Installation

Duplex Water-CooledHermetic CenTraVac™ WithCH530 Controller

CDHF-SVN01B-ENX39640669020

Cooling OnlyDirect Drive with CH530 Control Panel

© 2005 American Standard Inc. All rights reserved. CDHF-SVN01B-EN

Warnings andCautions

Warnings and CautionsNotice that warnings and cautionsappear at appropriate intervalsthroughout this manual. Warningsare provided to alert installingcontractors to potential hazards thatcould result in personal injury or

death, while cautions are designedto alert personnel to conditions thatcould result in equipment damage.

Your personal safety and the properoperation of this machine dependupon the strict observance of theseprecautions.

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

Read these carefully.

����� WARNING – Indicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury.

����� CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result inminor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION – Indicates a situation that may result in equipment or property-damage-only accidents.

3

Contents

CDHF-SVN01B-EN

Warnings and Cautions

General Information

Water Piping

Vent Line Piping

Insulation

Electrical Information

Trane Supplied Starter

Customer Supplied Starter

Line Power Supply

PFCC

PFCC and Unit Mounted Starters

Remote Starter

Starter to UCP Control Wiring

Control Circuit Wiring

System Control Wiring

Wiring Diagrams

2

4

25

35

41

43

44

45

47

48

50

51

53

54

56

59

CDHF-SVN01B-EN4

About this Manual

Original date of manual:

This manual contains informationregarding installation of ModelsCDHF 60 Hz and CDHG 50 Hz chillersequipped with Tracer CH530controller. Reference is made to theCDHF. All installation proceduresdescribed for the CDHF apply also tothe CDHG. By carefully reviewing theinformation in this manual andfollowing the instructions givenalong with the submittal packageprovided for the unit will assure thatthe chiller is installed correctly.

General Information

Product Description Block

Trane 60 Hz. Model CDHF hermeticCenTraVac™ units are defined by theproduct definition and selectionsystem (PDS). Each unit is defined bythe product description block whichappears on the unit nameplate. Anexplanation of the PDS product codeis provided in the unit operation andmaintenance literature.

5CDHF-SVN01B-EN

General Information

Warnings and Cautions

Notice that WARNINGS andCAUTIONS appear at appropriateintervals throughout this manual.WARNINGS are provided to alertinstalling contractors to potentialhazards that could result in personalinjury or death, while CAUTIONS aredesigned to alert personnel toconditions that could result inequipment damage.

Your personal safety and the properinstallation of this machine dependupon the strict observance of theseprecautions.

Unit Nameplate

The CDHF unit nameplate is locatedon the left side of the left hand unitcontrol panel (UCP). A typical unitnameplate is illustrated in Figure 1.The following information isprovided on the CDHF unitnameplate.

- Unit model and size descriptor

- Unit serial number

- Unit electrical requirements

- Correct operating charge and typeof refrigerant.

- Unit test pressures and maximumoperating pressures

- Unit Installation and Operation andMaintenance manuals

- Product description block (identifiesall unit components and unit“design sequence” used to orderliterature and make other inquiriesabout the unit).

Metric Conversion

The following conversions apply fortables and charts in this manual,

In. x 2.54 = cm

Ft. x 30.48 = cm.

Lb. x .453 = kg.

Commonly Used Acronyms

ASME = American Society ofMechanical EngineersASHRAE = American Society ofHeating, Refrigerant and AirConditioning Engineers

BAS = Building Automation SystemLBU = La Crosse Business UnitCABS = Auxiliary Condenser Tube-Bundle SizeCDBS = Condenser Bundle SizeCDSZ = Condenser Shell SizeCWR = Chilled Water Reset

DTFL = Delta-T at Full Load (i.e., thedifference between entering andleaving chilled water temperatures atdesign load)EVBS = Evaporator Bundle SizeEVSZ = Evaporator Shell Size

GPM = Gallons-per-Minute

HVAC = Heating, Ventilating, and AirConditioningIE = Internally Enhanced TubesIPC = Interprocessor Communication

PFCC = Power Factor CorrectionCapacitorPSID = Pounds-per-Square-Inch(differential pressure)PSIG = Pounds-per-Square-Inch(gauge pressure)

UCP = Chiller Control Panel

CH530 = Tracer CH530 ChillerController

CDHF-SVN01B-EN6

Figure 1 – Information from a Typical CDHF Unit Nameplate

General Information

MODEL: CDHF2000 DATE OF MFG (DD/MM/YY): @TODAY05MODEL NO:CDHF2000KR0TA2802745B0A106B0A1CFFRR10W4C0010330001SSERIAL NO: S.O. NO: SAMPLE

RATED VOLTAGE: 4160 VOLTS 60 HZ 3 PHVOLTAGE UTILIZATION RANGE: 3744-4576 VAC

LH CIRCUIT RH CIRCUITMINIMUM CIRCUIT AMPACITY: 96 AMPS 103 AMPSMAXIMUM OVERCURRENT PROTECTIVE DEVICE: 150 AMPS 175 AMPS

COMPRESSOR MOTOR MAX VOLTS-AC HZ PH RLA KW LRAYLH CIRCUIT 4160 60 3 75 480 400RH CIRCUIT 4160 60 3 82 523 473 VOLT HZ PHOIL TANK HEATER (LH&RH): 115 60 1 750 WATTSCONTROL CIRCUIT (LH&RH): 115 60 1 4000 VA MAXCARBON TANK HEATER (LH&RH):115 60 1 1.7 RLAPUMPOUT COMPRESSOR(LH&RH): 115 60/50 1 1.55 RLAPURGE COMP MTR(LH&RH): 115/110 60/50 1 8RLA 34.6LRA

WHEN MOTOR CONTROLLER PROVIDED BY OTHERSTRANE ENGINEERING SPEC. S6516-0513 APPLIES

REFRIGERANT SYSTEM LH RH FIELD CHARGED WITH: 1850 1850 LBS. OF R-123 ACTUALLY CHARGED WITH: LBS. OF R-123 MAXIMUM WORKING PRESSURE: 15 15 PSIG HIGH SIDE MAXIMUM WORKING PRESSURE: 15 15 PSIG LOW SIDE

FACTORY TEST PRESSURE: HIGH SIDE 45 PSIG LOW SIDE 45 PSIG FIELD LEAK TEST PRESSURE 8 PSIG MAX. TESTED AT PSIG

MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING U.S. PATENTS: 4232533 4686834 4689967 47151904751653 4800732 5031410 5056032 5058031 53556915434738 5537830 5553997 5563489 5600960 56759785836382 5848538 6065297 6098422 6250101

SERVICE LITERATURE INSTALLATION MANUAL: CDHF-SVN01A-EN OPERATION/MAINTENANCE MANUAL: CDHF-SVU01A-EN

PRODUCT DESCRIPTION:TVSQ 1 PTON 1975 VTR1 165 VTR2 165CTM1 75 CTM2 100 MAC1 6 MAC2 6MODL CDHF DSEQ R0 NTON 2000 VOLT 4160HRTZ 60 CPM1 512 CPD1 280 CPM2 588CPD2 274 EVSZ 210D EVBS 1850 EVTM TECUEVTH 35 EFLD WATE EVWT MAR EVWP 1EVWC STD EVPR 150 EVCO VICT EVWA RRLRCDSZ 210D CDBS 1900 CDTM TECU CDTH 35CFLD WATE CDWT MAR CDWP 1 CDWC STDCDPR 150 CDCO VICT CDWA LFRF ORC1 1265ORC2 1265 AGLT UL TEST CWSP TTOL SPCLWCNM BNMP CNIF CH53 OPST YES WPSR WFCTRMM TRM4 EPRO YES CDRP YES SPKG DOMASCL OUTS APTY STD SRT1 CXL SRT2 CXLSOPT 3RTD GENR NO

7CDHF-SVN01B-EN

General Information

Responsibilities of InstallingContractors

For your convenience, a summary ofthe contractor responsibilitiestypically associated with the chillerinstallation process is providedbelow. Table 1 further categorizesthese responsibilities bydifferentiating between Trane-supplied and field-supplied and fieldinstalled components.

Refer to the Installation section ofthis manual for more detailedinstructions.

• Locate and maintain the looseparts, i.e. isolators, bulb wells,temperature sensors, flow sensorsor other factory-ordered fieldinstalled options, for installation asrequired. Loose parts are located inthe starter panel on units withfactory-installed unit-mountedstarters or in the motor terminalbox for units with remote-mountedstarters.

• Install unit on a foundation with flatsupport surfaces level within 1/16”,and of sufficient strength tosupport concentrated loading.Place manufacturer-suppliedisolation pad assemblies underunit. (Use spring isolators for upperfloor installations).

• Install unit per applicable Traneinstallation manual.

• Complete all water piping andelectrical connections.

Note: Field-piping must be arrangedand supported to avoid stress on theequipment. It is stronglyrecommended that the pipingcontractor refrain from piping closerthan 3’-0” minimum to theequipment. This will allow for properfit-up upon arrival of the unit at thejobsite. Any adjustment that isnecessary can be made to the pipingat that time.

• Where specified, supply and installvalves in water piping upstreamand downstream of evaporator andcondenser water boxes to isolateshells for maintenance, and tobalance/trim system.

• Supply and install flow switches (orequivalent devices) in both chilledwater and condenser water piping.Interlock each switch with properpump starter to ensure unit canonly operate when water flow isestablished.

• Supply and install taps forthermometers and pressuregauges in water piping adjacent toinlet and outlet connections of bothevaporator and condenser.

• Supply and install drain valves oneach water box.

• Supply and install vent cocks oneach water box.

• Where specified, supply and installstrainers ahead of all pumps andautomatic modulating valves.

• Supply and install pressure reliefpiping from pressure-relief rupturedisc to atmosphere.

• If necessary, supply sufficientRefrigerant-HCFC-22 (maximum of1 lb. per machine) and dry nitrogen(8 psig per machine) for pressuretesting under manufacturer’ssupervision.

• Start unit under supervision of aqualified service technician.

• Where specified, supply andinsulate evaporator and any otherportions of machine as required toprevent sweating under normaloperating conditions.

• Unit-Mounted Starters Only,remove top of starter panel and cutaccess area for line-side wiring;front left quadrant of top providesrecommended access to starterlugs.

• Supply and install wire terminallugs to starter.

• Unit-Mounted Starters Only,Supply and install field wiring toline-side lugs of starter.

• Supply and install a RefrigerantMonitor per ASHRAE 15specifications. Reference thecompliance to ASHRAE Standard15 as shown on the “ModelCenTraVac™ Checksheet andRequest for Serviceman”.

To obtain a copy of “ModelCenTraVac™ Checksheet and Requestfor Serviceman” (Form 1-27.08-6)order from your local Trane office.

CDHF-SVN01B-EN8

General Information

Table 1 – Installation Requirements

Type of Trane-Supplied Trane-Supplied Field-SuppliedRequirement Trane-Installed Field-Installed Field-InstalledRigging A. Safety chains

B. Clevis connectorsC. Lifting beam

Isolation A. Isolation pads or A. Isolation pads or spring isolatorsspring isolators

Electrical A. Circuit breakers or A. Jumper bars A. Circuit breakers or fusiblefusible disconnects B. Temperature sensor disconnects (optional)(optional) (optional outdoor air) B. Remote-mounted starter

B. Unit-mounted C. Flow switches (may C. PFCCs (Remote-mountedstarter (optional) be field supplied) starter option only)

C. PFCCs (optional) D. Terminal lugsE. Ground connection(s)F. Jumper barsG. BAS wiring (optional)H. IPC wiring (remote-

mounted starters onlyI. Control voltage wiring

(remote-mounted starters only)J. Oil pump interlock wiring

(remote-mountedstarters only)

K. High condenser pressureinterlock wiring(remote-mounted starters only).

L. Chilled water pump contactorand wiring

M.Condenser water pumpcontactor and wiring

N. Option relays and wiring(See Table 14 & 16)

Water Piping A. Flow switches (May A. Thermometersbe field supplied) B. Water flow pressure gauges

C. Isolation and balancing valveswater piping

D. Vents and drain valves(1 each per class)

E. Pressure-relief valves(for water boxes as required)

Rupture Disc A. Rupture disc assy A. Vent line and flexible connectorInsulation A. Insulation (Optional) A. Insulation

9CDHF-SVN01B-EN

General Information

Unit Shipment

Each chiller ships from the factory asa hermetically assembled package; itis factory piped, wired and tested. Allopenings are covered or plugged toprevent contamination duringshipment and handling.

See Figure 2 for an illustration of atypical unit and its components. Assoon as the unit arrives at the jobsite, inspect it thoroughly fordamage and material shortages. Inaddition:

1. Verify the chiller’s hermeticintegrity by checking theevaporator pressure for anindication of holding chargepressure.

Note: Since there are two refrigerantcircuits both must be checked.

To prevent damaging moisture fromentering the unit and causingcorrosion, each chiller is pressurizedwith dry nitrogen before shipment.

Note: The holding charge shouldregister approximately 5 psig (at sealevel) on the gauge. If the charge hasescaped, contact your local Tranesales office for instructions.

2. Check the oil sump sight glassesto verify that the sump wasfactory-charged with 9 gallons ofoil. If no oil level is visible, contactyour local Trane sales office.

3. Compare the unit nameplate data(including electrical characteristics)with the corresponding orderingand shipping information to verifythat the correct unit was shippedto the job site.

If a thorough inspection of thechiller reveals damage or materialshortages, be sure to file theseclaims with the carrierimmediately. Specify the extentand type of damage found, andnotify the appropriate Trane salesrepresentative. Do not install adamaged unit without the salesrepresentative’s approval!

Storage

If the chiller will be stored at the jobsite for an extended period of timebefore it is installed, exercise theseprecautionary measures to protectthe unit from damage:

1. Do not remove the protectivecoverings factory-installed on thecontrol panel and compressorinlet vane actuator for shipment.

2. Store the chiller in a dry vibrationfree and secure area. If factoryinsulated, protect chiller fromprolonged exposure to sunlight.

CAUTION

Insulation Damage!

To prevent damage to the factory-installed insulation, do not allowexcessive exposure to sunlight.

3. Periodically check the condenserand evaporator pressure to verifythat the 5 psig dry nitrogen at 72°Fambient holding charge is still inthe chiller. If this charge escapes,contact a qualified serviceorganization and the Trane salesengineer that handled the order.

Note: The storage range for themicrocomputer-based devices in theunit control panel is -40°F to 158°F(-40°C to 70°C).

CDHF-SVN01B-EN10

Figure 2 – Typical CDHF Chiller

General Information

11CDHF-SVN01B-EN

General Information

Recommended UnitClearances

Adequate clearance around andabove the chiller is required to allowsufficient access for service andmaintenance operations.

Figure 3 illustrates therecommended clearances for unitswith and without options. Figure 4shows tube bundle locations. Noticethat, in each instance, the minimumvertical clearance above the chiller is3-feet.

In addition, be sure to provide atleast 3-feet of working space in frontof the unit control panel to satisfy theNational Electrical Code, and/or localcodes.

Important! Do not install piping orconduit above the compressormotor assembly or behind thesuction elbow!

Note: Specific unit clearancerequirements are also indicated inthe submittal package provided foryour unit.

Operating Environment

Besides assuring that the siteselected for chiller installationprovides the necessary clearances,consider the equipment’s operatingenvironment.

To assure that electrical componentsoperate properly, do not locate thechiller in an area exposed to dust,dirt, corrosive fumes, or excessiveheat and humidity. Note that themaximum ambient temperature forchiller operation is 95 to 100°F (35° -38° C).

CAUTION

Equipment Failure!

CDHF operation at ambienttemperatures exceeding 100°F(38°C) can fatigue the unit’s rupturedisc, causing it to break at a reducedrefrigerant pressure (i.e., <15 psig).Starter component damage can alsooccur because of the panel’s inabilityto dissipate heat adequately.

If any of these adverse operatingconditions are present, takewhatever action is necessary toimprove the equipment roomenvironment.

Foundation Requirements

Provide rigid, non-warpingmounting pads or a concretefoundation as a mounting surface forthe chiller. Ensure that the base is ofsufficient strength and mass toproperly support the chiller at its fulloperating weight (i.e., includingcompleted piping, and full operatingcharges of refrigerant, oil and water).

For your convenience, a summary ofstandard unit shipping and operatingweights is provided in Table 2.

Notice that the floor loading for allsizes of chillers is 60 pounds persquare inch.

To assure proper unit operation, thechiller must be level within 1/16”over its length and width when setinto place on the mounting surface.

Trane will not assume responsibilityfor equipment problems resultingfrom an improperly designed orconstructed foundation.

CDHF-SVN01B-EN12

General Information

Figure 3 – Clearance Requirements for Standard CDHF

Notes:

1. Per NEC Article 110 - Unit mounted starters from 0-600V require 42" clearance; 601-2500V require 48" clearance;2501-9000V require 60" clearance.

2. Clearance 1 can be at either end of machine and is required for tube pull clearanceClearance 2 is always at the opposite end of machine from Clearance1 and is required for service clearance

3. Clearance requirement for evaporator tube removal does not include water box. Add water box dimension to thisfigure.

UCP Clearance Requirements for Standard CDHF

CL1 CL2Shell Width Entire Width Height Length Entire Length Clearance 1 Clearance 2210 D 130.875 184.875 132.750 258.000 606.000 264.000 84.000250 D 142.625 196.625 136.875 258.000 606.000 264.000 84.000250 M 142.625 196.625 141.375 312.000 714.000 318.000 84.000250 X 142.625 196.625 141.375 360.000 810.000 366.000 84.000

13CDHF-SVN01B-EN

General Information

Figure 4 – Tube Bundle Locations for Model CDHF Units

Cooling Only and Free Cooling Units

EVSZ CDSZ A B C D E F G H210 D 210 D 4’-5-7/16" 5"-3/8" 7’-9/16" 1’-4-1/4" 5’-0-1/8" 3’-5-1/4" 2’-5" 3’-10-3/16"250 D 250 D 5’-0-3/4" 5"-1/4 6"-1/2 1’-7-1/4" 5’-8-3/4" 3’-10-5/8" 2’-4-1/8" 3’-11-5/8"250 M 250 M 5’-0-3/4" 5"-1/4 6"-1/2 1’-7-1/4" 5’-8-3/4" 3’-10-5/8" 2’-4-1/8" 3’-11-5/8"250 X 250 X 5’-0-3/4" 5"-1/4 6"-1/2 1’-7-1/4" 5’-8-3/4" 3’-10-5/8" 2’-4-1/8" 3’-11-5/8"

CDHF-SVN01B-EN14

General Information

Table 2 – Typical Shipping and Operating Weights

Operating Weight Shipping WeightTYPE NTON CPKW EVSZ CDSZ (lbs) (kg) (lbs) (kg)CDHF 1500-2000 957 210D 210D 80171 36366 68629 31130CDHF 2100-2500 1228 250D 250D 93186 42269 79213 35931CDHG 1250-1750 716 210D 210D 82349 37354 70807 32118CDHG 2150 892 210D 210D 89680 197710 78288 172595CDHG 2150 892 250D 250D 96964 43983 82991 37645CDHF 3000 1340 250M 250M 106659 48381 89425 40563CDHF 3500 1340 250X 250X 114445 51912 95077 43127

Notes:Weights shown above are accurate within +/- 3% and are based on the followingOperating weights include refrigerant, oil charge and waterShells are with largest bundles and TECU .028 wall tubesCompressor weight with medium voltage motor and above CPKWStarter weights not includedWaterboxes are 1 pass, 150 psig Non-MarineFor other configurations refer to submittal package

15CDHF-SVN01B-EN

General Information

Note: Immediately report any unitdamage incurred during handling orinstallation at the job site to theTrane sales office.

Rigging

Lifting is the recommended methodfor moving chillers. Suggested liftingarrangements for standard units areillustrated in Figure 5.

Note that each of the cables used tolift the unit must be capable ofsupporting the entire weight of thechiller. (See Table 2 for unit shippingand operating weights.) Notice thatthe lifting beam used to lift the unitmust be at least 23 feet long.

See Figure 5 and Table 2 forguidance in selecting cable or slinglengths.

� WARNING

Test Lift!

Verify chiller remains horizontal.

To avoid serious injury and possibleequipment damage, lift the chillerhorizontally; use the liftingarrangement and rigging shown inFigure 5. Failure to lift unit asrecommended could result in deathor serious injury or lead toequipment damage.

To lift the chiller properly, insertclevis connections at the pointsindicated in Figure 5; a 2-1/2”diameter lifting hole is provided ateach of these points. Next, attach thelifting cables or slings.

Once the lifting cables are in place,attach a safety cable or slingbetween the first-stage casting of thecompressor and the lifting beam. Todo this, remove a retaining bolt fromthe compressor first-stage castingand replace it with an eyebolt, orswivel clevis.

Note: There should not be tensionon this safety cable; it is used only toprevent the unit from rolling duringthe lift.

When the lift is completed, detachthe clevis connections and safetychain, then remove the eyebolt thatwas used to secure the safety chainto the compressor, and reinstall theretaining bolt in its place. If the chillercannot be moved using theconventional rigging method justdescribed, consider these points.

1. If job site conditions requirerigging of the chiller at an anglegreater than 45° from horizontal(end-to-end), dowel-pin the com-pressor and remove it from theunit. Be sure to contact a qualifiedservice organization for specificrigging instructions.

CAUTION

Oil Loss!

To prevent oil migration out of theoil tank during lifting procedures,remove the oil from the oil tank ifthe unit will be lifted at any anglegreater than 15° from horizontalend-to-end. If oil is allowed to runout of the oil tank into other areas ofthe chiller, it will be extremelydifficult to return the oil to the oiltank even during operation.

2. When lifting the chiller is eitherimpractical or undesirable, attachcables or chains to the jackingslots shown in Figure 5; then pushor pull the unit across a smoothsurface. Should the chiller be on ashipping skid, it is not necessary toremove the shipping skid from thechiller before moving it into place.

CAUTION

Equipment Damage!

To prevent possible equipmentdamage, do not use a fork lift tomove the chiller!

CAUTION

Compressor Alignment!

Lifting the compressor/motorassembly from the shells withoutfactory-installed doweling in thecompressor casting flanges mayresult in misalignment of thecompressor castings.

3. Position isolator pads (or springisolators) beneath the chiller feet;see “Unit Isolation” section forinstructions.

4. Once the isolators are in place,lower the chiller; again, work fromend to end in small increments tomaintain stability.

CDHF-SVN01B-EN16

General Information

TYPE NTON EVSZ CDSZ X Y HCDHF 1500-2000 210D 210D 143 in. 23 ft 24.75 inCDHF 2100-2500 250D 250D 143 in. 23 ft 24.75 inCDHG 1250-1750 210D 210D 143 in. 23 ft 24.75 inCDHG 2150 210D 210D 143 in. 23 ft 24.75 inCDHG 2150 250D 250D 143 in. 23 ft 24.75 inCDHF 3000 250M 250M 172 in. 27.5 ft 24.75 inCDHF 3500 250X 250X 199 in. 31.5 ft 24.75 in

Figure 5 – Recommended Lifting Arrangements for CDHF

X

Y

H

LIFTING BEAM

SafetyChain

Safety Chain

B

A

C

Jacking Points

Notes:

1. Lifting chains (or cables) are not the same length between point A and B, or between points A and C. Adjust asnecessary for an even lift.

2. Lifting holes provided on chillers to attach chains are 2 1/2 inch in diameter.

3. Attach safety chain (or cable) as shown, and without tension. The safety chain is not used for lifting, but is there toprevent the unit from rolling.

4. Do not fork-lift the unit.

17CDHF-SVN01B-EN

General Information

Unit Isolation

To minimize sound and vibrationtransmission through the buildingstructure - and to assure properweight distribution over themounting surface, always installisolation pads or spring isolatorsunder the chiller feet.

Note: Isolation pads (Figure 6) areprovided with each chiller unlessspring isolators are specified on thesales order.

Note: The center support isapproximately 1/2" shorter (higher)than the end supports. After unitleveling, shim the center isolatorpads. If spring isolators are used,shim the isolators for the centersupport. See Figure 7.

Specific isolator loading data isprovided in the unit submittalpackage. If necessary, contact yourlocal Trane sales office for furtherinformation.

Important! When determiningplacement of isolation pads or springisolators, remember that the controlpanel side of the unit is alwaysdesignated as the unit front.

Isolation Pads

When the unit is ready for finalplacement, position isolation padsunder the chiller feet as shown inFigure 7.

Remember that the chiller must belevel within 1/16” over its length andwidth after it is lowered onto theisolation pads. In addition, all pipingconnected to the chiller must beproperly isolated and supported sothat it does not place any stress onthe unit.

Spring Isolators

Spring isolators should beconsidered whenever chillerinstallation is planned for an upperstory location. Base isolator selectionand placement on the informationpresented in Figures 8-10a. (Noticethat 3 types of spring isolators - eachwith its own maximum loadingcharacteristics are used with CDHFchillers).

Spring isolators typically shipassembled and ready for installation.To install and adjust the isolatorsproperly, follow the instructionsgiven.

Note: Do not adjust the isolatorsuntil the chiller is piped and chargedwith refrigerant and water.

1. Position the spring isolators underthe chiller as shown in Figures 8and 9. Make sure that each isolatoris centered in relation to the tubesheet.

Note: Spring isolators shipped withthe chiller are not identical! Be sureto compare the data provided in theunit submittal package and Figures 8through 10a to determine properisolator placement.

2. Set the isolators on the sub-base;shim as necessary to provide aflat, level surface at the sameelevation for the end supports,and approximately 1/2" higher forthe center support. Be sure tosupport the full underside of theisolator base plate; do not straddlegaps or small shims.

Figure 6 – Isolation Pad

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

18"[457 mm]

6"[152.4 mm]

CDHF-SVN01B-EN18

General Information

Isolation Pad Loading (lb)TYPE NTON CPKW EVSZ CDSZ Left Pad Center Pad Right PadCDHF 1500-2000 957 210D 210D 25150 26718 28304CDHF 2100-2500 1228 250D 250D 29292 31056 32838CDHG 1250-1750 716 210D 210D 25997 27446 28907CDHG 2150 892 210D 210D 26507 29850 33322CDHG 2150 892 250D 250D 20680 32316 33967CDHF 3000 1340 250M 250M 33527 35546 37586CDHF 3500 1340 250X 250X 35975 38140 40330

Isolation Pad Loading (kg)TYPE NTON CPKW EVSZ CDSZ Left Pad Center Pad Right PadCDHF 1500-2000 957 210D 210D 11408 12119 12839CDHF 2100-2500 1228 250D 250D 13287 14087 14895CDHG 1250-1750 716 210D 210D 11792 12449 13112CDHG 2150 892 210D 210D 58438 65808 73462CDHG 2150 892 250D 250D 13916 14659 15407CDHF 3000 1340 250M 250M 15208 16123 17049CDHF 3500 1340 250X 250X 16318 17300 18294

Notes:Isolator pad loading is based on the followingOperating weights include refrigerant, oil charge and waterShells are with largest bundles and TECU .028 wall tubesCompressor weight with medium voltage motor and above CPKWStarter weights not includedWaterboxes are 1 pass, 150 psig Non-MarineFor other configurations refer to submittal package

Figure 7 – Isolation Pad Placement - CDHF, CDHG

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

19CDHF-SVN01B-EN

General Information

Figure 8 – Spring Isolator Placement - CDHF, CDHG

Estimated Spring Isolator Loading (lb)TYPE NTON CPKW EVSZ CDSZ LF MF RF LR MR RRCDHF 1500-2000 957 210D 210D 14120 14948 15785 11029 11770 12519CDHF 2100-2500 1228 250D 250D 13861 14721 15591 15431 16334 17247CDHG 1250-1750 716 210D 210D 14432 15193 15960 11564 12253 12947CDHG 2150 892 210D 210D 15623 17428 19299 10884 12422 14023CDHG 2150 892 250D 250D 14413 15209 16012 16267 17108 17955CDHF 3000 1340 250M 250M 15865 16850 17845 17663 18696 19741CDHF 3500 1340 250X 250X 17023 18080 19148 18952 20060 21182

Estimated Spring Isolator Loading (kg)TYPE NTON CPKW EVSZ CDSZ LF MF RF LR MR RRCDHF 1500-2000 957 210D 210D 6405 6780 7160 5003 5339 5679CDHF 2100-2500 1228 250D 250D 6287 6678 7072 7000 7409 7823CDHG 1250-1750 716 210D 210D 6546 6892 7239 5246 5558 5873CDHG 2150 892 210D 210D 34443 38422 42547 23995 27386 30915CDHG 2150 892 250D 250D 6538 6899 7263 7379 7760 8145CDHF 3000 1340 250M 250M 7196 7643 8095 8012 8480 8954CDHF 3500 1340 250X 250X 7722 8201 8686 8597 9099 9608

Notes:Vibration isolator loading is based on the followingOperating weights include refrigerant, oil charge and waterShells are with largest bundles and TECU .028 wall tubesCompressor weight with medium voltage motor and above CPKWStarter weights not includedWaterboxes are 1 pass, 150 psig Non-MarineFor other configurations refer to submittal package

CDHF-SVN01B-EN20

General Information

Figure 9 – Chiller Foot/Isolator Orientation

Side View of Unit End View of Unit

Note: The spring isolator must be centered in relationto the tube sheet. Do not align the isolator with theflat part of the chiller foot, because the tube sheet isoften off-center.

Note: Place isolator near outsideedge of tube sheet as shown.

Center tube sheetsupport leg

Center ofIsolator Spring

Outside edge oftube sheet

End of tubesheet

3. If required, bolt the isolators to thefloor through the slots provided,or cement the pads.

Note: Fastening the isolators to thefloor is not necessary unlessspecified.

4. If the chiller must be fastened tothe isolators, insert capscrewsthrough the chiller base and intothe holes tapped in the upperhousing of each isolator. However,do not allow the screws toprotrude below the underside ofthe isolator upper housing. Analternative method of fasteningthe chiller to the isolators is tocement the neoprene pads.

5. Set the chiller on the isolators;refer to “Rigging” for liftinginstructions.

The weight of the chiller will forcethe upper housing of each isolatordown, perhaps causing it to reston the isolator’s lower housing.(Figure 10, 10a illustrates springisolator construction.)

6.Check the clearance (labeled X inFigure 10, 10a ) on each isolator. Ifthis dimension is less than 1/4” onany isolator, use a wrench to turnthe adjusting bolt one completerevolution upward.

Note: When the load is applied tothe isolators (Step 5), the top plateof each isolator moves down tocompress the springs until either:

a. The springs support the load; or

b. The top plate rests on thebottom housing of the isolator.

1. If the springs are supportingthe load, screwing down onthe adjusting bolt (Step 7) willimmediately begin to raisethe chiller.

7.Turn the adjusting bolt on each ofthe remaining isolators to obtainthe required minimum clearanceat X (Figure 10, 10a ) of 1/4”.

8. Once the minimum requiredclearance is obtained on each ofthe isolators, level the chiller byturning the adjusting bolt on eachof the isolators on the low side ofthe unit. Be sure to work from oneisolator to the next. Rememberthat the chiller must be level towithin 1/16”: over its length andwidth, and that clearance X ofeach isolator must be at least 1/4inch.

21CDHF-SVN01B-EN

General Information

Figure 10 – Typical Spring Isolator Types and Construction

Isolator Maximum SpringType Load Deflection Color

and Size (lbs.) (Inches) CodingCT-4-25 1,800 1.22 RedCT-4-26 2,400 1.17 PurpleCT-4-27 3,000 1.06 OrangeCT-4-28 3,600 1.02 GreenCT-4-31 4,400 0.83 GrayCT-4-32 5,200 0.74 White

Type CT-4 Spring Isolators

Type CT-7 Spring IsolatorsIsolator Maximum Spring

Type Load Deflection Colorand Size (lbs.) (Inches) CodingCT-7-25 3,150 1.22 RedCT-7-26 4,200 1.17 PurpleCT-7-27 5,250 1.06 OrangeCT-7-28 6,300 1.02 GreenCT-7-31 7,700 0.83 GrayCT-7-32 9,100 0.74 White

9-1/4"[235 mm]C-Cfoundationbolts

7-1/2" [191 mm]

10-1/4"[260 mm] Adjusting Bolt

6-1/2" [165 mm]Free Height

Adjust the isolator sothat the upperhousing clears thelower housing by atleast 1/4” [6 mm]

Acoustical nonskidneoprene pad (topand bottom)

8-3/4" [222mm] C-Cfoundationbolts

7-1/4"[184 mm]

9-3/4"[248 mm]

Adjusting Bolt

6-5/8" [168mm] Free

Height

Adjust the isolator so thatthe upper housing clears thelower housing by at least1/4” [6 mm]

Acoustical nonskidneoprene pad (topand bottom)

Isolator Maximum SpringType Load Deflection Color

and Size (Kg) (mm) CodingCT-4-25 816 31 RedCT-4-26 1,089 30 PurpleCT-4-27 1,361 27 OrangeCT-4-28 1,633 26 GreenCT-4-31 1,996 21 GrayCT-4-32 2,359 19 White

Isolator Maximum SpringType Load Deflection Color

and Size (Kg) (mm) CodingCT-7-25 1,429 31 RedCT-7-26 1,905 30 PurpleCT7-27 2,381 27 OrangeCT-7-28 2,858 26 GreenCT-7-31 3,493 21 GrayCT-7-32 4,128 19 White

5/8"[16 mm]

5/8"[16 mm]

5/8" [16 mm]

CDHF-SVN01B-EN22

Figure 10A – Typical Spring Isolator Types and Construction

CT-12 Spring Isolators

General Information

Isolator Max Deflection SpringType/Size Load lb (kg) inches (mm) Color CodeCT-12-25 5,400 1.22 RedCT-12-26 7,200 1.17 PurpleCT-12-27 9,000 1.06 OrangeCT-12-28 10,800 1.02 GreenCT-12-31 13,200 0.83 GrayCT-12-32 15,600 0.74 White

(2) Adjusting Bolts

8-1/8" [206mm] Free

Height

Adjust the isolator so thatthe upper housing clears thelower housing by at least1/4” [6.4 mm]

Acoustical nonskidneoprene pad (topand bottom)

5/8"[16 mm]

5/8"[16 mm]

3-1/2"[89 mm]

7"[178mm]

14-3/4" [375 mm]

12-1/2"[318 mm]

7-3/8" [187 mm]

6-1/2" [165 mm]

6-5/8"[168 mm]

13-1/4" [337 mm]

23CDHF-SVN01B-EN

Isolator Max Deflection SpringType/Size Load lb (kg) inches (mm) Color CodeCT 16-26 9600 (4355) 1.17 (29.7) PurpleCT 16-27 12000 (5443) 1.06 (26.9) OrangeCT 16-28 14400 (6532) 1.02 (25.9) GreenCT 16-31 17600 (7983) 0.83 (21.1) GrayCT 16-32 20800 (9435) 0.74 (18.8) White

Isolator Max Deflection SpringType/Size Load lb (kg) inches (mm) Color CodeCT 20-26 12000 (5443) 1.17 (29.7) PurpleCT 20-27 15000 (6804) 1.06 (26.9) OrangeCT 20-28 18000 (8165) 1.02 (25.9) GreenCT 20-31 22000 (9979) 0.83 (21.1) GrayCT 20-32 26000 (11794) 0.74 (18.8) White

General Information

CT-16 and CT20Spring Isolators

CDHF-SVN01B-EN24

General Information

Unit Leveling

Follow the instructions outlinedbelow and illustrated in Figure 11 todetermined whether or not thechiller is set level.

1. Measure an equal distance upfrom each foot of the chiller(identified as X in Figure 11) andmake a punch mark at eachmeasured distance.

2. Suspend a clear plastic tube alongthe length of the chiller as shownin Figure 11.

Figure 11 – Checking Unit Levelness

3. Fill the tube with water until thelevel aligns with the punch mark atone end of the chiller; then checkthe water level at the oppositemark.

If the water level does not alignwith the punch mark, use full-length shims to raise one end ofthe chiller until the water level ateach end of the tube aligns withthe punch marks at both ends ofthe chiller

4. Once the unit is level across itslength, repeat Steps 1 through 3 tosee if unit is level across the width.

5. If isolation pads have been used,shim the center support.

Raise chiller at oneend to align matchmarks with waterlevel.

Measure and markan equal distanceup from eachchiller foot.

Clear Plastic Tube(Fill tube with water to punch mark.)

25CDHF-SVN01B-EN

Water Piping

Overview

Several water piping circuits must beinstalled and connected to the chiller.

Note: Field piping must be arrangedand supported to avoid stress on theequipment. It is stronglyrecommended that the pipingcontractor refrain from piping closerthan 3’-0” minimum to theequipment. This will allow for properfit-up upon arrival of the unit at thejob-site. Any adjustment that isnecessary can be made to the pipingat that time.

1. Pipe the evaporator into the chilledwater circuit.

2. Pipe the condenser into thecooling tower water circuit. Pipingsuggestions for each of the watercircuits listed above are outlinedlater in this section. Generalrecommendations for theinstallation of field-supplied pipingcomponents (e.g., valves, flowswitches, etc.) common to mostchiller water circuits are listedbelow.

Water Treatment

Since the use of untreated orimproperly treated water in aCenTraVac™ may result in inefficientoperation and possible tubedamage, be sure to engage theservices of a qualified watertreatment specialist if needed. Alabel with the following disclamatorynote is affixed to each CDHF unit:

Customer Note: “The use ofimproperly treated or untreatedwater in this equipment may resultin scaling, erosion, corrosion, algaeor slime. The services of a qualifiedwater treatment specialists shouldbe engaged to determine whattreatment, if any, is advisable. The

Trane warranty specifically excludesliability for corrosion, erosion, ordeterioration of Trane equipment,Trane assumes no responsibilitiesfor the results of the use of untreatedor improperly treated water, or salineor brackish water.”

CAUTION

Water Treatment!

Do not use untreated or improperlytreated water, or equipmentdamage may occur.

Pressure Gauges

Locate pressure gauge taps in astraight run of pipe. Place tap aminimum of one pipe diameterdownstream of any elbow, orificeetc. Example, for a 6” pipe, the tapwould be at least 6” from any elbow,orifice, etc.

Valves

1. Install field-supplied air vents anddrain valves on the water boxes.Each water box is provided with a3/4” NPTF vent and drainconnection.

Plastic plugs are factory-installed inboth openings for shipment;remove and discard these plugs asyou install the water box ventsand drain valves.

2. If necessary for the application,install pressure-relief valves at thedrain connections on theevaporator and condenser waterboxes. To do so, add a tee with therelief valve attached to the drainvalve. To determine whether ornot pressure-relief valves areneeded for a specific application,keep in mind that:

a) Vessels with close-coupledshutoff valves may cause high,potentially damaging hydro-static pressures as fluidtemperature rises; and,

b) Relief valves are required byASME codes when the shellwaterside is ASME. Consultguidelines or other applicablecodes to assure proper reliefvalve installation.

CAUTION

Overpressurization!

Failure to install pressure-reliefvalves in the condenser andevaporator water circuits may resultin shell damage due to hydrostaticexpansion.

Strainers

Install a strainer in the entering sideof each piping circuit to avoidpossible tube plugging in the chillerwith debris.

CAUTION

Tube Damage!

Failure to install strainers in all waterpiping entering the chiller can resultin tube plugging conditions thatdamage unit components.

Flow-Sensing Devices

Use either flow switches ordifferential pressure switches inconjunction with the pump interlocksto verify evaporator and condenserwater flows.

To assure adequate chillerprotection, wire the chilled-waterand condenser-water flow switchesin series with the appropriate waterpump interlock. Refer to the wiringdiagrams that shipped with the unitfor specific electrical connections.

CDHF-SVN01B-EN26

Water Piping

Unless stated otherwise, all flow-sensing devices must befield-supplied. Be sure to follow themanufacturer’s recommendationsfor device selection and installation.Also, review the general flow switchinstallation guidelines listed below.

1. Mount the flow switch upright in ahorizontal section of pipe. Allow atleast 5 pipe diameters of straight,horizontal run on each side of theswitch.

Avoid locations adjacent toelbows, orifices and valveswhenever possible.

2. To assure that the flow switchoperates as designed, adjust thelength of the flow switch paddle tocompensate for the pipe diameterand the height of the coupling teeused to install the switch.

3. Install the flow switch using acoupling that is large enough toallow the insertion of a bushingone pipe diameter larger than theflow switch base (Figure 12). Thiswill prevent interference with theflow switch paddle.

4. Verify that the direction-of-flowarrow on the switch points in thesame direction as actual waterflow through the piping circuit.

5. Remove all air from the pipingcircuit to prevent possible flowswitch “fluttering”.

6. Adjust the flow switch to openwhen water flow is less thannormal.

Evaporator and CondenserWater Piping

Figures 13 and 14 illustrate thetypical water piping arrangementsrecommended for the evaporatorand condenser.

Note: It is strongly recommendedthat the piping contractor refrainfrom piping closer than 3’-0”minimum to the equipment. This willallow for proper fit-up upon arrival ofthe unit at the job-site. Anyadjustment that is necessary can bemade to the piping at that time.

Figure 12 – Flow Switch Installation

1 Pipe size larger bushing to avoid paddle interference

Example Flow Switch

Pipe half coupling

5 pipe diameters 5 pipe diameters

Water piping connection sizes areidentified in Tables 3 and 4.Remember that entering and leavingevaporator and condenser watermust be piped in accordance withthe nameplate entering and leavingorientation.

IMPORTANT

Water flows must be piped inaccordance with nameplatedesignation.

Note: To assure that the evaporatorwater piping is clear, check it afterthe chilled water pump is operatedbut before initial chiller start-up. Ifany partial blockages exist, they canbe detected and removed to preventpossible tube damage resulting fromevaporator freeze-up or erosion.

For applications that include an“infinite source” or “multiple-use”cooling condenser water supply,install a valve bypass “leg”(optional) between the supply andreturn pipes; see Figure 14. Thisvalve bypass allows the operator toshort-circuit water flow through thecooling condenser when the supplywater temperature is too low.

Note: To prevent operatingproblems, pressure differentialbetween condenser and evaporatorshould not fall below 3 psid.

To accommodate lifting apparatus,lifting holes are provided in thestiffening ribs of each evaporatorwater box to enable attachment of aswivel clevis (field-supplied).Condenser water boxes are providedwith welded nuts that allowinstallation of the eyebolt included inthe unit’s loose parts-box.

27CDHF-SVN01B-EN

Water Piping

Figure 13 – Typical Evaporator Water Piping Circuit

Notes:

1.Flow switch 5S1 (Item 7 in Legend of Components) should be installed inthe leaving leg of the chilled water circuit.

2. It is recommended to pipe 1 gauge between entering and leaving pipes. Ashutoff valve on each side of the gauge allows the operator to read eitherentering or leaving water pressure.

Legend of Field-Supplied/Installed Components

1. Pressure Gauge2. Thermometer(s) (If field supplied)3. Union(s) or Flanged Connection(s)4. 1/2" NPT Coupling(s)5. Balancing Valve6. Gate (Isolation) Valve(s) or Ball Valve(s)7. Chiller Water Flow Switch (5S1)8. Strainer9. Evaporator Water Pump

5S1

CDHF-SVN01B-EN28

Figure 14 – Typical Condenser Water Piping Circuit

Water Piping

Notes:

1.Flow switch 5S2 (Item 7 in Legend of Components) should be installed inthe leaving leg of the chilled water circuit.

2. It is recommended to pipe 1 gauge between entering and leaving pipes.

3. Some type of field-supplied temperature control device may be required toregulate the temperature of the heat-recovery condenser water circuit. Forapplication recommendations, see Trane Applied Manual, AM-FND-8, titled“Heat-Recovery Engineering Seminar.”

4. Intalla bypass valve system to avoid circulating water through the auxiliaryshell when the unit is shut down.

Legend of Field-Supplied/Installed Components

1. Pressure Gauge2. Thermometer(s) (If field supplied)3. Union(s) or Flanged Connection(s)4. 1/2" NPT Coupling(s)5. Balancing Valve6. Gate (Isolation) Valve(s) or Ball Valve(s)7. Condenser Water Flow Switch8. 3-Way Valve (Optional)9. Condenser Water Pump

10. Strainer

29CDHF-SVN01B-EN

Water Piping

Table 3 – Evaporator Water PipingConnection Sizes –CDHF and CDHG

EvaporatorUnits Shell ConnectionSize Size Size

Range EVSZ 1 Pass1250-2000 210D 16"1250-2150 210D 16"2100-2500 250D 16"

3000 250M 18"3500 250X 18"

Table 4 – CondenserWater PipingConnection Sizes –CDHF and CDHG

CondenserUnits Shell ConnectionSize Size Size

Range CDSZ 1 Pass1250-2000 210D 16"1250-2150 210D 16"2100-2500 250D 16"

3000 250M 20"3500 250X 20"

Note:EVSZ = Evaporator Shell Size;D = Duplex

Note:CDSZ = Condenser Shell Size;D = Duplex

Water Piping Connections

All CDHF units, “A” and later designsequences, use grooved-pipeconnections. (See Table 5). These arecut-groove end NSP (Victaulic™-style)pipe connection .

Flanged connections for 300 PSIwaterboxes use welded flanges.

Piping joined using grooved typecouplings, like all types of pipingsystems, requires proper support tocarry the weight of pipes andequipment.

The support methods used musteliminate undue stresses on joints,piping and other components; allowmovement where required, andprovide for any other specialrequirements (i.e., drainage, etc.).

Table 5 – Water Piping Connection Components

Water BoxConnection Water Box Design Pressure

Unit Model Type 150 psig 300 psigCDHF or CDHG Victaulic Customer provided Customer provided

Victaulic Coupling Victaulic CouplingCDHF or CDHG Flanged Trane provided Trane Provided

Victaulic-to-Flange Welded onAdapter Flange

Figure 15 – Typical Grooved Pipe Connection

CDHF-SVN01B-EN30

Grooved Pipe Coupling

A customer-supplied, standardflexible grooved pipe coupling(Victaulic™ Style 77 or equivalent)should be used to complete theVictaulic connection for both 150 and300 psig water boxes. See Figures 15and 16 . When a flexible couplingsuch as this is installed at the waterbox connections (Figure 16 ), otherflexible piping connectors (i.e.,braided-steel, elastomeric arch, etc.)are usually not required to attenuatevibration and/or prevent stress onthe connections.

Water Piping

Figure 16 – Customer Piping Alternatives for CDHF Water Box Connections

Refer to the coupling manufacturer’sguidelines for specific informationconcerning proper piping systemdesign and construction methods forgrooved water piping systems.

Note: Flexible coupling gasketsrequire proper lubrication beforeinstallation to provide a good seal.Refer to the coupling manufacturer’sguidelines for proper lubricant typeand application.

31CDHF-SVN01B-EN

Flange-Connection Adapters

When flat-face flange connectionsare specified, flange-to-grooveadapters are provided (Victaulic Style741 for 150 psig systems), Figure 17.The adapters are shipped bolted toone of the chiller end-supports(Figure 18). Adapter weights aregiven in Table 6. The flange adaptersprovide a direct, rigid connection offlanged components to the grooved-pipe chiller water box connections.

In this case, the use of flexible typeconnectors (i.e., braided steel,elastomeric arch, etc.) isrecommended to attenuate vibrationand/or prevent stress at the waterbox connections.

Flange adapters are not provided forunits with 300 psig water boxes.(These require welded flanges).

All flange-to-flange assembly boltsmust be provided by the installer.Bolt sizes and number required aregiven in Table 6. The four draw-boltsneeded for the 16-inch Style 741 (150psig) adapters are provided. TheStyle 741, 150 psig flange adapterrequires a smooth, hard surface for agood seal.

Connection to other type flangefaces (i.e., raised serrated, rubber,etc.) will require the use of a flangewasher between the faces. Refer tothe flange adapter manufacturer’sguidelines for specific information.

Note: The flange-adapter gasketmust be placed with the color codedlip on the pipe and the other lipfacing the mating flange.

CAUTION

Piping Connection Leaks!

To provide effective seal, gasket-contact surfaces of adapter must befree of gouges, undulations ordeformities.

Victaulic™ Gasket Installation

1. Check gasket and lubricate: Checkgasket supplied to be certain it issuited for intended service. Codeidentifies gasket grade. Apply athin coat of silicone lubricant togasket lips and outside of gasket.

2. Install Gasket: Place gasket overpipe end, being sure gasket lipdoes not overhang pipe end. SeeFigure 17 for gasket configuration.

3. Join pipe ends: Align and bringtwo pipe ends together and slidegasket into position centeredbetween the grooves on eachpipe. No portion of the gasketshould extend into the groove oneither pipe.

4. Apply Vic-Flange. Open Vic-Flangefully and place hinged flangearound the grooved pipe end withthe circular key section locatinginto the groove.

5. Insert Bolt: Insert a standard boltthrough the mating holes of theVic-Flange to secure the flangefirmly in the groove.

6. Tighten Nuts: Tighten nutsalternately and equally untilhousing bolt pads are firmlytogether -metal-to-metal.Excessive nut tightening is notnecessary.

Note: Uneven tightening may causegasket to pinch.

Table 6 – Installation Data for CDHF 150 PSIG Flange Adapters

Nom. Size Assy Bolt Size No. Assy Bolt Pattern Weights(In/mm) (In)* Bolts Req. Dia. (In/mm) (lbs/kg)16/400 1 x 4-1/2 16 21.25/540 90.0/40.818/457 1.13 x 4.75 16 22.75/578 100/45.420/508 1.13 x 5.25 20 25.00/635 120/54.4

*Bolt size for conventional flange-to-flange connection. Longer bolts are required when flange washer must be used.

Water Piping

CDHF-SVN01B-EN32

Water Piping

Figure 17 – Typical Victaulic Flange Gasket Configuration

Figure 18 – Typical Shipping Location on Unit for Shipping Flange

SCREW ADAPTER

LEG SUPPORT

33CDHF-SVN01B-EN

Water Piping

Bolt-Tightening Sequence forWater Piping ConnectionsA bolt-tightening sequence forflanges with flat gaskets or O-rings isdescribed below and shown inFigure 19. Remember thatimproperly tightening flanges maycause a leak!

Note: Before tightening any of thebolts, align the flanges. Flange bolttorque requirements are given inTable 7.

Flanges with 4, 8 or 12 Bolts.Tighten all bolts to a snug tightness,following the appropriate numericalsequence for the flange. Repeat thissequence to apply the final torque toeach bolt.

Flanges with 16, 20 or 24 Bolts.Following the appropriate numericalsequence, tighten only the first halfof the total number of bolts to a snugtightness. Next, sequentially tightenthe remaining half of the bolts in theproper order.

Flanges with More than 24 Bolts.Refer to Figure 19 and sequentiallytighten the first 12 bolts to a snugtightness. Tighten the next 12consecutively numbered bolts insequence, to the final torque.

Then, apply final torque to the first12 bolts and the bolts not yettightened (i.e., unnumbered bolts inFigure 19). Be sure to start with bolt“1” and move progressively aroundthe flange in a clockwise direction.

Evaporator Water Box Covers.See Figure 19. Ensure that the waterbox head rests tightly against thegasket or tube sheet; then snuglytighten the bolts in sequential order.

If excessive tube sheet crownprevents the head from contactingthe tube sheet, tighten the boltslocated where the greatest gapsoccur. Be sure to use an equalnumber of bolt turns from side toside.

Then, apply final torque to each boltin sequential order. (Each bolt isidentified by number in Figure 19.)

Table 7 – Flange Bolt Torque Recommendations for O-Ring and Flat-GasketPiping Connections (See Note).

Bolt Size Gasket Type(In) O-Ring Flat3/8 25 (34) 12-18 (16-24)1/2 70 (95) 33-50 (45-68)5/8 150 (203) 70-90 (95-122)3/4 250 (339) 105-155 (142-210)

Note: Torques provided in Ft./Lbs. (Newton/metres)

CDHF-SVN01B-EN34

Water Piping

Figure 19 – Bolt Tightening Sequences for Water Piping Flanges andWater Boxes

Flanges with more than 24 bolts

Evaporator Water Box Covers

35CDHF-SVN01B-EN

Vent Line Piping

Refrigerant Vent-Line Piping

General RecommendationsBoth the purge and rupture disc ventlines must be routed to outsideatmosphere. Use only materialcompatible with the refrigerant inuse. The use of PVC (not CPVC)piping is acceptable if the pipe jointis properly primed and if theadhesive used has been tested forrefrigerant compatibility. Testingconducted in Trane laboratories hasapproved the use of the followingmaterials for PVC pipe construction.

Primer - Hercules, Primer for PVC#60-456;

Adhesive - Hercules, Clear PVC,Medium Body, Medium Set, #60-020.

Consult with the manufacturers ofany field-provided components ormaterials added to the refrigerant-side of the machine for acceptablematerial compatibility.

During vent line construction,provide a drip leg on the line that isof sufficient length to accommodatea minimum of one gallon of liquid.Provide a standard 1/4” FL x 1/4”NPT, capped refrigerant service valveto facilitate liquid removal.Accumulated liquid must be drainedfrom the drip leg into an evacuatedwaste container once every sixmonths, at a minimum; and moreoften if the purge operatesexcessively.

Purge Discharge Vent Line

On CDHF units, the purge dischargelines are factory-piped downstreamof the rupture discs on the unit.Since there are two separaterefrigerant circuits, there will be twopurges installed on each machine.Each purge has its own dischargeline.

Rupture Disc Vent Installation

All CenTraVac™ chillers are equippedwith carbon rupture discs. A cross-section of the rupture disc assemblyappears in Figure 20A along with anillustration indicating the location ofthe rupture disc on the suctionelbow. There are two rupture discson CDHF chillers, one per refrigerantcircuit. See Figure 20 for locations.

If refrigerant pressure within theevaporator exceeds 15 psig, therupture disc breaks, shell pressure isrelieved as refrigerant escapes fromthe chiller.

When constructing the rupture discvent line, be sure to consult localcodes for applicable guidelines andconstraints.

Several general recommendationsfor rupture disc vent line installationare outlined below.

1. Verify that the vacuum supportside of the rupture disc ispositioned as shown in the crosssection view that appears in Figure20.

Note: If the rupture disc wasremoved for any reason, it mustbe reinstalled as shown.

2. Do not apply threading torque tothe outside pipe assembly wheninstalling the connection pipe.

3. Rupture Disc InstallationInstructions. To prevent damage tothe rupture disc, use the followinginstallation procedure:

3.1 Install the bottom 2 bolts.

3.2 Install the rupture disc withcorrect orientation (Ref. arrowor vacuum support bar facinginside) and a gasket on eachside. See Figure 20.

3.3 Install the top 2 bolts.

3.4 Center the disc and gaskets toflange bore.

3.5 Hand tighten all bolts assuringequal pressure

3.6 Use a “Torque Wrench” set to240 In-Lb with a 9/16" socket.

3.7 Tighten bolts in a star pattern 1/2 turn each.

3.8 Torque bolts in a star pattern to240 In-Lbs. each.

CDHF-SVN01B-EN36

Vent Line Piping

4. Support the vent piping, use aflexible connection to avoidplacing stress on the rupture disc.(Stress can alter rupture pressureand cause the disc to breakprematurely.)

The flexible connector used toisolate the rupture disc fromexcessive vent line vibration must becompatible with the refrigerant inuse. Use a flexible, steel connectorsuch as the stainless-steel type MFP,style HNE, flexible pump connector(from Vibration Mounting andControl, Inc.) or equivalent.

See Figure 20C for a recommendedrelief piping arrangement.

Important! Vent pipe size mustconform to ANSI/ASHRAE Standard15, which discusses vent pipe sizing.Use Table 8 and then Figure 21 todetermine proper vent pipe size.

Note: To determine the total “C”value for a specific unit, add theappropriate “C” values for theevaporator, condenser andeconomizer. With this sum, refer toFigure 21 to determine the vent linepipe diameter needed to handleflow.

5. If the two vent lines are pipedtogether, size the common lineappropriately to handle the totalflow. (See Note 2, Table 8).

6. Normally, where multiple chillersare used, install a separate rupturedisc vent line for each unit.

7. Consult local regulations for anyspecial relief line requirementsand refer to CFC-GUIDE-2published by The Trane Company.

8. The discharge of the vent lineoutside should not be in thegeneral vicinity of any fresh airintakes to the building. Any gasventing from the vent line shouldnot be allowed to re-enter thebuilding.

Table 8 - “C” Value Used to Determine Rupture Disc Vent Line Size CDHF & CDHG

Evaporator Condenser TotalNTON Shell Shell Rupture “C” Value for Each Component for “C” Value for

Compressor Size Size Disc Each Duplex Side Each DuplexSize EVSZ CDSZ Diameter Evaporator Condenser Economizer Side

1250-2000 210D 210D 3" 53.6 40.4 17.4 111.41250-2150 210D 210D 3" 53.6 40.4 17.4 111.42100-2500 250D 250D 3" 59.1 43.9 17.4 120.4

3000 250M 250M 3" 72.2 53.8 19.5 145.53500 250X 250X 3" 83.3 62.0 19.5 164.8

Notes:1. Use the Total “C” Value for Each Circuit to determine the vent line diameter needed to handle the flow, refer to

Figure 21.2. If piping multiple rupture discs to a common vent line, first determine the total “C” value for each rupture disc, then

add all “C” values together and apply the result to the “Vent Pipe Sizing Chart” Figure 21.3. EVSZ = Evaporator Shell Size

D = Duplex4. CDSZ = Condenser Shell Size

D = Duplex

37CDHF-SVN01B-EN

Figure 20A - (Continued)

Vent Line Piping

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

Rupture Disccircled withdashed lines

CDHF-SVN01B-EN38

Vent Line Piping

Figure 20B - (Continued)

39CDHF-SVN01B-EN

Vent Line Piping

Figure 20C - (Continued)

CDHF-SVN01B-EN40

Vent Line Piping

Figure 21 - Rupture Disc Vent Pipe Sizing

41CDHF-SVN01B-EN

Insulation

Unit Insulation RequirementsFactory-installed insulation isavailable as an option for all units.Below is Table 9 showing unitinsulation requirements for CDHFunits.

In those instances where the chilleris not factory-insulated, installinsulation over the areas shaded inFigure 22. It may also be necessaryto insulate the compressor suctioncover if the unit is installed in an areasubject to high humidities. Thequantities of insulation requiredbased on unit size and insulation

thickness listed is determined atnormal design conditions which are:

- 85°F Dry Bulb Ambient Temperature

- 75% Relative Humidity

Note: If the unit is not factory-insulated: Install insulation aroundthe evaporator bulbwells; and,ensure that the bulbwells andconnections for the water box drainsand vents are still accessible afterinsulation is applied.

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

CAUTION

Insulation Damage!

If the factory-installed insulation willbe painted in the field, use onlywater-based latex paints! Thinnersand solvents used in other types ofpaints may cause seams in theinsulation to open as a result ofshrinkage. To prevent damage to thefactory-installed insulation, do notallow excessive exposure tosunlight.

Table 9 - CDHF Unit Insulation Requirements

EVSZ 3/4" Insulation 3/8" Insulation(Note: 1) (Note: 2) (Note: 3)

210D 1270 Sq. Ft. 193 Sq. Ft.250D 1308 Sq. Ft. 258 Sq. Ft.250M 1410 Sq. Ft. 280 Sq. Ft.250X 1500 Sq. Ft. 280 Sq. Ft.

Notes:1. EVSZ = Evaporator Shell Size, L = Long Shell, S = Short Shell, D = Duplex2. 3/4" sheet insulation is installed on the evaporator, evaporator waterboxes,

suction elbow and suction cover as indicated in Figure 22.3. 3/8" sheet insulation is installed on all economizers. All liquid lines and

other pipes require the use of 1/2"-wall pipe insulation, or 3/8" sheetinsulation.

CDHF-SVN01B-EN42

Figure 22 - Recommended Areas for Unit Insulation

43CDHF-SVN01B-EN

ElectricalInformation

About Wiring DrawingsThe typical Duplex customerconnection diagrams shown at theend of this manual arerepresentative of standard CDHFunits, and are provided only forgeneral reference. Because theseillustrations may not reflect theactual wiring of your unit alwaysrefer to the wiring diagrams thatshipped with the chiller for specificelectrical schematic and connectioninformation.

Note: Unit-mounted starters areavailable as an option on CDHFunits.

While this option eliminates mostfield-installed wiring requirements,the electrical contractor must stillcomplete the electrical connectionfor: (1) power supply wiring to thestarter, (2) other unit control optionspresent, and (3) any field-suppliedcontrol devices.

As you review this manual, alongwith the wiring instructionspresented in this section, keep inmind that:

1. Typical field connectionrequirements for remote-mountedstarters are shown in drawings atend of the manual andsummarized in Table below.

2. All field-installed wiring mustconform to NEC guidelines, aswell as to any applicable state andlocal codes. Be sure to satisfyproper equipment groundingrequirements per NEC.

3. Compressor motor electrical dataincluding motor kw, voltageutilization range, rated load ampsand locked rotor amps is listed onthe chiller nameplate.

4. All field-installed wiring should bechecked for proper terminations,and for possible shorts orgrounds.

General Requirements

����� WARNING!

Hazardous Voltage w/Capacitors!

Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure thepower cannot be inadvertentlyenergized. For variable frequencydrives or other energy storingcomponents provided by Trane orothers, refer to the appropriatemanufacturer’s literature forallowable waiting periods fordischarge of capacitors. Verify withan appropriate voltmeter that allcapacitors have discharged. Failureto disconnect power and dischargecapacitors before servicing couldresult in death or serious injury.

Note: For additional informationregarding the safe discharge ofcapacitors, see PROD-SVB06A-EN orPROD-SVB06A-FR.

Typical Duplex Wiring2309-4922C Schematic Legend2309-4902C Unit Mounted Wye Delta Starter (Applicable to Circuit 1 & 2)2309-4917B Purge (Applicable to Circuit 1 & 2)2309-4924A Unit Controls Schematic (Page 1 & 2)2309-4955A System Controls Schematic (Page 1 & 2)2309-4956A Options Schematic (Page 1 & 2)2309-4961A Connection Diagram LH Panel2309-4941A Connection Diagram RH Panel2309-4957A Connection Diagram - Trane Starter - Circuit 1

Page 1 of 22309-4957A Connection Diagram - Trane Starter - Circuit 1

Page 1 of 22309-4958A Connection Diagram - Customer Starter - Circuit 12309-4958A Connection Diagram - Customer Starter - Circuit 2

General

CDHF-SVN01B-EN44

ElectricalInformation

Trane Supplied Starters Wiring

Standard Field Power wiring: Reference Field connection diagram 2309-4957

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

This information is applicable to the starter 1 for Compressor 1 as well as starter 2 for compressor 2. (For wireestimation purposes please double the below list as there are two starters to be wired)

Table 10

Line Power wiring To Starter Panel(to Starter Panel) Terminals

3-Phase Line Voltage: Terminal Block 2X3-L1, L2, L3, All wiring to be inand GROUND accordance with

National ElectricalCode and anylocal codes.

3-Phase Line Voltage: Circuit Breaker 2Q1-L1,L2,L3,and GROUND

Starter to Motor Power Wiring Starters Motor

Remote Starter to T1 through T6 terminals T1 through T6 terminalsChiller Motor Junction BoxStarter to UCP To Starter From Unit Control

control wiring (120Vac) Panel Terminals Panel Terminations

120VAC Power Supply from starter to UCP 2X1-1-1, 1X1-1, #8 gauge2X1-2 1X1-12 minimum2X1-20(Ground) 1X1-18 (Ground) 40 amps circuit

High Pressure Cutout interlock 2X1-4, 1X1-4, 14 ga.2X1-6 1X1-3

Oil Pump Interlock 2X1-7, 1A7-J2-4, 14 ga.2X1-8 1A7-J2-2

Low Voltage Circuits To Starter From Unit Control

(less than 30VAC) Panel Terminals Panel Terminations

Standard Circuits

Inter Processor Communications (IPC) 2A1- J3-3 to 4, 1A1 –J5 1-2Remote Mounted or 2X1-12 to 2 wire w/ ground

13 if present Shield ground at Comm link.(do not ground 1X1- 22(GND) only.shield at starter )

Trane SuppliedRemote Starter

45CDHF-SVN01B-EN

ElectricalInformation

Customer Supplied Starter

Standard Field Power wiring: Please refer to Trane Specification S6516-0513.

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

This information is applicable to the Starter 1 for Compressor 1 as well as Starter 2 for Compressor 2. (For wireestimation purposes please double the below list as there are two starters to be wired)

Reference Field Connection Customer Supplied Starter diagram 2309-4958

Table 11

Line Power wiring Starter Panel(to Starter Panel) Terminals

Starter by others See “Starter by All wiring to be inPower wiring: others” schematic accordance with

National ElectricalCode and any

3-Phase Power Supply to Starter local codes.Starter to Motor Power Wiring Starters Motor

Remote Starter to T1 through T6 T1 through T6Chiller Motor Junction Box terminals terminalsStarter to UCP control wiring To Starter From Unit Control

(120VAC) Panel Terminals Panel Terminations120VAC Power Supply from See “Starter bystarter to UCP others” schematic #8 gauge minimum

5X1-1, 1X1-1, 40 amps circuit5X1-2 1X1-125X1-20 (ground) 1X1-18 (ground)

Power from UCP 1Q1 5X1-3 1X1-3, 1A23-J6-3 14 ga.Interlock Relay signal 5X1-4 1A23-J10-1 14 ga.Start contactor signal 5X1-5 1A23-J8-1 14 ga.Oil Pump Interlock 5X1-7, 1A7-J2-4, 14 ga.

5X1-8 1A7-J2-2Run Contactor signal 5X1-10 1A23-J6-12 14 ga.Transition Complete 5X1-14 1A23-J12-2 14 ga.Low Voltage Circuits To Starter From Unit Control(less than 30VAC) Panel Terminals Panel Terminations

Standard Circuits

Current Transformers* (Required) 5CT4- wht, blk 1A23-J7-1,25CT5- wht, blk 1A23-J7-3,4, Note: Phasing must5CT6- wht, blk 1A23-J7-5,6, be maintained

Potential Transformers* (Required) 5T17-236,237 1A23 –J5-1,2,5T18-238,239 1A23 –J5-3,4, Note: Phasing must5T19-240,241 1A23 –J5-5,6 be maintained

*see Table 12 (CT* wire sizes)

Customer SuppliedRemote Starter

CDHF-SVN01B-EN46

ElectricalInformation

Table 12 - Current Transformer and Potential Transformer Wire sizing tables for Customer Supplied starter to ChillerUnit Control Panel Starter module 1A23.

The maximum recommended wire length for secondary CT leads in a dual CT system are:Wire Maximum Wire Length Secondary CT Leads

AWG(mm2) Feet Meters8(10) 1362.8 415.510(6) 856.9 261.212(4) 538.9 164.3

14(2.5) 338.9 103.316(1.5) 213.1 65.017(1) 169.1 51.5

18(0.75) 134.1 40.920(0.5) 84.3 25.7

Note: 1. Wire lengths are for copper conductors only.2. Wire lengths are total “one way” distance that the CT can be from the Starter module.

The maximum recommended total wire length for PT’s in a single PT system:Wire Gauge Max lead length(ft) Max lead length (m)

8 5339 162710 3357 102312 2112 64314 1328 40416 835 25417 662 20118 525 16020 330 10021 262 7922 207 63

The maximum recommended total wire length (to and from) for PT leads in a dual PT system are:Max Wire Max Wire Max Wire Max Wire

Wire Length Length Length LengthGauge Primary (ft) Primary (m) Secondary (ft) Secondary (m)

8 3061 933 711 21710 1924 586 447 13612 1211 369 281 8514 761 232 177 5316 478 145 111 3317 379 115 88 2618 301 91 70 2120 189 57 44 1321 150 45 34 1022 119 36 27 8

Note: These wire lengths are for copper conductors onlyNote: The above lengths are maximum round trip wire lengths. The maximum distance the PT can be located fromthe Starter module is 1/2 of the listed value.

Customer SuppliedRemote Starter

47CDHF-SVN01B-EN

Line PowerWiring

Line Power Supply WiringTo assure that power supply wiringto the starter panels are properlyinstalled and connected, review andfollow the guidelines outlined below.Typical equipment room layouts areshown in Figures 25 and 26.

3-Phase Power Source1. Verify that the starter nameplateratings are compatible with thepower supply characteristics - andwith the electrical data on the CDHFnameplate.

2. If the starter enclosure must be cutto provide electrical access, exercisecare to prevent debris from fallinginside the enclosure.

CAUTION

Starter Damage!

Debris inside the starter panel maycause an electrical short thatseriously damages the startercomponents.

3. Use copper wire to connect the 3-phase power supply to theremote-or-unit-mounted starterpanel.

CAUTION

Use Copper ConductorsOnly!

Unit terminals are not designed toaccept other types of conductors.Failure to use copper conductorsmay result in equipment damage.

4. Size the power supply wiring inaccordance with NEC, using the RLAvalue stamped on the chillernameplate and transformer load onL1-and L2.

Note: All CDHF units are designed tocomply with NEC guidelines.

5. Make sure that the incomingpower wiring is properly phased;each power supply conduit run tothe starter must carry the correctleads to ensure equal phaserepresentation. See Figure 23.

6. As you install the power supplyconduit, make sure that its positiondoes not interfere with theserviceability of any of thecomponents, nor with structuralmembers and equipment. Also,assure that the conduit is longenough to simplify any servicing thatmay be necessary in the future (e.g.,starter removal).

Note: Use flexible conduit toenhance serviceability and minimizevibration transmission.

Circuit Breakers and FusibleDisconnectsIn compliance with NEC guidelines,size the circuit breaker or fuseddisconnect, the chiller nameplatemax. fuse size or max. circuit breakersize marking.

Note: Right hand and left handcircuits may have different RLAs.See unit nameplate.

7. Tightening torque. Follow startermanufacturers torque specificationsand annual inspection methods.

Note: Connect L1, L2, L3 per starterdiagram.

ElectricalInformation

Figure 23 - Proper Phasing for Starter Power Supply Wiring

CDHF-SVN01B-EN48

Optional PFCCsPower factor correction capacitors(PFCCs) are designed to providepower factor correction for thecompressor motor. Available as anoption for unit-mounted starters, andremote-mounted starter.

Note: Remember that the PFCCnameplate voltage rating must begreater than or equal to thecompressor voltage rating stampedon the unit nameplate. See Table 13to determine what is appropriate foreach compressor voltageapplication.

CAUTION

Equipment Damage!

PFCCs must be wired into thestarter correctly! Misapplication ofthese capacitors could result in aloss of motor overload protectionand subsequent motor damage.

PFCCs are wired as shown in Figure24 where the capacitor leads are runthrough the overload transformer.

Table 13 - PFCC Design Voltage per Compressor Voltage Application

PFCC Compressor Motor VoltageDesign Voltage (See CDHF Nameplate)

240V/60 Hz 200V/60 Hz208V/60 Hz

480V/60 Hz 380V/60 Hz440V/60 Hz460V/60 Hz480V/60 Hz

600V/60 Hz 575V/60 Hz600V/60 Hz

2400V/60 Hz 2300V/60 Hz2400V/60 Hz

4160V/60 Hz 3300V/60 Hz4000V/60 Hz4160V/60 Hz

PFCC Compressor Motor VoltageDesign Voltage (See CDHF Nameplate)

480V/50 Hz 380V/50 Hz440V/50 Hz460V/50 Hz480V/50 Hz4160V/50 Hz 3300V/50 Hz

ElectricalInformation PFCC

49CDHF-SVN01B-EN

ElectricInformation

Recommended Procedures forDischarging CapacitorsPrior to performing any service onenergized equipment, the properLockout-Tagout procedures mustalways be followed. Regardless ofthe equipment being serviced, thefollowing steps must be taken:

Lockout-Tagout Steps

1. Prepare the equipment forshutdown.

2. Shut down the equipment.

3. Disconnect any energy isolatingdevices.

4. Apply the necessary lockout ortagout devices.

5. Render safe all stored or residualenergy.

6. Verify the isolation and de-energization of the equipment.

Personal Protective EquipmentAlways wear appropriate personalprotective equipment in accordancewith applicable regulations and/orstandards to guard against potentialelectrical shock and flash hazards.

����� WARNING

Hazardous Voltage w/Capacitors!Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure thepower cannot be inadvertentlyenergized. For variable frequencydrives or other energy storingcomponents provided by Trane orothers, refer to the appropriatemanufacturer’s literature forallowable waiting periods fordischarge of capacitors. Verify withan appropriate voltmeter that allcapacitors have discharged. Failureto disconnect power and dischargecapacitors before servicing couldresult in death or serious injury.

Note: For additional informationregarding the safe discharge ofcapacitors, see PROD-SVB06A-EN orPROD-SVB06A-FR

Verifying Discharge of CapacitorsAfter following the proper lockout-tagout procedure it is important toverify that all applicable capacitorsare discharged and rendered safe.Many capacitors in HVAC equipmentinclude internal bleeder circuits thatwill automatically discharge thecapacitor. These circuits must beallowed sufficient time to dischargethe capacitor prior to performingservice.

While most capacitors contained inTrane equipment include internalbleeder circuits, this is not always thecase and these circuits cansometimes fail. In addition, somebleeder circuits can take up to 30minutes to fully discharge. It isimportant to verify that thecapacitor has been fully dischargedby using a voltmeter that is rated forthe voltage of the capacitor beingtested.

� � � � � WARNING

Live ElectricalComponents!During installation, testing, servicingand troubleshooting of this product,it may be necessary to work withlive electrical components. Have aqualified licensed electrician or otherindividual who has been properlytrained in handling live electricalcomponents perform these tasks.Failure to follow all electrical safetyprecautions when exposed to liveelectrical components could result indeath or serious injury.

Discharging CapacitorsIn the event that a capacitor does nothave an internal bleeder circuit, thebleeder circuit has failed, or thedischarge process is not complete,the capacitor must be dischargedproperly prior to performing service.In order to safely discharge acapacitor, a proper capacitordischarge tool must be used.Screwdrivers and other hand toolsare not designed to safely dischargecapacitors. Use of these tools mayresult in death or serious injury and/or equipment damage.

CDHF-SVN01B-EN50

ElectricInformation

Figure 24 - PFCC Leads Routed thru Overload Current Transformer

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

Notes:1. Refer to the unit field connection diagram for approximate UCP knockout

locations.Important: To prevent damage to the UCP’s components, do NOT routecontrol circuit conduit into the top of the UCP enclosure.

2. IPC circuit conduit must enter the left back portion of the UCP.3. See Starter Submittal drawing for location of incoming wiring to the starter.

PFCC and UnitMounted Starter

51CDHF-SVN01B-EN

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

Notes:1. Refer to the unit field connection for approximate UCP knockout locations.

Important: To prevent damage to the UCP’s components, do NOT routecontrol circuit conduit into the top of the UCP enclosure.

2. IPC circuit conduit must enter the left back portio nof the UCP.

ElectricalInformation Remote Starter

CDHF-SVN01B-EN52

ElectricalInformation

Starter to Motor (Remote-Mounted Starters)

Reference Table 17-43 and 44.

Ground Wire Terminal Lugs.Ground wire lugs are provided in themotor terminal box, and in thestarter panel.

Terminal Clamps. Terminal clampsare supplied with the motorterminals to accommodate eitherbus bars or standard motor terminalwire lugs. Terminal clamps provideadditional surface area to minimizethe possibility of improper electricalconnections.

Wire Terminal Lugs. Wire terminallugs must be field-supplied.

1. Use field-provided crimp-type wireterminal lugs properly sized for theapplication.

Note: Wire size ranges for thestarter-line and load-side wire lugsare listed on the starter submittaldrawings supplied by the startermanufacturer. Carefully review thesubmitted wire lug sizes forcompatibility by the electricalengineer or contractor.

2. A terminal clamp with a 3/8” boltis provided on each motorterminal stud; use the factory-supplied Belleville washers on thewire lug connections.

Figure 27 illustrates the juncturebetween a motor connection padand the wire terminal lug.

3. Tighten each bolt to 24 foot-pounds.

4. Install but do not connect thepower lead between the starterand compressor motor.) Theseconnections will be completedunder supervision of a qualifiedTrane service engineer after theprestart inspection).

Bus Bars. Install bus bars betweenthe motor terminals when a low-voltage “across-the-line”, “primaryreactor/resistor” or “autotransformer” starter is used.

Be sure to jumper motor Terminal T1to T6, T2 to T4, and T3 to T5.

Bus bars and extra nuts are availableas a Trane option.

Note: Bus bars are not needed inmedium or high-voltage applicationssince only 3 terminals are used in themotor and starter.

Figure 27 - Terminal Stud, Clamp and Lug Assembly

Remote Starter

53CDHF-SVN01B-EN

Starter to UCPControl Wiring

Starter to UCP (Remote-Mounted Starters Only)

Electrical connections requiredbetween the remote-mounted starterand the chiller control panel (UCP)are outlined in Table 10 or 11, asapplicable.

Note: Install separate conduitbetween the volt circuits; and theUCP to the starter for the IPC circuit.

When sizing and installing theelectrical conductors for thesecircuits, follow these guidelines.

CAUTION

Starter Damage!

Debris inside the starter panel maycause an electrical short thatseriously damages the startercomponents.

1. If the starter enclosure must be cutto provide electrical access,exercise care to prevent debrisfrom falling inside the enclosure.

2. Use only shielded twisted pair forthe IPC circuit between the starterand the UCP on remote mountedstarters. Recommended wire isBeldon Type 8760, 18 AWG forruns up to 1000 feet.

Note: The polarity of the IPC wirepair is critical for proper operation.

3. Separate low-voltage (less than30V) wiring from the 115V wiringby running each in its ownconduit.

4. As you route the IPC circuit out ofthe starter enclosure, make surethat it is at least 6” from all wirescarrying a higher voltage.

5. The IPC Shielded Twisted Pairwiring should be grounded on oneend only at UCP end.

The other end should be un-terminated and taped back on thecable sheath to prevent any contactbetween shield and ground.

6. Oil Pump Interlock - Both startersmust provide an interlock [N.O.]contact with the chiller oil pumpconnected to the UCP at Terminals1A7-J2-4 and 1A7-J2-2 [14 ga] ineach control panel. The purpose ofthis interlock is to power the oilpump on the chiller in the eventthat a starter failure, such aswelded contacts, keeps the chillermotor running after the controllerinterrupts the run signal.

CAUTION

Electrical Noise!

To ensure that electrical noise doesnot distort the signals carried by thelow-voltage wiring, including theIPC, maintain at least 6” betweenlow-voltage (<30V) and 115Vcircuits.

UCP Electrical SpecificationsFollowing is a list of constraints forthe UCP in the control panel:

Note that the control panel isdesigned to receive input from thesecondary of a power transformer inthe starter panel.

1. Nominal Voltage: 115 VAC, withoperating range of 98 to 132 VAC,inclusive.

2. Maximum VA: 1725 VA (15-ampfuse).

3. Power input wiring must be atleast 6” from low-voltage less than30V wiring.

4. All signal inputs are low-voltage,less than 30V.

5. UCP Storage Range: -40°F to 158°F(-40°C to 70°C).

ElectricalInformation

CDHF-SVN01B-EN54

Control CircuitWiring

Left Hand Control Panel

Table 14 - UCP Control Wiring 120Vac

Standard Unit Control Input or All wiring to be120 Vac Control Circuits: Panel Terminations Output Type in accordance with

National ElectricalCode and anylocal codes.Contacts

Chilled Water Flow Proving Input 1X1-5 to 1A6-J3-2 Binary Input Normally Open,closure with flow

Condenser Water Flow Proving Input 1X1-6 to 1A6-J2-2 Binary Input Normally Open,closure with flow

Chilled Water Pump Relay Output 1A5-J2- 4 to 6 Binary Output Normally OpenCondenser Water Pump Relay Output 1A5-J2-1 to 3 Binary Output Normally OpenOptional

Control Circuits status outputsIce Making Relay Output 1A5-J2-10 to 12 Binary Output Normally Open

* PROGRAMABLE OUTPUTSdefaults:Chiller Non-Latching Alarm Relay Output 1A8-J2-1 to 3 Binary Output Normally OpenChiller Limit Mode Relay Output 1A8-J2-4 to 6 Binary Output Normally OpenChiller Latching Alarm Relay Output 1A8-J2-7 to 9 Binary Output Normally OpenChiller Running Relay Output 1A8-J2-10 to 12 Binary Output Normally OpenMaximum Capacity Relay Output 1A9-J2-1 to 3 Binary Output Normally OpenChiller Head Relief Request Relay Output 1A9-J2-4 to 6 Binary Output Normally OpenCircuit 2 Purge Alarm Relay Output 1A9-J2-7 to 9 Binary Output Normally OpenCircuit 1 Purge Alarm Relay Output 1A9-J2-10 to 12 Binary Output Normally OpenAlternates;Circuit 1 RunningCircuit 2 RunningChiller AlarmCircuit 1 AlarmCircuit 2 AlarmPurge Alarm* Defaults as Factory programed; Alternates can be selected at startup using service tool.

ElectricalInformation

55CDHF-SVN01B-EN

Left Hand Control Panel

Table 15 - UCP Control Wiring less than 30 Vac

Standard

Low Voltage Circuits Unit Control Input or(less than 30VAC) Panel Terminations Output TypeExternal Auto Stop Input 1A13-J2-1 to 2 Binary Input Closure required for

normal operationEmergency Stop Input 1A13-J2-3 to 4 Binary Input Closure required for

normal operationCircuit 1 External Lockout 1A25-J2-1 to 2 Binary Input Closure required for

circuit lockout.Circuit 2 External Lockout 1A25-J2-3 to 4 Binary Input Closure required for

circuit lockout.Optional

Low Voltage CircuitsExternal Base Loading Enable Input 1A18-J2-1 to 2 Binary Input Normally OpenExternal Hot Water Control Enable Input 1A18-J2-3 to 4 Binary Input Normally OpenExternal Ice Machine Control Enable Input 1A19-J2-1 to 2 Binary Input Normally Open% RLA Compressor 1 Output(Circuit 1 Left Panel 1A15 ) 1A15-J2-1 to 3 Left Panel Analog Output 2-10 vdcExternal Condenser Pressure Output(Circuit 1 Left Panel 1A15 ) 1A15-J2-4 to 6 Left Panel Analog Output 2-10 vdcExternal Current Limit Setpoint Input 1A16-J2-2 to 3 Analog Input 2-10 vdc, or 4-20 mAExternal Chilled Water Setpoint 1A16-J2-5 to 6 Analog Input 2-10 vdc, or 4-20 mAExternal Base Load Setpoint Signal 1A17-J2-2 to 3 Analog Input 2-10 vdc, or 4-20 mAGeneric Refrigerant Monitor input 1A17-J2-5 to 6 Analog Input 2-10 vdc, or 4-20 mAOutdoor Air Temperature sensor IPC bus Connection Communication

and sensor and sensor.Tracer Comm 4 Interface 1A14 1A14-J2-1(+) to 2(-) Communication[note Comm 4 requires two modules; 1A14-J2-3(+) to 4(-) to Tracerone is mounted in each panel] Left PanelTracer Comm 5 Interface 1A14-J2-1(+) to 2(-) Communication[future, one Comm 5 module; 1A14-J2-3(+) to 4(-) to Tracerleft panel only] Left Panel only

Right Hand Control PanelOptional

Low Voltage Circuits [right panel]% RLA Compressor 2 Output 1A15-J2-1 to 3(Circuit 2 Right Panel 1A15 ) Right Panel Analog Output 2-10 vdcExternal Condenser Pressure Output(Circuit 2 Right Panel 1A15 ) 1A15-J2-4 to 6 Right Panel Analog Output 2-10 vdcTracer Comm 4 Interface 1A14 1A14-J2-1(+) to 2(-) Communication[note Comm 4 requires two modules; 1A14-J2-3(+) to 4(-) to Tracerone is mounted in each panel] Right Panel

Control CircuitWiring

ElectricalInformation

CDHF-SVN01B-EN56

ElectricalInformation

System Control Circuit Wiring

Water Pump Interlock Circuitsand Flow Switch Input

Chilled Water Pump. Wire theevaporator water pump contactor(5K1) to a separate 120 volt singlephase power supply with 14 AWG,600 volt copper wire, then connectthis circuit to 1A5-J2-6. Then use1A5-J2-4 120 VAC output to allow theUCP to control the evaporator waterpump, or wire the 5K1 contactor tooperate remotely and independentlyof the UCP. (Left panel only.)

Chilled Water Proof of FlowWire the auxiliary contacts of theevaporator water pump contactor(5K1) in series with the flow switch(5S1) installed in the evaporatorsupply pipe. Use 14 AWG, 600-voltcopper wire.

Connect this circuit to UCP terminalslX1-5 to 1A6-J3-2. (Left panel only.)

When installed properly, the chilledwater interlock circuit will only allowcompressor operation if theevaporator pump is running andproviding at least the minimumwater flow required.

Condenser Water Pump. Wire thecondenser water pump contactor(5K2) to a separate 120-volt, single-phase power supply with 14 AWG,600-volt copper wire; then connectthis circuit to UCP terminals 1A5-J2-3. Then use 1A5-J2-1 120 VAC outputto allow UCP to control thecondenser pump. (Left panel only.)

Condenser Water Proof of FlowNext, use 14 AWG, 600-volt copperwire to connect the auxiliary contactsof the condenser water pumpcontactor (5K2) in series with theflow switch (5S2) installed in thecondenser supply pipe.

Connect this circuit to UCP terminals1X1-6 to 1A6-J2-2. (Left panel only.)

When installed properly, thecondenser water lock circuit will onlyallow the compressor to operate ifthe condenser pump is running andproviding at least the minimumwater flow required.

Temperature Sensor Circuits

All temperature sensors are factory-installed except the optional outdoorair temperature sensor. This sensoris required for the outdoor airtemperature type of chilled waterreset. Follow the guidelines below tolocate and mount the outdoor airtemperature sensor. Mount thesensor probe where needed,however, mount the sensor modulein the UCP.

The outdoor temperature sensorsimilar to the unit mountedtemperature sensors in that itconsists of the sensor probe and themodule. A four-wire IPC bus isconnected to the module for 24 vdcpower and the communications link.

We recommend mounting thesensor module within the UCP andthe sensor two wire leads beextended and routed to the outdoortemperature sensor probe sensinglocation. This assures the four wireIPC bus protection and providesaccess to the module forconfiguration at start-up.

System ControlWiring

57CDHF-SVN01B-EN

ElectricalInformation

System ControlWiring

The sensor probe lead wire betweenthe sensor probe and the modulecan be separated by cutting the twowire probe lead leaving equallengths of wire on each device; thesensor probe and the sensormodule. Note this sensor andmodule are matched and mustremain together or inaccuracy mayoccur. These wires can then bespliced to with two 14-18 AWG 600Vwires of sufficient length to reach thedesired outdoor location, maximumlength 1000 feet (305 meters). Themodule four-wire bus must beconnected to the UCP four-wire bususing the Trane approvedconnectors provided.

The sensor will be configured (givenits identity and become functional) atstart-up when the servicemanperforms the start-up configuration.It will not be operational until thattime.

Note: If shielded cable is used toextend the sensor leads, be sure totape off the shield wire at thejunction box and ground it at theUCP. If the added length is run inconduit, do not run them in the sameconduit with other circuits carrying30 or more volts.

CAUTION

Electrical Noise!

MAINTAIN AT LEAST 6 INCHESBETWEEN LOW-VOLTAGE (<30V)AND HIGH VOLTAGE CIRCUITS.Failure to do so could result inelectrical noise that may distort thesignals carried by the low-voltagewiring, including the IPC.

CDHF-SVN01B-EN58

Optional Relay Circuits

Optional Control and Output Circuits

Install various optional wiring asrequired by the owner’sspecifications.

Optional TracerCommunication Interface

This control options allows the UCPto exchange information such aschiller status and operating setpoints with a Tracer system.

Note: The circuit must be run inseparate conduit to prevent electricalnoise interference.

Additional information about theTracer Comm option is published inthe installation manual andoperator’s guide that ships with theTracer.

See Table 15 for Tracer Connections.

Note: Comm 4 will require Tracer tobe connected to each panel forindividual circuit information.(Comm 5 will require connections tothe left panel only when available.

Unit Start-Up

All phases of initial unit start-up mustbe conducted under the supervisionof a qualified Trane local serviceengineer. This includes pressuretesting, evacuation, electrical checks,refrigerant charging, actual start-upand operator instruction.

Advance notification is required toassure that initial start-up isscheduled as close to the requesteddate as possible.

Starter Module Configuration

The starter module configurationsettings will be checked (andconfigured for Remote Starters)during start-up commissioning. Toconfigurate starter modules, andperform other starter checks, it isrecommended that the line voltagethree phase power be turned off andsecured (locked out), and then aseparate source control power (115vac) be utilized to power up thecontrol circuits. To do this, removecontrol coil circuit fuse, typically 2F4,and then connect separate sourcepower cord to starter terminal block1X1-5 (L1), 1X1-17 (L2), and Ground.This needs to be done in each panel.Use the “as-built starter schematic”to assure correct fuse and terminals.Verify correct fuse is removed,control circuit connections arecorrect, then apply the 115 vacseparate source power to service thecontrols.

ElectricalInformation

Forms Information

Samples of start-up and operatingforms along with other helpful formsare found in the OperationMaintenance manual which can beobtained from the nearest Traneoffice.

It is recommended that theserviceman contact the local Traneoffice to obtain the most recentprinting date of the form. The formsin the operation and maintenancemanual are only current at the timeof printing of the manual.

After obtaining the most recent form,complete all the information andforward it to your local Trane office.

System ControlWiring

59CDHF-SVN01B-EN

CDHF-SVN01B-EN60

61CDHF-SVN01B-EN

CDHF-SVN01B-EN62

63CDHF-SVN01B-EN

CDHF-SVN01B-EN64

65CDHF-SVN01B-EN

CDHF-SVN01B-EN66

67CDHF-SVN01B-EN

CDHF-SVN01B-EN68

69CDHF-SVN01B-EN

CDHF-SVN01B-EN70

71CDHF-SVN01B-EN

CDHF-SVN01B-EN72

73CDHF-SVN01B-EN

CDHF-SVN01B-EN74

75CDHF-SVN01B-EN

CDHF-SVN01B-EN76

77CDHF-SVN01B-EN

CDHF-SVN01B-EN78

79CDHF-SVN01B-EN

TraneA business of American Standard Companieswww.trane.com

For more information contact your local districtoffice or e-mail us at comfort@trane.com

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

Literature Order Number

File Number

Supersedes

Stocking Location

CDHF-SVN01B-EN

SV-RF-CTV-CDHF-SVN01B-EN-105

CDHF-SVN01A-EN

La Crosse