the unit controller. Optionalcommunication cards are available for communication viaLONWORKS®, Johnson N2 and BACnet MS/TP®.This shouldbe ordered with the chiller if required. An ethernetconnection is also provided on each unit. While fieldchanges can be made, please insure that the unit isordered set up for required communications to insure thatfactory testing includes end user configuration.

A complete software support package is available for yourPC allowing for system configuration, dynamic on-linedisplay screens, remote communication, graphing andmore. Downloads for the MCS-Connect software areavailable at www.mcscontrols.com at no charge. See“Downloading and Installing Unit Controller (MCS-Connect) Software,” p. 24 for download instructions. Allinformation needed to run the unit is available from theunit display; however, a laptop computer is invaluable forease of use of diagnosing or changing the unit setpoints.

Note: Not all setpoints can be changed with MCS-Connect; some require a configuration change.

A serial cable is included in each shipment for theconvenience of the field technician. If you do not have alaptop with a serial port, you will require a converter suchas a Black Box item number #IC199A-R3 serial-to-USBadaptor.

The CICA standard configuration allows for the unit to startat the lowest stage possible, and then add compressors asneeded to meet demand.

Important: All configuration changes need to be doneby factory representatives to ensure properoperation of the unit within designparameters. See CG-SVX030*-ENcontroller manual for sequence ofoperation and additional details.

Unit Controller

Software Installation and Setup

Downloading and Installing UnitController (MCS-Connect) Software

Go to www.mcscontrols.com.

Go to the software page and select MCS-CONNECT. SelectSAVE. After downloading, open and select RUN. Followprompts and software will be installed on your computer.

If your computer does not have a serial port, you will needto purchase a USB to Serial adapter. (Computer storesshould have this.) Install the software for the adapter. Ifyour computer has a serial port, you will not need anadapter.

You will need to know which Port your computer uses asthe COM PORT. In Microsoft®Vista, go to the CONTROLPANEL and select DEVICE MANAGER. Look for PORTS(COM & LPT), expand and you should see a COM PORTnumber. Windows® 7 is similar.

Start the MCS-CONNECT software. SelectSETUP>COMMUNICATIONS and then change LOCALCOM PORT to match your computer. Select SAVE and thenOK.

Connecting to the Chiller

Connect the supplied NULL MODEM cable between yourUSB adapter or serial port to the chiller. A standard serialcable will not work.

Connection directly through the 100 MBPS Ethernet porton the CICA unit controller or array controller to a PCrequires a crossover Ethernet cable. If all controllers in thearray are connected to an Ethernet switch, then anEthernet patch (straight) cable will be used to connect thePC to the Ethernet switch.

Start the MCS-CONNECT software and select LOCALSERIAL.You will see the site info page.The softwareshould scan and find the chiller. (If you see a Failed to opencom port error, or it scans and does not find the chiller,your com port settings are not correct.) Click the 1-CICAtab.The screen shows real time data.

Setpoint Changes

Click the VIEW ONLY button. Enter the password code2112. Select OK. Button should say SERVICE. Go tosetpoints and double-click on a value. Change and selectOK.

24 CG-SVX028A-EN

Controls Interface

Viewing andTroubleshooting ALARMS

The unit controller will record and store 30-second sensorinput data prior to and up to any LOCKOUTALARM. Selectthe ALARM tab, then INFO next to the alarm you want toanalyze.This will pop up a screen that shows operatingconditions just prior to the trip.You can easily determineif the fault was caused by a sudden or gradual change. Forinstance, a sudden increase in discharge pressure mightsuggest a condenser pump or fan failure etc. (This data canalso be viewed from the chiller LCD screen. SelectLOCKOUT ALARMS.)

Downloading and Viewing Graphs

The unit controller continuously records and stores sensorinput and relay/analog output data.This data is collectedin 10-second (default) intervals.The controller stores 1008packets of data replacing the oldest with the newest.Withthe time interval set at 10 seconds, you can downloadgraph data with a time span of 168 minutes.The timeinterval is adjustable.

In the MCS-CONNECT software, select GRAPH. Data willbe downloaded and then a graph setup page will appear.Select the input and output data you want to look at.TypeinY-axis parameters and select OK. Use the scroll bar at thebottom of the graph to view.You can go back to the setuppage at any time to change selections.You may save thegraph to view later.You don’t have to be connected to viewa saved graph file.Your saved graph will be located in afolder called GRAPH inside another folder called MCS onyour C: drive.

To change the default 10-second interval, make changesand select SAVE and then OK on the setup page.Thecontroller will now record data at this new interval.

To view a saved graph, select LOAD A GRAPH FILE.Thesefiles can be e-mailed to us for analysis if needed.

Updating Chiller Software andConfiguration Files

CICA chillers are programmed, set up, and tested prior toshipment. Sometimes after a unit arrives at the jobsite, thecustomer may want to enable an option such as 0–5 Vdctarget reset, etc.These options require a configurationchange. We will either have you download theconfiguration file from the chiller and e-mail it to us wherewe will modify it and return it to you, or we will modify adefault configuration file we have here at the factory andsend it to you. Modifying a configuration file you send uswill save any setpoint changes that have been made onsite. Otherwise, the controller will be set back to defaultfactory settings.

To e-mail a copy of your chiller’s configuration file, in theMCS-CONNECT software, establish communication withthe chiller and select RECEIVE CFG.Name it ”Unit (serial number)” and e-mail toengineering@nappsac.com.

To load a configuration file, turn off circuit enable switchesand selectTRANSMIT CFG. Locate the new file and pressOPEN.The file will be uploaded to the controller.Thecontroller will reboot itself.

Routine software (HEX FILE) updates are NOT necessary.However, if we think a software update is necessary toresolve an operating issue you may be having, we will e-mail the hex file in a zipped folder. Save the zipped folderto your desktop. Right click folder and select EXTRACTALL.This will create another folder by the same name onyour desktop. Inside this folder you’ll find the hex file. Itshould be about 2300 KB. In the MCS-CONNECT software,selectTRANSMIT SW. Locate the extracted hex file andselectTransmit.Watch the chiller LCD screen. After the fileis uploaded, the CICA unit controller will verify that it’s avalid file and then erase the flash memory. Next, it willwrite the new hex to memory. When completed, thecontroller will reboot itself.This process may take 15 or 20minutes. After the reboot is completed, close and restartthe MCS-CONNECT software to reestablishcommunication with the chiller.

CG-SVX028A-EN 25

Unit Start-Up Procedures

Prior to calling for start-up services or commissioning,CICA Compact Chiller Installation Completion Check Listand Request for Trane Service, CG-ADF003*-EN, must becompleted and submitted. Once that has been completedand submitted, CICA Compact Chiller Start-up Check List,CG-ADF004*-EN, must be followed and submitted. A hardcopy of each document is sent with the chiller in the IOMnotebook.

Start-up and commissioning must be performed by afactory authorizedTrane service technician.

Pre-Start

Complete each step in the “Pre-Start Up Procedures”included in the CICA Individual Chiller Start-up Check Listand check off each step as completed.

Sequence of Operation

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing couldresult in death or serious injury. Disconnect all electricpower, including remote disconnects before servicing.Follow proper lockout/tagout procedures to ensure thepower can not be inadvertently energized.

NOTICE:

Equipment Damage!

• To prevent overheating at connections and under-

voltage conditions at the compressor motor, check

tightness of all connections in the compressor power

circuit.

• To prevent compressor damage, do not operate the

unit with discharge or liquid line service valves

closed.

• The use of untreated or improperly treated water in a

Chiller may result in scaling, erosion, corrosion, algae

or slime. It is recommended that the services of a

qualified water treatment specialist be engaged to

determine what water treatment, if any, is required.

Trane assumes no responsibility for equipment

failures which result from untreated or improperly

treated water, or saline or brackish water.

• To prevent evaporator or condenser damage, pipe

strainers must be installed in the water supplies to

protect components from water born debris.Trane is

not responsible for equipment damage caused by

water born debris.

Figure 10. Unit power-up

Power Appliedto Unit Controller Call for Cooling

ChillerLevel

Unit Controller

Boot Time

Auto (Power up StartDelay)

Enforce Power UpStart Delay Time

Auto

Confirm EvaporatorWater Flow

Auto Waiting to

Start Running

(24 to 90 Sec) (30 to 120 Sec) (6 to 600 Sec) (0 to 5 Sec)

EnergizeCondenser Water

Pump Relay(Only if ChillerControls Pump)

LeadCircuit

Auto Auto Auto

Enforce RestartInhibit Timer

Running

(0 to 5 Mins)

OpenEXV

Energize

LeadCompressor

Start Chilled Water Pump(only if chillercontrols pump)

26 CG-SVX028A-EN

Unit Start-Up Procedures

Checking Operating Conditions

To prevent compressor damage and ensure full coolingcapacity, only use refrigerant specified on unit nameplate.

• If operating conditions indicate an overcharge, slowly(to minimize oil loss) remove refrigerant at the liquidline Schrader fitting. Do not discharge refrigerant intothe atmosphere.

• Once proper unit operation is confirmed, inspect fordebris, misplaced tools, etc. Secure control paneldoors in place.

Once the unit has been operating for about 10 minutes andthe system has stabilized, check operating conditions andcomplete the checkout procedures that follow.

• Recheck evaporator water and condenser water flowsand pressure drops.These readings should be stableat proper levels.

• Check suction pressure and discharge pressure.

• Discharge pressure:Take at Schrader fittingprovided on the discharge line. Normal dischargepressures are:

• 275 to 430 psig

• Suction pressure:Take at Schrader fittingprovided on the suction line. Normal suctionpressures are:

• 42°F to 60°F LWT: 104 to 155 psig

• 15°F to 39°F LWT: 60 to 103 psig

• Check compressor oil level.At full load, oil level shouldbe visible in the oil level sight glass on the compressor.If it is not, add or remove oil as required.

• Check the liquid line sight glass. Refrigerant flow pastthe sight glass should be clear. Bubbles in the liquidline indicate either low refrigerant charge or excessivepressure drop in the liquid line. Such a restriction canoften be identified by a noticeable temperaturedifferential on either side of the restricted area. Frostoften forms on the outside of the liquid line at this pointalso.

Important: The system may not be properly chargedalthough the sight glass is clear. Alsoconsider superheat, sub-cooling andoperating pressure.

• Once oil level, ampdraw and operatingpressures havestabilized, measure system suction superheat.

• Measure system liquid line sub-cooling.

• If operating pressure, sight glass, superheat and sub-cooling readings indicate refrigerant shortage, chargerefrigerant into each circuit. Refrigerant shortage isindicated if operating pressures are low and sub-cooling is also low.

Important: If suction and discharge pressures are lowbut sub- cooling is normal, no refrigerantshortage exists. Adding refrigerant, willresult in overcharging.

• Add refrigerant with the unit running by meteringliquid refrigerant through the Schrader valve betweenthe expansion valve and the evaporator refrigerantinlet until operating conditions are normal.

System Superheat

Normal superheat is 10°F to 16°F at full load. If superheat isnot within this range, adjust expansion valve superheatsetting.Allow 5 to 10 minutes between adjustments for theexpansion valve to stabilize on each new setting.

System Sub-cooling

Normal sub-cooling is 5°F to 10°F at full load wheresaturated discharge pressure and liquid line temperatureare measured at chiller liquid line.

NOTICE:

Evaporator/Condenser Damage!

Water (fluid) flow must be established in evaporatorand condenser before adding refrigerant, removingrefrigerant, or pulling vacuum to protect heatexchangers from freezing.

NOTICE:

Compressor Damage!

Do not allow liquid refrigerant to enter the suction lineas excessive liquid accumulation in the liquid linescould result in compressor damage.

CG-SVX028A-EN 27

28 CG-SVX028A-EN

Shut Down

Normal Unit Shutdown

Extended Shutdown Procedure

If the system is taken out of operation for long periods oftime, use this procedure to prepare the system forshutdown.

1. Test condenser and high side piping for refrigerantleakage.

2. Open electrical disconnect switches for evaporatorwater pump. Lock the disconnect in an open position.

3. Open the unit main electrical disconnect and unit-mounted disconnect and lock in open position.

Unit Restart

Unit Restart After Extended Shutdown

Use this procedure to prepare the system for restart afteran extended shutdown.

1. Close the unit main disconnect(s) and the unit-mounted disconnect.

2. Check compressor crankcase oil levels. Oil should bevisible in the compressor oil level sight glass

3. Fill the chilled water circuit if drained during shutdown.Vent the system while filling it.

4. Close the fused disconnect switches for the waterpumps.

5. Start the water pumps. With water pumps running,inspect all piping connections for leakage. Make anynecessary repairs.

6. With water pumps running, adjust chilled water flowand check water pressure drop through the evaporator.

7. Check the flow switch on the evaporator outlet pipingfor proper operation.

8. Stop the water pumps.

9. Complete each step in CICA Individual Chiller Start-upCheck List CG-ADF004*-EN.

10. Energize Crankcase Heaters. (Heaters must beenergized a minimum of 24 hours before startup.)

Figure 11. Normal unit shutdown

Local StopNormal Latching DiagnosticChiller Level Non-Latching DiagnosticTracer StopExternal Auto-Stop

Stopped

Run Inhibit

ChillerLevel Running Shutting Down

Evap Pump Off Delay Timer

(0 to 30 Minutes)De-EnergizeCondenserWater Pump Relay(If Chiller Controls Pump)

Stopped or Run Inhibit

Circuit 1 Shutting Down Auto

(1 to 5 Sec)De-EnergizeCurrent

Lead Compessor

De-EnergizeCurrent Lag Compr

Close EXV ForPumpdown

NOTICE:

Compressor Failure!

To protect compressors from premature failure the unitmust be powered and crankcase heaters energized atleast 24 hours BEFORE compressors are started.

NOTICE:

Compressor Damage!

To prevent compressor damage, be certain that allrefrigerant valves are open before starting the unit.

Maintenance

Periodic Maintenance

Perform all of the indicated maintenance procedures at theintervals scheduled.This will prolong the life of the unitand reduce the possibility of costly equipment failure. Allmaintenance tasks other than recording data must beperformed by a qualified service technician

Weekly Maintenance

Ensure the unit has been operating for about 10 minutesand the system has stabilized, check operating conditionsand complete the checkout procedures that follow.

• Check compressor oil levels. Oil should be visible in thesight glass when the compressor is running. Operatethe compressors for a minimum of three to four hourswhen checking oil level, and check level every 30minutes. If oil is not at proper level after this period,have a qualified service technician add or remove oil asrequired.

• Check suction pressure and discharge pressure.

• Check the liquid line sight glasses.

• If operating pressures and sight glass conditions seemto indicate refrigerant shortage, measure systemsuperheat and system sub-cooling.

• If operating conditions indicate an overcharge, slowly(to minimize oil loss) remove refrigerant at the liquidline service valve. Do not release refrigerant to theatmosphere.

• Inspect the entire system for unusual conditions. Usean operating log to record weekly operating conditionshistory for the unit. A complete operating log is avaluable diagnostic tool for service personnel.

Monthly Maintenance

Ensuretheunithasbeenoperatingforabout10 minutesandthe system has stabilized, check operating conditions andcomplete the checkout procedures that follow.

• Check compressor oil levels. Oil should be visible in thesight glass when the compressor is running. Operatethe compressors for a minimum of three to four hourswhen checking the oil level, and check level every 30minutes. Ifoil isnotatproperlevelafterthisperiod, havea qualified service technician add or remove oil asrequired.

• Check refrigerant superheat at the compressor suctionline. Superheat should be in the range of 10°F–20°F.

Note: A superheat calculated value is incorporatedinto the unit controller.

• Check the liquid line sight glasses.

• If operating pressures and sight glass conditions seemto indicate refrigerant shortage, measure systemsuperheat and system sub-cooling.

• If operating conditions indicate an overcharge, slowly(to minimize oil loss) remove refrigerant at the liquidline service valve. Do not release refrigerant to theatmosphere.

• Inspect the entire system for unusual conditions.Review the weekly operating log for conditions historyfor the unit and take note of any unusual trends inperformance.Take appropriate preventative actions ifnecessary.

Annually

Perform all weekly and monthly maintenance procedures.

• Have a qualified service technician check the settingand function of each control and inspect the conditionof and replace compressor and control contacts ifneeded.

• Ifchiller isnotpipedtodrainfacilities,makesuredrain isclear to carry away system water.

• Drain water from condenser and evaporator andassociated piping systems. Inspect all pipingcomponents for leakage, damage, etc. Clean outevaporator and condenser supply strainers.

• Clean and repaint any corroded surface.

Compressor Maintenance

Because scroll compressors are a uniquely differentdesign from traditional reciprocating compressors, theiroperating characteristics and requirements are adeparture from the reciprocating compressor technology.

WARNING

Hazardous Service Procedures!

Failure to follow all precautions in this manual and onthe tags, stickers, and labels could result in death orserious injury.Technicians, in order to protect themselves frompotential electrical, mechanical, and chemical hazards,MUST follow precautions in this manual and on thetags, stickers, and labels, as well as the followinginstructions: Unless specified otherwise, disconnect allelectrical power including remote disconnect anddischarge all energy storing devices such as capacitorsbefore servicing. Follow proper lockout/tagoutprocedures to ensure the power can not beinadvertently energized. When necessary to work withlive electrical components, have a qualified licensedelectrician or other individual who has been trained inhandling live electrical components perform thesetasks.

CG-SVX028A-EN 29

Maintenance

Compressor Oil

The R-410A scroll compressor uses POE oil as required bythe manufacturer of the compressor. Refer to compressormanufacturer for exact type and amount of oil in thespecific model in question.

Oil Level

While the compressor is running, the oil level may bebelow the sight glass but still visible through the sightglass.The oil level should NEVER be above the sight glass!

Oil Appearance

If the oil is dark and smells burnt, it was overheatedbecause of compressor operation at extremely highcondensing temperatures, a compressor mechanicalfailure, or occurrence of a motor burnout. If the oil is blackand contains metal flakes, a mechanical failure hasoccurred.This symptom is often accompanied by a highamperage draw at the compressor motor.

Notes:

• If a motor burnout is suspected, use an acid test kit tocheck the condition of the oil. If a burnout has occurred,test results will indicate an acid level exceeding 0.05mg KOH/g.

• The use of commercially available oil additives is notrecommended. Liability forany detrimental effects thatthe use of non-approved products may have onequipment performance or longevity must be

assumed by the equipment owner, equipment servicetechnician, or the oil additive manufacturer.

Scroll Compressor FunctionalTest

Since the scroll compressor does not use discharge orsuction valves, it is not necessary to perform a pump-down capability test, i.e. a test where the liquid line valveis closed and the compressor is pumped in a vacuum tosee if it will pump-down and hold. In fact, this kind of testmay actually damage the scroll compressor.

The proper procedure for checking scroll compressoroperation is outlined below:

1. Verify that the compressor is receiving supply power ofthe proper voltage.

2. With the compressor running, measure the suctionand discharge pressures/temperatures to determinewhether or not they fall within the compressoroperating map shown in Figure 12.

NOTICE:

Compressor Damage!

Do not pump the scroll compressor into a vacuum.Scroll compressors can pull internal low vacuums whenthe suction side is closed or restricted.This, in turn, canlead to compressor failure due to internal arcing andinstability in the scroll wraps.

Figure 12. Compressor operating map

70

80

90

100

110

120

130

140

150

-10 0 10 20 30 40 50 60 70 80

Compressor Operating Map

Sat

urat

ed C

onde

nsin

g Te

mpe

ratu

re (

°F)

Saturated Evaporating Temperature (°F)

30 CG-SVX028A-EN

Maintenance

Normal operating pressures for the unit with a scrollcompressor are the same as for a unit with a reciprocatingcompressor.

Compressor Operational Noises

Because the scroll compressor is designed toaccommodate liquids (both oil and refrigerant) in smallamounts without causing compressor damage, there aresome characteristic sounds that differentiate it from thosetypically associated with a reciprocating compressor.These sounds, which are described below, are normal anddo not indicate that the compressor is defective.

At low ambient startup: When the compressor starts upunder low ambient conditions, the initial flow rate of thecompressor is low. Under these conditions, it is notunusual to hear the compressor rattle until the suctionpressure climbs and the flow rate increases.These soundsare normal and do NOT affect the operation or reliability ofthe compressor.

Excessive Amp Draw

Excessive Amp Draw occurs either because thecompressor is operating at an abnormally highcondensing temperature OR because of low voltage at thecompressor motor.

Motor amp draw may also be excessive if the compressorhas internal mechanical damage. In this situation,vibration and discolored oil can also be observed.

Low Suctions

Continuous low suction pressures are most likely causedby low evaporator load coupled with a system anomalysuch as low chilled water flow.

Note: Operation of the chiller with saturated suctiontemperatures below freezing will cause damage tothe evaporator. If this occurs immediately stop themachine, diagnose and correct the problem.

CG-SVX028A-EN 31

Wiring

Figure 13. CICA wiring schematic page 1

NAPPS TECHNOLOGY CORPORATIONWITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSETHIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OFMUST BE MAINTAINED IN STRICT

NAPPS TECHNOLOGY CORPORATION,WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

EN

HP1SW

BLACK

WHITE

SHIELD

WHITE

WHITE

RELAY M-1C1

RUN LIGHT

RELAY M-2

RELAY M-4C2

HGI

RELAY M-3

CW VALVE

RELAY M-5

RELAY M-7ALARM

SPARE

RELAY M-6

GND

N

L/L1

RED

WHITE

BLACK &SHIELD

SENSOR M-11

CW IN PSI

AMPS COMP 2

SENSOR M-6

SENSOR M-5

AMPS COMP 1

CKT 1 DIS PSI

SENSOR M-4

SENSOR M-3

CKT 1 SUC PSI

CW OUT

SENSOR M-2+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

+5 GND SI

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

DIGITAL ANALOG

WHITE

REDBLACK & SHIELD

DIGITAL ANALOG

+5 GND SISENSOR M-1

CW IN

DIGITAL ANALOG

Termination

HGS 1HOT GAS SOLENOID

LP1SW

TBB7

RED

Unit C

ontroller

+ - GND

CM

P1&

2 ENA

BLE

SENSO

R M

-13

TO K

EYP

AD

/ DISP

LAY

CO

ND

WR

V

Co

m N

O N

C

(Shield tied at this end)

ETHERNET

+12VMCS IO RS485

SENSOR 12

SENSOR 11

SENSOR 10

SENSOR 9

SENSOR 8

SENSOR 7

SENSOR 5

SENSOR 6

SENSOR 3

SENSOR 4

SENSOR 1

SENSOR 2

DI-15DI-16 DI-13DI-14

+5+5+5

DIGITAL INPUTS ANALOG OUTSA-3A-4 A-1A-2

gn

d

gn

d

-485+

485

SCL

SDA

GN

D+

12V

KEYPAD LCD

115v

Voltage

Co

m N

O N

CC

om

NO

NC

Co

m N

O N

CC

om

NO

NC

Co

m N

O N

CC

om

NO

NC

Co

m N

O N

CC

om

NO

NC

Co

m N

O N

C

8

6

7

TBB5 3F

12TBA5

TBA613

TBA411

TBA310

Comp 1

C1

44ATBB6

5A

5

3A

RELAY M-8

RELAY M-9

RELAY M-10ALARM LIGHT

CW PUMP

7A

CONTACTOR

+5

SENSO

R M

-14O

PT P

WM

PW

R M

ON

ITOR

CompressorsOnly

25 ton SENSOR M-10

SENSOR M-9

BLACK

SHIELD

WHITE

WHITE

SHIELD

BLACK

SHIELDBLACK &

BLACKSHIELD

WHITE

To Customer Interface orCommunications Board

To Optional Exp BoardComm to MCS-SI16 or eq

WHITE

3B

3D

Only

25 tonCompressors

CND ENBL1

WH

ITE TO TB

B10

BLA

CK

/

(PUMP)

SHIELD

WHITE

REDBLACK & SHIELD

BLACK &

SHIELD

WH

ITE

BLACK&SHIELDSENSOR M-12

CW OUT PSI

RED

WHITE

SENSOR M-7

SENSOR M-8 BLACK

CKT 1 SUC TMP

SHIELD

WHITE

WHITE

SHIELDBLACK

CORE TEMP

WH

ITE

BLA

CK

/SHIELD

EXV

Driver

TBB4

5B

5B

9

3E

Run Light

CONTACTORComp 2

C2

21

22

23

3D

Alarm Light3C

TBA1

TBA2

TBB3

3E

MTR MOD 1

MTR MOD 2

14

TBA715

16TBA8

Only used if chiller is in array

+ -

GNDRS485

BlackWhiteTo Array

Controller MCS I/O

To RS485 of Next Chiller

in Array

-+

21

Notes :

First chiller in array is connected from RS485 port to the Array 1.Controller MCS I/O port.Consecutive chillers in array are daisey-chained through RS485 ports.2.2

1

25

REMOVE JUMPER

Switch HereDry Contact RemoteConnect Optional J

22

2324

25a

TBA

9

TBA

10

TBA

11TB

A12

SENSO

R M

-15

OFF/A

UTO

SENSO

R M

-16

FLOW

SWITC

H

REQUIRED if chiller NOT in

Array

32 CG-SVX028A-EN

Wiring

Figure 14. CICA wiring schematic page 2

Napps

B

LONGVIEW, TX 75606-3066P.O. BOX 3066NAPPS TECHNOLOGY CORP.

OF

APP'D BY:CHECKED BY:DRAWN BY:DATE:SCALE:

DWG. SIZE

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.

NAPPS TECHNOLOGY CORPORATIONWITHOUT THE EXPRESS WRITTEN CONSENT OF

OR USED FOR ANY PURPOSETHIS MATERIAL MAY BE REPRODUCED

CONFIDENCE AND NO PORTION OFMUST BE MAINTAINED IN STRICT

NAPPS TECHNOLOGY CORPORATION,WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

ENGINEER'S SEAL DATE REVISION# BY

WWW.NAPPSTECH.COM1 10/31/2014SMHWIRE COLOR FROM RED/WHT TO BLUE/YELLOW AND TBB1/TBB3 TOTBB8/TBB9

1

2 KRS 02/27/2015ADDED ALARM RELAY M-7, ADDED JUMPER TO M-16, ADDED RS485 DIAG, MINOR EDITS

R410 CHILLERS

FWC20-30-50 TON WATER-COOLED CHILLERS POWER/CONROL WIRING DIAGRAM

1 1

03/21/141.5"=12"

LAH SMH

2

KEYPAD/LCD CONNECTORTO MAGNUM

HGS 1HOT GAS SOLENOID

LP1SW

RED 3A

5 3F

Comp 1

C1

4

3A

CONTACTOR

WHITE

3B

80500032

TO AO1TBB10

-

UY1

Bellim

o

+120 VAC

TR2

24 VAC TBB9

TBB8

120 VAC FU1

FU2FU32 1RED

WHITE TR1

T3T2T1

L3

C1

L2L1L3L2

C2

L1

MOTOR

1211

C2 AUX 2 CCH 2

COMPRESSOR

T3T1 T2

CCH 1

COMPRESSORMOTOR

COMP 2

11 12

C1 AUX 1

COMP 1

L3L2L1PDB1

DSW1

DISCONNECT(OPTIONAL)

L1 L3

PWM

L2

(OP

TION

AL)

FU4 FU5 FU6

GROUNDPANEL

F2 F3F1

Menu8

7

5

1

4

6

2 3

+12vGndSCLSDA

+485-485

25 tonCompressors

OnlyMTR MOD 2 MTR MOD 1

OnlyCompressors

25 ton

TBB8

BLUEYELLOW

TBB9

YELLOWBLUE

WHITE

BLACK

TBB2

BAR

TBB4

Run Light

CONTACTORComp 2

C2

21

22

23

Alarm Light

TBA1

TBA2

3G

TBB3

TBB1

3F

J

- CH

W V

ALV

E

Y

+TBB11

TBB12

3H

Wh

ite

Bla

ck

Red

{

Gre

en

Blk

Wh

t

TO EXV

MCS EXV Driver-

8

TO DI-14

CHARGEMANUAL

POWER OKFUSE BLOWNPOWER

AUTO/ MANUAL

+

7

B

6

W

5

G

4

R

3

1

L N

2

SERIAL#

VALVE 0-10VDC

POWER90-270VAC

TO AO3{

+5

3

Bellim

o

CO

ND

WR

V

CG-SVX028A-EN 33

Wiring

Figure 15. Control panel layout - typical

Napps LONGVIEW, TX 75606-3066P.O. BOX 3066NAPPS TECHNOLOGY CORP.

APP'D BYCHECKED BY:DRAWN BY:DATE:SCALE:

TITLE:

NAPPS JOB NO.DRAWING NUMBER SHEET NO.REV.OR USED FOR ANY PURPOSE

THIS MATERIAL MAY BE REPRODUCEDCONFIDENCE AND NO PORTION OFMUST BE MAINTAINED IN STRICT

NAPPS TECHNOLOGY CORPORATION,WHICH IS THE PROPERTY OF

THE INFORMATION CONTAINED HEREON,

IMPORTANT

DATE REVISION# BY

WWW.NAPPSTECH.COM

Control Panel LayoutFWC50 Chiller

01/09/20151:1

KRS

Front Panel

CKT1Enable

MCS EXVDriver

-

8

CHARGEMANUAL

POWER OK

FUSE BLOWNPOWER

AUTO/ MANUAL

+

7

B

6

W

5

G

4

R

3

1

L N

2

SERIAL#

VALVE 0-10VDC

POWER90-270VAC

RE

LAY

M-1

0

RE

LAY

M-2

RE

LAY

M-1

RE

LAY

M-4

RE

LAY

M-5

RE

LAY

M-6

RE

LAY

M-3

RE

LAY

M-7

Volta

ge

RE

LAY

M-9

RE

LAY

M-8

115v

MCS Control Unit

CPS

21

1210

11

1210

11

86

57

86

57

34

12

34

12

9 9

TBATBB

992

14

3

21

43

75

68

75

68

1110

12

1110

12

Back Panel

PWM*

MCS

TBASW

EXV

GND

C1

CT1

DSW1

TR1

FU4-6*

TBB

TR2***

CT2

C2

ENGINEER'S SEAL*FU4,5,6 PWM CIRCUIT FUSES - KTK OR EQ

MCS EXV DRIVEREXV

ITEMS MARKED WITH * ARE

OPTIONAL AND ARE NOT ON

ALL UNITSCT1-CT2 CURRENT TRANSDUCER MODULES

TR2***24VAC CL2 TRANSFRM FOR COMPR MOTOR

MCS MCS MAGNUM DIGITAL CONTROLLER

LEGEND

C1-C2

DSW1

FU1,2,3

DISCONNECT SWITCH

TR1 PRIMARY CIRCUIT FUSES - KLDR OR EQ

COMPRESSOR CONTACTORS

TR1 250 VA TRANSFORMER

*PWM DIGITAL POWER MONITORSW TOGGLE SWITCHES

TERMINAL BLOCK

TBA TERMINAL BLOCK

TBB

GND GROUND LUG

MODULE AND/OR OPTIONAL WATER REG VLV

FU1-3

PDB1**

PDB1** POWER DISTRIBUTION BLOCK

FWC50 Control Panel Layout

ITEMS MARKED WITH ** ARE

ONLY ON 460V & 575V UNITS

ITEMS MARKED WITH *** ARE OPTIONAL ON

THE 20 & 30 TON ONLY AND

ARE NOT ON ALL 20 & 30

TON UNITS

34 CG-SVX028A-EN

Wiring

Figure 16. CICA field wiring diagram

Control Panel Representation - Front

Optional: Chill Water Pump Enable 125 VAC Max

Optional: Alarm Contacts 125 VAC Max

REQUIRED : Flow Switch (flow proving device), Dry Contacts Only

Optional: Remote Run/Stop, Dry Contacts Only

WARNINGHazardous voltage!Disconnect all electrical powerincluding remote disconnects beforeservicing unit. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.Failure to do so can cause death orserious injury.

CAUTIONUse copper conductors only!Unit terminals are not designed toaccept other type conductors. Failureto use copper conductors may causeequipment damage. Notes :

All customer control-circuit wiring must have a minimum rating of 1.150V.All field wiring must be in accordance with National Electric Code and 2.State & Local requirements.(Required) Factory supplied or approved alternate field installed flow 3.proving device connection.First chiller in array is connected from RS485 port to the Array 4.Controller MCS I/O port.Consecutive chillers in array are daisey-chained through RS485 ports.5.Remove RS485 Berg Termination Jumper if chiller is not the last unit 6.in array.

CAUTIONDo not energize the unit until check-out and start-up procedures havebeen completed. 3

4

PANELGROUND

L3L2L1PDB1

DSW1

Control Panel Representation - Back

Optional: Condenser Pump Enable 125 VAC Max

TBA

92

14

37

56

811

1012

Unit Controller11

5v

RE

LAY

M-8

RE

LAY

M-9

Volta

ge

RE

LAY

M-7

RE

LAY

M-3

RE

LAY

M-6

RE

LAY

M-5

RE

LAY

M-4

RE

LAY

M-1

RE

LAY

M-2

RE

LAY

M-1

0

12

34

56

78

910

1112

*

*

Items NOT USED if chiller is in an array

-+

GND

-+GND

RS485

RS48

5

**Berg Jumper

3

Blac

k

Whit

e

**To Array Controller MCS I/O

**To RS485 of Next Chiller in Array

- +

6

5

6

4

**

*

5

**

*

Items USED if chiller is in an array

***

**

CG-SVX028A-EN 35

Appendix A

Warranty

I. LIMITED PRODUCT WARRANTY & SERVICE POLICY

NappsTechnology Corporation (NAPPS) warrants for aperiod of twelve (12) months from date of originalshipment that all products, manufactured by NAPPS, withthe exception of packaged refrigeration products, are freefrom defects of material and workmanship when usedwithin the service, range, and purpose for which they weremanufactured. Packaged refrigeration products shall be sowarranted for a period of twelve (12) months from date ofstart-up or eighteen (18) months from date of originalshipment, whichever may first occur. Service Parts shall beso warranted for a period of ninety (90) days from date ofinstallation, or twelve (12) months from date of originalshipment, whichever may first occur.

In case material is rejected on inspection by the buyer asdefective, NAPPS shall be notified in writing within ten (10)days from receipt of said material. NAPPS will then havethe option of re-inspection at the buyer's plant or its ownplant before allowing or rejecting the buyer's claim.Expenses incurred in connection with claims for whichNAPPS is not liable may be charged back to the buyer. Noclaim for correction will be allowed for work done in thefield except with the written consent of NAPPS. Defectsthat do not impair service shall not be cause for rejection.NAPPS assumes no liability in any event for consequentialdamages. No claim will be allowed for material damagedby the buyer or in transit. Defective equipment or partsshall be returned to NAPPS freight prepaid.

NAPPS will, at its option, repair, replace or refund thepurchase price of products found by NAPPS to bedefective in material or workmanship provided thatwritten notice of such defect requesting instruction forrepair, replacement or refund is received by NAPPS withinten (10) days of determination of said defect, but not morethan one (1) year after the date of shipment, and providedthat any instructions given thereafter by NAPPS arecomplied with.

Any products covered by this order found to NAPPS'satisfaction to be defective upon examination at NAPPS'factory will, at NAPPS' option, be repaired or replaced andreturned to Buyer via lowest cost common carrier, orNAPPS may, at its option, grant Buyer a credit for thepurchase price of the defective article.

Without limitation of the foregoing, this warranty shall notapply to (i) deterioration by corrosion or erosion ofmaterial or any cause or failure other than defect ofmaterial or workmanship; (ii) the performance of anysystem of which NAPPS' products are a component part;or (iii) any of NAPPS' products or parts thereof which havebeen subjected to alteration or repair by anyone other thanNAPPS or someone authorized by NAPPS, or subjected tomisuse, neglect, free chemicals in system, corrosiveatmosphere, abuse or improper use or misapplicationsuch as breakage by negligence, accident, vandalism, the

elements, shock, vibration or exposure to any otherservice, range or environment of greater severity than thatfor which the products were designed, or if operation iscontrary to NAPPS' or manufacturer's recommendation,or if the serial number has been altered, defaced orremoved.

Hermetic motor/compressors furnished by NAPPS aresubject to the standard warranty terms set forth above,except that the hermetic motor/compressor replacementsor exchanges shall be made through the nearestauthorized wholesaler of the hermetic motor/compressormanufacturer (not NAPPS' factory) and no freight shall beallowed for transportation of the hermetic motor/compressor to and from the wholesaler. ForTRANEhermetic motor/compressors, the nearest wholesalerreferred to herein shall be the nearestTRANE PARTSCENTER.The replacement hermetic motor/compressorshall be identical to the model of the hermetic motor/compressor being replaced. Additional charges, whichmay be incurred through the substitution of other thanidentical replacements, are not covered by this warranty.Evaporator failure due to fluid freezing that is the result oflow fluid flow or inadequate fluid freeze protection, forapplications with leaving fluid temperatures below 40° F, isnot covered by this warranty

THE WARRANTY PROVIDED ABOVE ISTHE ONLYWARRANTY MADE BY NAPPS WITH RESPECTTO ITSPRODUCTS OR ANY PARTSTHEREFORE AND IS MADEEXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, BYCOURSE OF DEALING, USAGES OFTRADE OROTHERWISE, EXPRESSED OR IMPLIED, INCLUDING BUTNOT LIMITEDTO ANY IMPLIED WARRANTIES OFFITNESS FOR ANY PARTICULAR PURPOSE OR OFMERCHANTABILITY UNDERTHE UNIFORMCOMMERCIAL CODE. IT IS AGREEDTHATTHISWARRANTY IS IN LIEU OF AND BUYER HEREBY WAIVESALL OTHERWARRANTIES, GUARANTEES OR LIABILITIESARISING BY LAW OR OTHERWISE. NAPPS SHALL NOTINCURANY OTHER, OBLIGATIONS OR LIABILITIES OR BELIABLETO BUYER OR ANY CUSTOMER OF BUYER FORANY ANTICIPATED OR LOST PROFITS, INCIDENTAL ORCONSEQUENTIAL DAMAGES, OR ANY OTHER LOSSESOR EXPENSES INCURRED BY REASON OFTHEPURCHASE, INSTALLATION, REPAIR, USE OR MISUSE BYBUYER ORTHIRD PARTIES OF ITS PRODUCTS(INCLUDING ANY PARTS REPAIRED OR REPLACED); ANDNAPPS DOES NOT AUTHORIZE ANY PERSONTOASSUME FOR NAPPS ANY OTHER LIABILITY INCONNECTION WITHTHE PRODUCTS OR PARTSTHEREFORE. NAPPS SHALL NOT BE RESPONSIBLE FORTHE LOSS OR REPLACEMENT OF ORTHE ADDITION OFCOMPRESSOR OIL, OR REFRIGERANT.THIS WARRANTYCANNOT BE EXTENDED, ALTERED OR VARIED EXCEPTBY A WRITTEN INSTRUMENT SIGNED BY NAPPS ANDBUYER.

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Appendix A Warranty

II. LIMITATION OF LIABILITY

NAPPS shall not be liable, in contract or in tort, for anyspecial, indirect, incidental or consequential damages,such as, but not limited to, loss of profits, or injury ordamage caused to property, products, or persons byreason of the installation, modification, use, repair,maintenance or mechanical failure of any NAPPS product.

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Appendix B

Vendor Data Sheets

The following vendor data sheets are attached:

• MCS-CT300 Current Sensor Data Sheet

• MCS-667 PressureTransducer Data Sheet

• MCS-T100Temperature Sensor Data Sheet

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Appendix B Vendor Data Sheets

MCS-CT300 Current Sensor Data Sheet

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Appendix B Vendor Data Sheets

MCS-667 PressureTransducer Data Sheet

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Appendix B Vendor Data Sheets

MCS-T100Temperature Sensor Data Sheet

CG-SVX028A-EN 41

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Appendix C

Piping System Flushing

Procedure

Prior to connecting the chiller to the condenser and chilledwater loop, the piping loops shall be flushed with adetergent and hot water (110-130°F) mixture to removepreviously accumulated dirt and other organics. In oldpiping systems with heavy encrustation of inorganicmaterials consult a water treatment specialist for properpassivation and/or removal of these contaminants.

During the flushing, 30 mesh (max.)Y-strainers (oracceptable equivalent) shall be in place in the systempiping and examined periodically as necessary to removecollected residue.The use of on-board chiller strainersshall not be acceptable.The flushing process shall take noless than 6 hours or until the strainers when examinedafter each flushing are clean. Old systems with heavyencrustation shall be flushed for a minimum of 24 hoursand may take as long as 48 hours before the filters runclean. Detergent and acid concentrations shall be used instrict accordance with the respective chemicalmanufacturer's instructions. After flushing with thedetergent and/or dilute acid concentrations the systemloop shall be purged with clean water for at least one (1)hour to ensure that all residual cleaning chemicals havebeen flushed out.

Prior to supplying water to the chiller theWaterTreatmentSpecification shall be consulted for requirementsregarding the water quality during chiller operation.Theappropriate chiller manufacturer's service literature shallbe available to the operator and/or service contractor andconsulted for guidelines concerning preventativemaintenance and off-season shutdown procedures.

WaterTreatment Requirements

Supply water for both the chilled water and condenserwater circuits shall be analyzed and treated by aprofessional water treatment specialist who is familiarwith the operating conditions and materials ofconstruction specified for the chiller's heat exchangers,headers and associated piping. Cycles of concentrationshall be controlled such that recirculated water quality forcompact chillers using 316 stainless steel brazed plate heatexchangers and carbon steel headers is maintained withinthe following parameters.

Table 7. Water property limits

Water Property Concentration Limits

Alkalinity (HCO3-) 70-300 ppm

Sulfate (SO42-) Less than 70 ppm

HCO3- / SO42- Greater than 1.0

Electrical Conductivity 10 - 500 μS/cm

pH 7.5 – 9.0

Ammonia (NH3) Less than 2 ppm

Chlorides (Cl-) Less than 300 ppm

Free Chlorine (Cl2) Less than 1 ppm

Hydrogen Sulfide (H2S) Less than 0.05 ppm

Free (aggressive) Carbon Diox-ide(CO2)

Less than 5 ppm

Total Hardness (°dH) 4.0 - 8.5

Nitrate (NO3) Less than 100 ppm

Iron (Fe) Less than 0.2 ppm

Aluminum (Al) Less than 0.2 ppm

Manganese (Mn) Less than 0.1 ppm

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader increating and sustaining safe, comfortable and energy efficient environments,Trane offers a broad portfolio of advancedcontrols 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.

We are committed to using environmentally

conscious print practices that reduce waste.

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