Product Catalog — Cold Generator™ Compact Chiller Series ... · Trane Cold Generator™ Compact model CICA water-cooled chillers were designed with flexibility,

Cold Generator™ Compact Chiller Series

Model CICA

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

June 2017 CG-PRC028D-EN

Product Catalog

Introduction

Trane Cold Generator™ Compact model CICA water-cooled chillers were designed with flexibility,expandability and serviceability in mind.These high efficiency chillers provide quiet, reliableoperation and are built to withstand demanding continuous duty cycles. Each chiller meets orexceeds ASHRAE 90.1-2013 energy efficiency standard that went into effect January 1, 2015.

At the heart of the CICA product line is the highly efficient scroll compressor. Additionally the CICAutilizes brazed plate evaporators, brazed plate condensers, and state of the art electronic expansionvalves for increased reliability.

CICA compact water-cooled chillers can be easily combined to meet higher capacity demands andare easy to install in most building layouts.This makes them the ideal choice for retrofit or newbuilding designs where reliability, high efficiency, flexibility, and expandability are critical.

©2017 Ingersoll Rand CG-PRC028D-EN

Introduction

Copyright

This document and the information in it are the property ofTrane, and may not be used orreproduced in whole or in part without written permission.Trane reserves the right to revise thispublication at any time, and to make changes to its content without obligation to notify any personof such revision or change.

Trademarks

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

Revision History

• Updated certification information in Mechanical Specifications.

• Updated AHRI logo on back cover.

CG-PRC028D-EN 3

4 CG-PRC028D-EN

Table of Contents

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

Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Application Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Model Number Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Appendix A —Piping System Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Features and Benefits

Trane Cold Generator™ Compact Series model CICA water cooled chillers are complete, factory-assembled units designed for a wide range of 20-50 ton capacity comfort and process coolingapplications, but also have the ability to be piped into a multistage array of up to ten (10) chillersfor much larger capacities.

Standard Features

• All CICA chillers meet or exceed ASHRAE 90.1-2013 energy efficiency requirements effective1/1/2015.

• All CICA chillers areAHRI performance certified underAHRI Standard 550/590(I-P)-2011 and ETLsafety compliant under ANSI/UL1995, CAN/CSA C22.2 236-11, 4th edition.

• Factory-assembled CICA chillers are pressure tested, dehydrated and charged with operatingcharge of POE compressor oil and 410A refrigerant before shipment.

• Every CICA chiller is run tested over a range of full and part load conditions before shipment,minimizing startup delay. A data log is retained at the factory for each unit shipped.

• Every CICA chiller’s dimensions, including the detachable water header section and all standardor optional valving, are 30” wide X 72” tall X 60” deep.

• All CICA chillers have a single refrigeration circuit with (2) scroll compressors arranged in atandem configuration for higher part load efficiencies and electronic expansion valve forincreased reliability.

• The refrigerant circuit on all CICA chillers has (4) service ports, including one charging portlocated between the expansion device and the evaporator inlet.

• The standard hot gas injection feature is suction pressure actuated and is provided to stabilizethe suction pressure/temperature in the evaporator during transient conditions which avoidspotential nuisance safety trips.

• Core temperature sensors are installed in every CICA evaporator as a redundant low watertemperature safety.

• CICA chillers have manual isolation valves andVictaulic couplings making it easy to isolate theheat exchangers.

• UL-listed brazed-plate evaporators have inlet and outlet pressure transducers that report waterdifferential pressure to the unit controller which can be read from the keypad display for flowproving and system balancing.

• UL-listed brazed-plate condensers have inlet and outlet pressure gauge service ports formanually measuring the water differential pressure.

• Every CICA chiller has a detachable water header section consisting of left-hand or right-handevaporator and condenser customer connections. Customer connections are Victaulic andarrive ready for immediate connection to the customer supply/return lines and, if applicable,to other adjacent CICA chillers.

• All cold refrigerant and water surfaces are insulated with closed-cell flexible insulation.

• All CICA power distribution and control components are located in (1) two-level control cabinetwith operator keypad/display, non-fused disconnect, alarm light, run light and off/auto switchmounted on the exterior of the control cabinet door.

• The CICA unit controller is a microprocessor based controller capable of performing all of theoperational, safety, data retention, communication and fault related functions of the chillerwhile providing compressor management through lead/lag logic.

• BACnet®/IP and Modbus™TCP/IP (or RTU) capability are the standard protocols for buildingautomation and control network communication if needed.

• CICA chillers come with a complete unit parts warranty (excluding refrigerant) for one (1) yearfrom startup or 18 months from shipment, whichever occurs first.

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Factory-Installed Options

• The integral condenser water regulating valve option is available to stabilize and maintain therefrigerant condensing pressure within the operating limits of the CICA chiller.The valve wouldreplace one of the manual isolating valves that come standard on every chiller and would alsobe used to isolate the condenser from the cooling water circuit when needed.

• A fused disconnect with through-the-door operator is available on most CICA models andwould replace the standard non-fused disconnect.

• A 100kA SCCR electrical rating, if needed, could replace the standard 5kA SCCR electrical ratingon all CICA chillers by use of current-limiting fuses.

• Sound attenuation enclosures are exterior panels designed to completely enclose thecompressor section of the CICA chiller.

• Compressor blankets are used to dampen the sound produced by the compressors and can beused alone or in combination with the sound attenuation enclosures.

• The factory-installed phase/power monitor is designed to protect the chiller from prematurefailure and damage due to common voltage faults such as voltage unbalance, over/undervoltage, phase loss, reversal, incorrect sequencing and rapid short cycling.

• BACnet® MS/TP, Johnson N2 and LonTalk® protocols for building automation and controlnetwork communication are available for the CICA unit controller.

• A controller expansion board can be installed if advanced peripheral control is needed.

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Factory-Provided/Field-Installed Options

• Wye-strainers with removable stainless steel 20-mesh screen, epoxy paint, tapped NPTblowdown connection and inlet/outlet pressure gauge taps are available in sizes ranging from2”-8”. Wye-strainers with a minimum of 20-mesh are required to be field-installed before thecustomer connections to the chiller’s evaporator and condenser inlets.

• An evaporator flow-proving device is required for all CICA applications. A paddle style liquidflow switch is available with a NEMAType 4X enclosure for field-installation.

• When opting to connect more than (1) CICA chiller together to form a larger capacity, multistagechiller array, the factory-provided/field-installed array controller can control up to (10) CICAchillers.The array controller package also includes:

• The entering and leaving chilled water temperature sensors and temperature wells to befield-installed in the array’s common supply and return chilled water lines (factory-provided/field-installed)

• All couplings and fittings needed to connect adjacent chillers (factory-provided/field-installed)

• CICA header pipe size optimization for its position in the chiller array (factory-installed)

• Wireless router for wireless access to each individual chiller and the array control panel(factory-provided/field-installed, Ethernet cable field-provided)

• For critical cooling applications, the “N+1” option allows for a dormant backup chiller to beavailable in a multiple CICA chiller array. If an active CICA chiller fails, the “N+1” logic will openthe chilled and condenser water valves and enable the backup chiller while closing the chilledand condenser water valves and disabling the failed chiller.The“N+1” option package includes:

• The array controller package (factory-provided/field-installed)

• (1) backup CICA chiller to be connected to the “N” number of CICA chillers needed to satisfythe design cooling load (factory-provided/field-installed)

• Array controller “N+1” logic programming (factory-installed)

• Motorized valves on all CICA chillers’ evaporator and condenser outlets (factory-installed)

• Neoprene isolator pads can be provided for all (6) load bearing points on the CICA chillers.

• The wheel kit, containing (4) swiveling casters, is easily installed to predrilled holes in the baseof each CICA chiller and allows the chiller to be easily maneuvered and rolled into positionacross smooth surfaces.

• The rigging bracket kit includes four (4) steel rigging brackets with 1-5/8” lifting holes designedfor chiller’s weight and easily mounted to predrilled holes on chiller frame. Hardware isincluded.

• The forklift pocket kit include four (4) steel forklift pockets designed for the chiller’s weight andeasily mounted to predrilled holes on chiller frame. Hardware included.

• Ice build logic can be factory programmed into the CICA unit controller for use with a field-provided and installed dry contact closure device in ice storage applications. Available forsingle chiller application only.

• Condenser water temperature sensors allow measurement and monitoring of the condenserentering and leaving water temperatures.

• Ambient temperature sensor allows for measuring and monitoring of ambient temperature.

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Other Features and Benefits

Flexibility & Expandability

• Trane Cold Generator™ CICA compact series scroll chillers were specifically scaled to fitthrough a standard 36” doorway and to fit onto a standard elevator, ensuring fast and easydelivery and installation.

• Because the CICA compact series can be applied as an individual chiller or applied as a highcapacity multi-stage, multi-chiller array by using the optional array controller package, the CICAchillers can be configured to meet capacity needs ranging from 20 tons to 500 tons.

• For atypical mechanical room configurations sometimes encountered with retrofit andrenovation applications, CICA chiller arrays are not required to be installed side-by-side. Iflimited on space or dealing with a challenging layout,Trane will design custom pipe sizes to suitthe unique needs of your facility’s chiller array layout.

• The array controller option allows the CICA chiller to be an ideal solution for facilities withgrowing occupancy and structural expansion plans because chillers can be added as capacityneeds increase.

Serviceability

• The CICA compact chiller was designed in such a manner that the compressors, evaporator,condenser, refrigerant specialties and water pipe components can all be easily serviced orremoved. When installed in an array, these components can all be easily serviced or removedfrom any one chiller in the array while the other chillers in the array continue to operate.

• Standard, integral valving makes it possible to isolate the CICA heat exchangers for routinemaintenance. Once isolated, both heat exchangers have inlet and outlet Victaulic connectionsreadily accessible to allow for backflushing and cleaning without having to remove theexchanger. If a heat exchanger must be removed and replaced, all necessary work can beperformed at the back of the chiller without having to remove other unrelated parts.

• If needed, an entire CICA chiller can be removed from an array of chillers by using the integralvalving,Victaulic connections and the detachable water header section. Because the detachablewater header section was designed with its own support frame, the water header section canbe left in place to feed adjacent chillers allowing them to continue operating.

• In an array application, if the array controller fails or if communication is lost between theindividual CICA chillers and the array controller, the individual chillers can be switched to“standalone” mode and continue operating on their own to control the chilled leaving watertemperature within the control zone of a pre-set default setpoint.

• The CICA controller stores operational and diagnostic information that can be accessed locallyusing the chiller keypad/display or the PC connection inside the chiller control panel.Thisinformation can also be accessed from a remote location using an Ethernet or other typeinterface.

Single Source Responsibility

Single source responsibility allows the customer to source all building comfort systems throughtheir localTrane Sales Office.

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Application Consideration

Unit Location

Trane CICA compact chillers are designed for indoor installations only that remain above 32°F andbelow 125°F at all times. Locate the chiller away from sound-sensitive areas on a level foundationor flooring strong enough to support 150 percent of the operating weight and large enough to keepwith service clearances. Also, the chiller foundation or flooring must be rigid enough to minimizevibration transmission. Please see “General Data,” p. 13 for compressor sound data and “AppendixA — Piping System Flushing Procedure,” p. 31 for unit operating weights and clearances to ensurethe chiller will work for your application. If necessary, options are available for sound attenuationand vibration reduction.

Water Circuit Requirements

BecauseTrane CICA compact chillers are equipped with brazed plate evaporators and condensers,it is imperative the water/fluid circuits to be used with these chillers are designed and installedfollowing sound engineering practices and procedures as well as any applicable local and industrystandards with the utmost attention being focused on filtration and water quality.

Prior to connecting a CICA chiller into a newly installed or existing water piping system, it isrequired to flush the system with a detergent and hot water mixture to remove previouslyaccumulated dirt and other organics. In old piping systems with heavy encrustation of inorganicmaterials, a water treatment specialist should be consulted for proper passivation and/or removalof these contaminants. For more specifics on the flushing procedure and for the type of strainersto be used during the procedure, please see “Appendix A — Piping System Flushing Procedure,” p. 31.

Filtration - Particulate fouling is caused by suspended solids (foulants) such as mud, silt, sand orother particles in the heat transfer medium.The best way to avoid particulate fouling is to keep allsystem water clean and with open loop system water, maintain proper bleed rates and make upwater. Strainers with a 20-mesh screen (or screen with 0.5 mm sized openings or less) are requiredto be installed before the inlet of the heat exchangers. Wye strainers are available as a factory-provided, field-installed option. If an application is highly susceptible to foulant contamination,additional filtration methods should be investigated.

Water quality – Poor water quality can cause another type of fouling called scaling. Scaling iscaused by inorganic salts in the water circuit of the heat exchangers. Scaling increases pressuredrop and reduces heat transfer efficiency.The likelihood of scaling increases with increasedtemperature, concentration and pH. In addition to scaling, poor water quality can cause otherissues like biological growths and corrosion.Therefore, water quality and water quality controlneeds to be an application consideration. Please review the water quality requirements for use withthe brazed plate heat exchangers on the CICA compact chiller. For more specifics on the watertreatment requirements, please see “Appendix A — Piping System Flushing Procedure,” p. 31.

Table 1. 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

CG-PRC028D-EN 9


Evaporator FluidTemperatures and Flow Requirements

Standard evaporator leaving water temperature range for the CICA chiller is 42°F - 60°F. Forevaporator loops containing the appropriate amount of glycol, the chilled water leavingtemperature range can be shifted to 15°F - 60°F.

The evaporator minimum and maximum flow rates are listed in “General Data,” p. 13. In general,the listed flow rate ranges will develop temperature differentials across the evaporator between 7°F- 20°F. If your application conditions are unconventional or do not fit these requirements, pleasecontact your localTrane representative to determine if the CICA chiller is the correct chiller for yourneeds.

For all CICA chiller applications, the flow to the evaporator must be proven using a chilled waterflow-proving device. A factory-provided flow-proving device is available as a field-installed option.

Chilled Water System Volume

As a minimum, a 3-minute loop time is required for the evaporator chilled water system. For yourspecific application, you can calculate the required chilled water system volume by multiplying thedesign evaporator flow rate in GPM by 3 minutes. Depending on the system, a tank with baffles formixing may need to be installed into the loop to meet the required volume.

Condenser FluidTemperatures and Flow Requirements

Standard condenser entering water temperature range for the CICA chiller is 65°F - 125°F.Thecondenser leaving water temperature (LWT) maximum is 130°F, and the condenser LWT minimumis 77°F. When the condenser LWT is lower than 77°F, the refrigerant condensing temperature candrop below 80°F and fall outside of the CICA compressors’ operating envelope. For theseapplications, provisions must be made to control the condenser water that results in a stablerefrigerant condensing temperature/pressure that remains above 80°F (235 psig) throughout allsteady state, part load and transient operating conditions.The integral factory-installed condenserwater regulating valve option is perfect for these applications and is highly recommended.

The condenser minimum and maximum flow rates are listed in “General Data,” p. 13. In general,the listed flow rate ranges will develop temperature differentials across the condenser between 5°F- 30°F. If your application conditions are unconventional or do not fit these requirements, pleasecontact your localTrane representative to determine if the CICA chiller is the correct chiller for yourneeds.

Variable Flow Applications

CICA compact chillers can be applied in variable flow applications where the flow is varied andcontrolled by others.The flow being delivered to the chiller must not go outside the statedminimum and maximum flow rates in “General Data,” p. 13. Also, the chilled water system volumeshould be calculated using the highest evaporator flow rate to be delivered to the chiller, and therate of change in flow rate must not exceed 10% of design flow GPM per minute.

Free (aggressive) Carbon Dioxide (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

Table 1. Water property limits (continued)


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Multiple Chiller Applications

Anytime more than one CICA chiller is piped together (to form an array of chillers) for highercapacity and/or redundant chiller applications, a field-installed array controller package will beprovided from the factory.The array controller included in the package can control up to (10) CICAchillers.

The number of chillers that can be physically piped together to form an array and share a commonheader is limited to approximately 250 total tons. In general, if the total tonnage is 250 tons or less,one common evaporator supply/return line and one common condenser supply/return line can beused. If the total tonnage needed is greater than 250 tons, the flow from these common lines canbe split between two arrays of chillers. Figure 1 shows examples of acceptable and unacceptablearray piping configurations. For help with determining the most effective array configuration foryour application, please contact your localTrane sales representative.

The header system on an array of chillers has optimized chilled and condenser water pipe sizessuited for the flow rates specific to each chiller’s location in the array.This means that the headerpipes will not all be the same size, but will graduate down from larger to smaller to keep velocitiesup at each chiller. The customer would tie into the array's header system at the end of the arraywith the largest piping. All left-hand or all right-hand customer connections must be specified. SeeFigure 6, p. 25 for CICA array dimension details.

To provide power to an array of chillers, power must be connected to each individual chiller.Depending on the size of the application, an alternative method for powering an array may beavailable. Please contact your localTrane sales representative for more information.

Figure 1. Chiller configuration examples

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Model Number Descriptions

Digits 1-3 — UnitTypeCIC = Compact indoor chiller

Digit 4 — ModelA = Model A

Brazed plate evaporatorBrazed 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


Digit 15— Water Piping PackageCondenser Entering


12

Digit 16— Water Piping PackageCondenser Leaving


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 = Standard 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)

CG-PRC028D-EN

CG-PRC028D-EN 13

General Data

Table 2. 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)

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

dbA 78 81 89

Compressor Sound Data with Sound Blankets Only(b)

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

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

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Performance Data

Table 3. CICA performance data

Unit Size

% Load Tons kw

% Load EER

IPLV EER

20

100 22.4 16.1 16.7

21.475 16.8 10.4 19.4

50 11.2 5.9 22.8

25 5.6 2.8 24.0

30

100 32.2 23.1 16.7

21.675 24.1 14.8 19.5

50 16.1 8.4 23.0

25 8.1 4.0 24.3

50

100 50.2 37.6 16.0

22.175 37.6 23.1 19.5

50 25.1 12.7 23.7

25 12.5 6.0 25.0

Notes:

1. Rated in accordance with AHRI Standard 550/590, based on TOPSS version 180: evaporator leaving temperature of 44°F and 2.4 gpm/ton, condenser entering temperature of 85°F and 3 gpm/ton with condenser relief at part loads, evaporator fouling of 0.0001oF.ft2.h/Btu and condenser fouling of 0.00025oF.ft2.h/Btu

2. Consult Trane representative for additional performance information 3. EER - Energy Efficiency Ratio (Btu/w.h)

Controls

TheTrane Cold Generator™ CICA compact series scroll chiller control panel is designed to savespace and provide one convenient area for all necessary field-wiring.The control panel consists oftwo levels which separate the power and control components.

The power distribution section is located on the fixed back panel and contains the input powerground lug and non-fused disconnect switch for customer connection, power distribution block,across-the-line contactors, current transformers and control circuit power transformer withprimary and secondary fuses.

The controls section is located on the hinged interior panel and contains the unit controller, displaywith keypad (control panel door), power monitor (optional), electronic expansion valve driver,service friendly terminal strips to facilitate circuit diagnosis and a field connection terminal strip.

Microprocessor-Based Controller

The unit controller is a durable microprocessor-based controller designed to be the primarymanager of the CICA compact chiller.The controller is capable of performing all operational, dataretention and communication functions for the chiller while providing lead/lag logic to equalize runtime on the individual compressors. When necessary, it will perform appropriate evasive actionsin the event a sensor input returns a reading that is out of range based on setpoints.

The data retention capabilities of the unit controller include storage of up to 1,008 packets ofinformation that can be graphically presented based on an adjustable, set time interval.Thecontroller also maintains a fault history including the date and time of day for each fault (up to thelast 99 occurrences). If a fault results in a compressor lockout, 120 seconds of history prior to thelockout is saved.The history leading up to the lockout gives the technician a clear picture of whatthe chiller was experiencing just before the failure and is very helpful for diagnosing the causes.

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Controls

Operator Interface

The unit controller can be accessed using the keypad-display screen and uses a clear languageformat for easy interpretation by the user.The keypad-display is mounted to the front of the controlpanel door along with the non-fused disconnect switch actuator, off/auto switch, run indicator lightand alarm indicator light.

All information needed to run the chiller is available and can be changed and viewed using thekeypad-display screen; however, a laptop or PC is invaluable for ease of use, for viewing dynamicon-line display screens, for better graphing capability and for downloading data files. A free PC/laptop software package called MCS-Connect is available for download at www.mcscontrols.com.Once installed, the unit controller can be accessed from the PC or laptop by using (1) of the (4)different ports located inside the control panel:

1. RS-485 network access through RS-232 serial port located on backside of keypad-display

2. RS-485 network access port located on backside of keypad-display

3. RS-485 network access port located on corner of unit controller

4. Ethernet port located on corner of unit controller

Note: If only one of the RS-485 network accesses is already being used (#1-#3) for BMScommunication or for an array controller, the Ethernet port would be the only port that canbe used for PC or laptop access.

Building Communications

When theTrane Cold Generator™ CICA chiller is used in conjunction with a building managementsystem such asTracer, the chiller can be monitored and given input from a remote location.Thechiller can be set up to fit into the overall building control strategy by using remote run/stop input,remote demand limit reset and/or remote chilled water reset functions.

As standard, the unit controller Ethernet port is always ready to talk BACnet IP and ModbusTCP/IP (Modbus RTU uses the RS485 network port). BACnet MS/TP, Johnson N2 and LonTalk areoptional protocols that can be factory-installed.The unit controller can facilitate the following BMScommunications:

• Remote Off/Auto signal (input from BMS)

• Demand Limit Reset signal (input from BMS)

• Chilled WaterTemperature Reset signal (input from BMS)

• Customer Alarm relay (view only)

• Chiller Run Indication (view only)

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http://www.mcscontrols.com

Controls

• Entering Chilled WaterTemperature (view only)

• Leaving Chilled WaterTemperature (view only)

• Chilled Water Flow Switch input (view only)

• Condenser Pump relay (view only)

• Chilled Water Pump relay (view only)

System Protection

A complete safety lockout system with alarms protects the CICA compact chiller operation to avoidcompressor and evaporator failures.The unit controller directly senses pressures, temperatures,amperage, motor faults, etc. All control variables that govern the operation of the chiller areevaluated every second for exact control and protection.The following is an abbreviated list ofsafeties that are incorporated into the standard chiller algorithm control. For a complete list, pleaserefer to the more detailed controls manual, CG-SVX030*-EN.

• No Flow Protection –To protect the chiller from no water flow to the evaporator, the chilleris enabled to run only if the required flow proving device indicates there is flow present. If thechiller is active and flow is lost; the chiller will lock out, and an alarm is generated.

• Low Suction Pressure –To protect the compressors and evaporator, if the refrigerant suctionpressure drops below the set point value for a specified period of time, a safety trip occurs.Thissafety is bypassed when the compressor is in a Pump Down state.

• Unsafe Suction Pressure –To protect the compressors and evaporator, if the refrigerantsuction pressure drops below the set point value for a specified period of time, the chiller willimmediately lock out, and an alarm is generated.

• Freeze Protection –To protect the evaporator from low water temperatures, the chilled watertemperature is monitored inside the core of the evaporator and leaving the evaporator. If thesestemperatures fall below their set point temperatures for the set period of time, the entire systemwill lock out and an alarm is generated.

• Hot Gas Injection – Working in conjunction with the low suction pressure and freezeprotection safeties to avoid nuisance safety trips, the hot gas injection valve is opened whenthe suction pressure goes below the lower set point value and allows hot discharge gas to beinjected directly before the inlet to the evaporator.The valve will stay open until the suctionpressure rises safely above the upper set point level.

• High & Low Discharge Pressure, High & Low Superheat, High & Low CompressorAmps –The compressors will be locked out if any one of these control variables rises abovethe upper set point value or falls below the lower set point value for the set amount of time foreach, and an alarm is generated.

• Compressor Motor Protection Module –The compressors on the CICA050 are equippedwith an extra layer of protection.The pre-installed motor protection module, in the compressorterminal box, provides for an extra layer of protection against motor overheating andoverloading, as well as phase loss/reversal. Should one of these parameters be incorrect, themotor module relay will lock out (open) and the red LED on the module will blink.The unitcontroller will indicate the lockout, and an alarm is generated.

• Optional Phase/Power Monitor –The factory-installed phase/power monitor continuouslymonitors the incoming power supply to the chiller, before it reaches the compressors, for lowvoltage, phase rotation reversal, loss of phase and phase imbalance. Should one of theseparameters be incorrect, the phase/power monitor relay will lock out (de-energize) and the faultLED on the monitor will blink.The unit controller will indicate the lockout, and an alarm isgenerated.

As an additional layer of system protection, mechanical high and low pressure switches are usedin conjunction with the refrigerant circuit high and low pressure transducers and unit controller.

CG-PRC028D-EN 17

Controls

Standard Peripheral Control Features

The following peripheral control features and program logic come standard on all CICA compactchillers. Designated terminals on the field connection terminal strip in the control panel areprovided for field connection of:

• Remote Off/Auto (dry contact closure from a remote device - input)

• Required Flow Proving Device (dry contact closure from a remote device - input)

• Remote Alarm (dry contact closure to a remote device - output)

• Chilled Water Pump Enable (dry contact closure for 1 chilled water pump - output)

• Condenser Water Pump Enable (dry contact closure for 1 condenser water pump - output)

Standard Capacity Control

Standard capacity control on the CICA compact chillers is accomplished by staging the scrollcompressors on and off.The unit controller will maintain a set point leaving chilled watertemperature within a control zone using proportional, integral derivative (PID) logic. If the leavingchilled water temperature starts to decrease and falls below the set point, the unit controller willturn one compressor off. A further reduction in temperature will result in the second compressorbeing turned off.The reverse is true as the leaving chilled water temperature increases. Lead/laglogic is used to even the run time on the individual compressors.

Optional Capacity Control

Chilled water temperature reset can be accomplished in two ways. In buildings with a buildingmanagement system, the CICA unit controller allows the BMS to communicate an offset to thechilled water temperature set point. If a BMS is not being used, the unit controller can accept a field-provided 0 to 5 VDC analog input signal. As the input voltage varies away from center (2.5V), thechilled water temperature set point will be offset proportionally. Note:This control logic is factory-installed and must be denoted at the time of ordering.

Demand limiting is a form of capacity control that limits the number of capacity steps the chilleris allowed to operate. It can be accomplished in the same two ways as the chilled water temperaturereset: through BMS or field-provided 0 to 5 VDC input signal. Note:This control logic is factory-installed and must be denoted at the time of ordering.

18 CG-PRC028D-EN

Controls

Array Control

The optional array controller package offers yet another form of capacity control.This optionallows up to 10 CICA compact chillers to be controlled and operated like a single, much highercapacity, multistage chiller.With this option, capacity modulation and equalization of compressorrun time is shifted to the array controller.The array controller uses the same standard capacitycontrol logic as an individual CICA unit controller but with more stages of capacity.There are othersimilarities and some differences in CICA array control when compared to individual CICA unitcontrol.The list below briefly summarizes the comparison of the two:

• The factory-provided, field-installed CICA array control panel uses the same microprocessor-based controller and keypad-display as an individual CICA unit control panel. Power (115VAC)must be provided to a 2A circuit breaker inside the array control panel to power the array controlcircuit.The array control panel also contains a field connection terminal strip and door-mountedoff/auto switch, run indicator light and alarm indicator light.

• The array controller is accessed in the same manner as the unit controller, through the keypad-display or PC/laptop. Note: If only one of the RS-485 network accesses is already being used (#1-#3) for BMS communication, the Ethernet port would be the only port that can be used for PCor laptop access; or vice versa, if the Ethernet port is already being used (#4) for BMScommunication, one of the RS-485 network access ports would be the only means for PC orlaptop access.

• The array controller can facilitate the same standard and optional BMS protocols andcommunications for an array as with a single chiller application. In addition, the array controllercan also communicate the optional array condenser entering and leaving water temperaturesfor viewing by the BMS (if applicable).

• System protection is still provided by the individual unit controllers with the addition of thefollowing being monitored and recorded by the array controller:

• Chiller Array Fault – Low/No array chilled water flow

• Chiller Array Fault – Low array chilled LWT

• Chiller Unit Fault – Displays chiller unit number for unit where fault occurred

• The same peripheral control features can be controlled by the array controller for an array ofCICA chillers as with an individual unit application, but with a few extras:

• Required Chilled Water Pump Enable and optional 2nd Chilled Water Pump Enable(dry contact closures for 2 chilled water pumps - output)

• Condenser Water Pump Enable (dry contact closures for 2 condenser water pumps -output)

• Array On/Off Status (dry contact closure for remote device – output)

If communication between the individual CICA chiller unit controllers and the array controller is lostor the array controller fails for whatever reason, the individual CICA chillers can be shifted intomanual mode to operate independent from the array controller and will maintain a“manual mode”chilled LWT set point.

CG-PRC028D-EN 19

20 CG-PRC028D-EN

Electrical

Table 4. 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).

Electrical Connections

Figure 2. Field wiring — CICA unit control panel, single chiller application

98

1011

GROUND

92

14

37

56

811

1012

Unit Controller

115v

Volt

age

12

34

56

7

PANEL

12

REQUIRED

TBA

Flow Switch/Flow-Proving Device - Input from Dry :

3.

OPTIONAL:

Representation - Front Panel

Contact Closure Only

Do not energize the unit until check- (Required) Factory supplied or approved alternate field installed flow

3

out and start-up procedures have

Chilled Water Pump #1 - 125 VAC Max

OPTIONAL:

REQUIRED

State & Local requirements.

:

accept other type conductors. FailureUnit terminals are not designed toUse copper conductors only!

All field wiring must be in accordance with National Electric Code and

tagout procedures to ensure powercannot be inadvertently energized.Failure to do so can cause death or

CAUTION

Remote Alarm - 125 VAC Max

been completed.

to use copper conductors may cause

Condenser Pump #1 - 125 VAC Max

Representation - Back Panel

DSW1

CAUTIONproving device connection.

2.

Disconnect all electrical power

OPTIONAL:

equipment damage.

including remote disconnects beforeservicing unit. Follow proper lockout/

OnlyRemote Off/Auto - Input from Dry Contact Closure

serious injury.

Hazardous voltage!WARNING

Notes:

All customer control-circuit wiring must have a minimum rating of 1.150V.

3

CG-PRC028D-EN 21


Figure 3. Field wiring — CICA unit control panel, array application

18

1011

GROUND

92

14

37

56

811

1012

Unit Controller11

5v

RE

LAY

M-8

RE

LAY

M-9

Volt

age

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

92

34

56

7

PANEL

12

TX R

S-48

5

Representation - Back Panel

7

Representation - Front Panel

Disconnect all electrical powerHazardous voltage!WARNING

Remote Alarm - 125 VAC MaxOPTIONAL:

ETHERNET

OnlyRemote Off/Auto - Input from Dry Contact Closure OPTIONAL:

7

TX485

_

7

Previous Chiller in Array

if Applicable6 Last Chiller in Array

7

Middle Chiller(s) in Array,

including remote disconnects beforeservicing unit. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.

serious injury.

Unit terminals are not designed toaccept other type conductors. Failureto use copper conductors may causeequipment damage.

Failure to do so can cause death or

CAUTIONUse copper conductors only!

chiller in the array.7. on the last EXCEPT

been completed.out and start-up procedures haveDo not energize the unit until check-

TBA

_

+

GND

7

DSW1

TX R

S-48

5

TERMINATION

From Array

6.

Next Chiller in Array

CAUTION

Ensure all TX RS-485 Berg Termination Jumpers are removed

5

Controller MCS I/O

_

6

+

To TX RS-485 on

JP4

TX485

+

+

TX R

S-48

5

_

_

Next Chiller in Array

JP4

GND

+ TX R

S-48

5_

TX485

TERMINATION

JP4

GND

+ ++From TX RS-485 on

TERMINATION

_ _

To TX RS-485 on

Previous Chiller in Array

5 First Chiller in Array

From TX RS-485 on

Notes:All customer control-circuit wiring must have a minimum rating of 150V.1.All field wiring must be in accordance with National Electric Code and State & Local 2.requirements.All field provided RS-485 network cable must be 24 GA, shielded, 2-conductor with drain 3.wire (Belden 9841 or equivalent).All field provided ethernet cables must be Cat 5 or higher ethernet straight (patch) cables.4.Only the first chiller in array is connected from TX RS-485 port to the Array Controller 5.MCS I/O port in the Array Control Panel.Consecutive chillers in array are daisy-chained through TX RS-485 ports.

Ethernet Cable to16 Port Ethernet Switchin Array Control Panel

22 CG-PRC028D-EN


Figure 4. Field wiring — CICA array control panel

OPTIONAL:

CHW Reset

16 Port Ethernet Switch

Array C

ontroller

115V

RELAY M-8

RELAY M-9

RELAY M-7

RELAY M-3

RELAY M-6

RELAY M-5

RELAY M-4

RELAY M-1

RELAY M-2

RELAY M-10

12

11

10

98

76

54

32

113

14

1515

14

13

12

11

10

98

76

54

32

1

PANEL GROUND

MCS I/O

_MCS I/O

Black

White

Shield

White

ShieldBlack

White

ShieldBlack

White

ShieldBlack

White

Cond LWTOPTIONAL:

Ambient Temp

Analog Signal

ShieldBlack

Evap LWT

Shield

:

Cond EWT

REQUIREDEvap EWT

16

16

17

17

SE

NS

OR

1SE

NS

OR

2 SE

NS

OR

3S

EN

SO

R 4S

EN

SO

R 5

0-5VDC

ETHERNET

SE

NS

OR

6

TX RS-485

OPTIONAL:

:

REQUIRED

OPTIONAL:

Yellow

Wireless RouterWireless RouterPower Cord From

OPTIONAL:

Each Chiller Module(Factory Provided)

4.

(Field Provided)

Ethernet Cable From

115 VAC

OPTIONAL:

(Factory Provided)

Do not energize the unit until check-


OPTIONAL:

serious injury.

:-

Hazardous voltage!

Chill Water Pump #1 - 125 VAC MaxREQUIRED

CAUTION

REQUIRED

requirements.

GND

Disconnect all electrical power

CAUTION

:

Array On/Off Status - 125 VAC Max

Contact Closure OnlyRemote OFF/Auto - Input from Dry

OPTIONAL:

CABLE TO "TX RS-485" ON

including remote disconnects beforeservicing unit. Follow proper lockout/tagout procedures to ensure powercannot be inadvertently energized.

Unit terminals are not designed toaccept other type conductors. Failure

All field provided RS-485 network cable must be 24 GA, shielded, 2-conductor with drain wire (Belden 9841 or equivalent)

out and start-up procedures have


Circuit Breaker

been completed.

OPTIONAL:

Chill Water Pump #2 - 125 VAC Max

+ Flow Switch/Flow-Proving Device -

Neutral

to use copper conductors may causeequipment damage.

Failure to do so cause death or

Input from Dry Contact Closure Only

WARNING

Use copper conductors only!

3. All field provided ethernet cables must be Cat 5 or higher ethernet straight (patch) cables.

CHILLER IN ARRAYCONTROLLER OF FIRST

OPTIONAL:Remote Alarm - 125 VAC Max

NOTES:All field provided control-circuit wiring must have a minimum rating of1.150V.All field wiring must be in acco rdance with NEC, State & Local 2.

REQUIRED:ROUTE RS-485 NETWORK

Ethernet Cables From

+

CG-PRC028D-EN 23

Dimensions and Weights

DimensionsFigure 5. CICA unit dimensions

30"

"B"

"B"

Qty

4 -

"A" V

ic

(if R

ight

Con

figis

ord

ered

)

Qty

4 -

"A" V

icC

ust C

onne

ctio

ns(if

Lef

t Con

figis

ord

ered

) 7

2"

60"

49

1 4"

5" E

vap

Out

141 2

"Ev

ap In

231 2

"C

ond

Out

32"

Con

dIn

6X

3 4"

2X

3" 2

X 24

"

2X

3"

2X

381 2

" 2

X 4"

6

5 8"

16

3 4"

NO

TE:

Head

er p

ipes

will

be se

aled

and

cap

ped

on

oppo

site

end

from

cus

tom

er c

onne

ctio

ns.

In so

me

view

s, pa

rts m

ay b

e hi

dd

en fo

r cla

rity.

Cus

t Con

nect

ions

24 CG-PRC028D-EN


Figure 6. CICA array dimensions

4X "

B"

4X "

B"

"W

" 3

0" T

yp

Qty

4 -

"A"

Vic

Cus

tom

erCon

nect

ions

(if

Rig

ht C

onfig

is o

rder

ed)

Qty

4 -

"A"

Vic

Cus

tom

erCon

nect

ions

(if Le

ft C

onfig

is o

rder

ed)

72"

49

1 4"

Eva

p O

ut 5"

Eva

p In

14

1 2"

231 2

"Con

dO

ut

32"

Con

dIn

60"

2X 3

" Ty

p

16

3 4"

Typ

35 8

" Ty

p

2X 3

5"

Typ

"C"

"C" 6

n X

3 4"

3"

Typ

38

1 2"

Typ

4"

Typ

NO

TE:

Rig

ht C

onfig

urat

ion

show

n, s

o le

ft e

nd o

f he

ader

s ar

e ca

pped

and

sea

led.

In

som

e vi

ews,

par

ts m

ay b

e hi

dden

for

cla

rity

.

CG-PRC028D-EN 25


Clearances

Notes:

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

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

• 42” clearance is recommended above the chiller.

• Clearances remain the same when more than one chiller is present.

Weights

Figure 7. Clearance — CICA 20, 30 50 ton

36"

36" 36"

42"

Table 5. CICA unit weights

Shipping Weight Operating Weight

Size lbs kg lbs kg

20 1570 712 1501 681

30 1670 758 1641 744

50 2190 993 2223 1008

26 CG-PRC028D-EN

Mechanical Specifications

General

Trane Cold Generator® Compact Model CICA water-cooled chillers are designed with highefficiency, reliability, serviceability and expandability in mind. CICA chillers can be applied asstandalone chillers or in an array of up to ten (10) chillers controlled by an array controller to forma single high capacity multistage package chiller.The header pipe section is detachable and hasoptimized chilled and condenser water pipe size suited for the flow rates specific to the chiller’slocation in the array.

Each CICA chiller is pressure tested, dehydrated, charged with refrigerant R-410A and POE oil, andrun tested at full and part load conditions. Completed chillers are then top coated with industrialtwo-part epoxy direct-to-metal paint prior to shipment.

Standalone chillers only require field connection of chilled and condenser water piping, chilled andcondenser water wye strainer, and power and control wiring to the control panel terminal block /strip. CICA chillers installed in an array require additional coupling of water piping between chillersand mounting and wiring of array controller panel.

Chilled and condenser water inlet and outlet connections are Victaulic for ease of installation andservice. Chilled water flow proving device, and chilled and condenser water 20 mesh wye strainerare required and must be field installed.

Certified AHRI Performance

Trane water-cooled chillers are rated within the scope of the Air-Conditioning, Heating &Refrigeration Institute (AHRI) Certification Program and display the AHRI Certified® mark as avisual confirmation of conformance to the certification sections of AHRI Standard 550/590 (I-P) andANSI/AHRI Standard 551/591 (SI).The applications in this catalog specifically excluded from theAHRI certification program are:

• Custom Units

• Condenserless Chillers

• Evaporatively-cooled chillers

• Units with evaporators or condensers that use fluid other than fresh water except unitscontaining freeze protection fluids in the condenser or in the evaporator with a leaving chilledfluid temperature above 32°F [0°C] are certified when rated per the Standard with water.

Agency Listing

Each CICA chiller is ETL Listed to U. S. and Canadian safety standards

Compressor – Motor

Fully hermetic direct drive scroll compressors are mounted on vibration isolators. Lubricationsystem with oil level sight glass is arranged to ensure adequate lubrication during starting,stopping and normal operation. Motor is suction gas cooled, runs at a constant speed of 3600 rpms,has motor protection and is designed for across-the-line start.

Evaporator

Brazed plate evaporator is UL Listed for US & Canada. Refrigerant side has maximum design/abnormal pressure rating (PS) of 609 psi (42 bar) atTS of 437°F (225°C). Water side has maximumdesign/abnormal pressure rating (PS) of 392 psi (27 bar) atTS of 437°F (225°C). Evaporators haveone (1) refrigerant circuit and one (1) chilled water circuit. Evaporator is insulated with 0.5 inch (12.7mm) thick closed-cell flexible insulation with a K value of 0.26 BTU/ (hr-ft.-°F) and is furnished withcore, inlet and outlet water temperature sensors.

CG-PRC028D-EN 27


Condenser

Condenser is brazed plate type and is UL Listed for US & Canada. Refrigerant and water side havemaximum design/abnormal pressure rating (PS) of 650 psi atTS of 400°F. Condensers have one (1)refrigerant circuit and one (1) chilled water circuit.

Refrigerant Circuit

All CICA chillers have one (1) refrigeration circuit with compressors arranged in a tandemconfiguration for higher part load efficiencies. Manufacturer approved tandem header systemsinclude discharge line, suction line and oil equalization line. Each refrigerant circuit has liquid linedrier, electronic expansion valve with integral refrigerant sight glass, hot gas injection solenoidvalve and interconnectingType K copper pipe.

Water Flow Balancing Devices

Water flow through evaporator and condenser of each chiller in an array can be easily balanced byadjusting differential pressure. Chilled water inlet and outlet pressure is measured by pressuretransducers and reported by the unit controller. Condenser water inlet and outlet pressure ismeasured by using onboard pressure gauge service ports. Water flows can then be adjusted byusing onboard manual isolation valves.

Compact Chiller Control Panel

The two-level control cabinet contains a power distribution section (back panel) and a controlssection (hinged interior panel). Unit controller is located in the controls section with displaymounted on the exterior of the control cabinet door.

Power distribution section contains input power and ground lugs for customer connection, across-the-line contactors, non-fused disconnect, current transformers, and control power transformerwith primary and secondary fuses.

Controls section contains the unit controller with standard and optional expansion boards,keyboard and display (exterior of control cabinet door), power monitor (optional), service friendlyterminal strips to facilitate circuit diagnosis and a field connection terminal strip. If the chiller isoperated as a single unit (not in an array with other CICA chillers), provisions at the field connectionterminal strip have been made for “Remote Off/Auto” (input), “Remote Alarm” (output), “RemoteChilled Water Enable” for one (1) chilled water pump (output), “Condenser Water Pump Enable”for one (1) condenser water pump (output), and required “Flow Switch (flow proving device)”(input).

The standalone unit controller monitors, displays and logs operating and fault conditions, andprovides safety protection for low and high refrigerant operating pressure, low and high refrigerantsuperheat, low refrigerant differential pressure between low and high side, low chilled watertemperature, low chilled water flow, compressor over amperage, and abnormal power conditionswhen fitted with optional power monitor. Mechanical high and low pressure switches, andcompressor thermal protection devices are not located in the controls section, but are monitoredand reported by the unit controller.

The unit controller will also stage compressors using lead/lag logic to maintain the chiller’s leavingchilled water temperature set-point in a single chiller application (not in an array with other chillers)or in an array with other CICA chillers if the array controller fails.

When a CICA chiller is being operated as a single unit, the unit controller adjusts the leaving chilledwater temperature by staging compressors using proportional, integral, derivative (PID) logic. Unitcontroller has RS232, RS485 and Ethernet communications ports for user interactivecommunication, or for interface with Building Management Systems (BMS). Controller hasstandard BMS compatibility with BACnet® IP and Modbus™ RTU and can be fitted with an optional

28 CG-PRC028D-EN


interface gateway for compatibility with Johnson N2, LonTalk® and BACnet MS/TP.The controlleris capable of responding to a BMS signal for “Run/Stop”, “Leaving Chilled WaterTemperatureReset” or “Demand Limiting Reset”. “Leaving Chilled WaterTemperature” can also be reset usinga 0 to 5 VDC input signal.

Array Control Panel

An array control panel (shipped loose) is required for operation of more than one (1) nestedcompact chiller.The array control panel contains the array controller, keyboard and display(exterior of control cabinet door), 120 VAC circuit breaker for input power to the panel, and fieldconnection terminal strip for connection of “Remote Off/Auto” (input), “Remote Alarm” (output),“Remote Chilled Water Enable” for up to two (2) chilled water pumps (output), “Condenser WaterPump Enable” for one (1) condenser water pump (output), “Array On/Off Status” (output), andrequired “Flow Switch (flow proving device)” (input).

The array controller controls the leaving chilled water temperature by staging compressors usingproportional, integral, derivative (PID) logic. Entering and leaving chilled water temperaturesensors, addressed by the array controller, are shipped loose for installation by others in thecommon array chilled water lines. One compressor is cycled in each chiller before secondcompressor is cycled using lag/lead logic. Array controller has RS232, RS485 and Ethernetcommunications ports for user interactive communication, or for interface with BMS. Controllerhas standard BMS compatibility with BACnet® IP and Modbus™ RTU and can be fitted with anoptional interface gateway for compatibility with Johnson N2, LonTalk® and BACnet MS/TP.Thecontroller is capable of responding to a BMS signal for “Run/Stop”, “Leaving Chilled WaterTemperature Reset” or “Demand Limit Reset”. “Leaving Chilled WaterTemperature” can also bereset using a 0 to 5 VDC input signal.

N+1 Logic

N+1 logic can be utilized when each chiller in an array is equipped with optional chilled watermotorized on-off valve and optional condenser water regulating valve, and a standby chiller isinstalled in the array. In the event of a chiller failure, the N+1 Logic automatically performs thefollowing functions:

• Electrically locks out the failed chiller

• Opens the chilled and condenser water valves in the standby chiller

• Closes the chilled and condenser water valves in the failed chiller

• Enables the standby chiller for normal operation in the array

Operator Interface

Exterior cabinet door of chiller control panel and array control panel includes a controller interfacewith keypad, 128 X 64 dot pixel display screen. Controller can be accessed using the local keypadand display screen for all unit control setpoints, faults and alarm conditions with history, andoperating conditions in clear language format for easy interpretation by the user / operator.Controller can also be accessed from a remote computer such as a laptop using MCS Connectsoftware having all functions available through the local interface with the additional ability todownload fault history.This feature allows one to review history graphically.The controller stores1,008 packets of information that can be graphically presented on the remote computer. Data canbe taken from the controller for graphical display based on the set time interval.The time intervalis factory set at 15 seconds, but is adjustable. Up to 99 fault conditions are stored in the controllerand 120 seconds of history is saved any time a fault occurs that results in a compressor lockout.

Insulation

All cold surfaces are insulated with 0.5 inch (12.7mm) thick closed-cell flexible insulation with a Kvalue of 0.26 BTU/ (hr-ft.-°F).

CG-PRC028D-EN 29


Chilled and Condenser Water Wye Strainers

Chilled and condenser water wye strainers with removable 20 mesh screen and blow downprovision are required for all individual chiller and chiller array installations. Strainers are shippedloose and are to be installed by others.

30 CG-PRC028D-EN

CG-PRC028D-EN 31

Appendix A —

Piping System Flushing Procedure

Prior to connecting the chiller to the condenser and chilled water loop, the piping loops shall beflushed with a detergent and hot water (110-130° F) mixture to remove previously accumulated dirtand other organics. In old piping systems with heavy encrustation of inorganic materials consulta water treatment specialist for proper passivation and/or removal of these contaminants.

During the flushing, a 30 mesh (max.) wye strainer (or acceptable equivalent) shall be in place inthe system piping and examined periodically as necessary to remove collected residue.The useof on board chiller strainers shall not be acceptable.The flushing process shall take no less than6 hours or until the strainers when examined after each flushing are clean. Old systems with heavyencrustation shall be flushed for a minimum of 24 hours and may take as long as 48 hours beforethe filters run clean. Detergent and acid concentrations shall be used in strict accordance with therespective chemical manufacturer's instructions. After flushing with the detergent and/or diluteacid concentrations the system loop shall be purged with clean water for at least one (1) hour toensure that all residual cleaning chemicals have been flushed out.

Prior to supplying water to the chiller the WaterTreatment Specification shall be consulted forrequirements regarding the water quality during chiller operation.The appropriate chillermanufacturer's service literature shall be available to the operator and/or service contractor andconsulted for guidelines concerning preventative maintenance and off-season shutdownprocedures.

WaterTreatment Requirements

Supply water for both the chilled water and condenser water circuits shall be analyzed and treatedby a professional water treatment specialist who is familiar with the operating conditions andmaterials of construction specified for the chiller's heat exchangers, headers and associated piping.Cycles of concentration shall be controlled such that recirculated water quality for compact chillersusing 316 stainless steel brazed plate heat exchangers and carbon steel headers is maintainedwithin the following parameters.

Table 6. Water property 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 Dioxide (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

Ingersoll Rand has a policy of continuous product and product data improvement and reserves the right to change design and specificationswithout notice.We are committed to using environmentally conscious print practices.

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©2017 Ingersoll RandCG-PRC028D-EN 21 Jun 2017Supersedes CG-PRC028C-EN (28 Jul 2016)

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Product Catalog — Cold Generator™ Compact Chiller Series ... · Trane Cold Generator™ Compact model CICA water-cooled chillers were designed with flexibility,