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Thermachill™

Absorption Chillers

Thermachill™ Two-Stage Direct-Fired

Absorption Chillers

100-1100 Tons

ABS-PRC007-ENOctober 2004

ABS-PRC007-EN©American Standard Inc. 2001

Features andBenefits

Thermachill™ AbsorptionChillers

The Thermachill direct-fired absorptionchiller is available from 100 to 1100 tons.All sizes have the ability to produce bothchilled water for space cooling and hotwater for space heating. And for someapplications, the direct-fired absorptionchiller can replace the traditionalcombination of chiller plus boiler, savinga significant amount of floor space.

The Trane direct-fired absorption chilleruses a two-stage absorption cycleresulting in a COP of 1.0, including theburner. Again, these performancecharacteristics make the direct-firedabsorption chiller ideal for areas whereelectric rates have risen dramatically inrecent years.

Continuing the Trane Tradition ofReliabilityThe Thermachill absorption chiller is verysimilar to the conventional steam andhot water fired absorption chillers thatTrane has manufactured for over 30years. The design of the direct-firedabsorption machine is based ontraditional absorption and burnertechnology. In place of the conventionalsteam/hot water generator, a burner —which is an integral part of the chiller —uses natural gas or other fuels to fire theabsorption refrigeration cycle. Therefrigeration cycle uses the proven, safeand environmentally compatible lithiumbromide and water combination.

Customer satisfaction with theperformance and reliability of its chillershas solidified Trane as the world leader incommercial water chillers. The TraneThermachill absorption chiller continuesin the Trane tradition of commitment toinnovation, quality and reliability,offering you a proven choice in how youconsume energy to produce chilledwater.

Thermachill Absorption ChillerTechnology

• Energy efficient design uses a patentedtwo-stage, reverse cycle. A highefficiency heat economizer furtherenhances energy savings byrecovering thermal energy fromexhaust gas.

• Welded body construction and designresults in hermetic integrity for quality,airtight construction.

• High temperature generator andexhaust gas economizer use asimplified design to reducemaintenance costs and improvereliability. A unique generator designeliminates tubes.

• Factory-installed and wired controlpanel.

• Factory-installed and tested purgepump to assure hermetic integrity andimprove reliability.

• Integral absorber-to-condensercrossover pipe.

• Run-tested at design conditions toassure dependable performance.

• High efficiency option available.

• Gordon-Piatt burner provides flexibilityto meet local U.S. codes.

• Optional dual fuel burners fired bynatural gas, No. 2 oil or LPG.

• Other burners are also available forinternational applications.

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Contents

Features and Benefits

Refrigeration Cycle

Application Considerations

Selection Procedure

Model Number Description

Performance Data

Dimensional Data

Sequence of Operation

Typical Wiring Diagrams

Jobsite Connections

Disassembled Shipment

Mechanical Specifications

2

6

10

16

17

18

20

26

28

32

46

48

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FeaturesSummary

Hermetic IntegrityHigh quality design, construction andtesting are critical to assuring hermeticintegrity. Since the absorption chilleroperates in an extreme vacuum, it iscritical that this condition be maintainedfor both efficiency and reliability. Airleakage into the machine decreasescapacity, increases fuel consumption anddepletes the solution inhibitors. Airleakage must be minimized and inhibitorlevels must be maintained to preventcorrosion from reducing the life of themachine. The Trane design assures thatpurge requirements are minimal.

State-of-the-art mass spectrometertesting is performed on everyThermachill chiller to make sure the unitis leak-tight before leaving the factory.Minimal use of valves and gasketedjoints further insures leak tightness.

This is a key item for long life, reducedcrystallization potential and for excessiveinhibitor consumption in any absorptionproduct.

Necessary valves are either a diaphragmtype or a special design system typewith an effective double seal. This leak-tight construction requires purging onlya few times per year by the mechanicalpurge pumps. In Japan, models 240 tonsand below are not even equipped withmechanical purge pumps.

Energy Efficient CycleA unique reverse solution flow allowsthis design to greatly reduce fuelconsumption. The use of an economizerenhances fuel consumption. Cooling andheating efficiency is increased byrecovering thermal energy from theexhaust gas.

Auxiliary Component OperationUnnecessary During Shutdown CycleOperation of auxiliary equipmentsuch as cooling water pumps, chilledwater/hot water pumps and coolingtower fans during a dilution cycle isunnecessary, further reducing energycosts.

Simplified Generator DesignThe high-temperature or direct-firedgenerator uses a concentric cylinderdesign which contains no tubes in thefire chamber. This both increasesreliability and reduces maintenance.Solution recirculation provides uniformtemperatures and reduces thermalstresses.

Gordon-Piatt Combustion BurnerTrane is working with the U.S. burnermanufacturer that has set the standardfor combustion burners in the UnitedStates for over 40 years. Gordon-Piattsupplies burners for many heatingproducts and almost all direct-firedabsorption chillers supplied in the UnitedStates. They bring the knowledge,experience and flexibility to meet localcodes. The combustion burner, burnercontrol panel and pre-piped gas trainship directly to the jobsite for installationindependent from the chiller.

Factory-Installed and Wired ControlPanel and Purge AssemblyBoth the unit control panel and thepurge pump assembly are factorymounted and tested, and ship on theunit. The unit control panel will besupplied with an interconnecting cablefor connection to the burner controlpanel. The purge assembly requires nofield-mounting or field-wiring.

Single Cooling/Heating Switch ValveAll models can provide heating orcooling from the same evaporatorsection. This concept minimizesinstallation piping and control. Thechangeover from cooling to heating orback is accomplished by simplyswitching one valve on the machine.Four-pipe cooling/heating systemsrequire additional installation andcontrol.

Factory Performance TestedEvery assembled unit is factoryperformance tested at specific designconditions. The performance of thechiller is detailed, assuring that the chillermeets specified performance before itleaves the factory. This test is certifiedwith a report, signed by an officer of thecompany.

Crossover PipeIntegral to the design is the crossoverbetween the absorber and condensersections which supplies cooling water tothe unit. This feature saves the installingcontractor both material and labor.

Other Cost-Solving FeaturesProject costs are further reducedbecause units up through the modelABDL-900 can ship factory-charged withproper solution levels. Optionally,models ABDL-800 to 1100 can shipdisassembled for critical access jobsitelimitations, and are field run-tested.

All units come with a factory-installedrupture disk, in accordance with ANSI/ASHRAE 15.

Models ABDL-800 to 1100 are providedwith marine-style water boxes asstandard, reducing maintenance costsby allowing tubes to be cleaned withoutdisconnecting large system water piping.

All sizes use a single burner with one topexhaust flue connection. A flue accessduct connection is provided for fieldinstallation to the stack.

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Reliable byDesign

ExperienceThe Trane Company has been theleading manufacturer of absorptionchillers in the United States for over40 years. Trane has been the onlycompany that has continued to producedomestically and remain in themarketplace through the changing ofabsorption markets. This has given Tranea solid base for continuingimprovements which provide customerswith high efficiency alternatives for theeconomics of energy choices in the nextdecade.

Trane is pleased to work with theJapanese leader in large tonnageabsorption chillers, Kawasaki ThermalEngineering (KTE). This specific designhas a proven record of superior reliabilityin over 2000 installations for nearly 10years.

Advanced Operating CycleThe reverse solution flow cycle used onthe Thermachill product is one of themost efficient refrigerant cycles inproduction today. Reverse solution flowsimply means the lithium bromidesolution is pumped to the lowtemperature generator first and then tothe direct-fired or high temperaturegenerator. Improved efficiencies ofCOP’s near 1.04 (HHV) are achieved byoperating at higher concentrations in thehigh-temperature generator.

These concentrations are at safe levelsbecause the operating temperatures arefarther from the crystallization line thanthe temperatures of solutions leavinglow temperature heat exchangers onother designs. These concentrations aremixed to safe levels as they are cooledthroughout the cycle.

Control SystemControl of the chiller is an integratedcircuit with built-in logic to operate andprotect an unsafe condition. Standardsafety controls include crystallizationconcentration limiting, high and lowtemperature and pressure limits, andadditional safeties are added externallyto meet UL requirements. Crystallizationconcentration limiting senses impendingcrystallization and takes action toprevent it.

Materials and ConstructionThe solution and refrigerant pumps are ahermetic design with long-life, self-lubricating carbon bearings. Stainlesssteel construction is used for both pumpand motor construction. Periodicmaintenance is not required.

The basic unit is constructed with steelshells and tubesheets with many internalparts being stainless steel, such asscreens, eliminators and flowdistribution devices. Tubing is steel,copper and stainless steel which arecompatible with the inhibitor systemused.

The absorbent-refrigerant used in theThermachill design is lithium bromideand water. The Thermachill unit uses ahighly successful proprietary inhibitor toprotect against corrosion. Trane hasbroad experience with corrosioninhibitors and fully recognizes thesuperiority of the KTE system.

The Thermachill inhibitor system in usefor about 15 years has proven that thechoice of tube and shell materialsprovides a reliable design. Further, thedesign of the direct-fired generatoravoids the use of tubes in the firechamber and has a unique solutiondistribution pattern that eliminates hotspots which can cause excessiveinhibitor depletion, thermal stress andtube failures.

PurgingEvery Thermachill chiller has a dualpurge system that operates with the unit.First the system collects and traps non-condensable gas in a chamber externalto the unit so that it can periodically beremoved by the mechanical vacuumpump. This operation is required only afew times per year. Secondly, in anyabsorption unit, small amounts ofhydrogen gas are generated. Palladiumcells are provided which will selectivelyremove hydrogen gas and expel it fromthe unit to prevent inefficient operation.

SummaryAnd finally, one more point which webelieve adds a real touch of reliability—the Trane name. As the worldwide leaderin water chillers and the domestic leaderin Classic and Horizon style absorptiondesign, Trane understands chilled watersystem design

To protect you long term, warranty andservice contract programs can betailored to your individual needs. AndTrane Integrated Comfort™ systems canoffer a higher level of control, monitoringand diagnostics.

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Cooling Cycle

RefrigerationCycle

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RefrigerationCycle

Heating Cycle

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Cooling Cycle OverviewThe absorbent/refrigerant combination isa traditional lithium bromide/watersolution. The dilute solution is firstpumped from the absorber to the lowtemperature generator where it ispartially concentrated. A heat exchangertransfers heat from the generator andpreheats the incoming solution.

Part of the solution is then pumped tothe direct-fired (high temperature)generator where it is furtherconcentrated, while the rest of the flowfrom the low temperature generator ismixed with the strong solution from thedirect-fired high temperature generator.This process forms the mixedconcentration absorber spray.Refrigerant for the cycle is produced inboth generators and is condensed in thecondenser and flows to the evaporatorthrough orifices.

Evaporator/AbsorberLiquid refrigerant (water) enters theevaporator from the condenser orifice.As refrigerant passes to the low pressureevaporator, flashing occurs, cooling theremaining liquid refrigerant to theevaporator saturation temperature. Thischilled refrigerant falls to the evaporatorpan and is circulated continuously to theevaporator sprays by the refrigerantpump. The transfer of heat from thesystem water to the refrigerant causesthe refrigerant to vaporize, cooling thesystem water. This refrigerant vaporflows to the lower pressure absorber.

In the absorber, refrigerant is absorbedby the lithium bromide solution, becauseit has a high affinity for water vapor. Thisis the fundamental principal of theabsorption process. The pressure in theabsorber is determined by thetemperature and concentration of thesolution sprayed over the tubes. A mixedconcentration is used to provide agreater quantity of solution in theabsorber for more effective tube wetting.As the refrigerant vapor is absorbed bythe solution, it transfers the heatacquired in the evaporator to the coolingwater which is pumped through theabsorber tubes. The dilute solution isthen pumped through heat exchangersby the solution pumps to the generatorsfor regeneration.

Low Temperature GeneratorThe dilute solution is pumped into thelow temperature generator after beingpreheated by the low temperature heatexchanger. The primary purpose of thisgenerator is to produce refrigerant vaporfor this cycle. To achieve this, vapor fromthe direct-fired generator is used as theenergy source to boil the solution. Thisvapor condenses inside the tubes andflows to the condenser sump. Theintermediate concentration solutionleaving the low temperature generatorhas two paths: the first is to thegenerator pump and on to the direct-fired generator; the second is mixed withstrong concentrated solution forming amixed concentration for the absorberspray.

Solution Heat ExchangersThe low temperature heat exchangerrecovers heat from the mixedconcentration and preheats the dilutesolution going to the low temperaturegenerator. Preheating the dilute solutionreduces the heat energy required toinduce boiling within the lowtemperature generator. In turn, thereduction in mixed solution temperaturedecreases the load on the cooling tower.

The high temperature heat exchangerrecovers heat from the strongconcentration solution and preheats theintermediate concentration solutiongoing into the direct-fired generator. Lessheat is needed in the direct-firedgenerator to further concentrate thepreheated intermediate solution.Preheating the solution results inimproved cycle efficiency.

RefrigerationCycle

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RefrigerationCycle

Direct-Fired High Temperature GeneratorThe direct-fired high temperaturegenerator uses combustion of naturalgas, No. 2 fuel oil or LP gas as an energysource.

The intermediate concentration solutionenters at the bottom of the generatorafter being preheated by the hightemperature heat exchanger. Heat fromcombustion and the flue gas economizerare used to produce refrigerant vapor forthe low temperature generator.

The solution then flows into a chamberwhere liquid and vapor are separated.From there, the refrigerant vapor flowsto the low temperature generator, andthe concentrated solution returns to theabsorber through the high temperatureheat exchanger.

CondenserRefrigerant is introduced into thecondenser from two sources: Liquidrefrigerant from the tube side of the lowtemperature generator; and refrigerantvapor produced by the low temperaturegenerator.

All refrigerant vapor condenses andreturns to the evaporator through anorifice. The orifice further reducestemperature and pressure as therefrigerant enters the evaporator. Thecycle is now completed.

The cooling water within the condenserbundle is the same water that flowedthrough the absorber. The absorber/condenser cooling water crossover pipeis integral to the design.

Heating CycleBy simply turning the cooling/ heatingswitch valve, hot water can be deliveredin a heating mode by the same systemline used to supply chilled water in acooling mode.

The evaporator becomes a condenser inthe heating mode, condensingrefrigerant vapor produced by the direct-fired generator. While condensing on thetube bundle, heat is transferred to thesystem water and condensed refrigerantfalls to the evaporator pan and overflowsinto the absorber.

The dilute solution flows through thelow temperature generator and heatexchangers on its way to the direct-firedhigh temperature generator. No boilingoccurs in the low temperature generatorbecause no condenser/absorber water isbeing circulated during the heatingmode to remove heat.

The dilute solution coming from the heatexchangers enters the direct-fired, hightemperature generator where refrigerantis vaporized and flows through the lowtemperature generator on to theevaporator to repeat the process.

ABS-PRC007-EN10

Gas CoolingApplicationConsiderations

Basic InformationThe Thermachill is a high efficiency two-stage direct-fired machine that utilizesthe evaporator section to provide chilledwater for cooling or hot water for heatingon commercial HVAC systems.

The machine is UL listed and is exemptwithin the ASME Section VIII codebecause of the vacuum operationpressure. Standard machine safetydevices provide machine protection fromoverpressure, high and lowtemperatures, and solutioncrystallization. The burner controlprovides combustion safety protection.

Fuel HandlingThe burner is designed for natural gas oroil as the primary fuel sources. Localcodes determine how these fuels areemployed. The gas supply systems areselected by the burner manufacturerbased upon the local codes, availablegas pressure, and the gas flow rate. Thegas train supplied is pre-piped and wiredfor ease of installation. The gas train issized for minimum seven inches watercolumn at the inlet for sizes ABDL 100-240 and fourteen inches water columnminimum on ABDL 300-1100. The burner,gas train, burner control panel, andburner front plate sections are provided.They must be field-mounted by theinstalling contractor. Refer to “BurnerInstallation” within the JobsiteConnections section for details.

Electrical ServiceA 200-volt three-phase power source isrequired to power the unit. Table PD-3identifies the power requirements. Allfield wiring must be in accordance withthe national electric code (NEC), stateand local requirements.

The 200-volt three-phase power serviceand other field panel wiring is theresponsibility of the installing contractor.All burner related wiring is factorysupplied with cabled assemblies. Theinstalling contractor must connect oneend of the cable assembly.

See specific submittal drawings fordetailed information.

Machine InstallationA housekeeping pad or support rails arenecessary to elevate the machine formaintenance and to provide clearancefor the burner housing. Any foundationpad should provide adequate structuralsupport and keep the installed machinelevel within 1/16-inch by length and widthfor reliable operation. Leveling marks onthe lower shell can be used to check themachine after its positioned on the pad.Refer to “Field Installation” within theJobsite Connections section for details.

Exhaust Gas DuctA duct section with pre-drilled flanges isprovided for field installation. It has aninspection cover, condensate drain,temperature gauge port, andconnections for exhaust gas analysis.This section should be connecteddirectly to the generator exhaust flange.The field constructed duct should have aremovable section above the factorysupplied section that can be removed forduct and machine maintenance. Formultiple machine installation, it isadvisable to connect each machinedirectly to the main stack using separateducts, each having balancing dampers.The stack and connecting duct must beheat resistant to 675 F.

Duct dampers must be employed tomaintain the machine exhaust outletpressure between 0 and -0.2 incheswater column. This requirement ensuresreliable and efficient burner combustion.ASHRAE Equipment Handbook offersdesign details.

Operating AmbientsThe minimum recommended ambienttemperature with the machine shutdownin the cooling mode is 40 F. If shut downin the heating mode the minimumtemperature is 25 F. If lower ambienttemperatures are expected, specialadditional protective measures arerequired. Machines installed outdoorswhere ambient temperatures will dropbelow the minimums indicated musthave heated enclosures.

The machine room must be ventilated toinsure that all exhaust gas is removedand sufficient burner makeup air isavailable for efficient combustion.Maintain a positive equipment roompressure. At no time should theequipment room pressure be allowed todrop below the exhaust pressure.

Separated Machine SectionsDisassembled machines ship to thejobsite in two main sections. One sectioncontains the evaporator/absorber/condenser and low temperaturegenerator. The other section is the hightemperature generator. Both sectionsship empty with a nitrogen holdingcharge. The sections must be field-connected and leak-tested. Lithiumbromide charge is supplied in barrelswith the machine.

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MachineInstallation

ApplicationConsiderations

Figure AC-1 — Machine Installation

Load

Air Vent Valve Fuel

Chilled/Hot Water Pump

Our Scope of Supply of Chiller - HeaterExhaust

Gas Stack

PressureGauge Thermometer

Temp. Controller

CoolingTower

Cooling Water PumpDrain Valve

Stop Valve for Chemical CleaningOutside of this line . is out of Trane scope of supply

Expansion Tank

StopValve

Machine Piping and InstrumentsFigure AC-1 illustrates the recommendedinstrumentation and hardware that iscontractor supplied and installed. Detailitems related to water piping are alsodiscussed. All connecting water pipesshould have a short flanged section thatcan be removed to access the waterboxes for maintenance.

1. All instruments illustrated on pipingoutside of the chiller-heater arestandard.

2. A dedicated chilled/hot water pumpand a cooling water pump isnecessary for each machine. In caseonly one cooling water pump isprovided for two or more chiller-heaters, please contact your localsales office for advise.

3. The chilled/hot water and coolingwater flow rates must be maintainedat design conditions. When the chilled/hot water flow rate lowers belowminimum, the chiller-heater will stopand cannot be operated.

4. Provide air vent valves at the top ofthe outlet of the chilled/hot water andcooling water piping.

5. Provide drain valves at the bottom ofthe inlet of the chilled/hot water andcooling water pipes.

6. Provide valves (two places) on thecooling water piping for chemicalcleaning.

7. Drain the water in the piping of thechiller-heater to prevent freezingduring cold-season shutdown whennecessary.

8. The header cover of the machine isbolted for ease of removal forbrushing or exchange of tubes. Waterleakage may occur if the connectingpipe is not supported. Therefore, makesure that the machine water boxes donot have excessive loads from thepiping system.

9. The water in the cooling water line ofthe chiller-heater can reachtemperatures up to 195 F duringheating operation unless it is drained.Use lined or steel pipes at least for thepiping between chiller-heater andisolation valves.

10. Provide valves in the supply andreturn pipes of the cooling watercircuit to be used for isolation. Theabsorber and condenser sections arenot used during the heating mode andmust be drained before converting toheating.

ABS-PRC007-EN12

Water SystemApplicationConsiderations

Cooling WaterRegular maintenance of evaporator andcooling water quality is critical forefficient daily operation and long termtube life.

Cooling tower water temperature mustbe maintained at or above 72 F forreliable part load operation and 78 F forfull load operation. Control panel logiccircuits allow start-up at temperaturesbelow 72 F and also protect againstunsafe conditions but must be warmedto 72 F minimum within 20 minutes ofoperation. Typical cooling tower controlis illustrated below. A cooling towerbypass is recommended for reliablecontrol. Recommended cooling waterfan thermostat examples follow.

Water TreatmentThe use of untreated or improperlytreated water in chillers may result inscaling, erosion, corrosion, algae orslime. It is recommended that theservices of a qualified water treatmentspecialist be engaged to determine whattreatment, if any, is advisable. The TraneCompany assumes no responsibility forthe results of untreated, or improperlytreated water.

Table AC-1 — Typical Cooling Tower Control

System 1 – Operation for summer seasonRecommendations for cooling tower fan thermostat calibration.

2 FansSetting Temperature 1 Fan No. 1 Fan No. 2 FanFan Off 78 F 78 F 81 F

On 84 F 82 F 84 F

System 2 – Operation for low load and winter seasonIncorporate a three-way valve. Start and stop the cooling tower fan based upon the followingfan thermostat temperature of 78 F to 84 F.

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Controls andInterface

ApplicationConsiderations

ControlsThe panel switch determines theoperating mode (cooling or heating).Switched to either position the panel willcontrol the machine to providetemperature control from the evaporatorsection for cooling or heating. The actualtemperature is determined by calibratedset points for both cooling and heating.Conversion from cooling to heating andback is a manual operation.

Panel lights indicate machine status, theyare, power on, operation andcombustion. There are nine abnormalcondition lights to determine what eventterminated normal operation. A normalsequence for cooling service assumesthe machine is prepared for coolingoperation.

CoolingWith the machine panel switched tocooling the panel will start the chilledwater and cooling water pumps insequence, confirm chilled water flow andconfirm that all machine safeties are go.Then the machine solution pumps arestarted. The burner executes its flamesafeguard start-up and initialcombustion. Control of burner firing rateand refrigerant pump operation iscontrolled by the machine panel as thewater temperature changes. Between 30and 100 percent of cooling the burnerfiring rate is adjusted to meet the coolingload. Below 30 percent of design theburner is cycled while all machinepumps remain on to allow a 10 percentminimum load. At minimum designcooling the refrigerant pump is cycled.An increase in chilled water temperaturewill initiate a restart sequence of therefrigerant pump and/or burner asrequired. The chilled water andcondenser water pumps continue tooperate along with the solution pumpsuntil the panel is switched off or anabnormal condition occurs. Duringnormal operation the cycle guard controlmonitors machine temperatures toprotect solution concentrations.

HeatingThe machine must be converted toheating service before the panel heatingswitch is activated. With the panel switchactivated the panel starts the evaporatorwater pump, confirms flow and checksmachine safeties. The condenser waterpump and refrigerant pump remain offin heating. Solution pumps and theburner are started with the burner firerate modulated with heating load. Below30 percent of design the burner is cycled.The burner is restarted when evaporatorwater drops below a predeterminedtemperature. A 15 minute dilution cycleis initiated upon placing the operationalswitch to stop position. During this 15minute dilution cycle the solution pumpsand operation indicator remain on.

Automation System Interface

Tracer™ InterfaceRemote monitoring and control viaTracer products can be accomplished byusing an intermediate interface panel, orby hard-wiring the individual controlpoints to a Tracer.

TIM-E InterfaceThe TIM-E provides six binary outputs,three binary inputs and three analoginputs that can be controlled/monitoredby the Tracer. These points can beconnected in whatever arrangement bestsuits the customer; a recommendedarrangement follows.

BOP1 Chiller Enable/DisableBIP1 Operation IndicationBIP2 Cooling IndicationBIP3 Alarm IndicationAIP1 Leaving Chilled Water

TemperatureAIP2 Entering Chilled Water

TemperatureAIP3 Entering Condenser Water

Temperature

Hard-Wired InterfaceTracer hard-wired interface is the sameas the interface for generic BAS Interfacesystems.

Multiple Unit ControlThe chiller control panel is compatiblewith the Chiller sequencing programfound in Tracer products, and is alsocompatible with the Tracer DDC ChillerSequencer Panel. For information on thefeatures of the Chiller Sequencingprogram, contact your local Trane office.

Generic BAS Interface

Standard Control Panel Interface Points

Remote Control. The control panel has abinary input point that can be used toremotely start and stop the chiller.

Cooling Indicator. The control panelprovides a binary output that closedwhenever the chiller is set to the coolingmode.

Heating Indicator. The control panelprovides a binary output that closeswhenever the chiller is set to the heatingmode.

Operation Indicator. The control panelprovides a binary output that closeswhenever the chiller is enabled toprovide cooling or heating.

Combustion Indicator. The control panelprovides a binary output that closeswhenever the burner is firing. Burneroperation is not continuous under lowload conditions.

Alarm Indicator. The control panelprovides a binary output that closeswhenever an abnormal operationcondition exists at the chiller.

External Interlock. The control panelprovides a binary input that can be usedto shut down and lock out chilleroperation. When this input opens, chilleroperation is terminated following adilution cycle; operation is preventeduntil the chiller is manually reset at thefront panel.

Non-Standard Interface PointsThe standard chiller controls do notinclude any provisions for monitoringtemperatures. Monitoring unittemperatures requires field selection andinstallation of sensors.

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System PipingApplicationConsiderations

Chiller Supply TemperatureWhen the chiller load falls below 30percent, the burner must cycle to keepthe supply water temperature fromdropping too far below set point.Although this cycling provides theproper average level of system cooling,the supply water temperature fluctuates.

In systems with two or more chillers,burner cycling is not normally a problemsince the building load rarely falls belowthe minimum load of one chiller. This isespecially true if the chillers areunequally sized and the smallest chilleris the last on.

Burner cycling does not normally causebuilding space temperature variations insingle-chiller systems, either. Sincecycling occurs when the building load islight, flow modulation at the coils caneasily compensate for supply watertemperature fluctuations.

Supply water temperature can be heldto the normal range provided by thechiller’s proportional control scheme bydesigning the chilled water system asshown in Figure AC-2. Whenever thechiller is operating at part-loadconditions, the tank is charged withchilled water. When the burner cycles off,the chiller pump is turned off and chilledwater is pulled from the tank. The chillerand its chilled water pump are restartedwhen the tank is discharged.

Heating and Cooling SystemsThe chiller can be used to satisfy both theheating and cooling needs of thebuilding, but only if the system wasdesigned to handle both functions. Thereare a wide variety of system designsintended to meet the dual requirementsof heating and cooling. One of thesimplest is the two-pipe changeoversystem illustrated in Figure AC-3. Thesimplicity of this system lies in the use ofthe same set of components (i.e., pipes,coils, pumps) for both heating andcooling. Typically, the system is switchedbetween these modes and on a seasonalbasis.

Several alternatives are also available toprovide simultaneous heating andcooling if it is required. On a two-pipesystem, simultaneous heating andcooling demands during the transitionbetween heating and cooling seasonscan be addressed using outside air orsome secondary heating or coolingsource.

When outside air is not an acceptablemethod for providing simultaneousheating and cooling, other system types— such as a four-pipe system — shouldbe explored. Four-pipe systems provideall or selected loads with both hot andchilled water at all times. Selection of thesystem configuration depends on thevariation in heating and coolingdemands. Using multiple chillers affordsa great deal of flexibility for matchingheating and cooling loads to the heatingand cooling capacities of the chillers. Inthe sample shown in Figure AC-4, anycombination of chillers can be used forheating and cooling.

As depicted in Figure AC-5, simultaneousheating and cooling can also beaccomplished in single-chillerapplications by adding an auxiliaryheater.

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System PipingApplicationConsiderations

Figure AC-2

Figure AC-5

Figure AC-4

Figure AC-3

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SelectionProcedure

The Thermachill Absorption Chillerperformance is rated in accordance withARI Standard 560. The product lineprovides numerous individual unitselections over a capacity range of 100 to1100 tons. This catalog containsperformance data for all standard units.Additional chiller selections andperformance information can beobtained through the use of theThermachill Absorption Chiller selectionprogram available through local Tranesales offices.

PerformanceThe information on the following pagesprovide performance data at ARIstandard conditions, including capacityin tons, C.O.P., heating capacity, flowrates and water pressure drops. Allcapacities are net tons and are based onstandard fouling factors for theevaporator and absorber/condenserwatersides. For the other fouling factors,refer to the paragraph on nonstandardfouling factors below. All final selectionsshould be made using the computerselection program.

Fouling FactorsUnit performance at non-standardfouling factors will vary from standardperformance. Fouling factors estimatethe heat transfer penalty that occurs asthe tubing gets dirty through normalchiller operation. ARI tube foulingstandards are shown below:Fouling factors @ ARI 560-92

Clean Standard Excessive0.00000 0.00025 0.00075

All selections should have a minimumfouling factor of 0.00025 to best estimatethe chiller performance in an equipmentroom and to comply with ARI 560-1992.Any selection that uses a fouling factorabove 0.00025 is a more conservativeestimate that should only be used ifthere is an abnormal amount of foulingcontamination in the water system. Theeffect of non-standard fouling factorsshould be determined by the TraneDirect-Fired Absorption SelectionProgram.

General Data TablesGeneral unit data is shown in the datasection. General unit informationincludes refrigerant charge, absorbentcharge, chiller shipping and operatingweights.

Evaporator and Absorber/CondenserData TablesLocated in the data section, evaporatorand absorber/condenser data includeswater storage capacities, minimum andmaximum flow limits, pressure drop atnominal flow, water connection size, andnumber of passes. If the maximum flowlimit is exceeded, tube erosion mayresult. Flow rates less than the minimumresult in laminar flow with a resultantreduction in performance and increasedfouling and corrosion potential.

Part Load PerformanceThe Thermachill Absorption Chillerexhibits good part load performancecharacteristics. Air conditioning systemloads are usually significantly less thanfull load design conditions. Therefore, thechillers operate at full load relatively littleof the time. Part load chiller operation isnormally associated with reducedcondenser water temperatures. At partload operation, the heat rejected to thecooling tower is less than at full loadoperation. Also, part load operation istypically associated with reduced outsidewet bulb temperatures, resulting inimproved cooling tower performance.The net result of less heat rejection andlower wet bulb temperature is coolercondenser water entering the chiller andimproved unit performance to a point. Todetermine specific unit part loadperformance, use of the ThermachillAbsorption Chiller selection program isrecommended. A minimum of 72degrees F entering cooling water to theabsorber/condenser must be maintainedat all load conditions.

Unit Performance with Fluid MediaOther Than WaterThe performance examples contain datausing water as cooling and heat rejectionmedia. For media other than water,contact the local Trane sales office.

Electrical DataTotal kW and MCA are shown for theThermachill Absorption Chiller parasiticcomponents. These include solution andrefrigerant pump motors, purge pumpmotor, control panel, and combustionburner fan motor. The unit is to besupplied with 200V, 3 Phase, 60 hertz (50hertz optional for internationalapplications) power. Field wiring shouldbe properly sized in accordance with theNational Electric Code.

Dimensional DrawingsThe dimensional drawings illustrateoverall measurements of the unit. Therecommended service clearancesindicate clearances required to easilyservice the Thermachill AbsorptionChiller. All catalog dimensional drawingsare subject to change. Current submittaldrawings should be referred to fordetailed dimensional information.Contact the local Trane sales office forsubmittal and template information.Note the requirement for a “pad” or railsto allow burner mounting and serviceaccess. A minimum of a 6” pad isrequired on all sizes except the ABDL -500 and 550 packaged units, whichrequire 14” minimum pad height.

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Model NumberDescription

The components and options for anyThermachill Absorption unit can beidentified by referring to thealphanumeric product coding blocklocated on the service nameplate for theunit. The coding block precisely identifiesall characteristics of a unit. An exampleof a typical product code is given at right:

Model Number Description

MODL-ABDL NTON-100 VOLT-200

HTRZ-60 ENSR-DGAS TYPE-STD

AGLT-UL EVPR-150 CDPR-150

TEST-CWTR OPTI-DSSY

Product Code Explanation

MODL — Unit ModelABDL = Direct Fired Absorption

DSEQ — Design Sequence1A = Direct Fired

NTON — Unit Nominal Tonnage100 = 100 Nominal Ton Unit120 = 120 Nominal Ton Unit150 = 150 Nominal Ton Unit180 = 180 Nominal Ton Unit200 = 200 Nominal Ton Unit240 = 240 Nominal Ton Unit300 = 300 Nominal Ton Unit350 = 350 Nominal Ton Unit400 = 400 Nominal Ton Unit450 = 450 Nominal Ton Unit500 = 500 Nominal Ton Unit550 = 550 Nominal Ton Unit600 = 600 Nominal Ton Unit700 = 700 Nominal Ton Unit800 = 800 Nominal Ton Unit900 = 900 Nominal Ton Unit

1000 = 1000 Nominal Ton Unit1100 = 1100 Nominal Ton Unit

VOLT — Unit Voltage200 = 200 Volt Unit

HRTZ — Unit Hertz50 = 50 Hertz Unit60 = 60 Hertz Unit

ENSR — Unit Energy SourceDGAS = Direct Fired GasDUAL = Direct Fired Gas/OilDGLP = Direct Fired Gas/LP GasDOIL = Direct Fired Oil

TYPESTD = StandardHIEF = High Efficiency

AGLTUL = U.L. Listed (Standard)IRI = I.R.I. CertifiedFCMT = Factory MutualBKUG = Brooklyn Union GasCLCA = California Code ApprovalCONN = Connecticut Natural Gas Corp.ILSR = Illinois School 145 (Retrofit)ILSN = Illinois School 157 (New)IRM = Improved Risk MutualsLILI = Long Island LightingMASS = Massachusetts CodeMINN = Minnesota Code ApprovalNYC = New York City

(Bureau of Air Resources)NCAR = North Carolina School CodeSPL = Special

EVPR — Evaporator Water Side Pressure150 = 150 PSIG

CDPR — Condenser/Absorber Water SidePressure

150 = 150 PSIG

TEST — Factory Performance TestPTR = Performance Test and Report

(standard)CWTR = Customer Witnessed Test andReport

Unit OptionsDSSY = Disassembled (NTON 600-1100)AAZ = Asia/America Zone Specification

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PerformanceData

Table PD-1 — Performance DataCoefficient Of Performance (COP) Cooling Duty Fuel Consumption (MBH) Heating Performance

Capacity Std. Eff. Unit High Eff. Unit Std. Eff. Unit High Eff. Unit Capacity Fuel Consumption (MBH)Model (tons) (HHV) (LHV) (HHV) (LHV) (HHV) (LHV) (HHV) (LHV) (MBH) (HHV) (LHV)ABDL-100 96 0.97 (1.07) 1.03 (1.14) 1,191 (1,072) 1,119 (1,007) 1,099 1,286 (1,157)ABDL-120 115 0.97 (1.08) 1.03 (1.14) 1,429 (1,286) 1,343 (1,209) 1,317 1,543 (1,389)ABDL-150 144 0.97 (1.08) 1.03 (1.14) 1,787 (1,608) 1,679 (1,511) 1,651 1,928 (1,736)ABDL-180 173 0.97 (1.08) 1.03 (1.14) 2,144 (1,929) 2,015 (1,813) 1,980 2,314 (2,083)ABDL-200 192 0.97 (1.08) 1.03 (1.14) 2,382 (2,144) 2,238 (2,015) 2,198 2,571 (2,314)ABDL-240 230 0.97 (1.08) 1.03 (1.14) 2,859 (2,573) 2,686 (2,417) 2,639 3,086 (2,777)ABDL-300 288 0.97 (1.08) 1.03 (1.14) 3,573 (3,216) 3,358 (3,023) 3,297 3,856 (3,471)ABDL-350 336 0.97 (1.08) 1.03 (1.14) 4,169 (3,752) 3,918 (3,526) 3,849 4,502 (4,051)ABDL-400 384 0.97 (1.08) 1.03 (1.14) 4,764 (4,288) 4,478 (4,030) 4,397 5,142 (4,627)ABDL-450 432 0.97 (1.08) 1.03 (1.14) 5,360 (4,824) 5,037 (4,534) 4,948 5,787 (5,208)ABDL-500 480 0.97 (1.08) 1.03 (1.14) 5,956 (5,360) 5,597 (5,037) 5,496 6,427 (5,785)ABDL-550 528 0.97 (1.08) 1.03 (1.14) 6,551 (5,896) 6,157 (5,541) 6,047 7,073 (6,365)ABDL-600 576 0.97 (1.08) 1.03 (1.14) 7,146 (6,432) 6,717 (6,045) 6,595 7,714 (6,942)ABDL-700 672 0.97 (1.08) 1.03 (1.14) 8,337 (7,504) 7,836 (7,052) 7,694 8,999 (8,099)ABDL-800 768 0.97 (1.08) 1.03 (1.14) 9,528 (8,575) 8,956 (8,060) 8,793 10,285 (9,257)ABDL-900 864 0.97 (1.08) 1.03 (1.14) 10,719 (9,647) 10,075 (9,067) 9,892 11,571 (10,414)ABDL-1000 960 0.97 (1.08) 1.03 (1.14) 11,910 (10,719) 11,194 (10,075) 10,991 12,856 (11,571)ABDL-1100 1056 0.97 (1.08) 1.03 (1.14) 13,101 (11,791) 12,314 (11,082) 12,090 14,142 (12,728)Based upon the following conditions:cooling duty: 54-44 F chilled water, 85-95 F condenser water, std. fouling factors.heating duty: 130-140 F hot water, std. fouling factor.

Table PD-2 — WeightsBasic Model Enclosed Outdoor Model Unit Brine Charge

Standard Efficiency High Efficiency Standard Efficiency High Efficiency Standard Model High Efficiency ModelShipping Operation Shipping Operation Shipping Operation Shipping Operation Solution Refrig. Solution Refrig.

Model (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Lbs.) (Gals.) (Lbs.) (Gals.)ABDL-100 9,500 10,800 10,100 11,400 11,600 10,300 12,300 11,200 1,466 23 1,620 21ABDL-120 10,600 11,900 11,200 12,800 12,800 11,400 13,600 12,300 1,720 27 1,885 25ABDL-150 12,100 13,700 13,000 14,500 14,500 13,100 15,600 14,000 2,083 33 2,271 32ABDL-180 14,100 15,900 15,200 17,000 17,000 15,300 18,100 16,200 2,623 37 2,778 36ABDL-200 15,200 17,100 16,500 18,400 18,400 16,200 19,700 17,700 2,877 40 3,120 36ABDL-240 17,200 19,300 18,500 20,700 20,900 18,500 22,000 19,800 3,395 50 3,759 49ABDL-300 25,000 29,000 26,800 30,800 32,300 28,200 34,000 30,000 4,541 70 4,971 68ABDL-350 27,900 32,200 29,600 34,200 35,400 31,000 37,400 32,800 5,181 82 5,666 79ABDL-400 30,200 35,000 32,400 37,200 38,200 33,400 40,400 35,600 5,820 93 6,360 91ABDL-450 33,100 38,100 35,500 40,800 42,400 37,300 45,100 39,700 6,911 95 7,540 93ABDL-500 36,700 42,500 39,200 45,200 46,800 40,900 49,400 43,400 7,617 106 8,267 102ABDL-550 41,400 47,600 44,200 50,400 52,900 46,600 55,800 49,500 8,344 116 9,017 111ABDL-600 51,400 60,400 56,000 65,200 N/A N/A N/A N/A 9,612 114 10,637 109ABDL-700 55,100 64,800 61,500 71,100 N/A N/A N/A N/A 10,351 130 11,552 123ABDL-800 61,900 73,300 69,000 80,300 N/A N/A N/A N/A 12,280 154 13,702 146ABDL-900 69,400 81,200 77,100 88,900 N/A N/A N/A N/A 13,547 169 15,090 161ABDL-1000 67,300 93,500 74,100 101,500 N/A N/A N/A N/A 14,363 188 16,027 179ABDL-1100 72,000 100,200 79,700 109,200 N/A N/A N/A N/A 16,468 206 18,353 196

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Table PD-3 — Selection DataChilled Water Hot Water Cond./Abs. Water Aux. Power

Without WithCombustion Exhaust High-Temp. High-Temp

Flow Rate Pr.Drop Flow Rate Pr.Drop Flow Rate Pr.Drop Air Gas Hot Water Hot WaterModel (GPM) (Feet) (GPM) (Feet) (GPM) (Feet) (CFM) (CFM) (KW) (KW) (KVA)ABDL-100 230 12.6 219 11.4 423 16.2 250 410 3.92 4.07 27.8ABDL-120 276 12.3 266 11.4 507 24.7 300 490 4.15 4.30 28.7ABDL-150 346 13.5 332 12.5 635 18.6 380 620 4.50 4.65 30.8ABDL-180 415 15.1 397 13.9 762 28.3 450 740 5.95 6.10 36.8ABDL-200 461 10.6 441 9.8 847 20.1 500 820 5.95 6.10 36.8ABDL-240 553 10.9 529 10.0 1,014 30.4 600 990 5.95 6.10 36.8ABDL-300 691 15.2 660 13.9 1,270 23.5 750 1,230 8.90 9.10 50.9ABDL-350 806 10.1 769 9.3 1,482 12.8 870 1,440 8.90 9.10 50.9ABDL-400 922 11.4 879 10.5 1,693 17.4 1,000 1,640 8.90 9.10 50.9ABDL-450 1,037 15.4 992 14.2 1,905 22.9 1,120 1,850 9.30 9.50 52.9ABDL-500 1,152 20.1 1,101 18.6 2,117 29.5 1,240 2,050 9.30 9.50 52.9ABDL-550 1,267 25.8 1,210 23.7 2,328 37.2 1,370 2,260 9.30 9.50 52.9ABDL-600 1,382 18.7 1,318 17.1 2,540 25.6 1,490 2,460 9.70 11.40 62.8ABDL-700 1,613 26.6 1,538 24.5 2,963 36.0 1,740 2,870 14.4 14.50 79.4ABDL-800 1,843 13.4 1,758 12.2 3,387 28.6 1,990 3,280 14.4 14.50 79.4ABDL-900 2,074 17.5 1,977 16.1 3,810 37.2 2,240 3,690 14.4 14.50 79.4ABDL-1000 2,304 10.5 2,197 12.2 4,233 18.6 2,490 4,100 18.0 18.10 99.1ABDL-1100 2,534 13.4 2,417 12.2 4,657 23.1 2,740 4,510 18.0 18.10 99.1Notes:1. Based upon the following conditions:

cooling duty: 54-44 F chilled water, 85-95 F condenser water, std. fouling factors.heating duty: 130-140 F hot water, std. fouling factor.

2. Auxiliary power includes the electrical power consumption of the following components:refrigerant pump, solution pumps, burner fan, control power, palladium cells.

Table PD-4 — Water Flow RatesFlow Rate Limitations System Water

Std. Evaporator Hi Eff. Evaporator Condenser/Absorber CapacityMin Max Min Max Min Max Evap. Cond/Abs.

Model (GPM) (GPM) (GPM) (GPM) (GPM) (GPM) (Gal.) (Gal.)ABDL-100 167 379 167 379 277 528 29 71ABDL-120 203 387 203 387 335 528 34 82ABDL-150 255 511 255 511 423 894 40 95ABDL-180 308 511 308 511 511 894 48 111ABDL-200 339 766 339 766 559 1,057 53 119ABDL-240 410 766 410 766 678 1,057 61 140ABDL-300 511 801 511 801 845 1,458 82 293ABDL-350 594 1,224 594 1,224 986 2,166 90 325ABDL-400 678 1,224 678 1,224 1,127 2,171 100 357ABDL-450 766 1,224 766 1,224 1,268 2,171 108 388ABDL-500 854 1,466 854 1,466 1,413 2,457 122 428ABDL-550 938 1,462 938 1,462 1,554 2,453 129 460ABDL-600 1,022 1,933 1,022 1,620 1,708 2,774 291 608ABDL-700 1,198 1,933 1,198 1,625 1,995 3,325 317 634ABDL-800 1,365 2,897 1,365 2,439 2,281 3,844 370 766ABDL-900 1,541 2,906 1,541 2,439 2,567 4,161 396 819ABDL-1000 1,708 3,800 1,708 3,206 2,853 5,504 449 1,110ABDL-1100 1,880 3,813 1,880 3,192 3,135 5,504 476 1,136

PerformanceData

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DimensionalData

Figure DD-1 — Unit Sizes 100-240

Table DD-1 — Unit Sizes 100-240Figure Unit Sizes with Dimensions

Reference 100 120 150 180 200 240A 2'- 8 5/8" 2'- 8 5/8" 2'- 8 5/8" 3'- 1 5/8" 3'- 1 5/8" 3'- 1 5/8"B 10 1/2" 10 1/2" 10 1/2" 1'-1 1/8" 1'-1 1/8" 1'-1 1/8"C 7'-2" 7'-2" 7'-2" 7'-4 5/8" 7'-4 5/8" 7'-4 5/8"D 4'-10 1/2" 4'-10 1/2" 4'-10 1/2" 5'-3 3/8" 5'-3 3/8" 5'-3 3/8"E 7 3/8" 7 3/8" 7 3/8" 10" 10" 10"F 4'-3/8" 4'-3/8" 4'-3/8" 4'-2 3/4" 4'-2 3/4" 4'-2 3/4"G 7 3/8" 1'-0" 1'-5 5/8" 1'-3 1/4" 2'-3" 4'-4 1/4"H 9'-7 3/8" 10'-3 1/4" 11'-5" 13'-1" 14'-3 3/4" 16'-11 1/8"J 10'-10 3/8" 11'-6 1/4" 12'-8" 14'-4" 15'-6 1/4" 18'-2 1/8"K 7'-3/8" 7'-3/8" 7'-3/8" 7'-2 3/4" 7'-2 3/4" 7'-2 3/4"L 6'-10 1/2" 7'-6 3/8" 8'-8 1/4" 8'-8 3/4" 9'-11" 12'-7"M 1'-4 3/8" 1'-5 3/4" 1'-6 3/4" 1'-7 7/8" 1'-8 7/8" 1'-11 1/4"N 1'-2 7/8" 1'-4 1/8" 1'-5 1/8" 1'-6 1/4" 1'-7 1/4" 1'-9 5/8"P 1'-1" 1'-2 1/4" 1'-3 1/4" 1'-4 3/8" 1'-5 3/8" 1'-7 3/4"

R (Qty.) 12 12 12 16 16 16Note:All dimensions listed in above figure are similar for unit sizes 100 thru 240. Dimensions that vary in unit size are identified by letter (A thru R) and must reference above table forspecific dimension(s).

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DimensionalData

Figure DD-2 — Unit Size 300-550

Table DD-2 — Unit Size 300-550Figure Unit Sizes with Dimensions

Reference 300 350 400 450 500 550A 3’-1” 3’-1” 3’-1” 3'-6 1/2" 3'-6 1/2" 3'-6 1/2"B 1’-3” 1’-3” 1’-3” 1'-5 3/4" 1'-5 3/4" 1'-5 3/4"C 4 3/4” 4 3/4” 4 3/4” 5 1/8" 5 1/8" 5 1/8"D 6’-2” 6’-2” 6’-2” 6'-7 1/2" 6'-7 1/2" 6'-7 1/2"E 6 1/4” 6 1/4” 6 1/4” 6 1/4" 2'-5 3/8" 2'-5 3/8"F 11 7/8” 11 7/8” 11 7/8” 1'-2 5/8" 3' 3'G 6’-6 3/4” 6’-6 3/4” 6’-6 3/4” 7'-5/8" 7'-5/8" 7'-5/8"H 4” 4” 4” 4" 1'-2" 1'-2"J 4 3/8” 6 3/8" 6 3/8" 1'-1 7/8" 1'-1 7/8" 1'-1 7/8"K 7 1/2” 1'-6 1/8" 2'-4" 3'-3/8" 3'-7 3/4" 4'-6 3/8"L 1’-11 3/8” 1'-11 3/8" 1'-11 3/8" 1'-11 3/8" 2'-6 1/4" 2'-6 1/4"M 14’-7 1/8” 16'-5 3/8" 18'-5" 20'-3 1/8" 22'-5 7/8" 24'-4"N 13’-11 1/8” 15'-7 3/8" 17'-7" 18'-2 1/8" 20'-4 7/8" 22'-3"P 3 5/8” 3 5/8" 3 5/8" 11 1/8" 11 1/8" 11 1/8"R 4 1/8” 4 1/8" 4 1/8" 11 3/4" 11 3/4" 11 3/4"S 9’-7 1/8” 11'-3 3/8" 13'-3" 13'-1 3/4" 15'-4 1/2" 17'-2 1/2"T 1’-11 1/8” 2'-1 1/2" 2'-1 7/8" 2'-1 7/8" 2'-3 3/8" 2'-4 3/8"U 1’-9 5/16” 1'-11 3/4" 2'-1/4" 2'-1/4" 2'-1 5/8" 2'-2 5/8"V 1’-7 5/8” 1'-10" 1'-10 7/16" 1'-10 7/16" 1'-11 7/8 2'-7/8"

W (Qty.) 16 20 20 20 24 24Note:All dimensions listed in above figure are similar for unit sizes 300 thru 550. Dimensions that vary in unit size are identified by letter (A thru W) and must reference above table forspecific dimension(s).

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DimensionalData

Figure DD-3 — Unit Sizes 600-1100

Table DD-3 — Unit Sizes 600-1100Figure Unit Sizes with Dimensions

Reference 600 700 800 900 1000 1100A 5’-11 1/8” 5’-11 1/8” 6’-5 1/2” 6'-5 1/2” 7'-7 3/8” 7'-7 3/8”B 1’-5 7/8” 1’-5 7/8” 1'-9 1/4” 1'-9 1/4” 1'-10 1/2” 1'-10 1/2”C 10'-11 1/8” 10’-11 1/8” 10'-11 1/8” 10'-11 1/8” 12'-7/8” 12'-7/8”D See unit submittals for specific dimensions.E 10’-1/4” 10’-1/4” 10’-1/4” 10'-1/4” 1'-1 3/8” 1'-1 3/8”F 8’-10 7/8” 8’-10 7/8” 9'-5 3/8” 9'-5 3/8” 11'-1 1/8” 11'-1 1/8”G 9’-9 1/8” 9’-9 1/8” 10'-3 5/8” 10'-3 5/8” 12'-2 1/2” 12'-2 1/2”H 4’-9 1/2” 4’-9 1/2” 4'-11” 4'-11” 5'-8 7/8” 5'-8 7/8”J 3’-5 5/8” 3’-4 5/8” 4'-2 3/8” 5'-3” 4'-3 7/8” 4'-7 3/4”K 10’-6 3/8” 12’-11 1/8” 15'-7 7/8” 15'-8 1/8” 13'-2” 14'-5”L 19’-3/4” 20’-9-3/8” 24'-5/8” 26'-1 7/8” 22'-1 1/4” 23'-8”M 5’-3/4” 4’-5 5/8” 4'-2 3/8” 5'-2 3/4” 4'-7 3/8” 4'-7 3/8”N 10’-7/8” 10’-7/8” 10’-7/8” 10’-7/8” 11'-1 3/8" 11'-1 3/8"P 4’-2 3/8” 3’-7 1/8” 3’-4” 4'-4 1/4” 3'-8” 3'-8”R 8’-10 1/4” 9’-11” 12’-4 1/2” 13'-9” 11'-1 3/4” 12'-4 3/4”S 2’-6 3/4” 2’-8” 2’-11 1/8” 3'- 7/8” 3'-5 7/8” 3'-5 7/8”T 2’-5 1/16” 2’-6 5/16” 2'-9 1/2” 2'-11 1/4” 3'-4 1/8” 3'-4 1/8”U 2’-3 1/2” 2’-4 3/4” 2'-7 7/8” 2'-9 5/8” 3'-2 5/8” 3'-2 5/8”

V (Qty.) 24 24 28 28 32 32Note:All dimensions listed in above figure are similar for unit sizes 600 thru 1100. Dimensions that vary in unit size are identified by letter (A thru V) and must reference above table forspecific dimension(s).

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DimensionalData

Figure DD-4 — Unit Sizes 100, 120

Water ConnectionLocation



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DimensionalData


Figure DD-7— Unit Size 300

Table DD-4 — Water Connections, Unit Sizes 150 to 550Water Connection Dimension by Unit Size

Dimension 100 120 150 180 300 350 400 450 500 550A 3'-11 7/8” 3'-11 7/8” 3'-11 7/8” 4'-4 3/4” 5'-5 1/2" 5'-5 1/2" 5'-5 1/2" 5'-11 1/8" 5'-11 1/8" 5'-11 1/8"B 2'-9 1/8" 2'-9 1/8" 2'-5 3/8” 2'-10 1/4” 3'-8 5/8" 3'-8 5/8" 3'-8 5/8" 4'-2 1/4" 4'-2 1/4" 4'-2 1/4"C 6'-3 1/4" 6'-3 1/4" 6'-2 5/8” 6'-5” 7'-10 1/4" 7'-10 1/4" 7'-10 1/4" 7'-10 1/4" 7'-10 1/4" 7'-10 1/4"D 3'-11 3/8" 3'-11 3/8" 3'-11” 4'-1 3/8” 5'-0 5/8" 5'-0 5/8" 5'-0 5/8" 5'-0 5/8" 5'-0 5/8" 5'-0 5/8"E 3'-1 1/2" 3'-1 1/2" 3'-2 3/8” 3'-4 3/4” 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0"F 2'-6 3/4" 2'-6 3/4" 2'-7 1/8” 2'-9 1/2” 3'-5 1/8" 3'-5 1/8" 3'-5 1/8" 3'-5 1/8" 3'-5 1/8" 3'-5 1/8"G 4'-1 3/4" 4'-1 3/4" 3'-4 3/4” 3'-9 5/8” 5'-2 5/8" 5'-2 5/8" 5'-2 5/8" 5'-8 1/8" 5'-8 1/8" 5'-8 1/8"H 4'-3 5/8" 4'-3 5/8" 3'-10 7/8” 4'-3 3/4” 5'-8 1/4" 5'-8 1/4" 5'-8 1/4" 6'-1 7/8" 6'-1 7/8" 6'-1 7/8"J 3 1/4" 3 1/4" 3 1/4" 3 1/4" 4 3/8" 6 3/8" 6 3/8" 11 7/8" 11 7/8" 11 7/8"K 3 1/4" 3 1/4" 3'-5/8" 3'-5/8" 3'-5/8" 11 1/8" 11 1/8" 11 1/8"

Table DD-5 — Inlet and Outlet Diameters, Unit Sizes 100 to 550Water Connection Pipe Size Diameters (Inches) by Unit Size

Inlet/Outlet 100, 120 150, 180 200, 240 300, 350, 400, 450, 500, 550Evaporator 4 5 6 8Absorber 5 6 8 10Condenser 5 6 8 10

Figure DD-8 — Unit Sizes 350, 400, 450, 500, 550

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DimensionalData


Figure DD-6 — Water Connections, Unit Sizes 600 to 1100Water Connection Dimension by Unit Size

Dimension 600 700 800 900 1000 1100A 2’-8 1/2” 2’-7 3/8” 3'-5 3/8" 4'-6” 3'-5 3/4” 3'-9 1/2”B 2’ 1’-11” 2'-8 3/4” 3'-9 3/8” 2'-10 1/2” 3'-2 3/8”C 2'-8 1/4” 3'-8 3/4” 2'-8 1/2” 3'- 3/8”D 3’-6 5/8” 2’-11 3/8” 2'-8 3/4” 3'-9 1/8” 3'-2 1/4” 3'-2 1/4”E 9’-6 1/8” 9’-6 1/8” 9'-6 3/8” 9'-6 3/8” 10'-7” 10'-7”F 7’-6 1/8” 7’-6 1/8” 7'-7 1/2” 7'-7 1/2” 8'-3” 8'-3”G 2’-10” 2’-10” 2'-10” 2'-10” 2'-9 1/8” 2'-9 1/8”H 2’-0 3/8” 2’-0 3/8” 2'- 3/8” 2'- 3/8” 2'-4 1/8” 2'-4 1/8”J 9’-9 1/8” 9’-9 1/8” 10'-3 5/8” 10'-3 5/8” 12'-2 1/2”

Table DD-7 — Inlet and Outlet Diameters, Unit Sizes 600 to 1100Water Connection Pipe Size Diameters (Inches) by Unit Size

Inlet/Outlet 600, 700 800, 900 1000, 1100Evaporator 8 10 12Absorber 12 12 16Condenser 12 12 16

Figure DD-10 — Unit Sizes 800, 900, 1000, 1100


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For initial start-up, the chiller/heateroperation switch C-S should be in the“STOP” position, and the burner controlswitch S-1 is on. And on dual fuelmodels, select the type of fuel. Powermust be applied to the control panel andthe electric “source” lamp, LN1, shouldbe lit. Abnormal lamps LN4-12 must notbe lit. The hand operated fuel stop valvefor the chiller/heater must be open.Power must be applied to the C/H waterpump starter and the ventilator motorstarter.

To start the Thermachill chiller, theoperation switch C-S is moved to the“HEATING” position. The C/H waterpump and the ventilator are immediatelystarted. After the C/H water flow switchsignal is received, the two refrigerantsolenoid valves, the high temperaturesolution pump, and the low temperaturesolution pump are started 15 secondslater. The “OPERATION” lamp, LN2,should be lit.

The refrigerant pump and combustioncontrol sensors then monitor the C/Hwater outlet temperature. If there issufficient differential between the C/Hwater outlet temperature and therefrigerant pump set point, then the fiveminute refrigerant pump antirecycletimer starts timing and the combustioncontrol set point, and approximatelythree minutes has elapsed since powerup or the last C/H cycle, combustion isinitiated and the “CALL FOR HEAT” lampon the burner control panel is lit.

The burner now follows the flamesafeguard sequence. The firing ratemotor drives toward the “full fire”position, opening the burner air louver toprovide the maximum open louver pre-purge. The firing rate motor requiresapproximately 30 seconds to drive“open” from the “full closed” position.The firing rate motor purge rate switchmust be made showing 60 percent of fullfire rate air flow or the flame safeguardtiming will stop and then restart whenthe switch does make. If the purge rateswitch is not used, the flame safeguardtiming will continue to run. Air flow mustbe proven or the ignition portion of thesequence will not occur. The firing ratemotor then drives to the “low fire”position. The firing rate motor minimumposition switch must be made or theflame safeguard timing will stop andthen restart when this switch does make.The “IGNITION ON” lamp on the burnercontrol panel then lights. The gas pilotignition transformer is energized and thesafety shutoff pilot valve opens to ignitethe pilot. Gas pilot flame must be provenor the flame safeguard will lock out.Provided the pilot flame is proven, the“FUEL ON” lamp on the burner controlpanel is lit, and the “IGNITION ON” lampgoes out. If firing on gas, the safetyshutoff and the second safety shutoff, ifused, gas valves open. The normallyopen vent valve, if used, is energized andthe main burner ignites at low fire rate. Iffiring on oil, provided safe oil pressure isproven, if the oil pressure switch(es) areused, the safety shutoff and secondsafety shutoff, if used, oil valves open toignite the main burner at low fire rate.The “COMBUSTION” indicator lamp onthe unit control panel lights uponconfirmation of combustion.

With the firing rate mode selector switchin the burner control panel in the“AUTO” position, the burner firing ratemotor is now released to automaticfiring rate control and the firing rate ismodulated in proportion to the change inC/H outlet water temperature.

If the system load drops to a level wherechiller/heater operations is no longerrequired, an automatic shutdownsequence occurs. The fuel valves close. Iffiring on gas, the normally open ventvalve, if used, opens. The flamesafeguard timing starts. The firing ratemotor drives to the “closed” position.The burner motor and flame safeguardtiming stop. The “COMBUSTION”indicator lamp on the unit control panelgoes out. The chiller/heater is now readyshould heating operation again berequired.

If the chiller/heater is shutdownmanually, either by placing the C-Sswitch in the “STOP” position, orremotely, the following sequence occurs.The C/H water pump turns off. Theburner motor shuts down in the samemanner as automatic operation. Thedilution cycle is then initiated. After 15minutes the dilution cycle is completedand the high temperature solutionpump, the low temperature solutionpump, and the ventilator motor stops.The refrigerant solenoid valves thenclose. The “OPERATION” lamp, LN2,should go out.

Sequence ofOperation Cooling

27ABS-PRC007-EN

Sequence ofOperation Heating

For initial start-up, the chiller/heateroperation switch C-S should be in the“STOP” position, and the burner controlswitch S-1 is on. And on dual fuelmodels, select the type of fuel. Powermust be applied to the control panel andthe electric “SOURCE” lamp, LN1,should be lit. Abnormal lamps LN4-12must not be lit. The hand operated fuelstop valve for the chiller/heater must beopen. Power must be applied to the C/Hwater pump and cooling tower pumpstarters, and the ventilator motor starter.

To start the Thermachill chiller/heater, theoperation switch C-S is moved to the“COOLING” position. The C/H waterpump and the ventilator motor areimmediately started. After the C/H waterflow switch signal is received, thecooling tower pump, the hightemperature solution pump, and the lowtemperature solution pump are started15 seconds later. The “OPERATION”lamp, LN2, should be lit.

The refrigerant pump and combustioncontrol sensors then monitor the C/Hwater outlet temperature. If there issufficient differential between the C/Hwater outlet temperature and therefrigerant pump set point, then the fiveminute refrigerant pump antirecycletimer starts timing and the combustioncontrol set point, and approximatelythree minutes has elapsed since powerup or the last C/H cycle, combustion isinitiated and the “CALL FOR HEAT” lampon the burner control panel is lit.

The burner now follows the flamesafeguard sequence. The firing ratemotor drives toward the “full fire”position, opening the burner air louver toprovide the maximum open louver pre-purge. The firing rate motor requiresapproximately 30 seconds to drive“open” from the “full closed” position.The firing rate motor purge rate switchmust be made showing 60 percent of fullfire rate air flow or the flame safeguardtiming will stop and then restart whenthe switch does make. If the purge rateswitch is not used, the flame safeguardtiming will continue to run. Air flow mustbe proven or the ignition portion of thesequence will not occur. The firing ratemotor then drives to the “low fire”position. The firing rate motor minimumposition switch must be made or theflame safeguard timing will stop andthen restart when this switch does make.The “IGNITION ON” lamp on the burnercontrol panel then lights. The gas pilotignition transformer is energized and thesafety shutoff pilot valve opens to ignitethe pilot. Gas pilot flame must be provenor the flame safeguard will lock out.Provided the pilot flame is proven, the“FUEL ON” lamp on the burner controlpanel is lit and the “IGNITION ON” lampgoes out. If firing on gas, the safetyshutoff and second safety shutoff, ifused, gas valves open. The normallyopen vent valve, if used, is energized andthe main burner ignites at low fire rate. Iffiring on oil, provided safe oil pressure isproven, if the oil pressure switch(es) areused, the safety shutoff and secondsafety shutoff, if used, oil valves open toignite the main burner at low fire rate,the “COMBUSTION” indicator lamp onthe unit control panel light uponconfirmation of combustion.

With the firing rate mode selector switchin the burner control panel in the“AUTO” position, the burner firing ratemotor is now released to automaticfiring rate control and the firing rate ismodulated in proportion to the change inC/H outlet water temperature.

If the system load drops to a level wherechiller/heater operation is no longerrequired, an automatic shutdownsequence occurs. The fuel valves close. Iffiring on gas, the normally open ventvalve, if used, opens. The flamesafeguard timing starts. The firing ratemotor drives to the “closed” position.The burner motor and flame safeguardtiming stop. The “COMBUSTION”indicator lamp on the unit control panelgoes out. The chiller/heater is now readyshould cooling operation again berequired.

If the chiller/heater is shutdownmanually, either by placing the C-Sswitch in the “STOP” position, orremotely, the following sequence occurs.The C/H water pump, the cooling towerwater pump, and the refrigerant pumpturn off. The two refrigerant solenoidvalves are opened to initiate the dilutioncycle. The burner motor shuts down inthe same manner as automaticoperation. After 15 minutes the dilutioncycle is completed and the hightemperature solution pump and the lowtemperature solution pump stops andthe ventilator motor stops. Therefrigerant solenoid valves then close.The “OPERATION” lamp, LN2, should goout.

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Typical WiringDiagrams

FieldConnections

29ABS-PRC007-EN


FieldConnections

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FieldConnections

31ABS-PRC007-EN


FieldConnections

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JobsiteConnections

Field Installation100 thru 550 Tons

Customer Notes:

1. Refer to unit submittal for specific unitdetails and surrounding spacerequirements.

2. Unit must be elevated with clearancefor burner extension below unit.

3. Overall slab or rail size to bedetermined by customer.

4. Foundation finish to be flat andsmooth. Grade not to exceed .20" overlength of unit.

5. Use unit anchoring holes, as required,to meet local codes.

6. Units with enclosure: opening(s)under unit base must be sealed off toprevent wind effect on burner.

Unit Max. Weight PerNominal Anchoring Bolt

Tons A B C D E F G H (lbs)100 9’-7 3/8” 4’-10 1/2” 2’-5” 2 3’-0” 2 1/2” 2’-1” 6 3,100120 10'-3 1/4" 4’-10 1/2” 2’-5” 2 3'-5" 2 1/2” 2’-1” 6 3,400150 11'-5" 4’-10 1/2” 2’-5” 2 3'-10" 2 1/2” 2’-1” 6 3,900180 13'-1" 5'-3 3/8" 2'-9 7/8" 2 3'-8" 2 1/2” 2'-5 7/8" 6 4,600200 14'-3 1/4" 5'-3 3/8" 2'-9 7/8" 2 4'-8" 2 1/2” 2'-5 7/8" 6 5,000240 16'-11 1/8" 5'-3 3/8" 2'-9 7/8" 2 6'-9" 2 1/2” 2'-5 7/8" 6 5,500300 13'-11 1/8" 6'-2" 3'-3 3/8" 4 3'-3" 4 1/2” 2'-8 3/8" 6 5,700350 15'-7 3/8" 6'-2" 3'-3 3/8" 4 4'-0" 4 1/2” 2'-8 3/8" 6 6,300400 17'-7" 6'-2" 3'-3 3/8" 4 4'-10" 4 1/2” 2'-8 3/8" 6 6,800450 18'-2 1/8" 6'-7 1/2" 3'-8 7/8" 4 5'-6" 4 1/2” 3'-1 7/8" 6 5,700500 20'-4 7/8" 6'-7 1/2" 3'-8 7/8" 4 6'-9" 4 1/2” 3'-1 7/8" 1'-2" 6,200550 22'-3" 6'-7 1/2" 3'-8 7/8" 4 7'-8" 4 1/2” 3'-1 7/8" 1'-2" 7,000

Isolation Pad Placement By OthersUnit with 6 anchor holes shown.Other units are similar

End ElevationRail Mounting Method

End ElevationSlab Mounting Method

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JobsiteConnections Field Installation

ABS-PRC007-EN34

JobsiteConnections

Customer Notes:

1. Sample unit is shown. Refer to unitsubmittal for specific unit details andsurrounding space requirements.

2. 600 and 700 ton units must beelevated to provide clearance forburner extension below unit.

3. 800 and 900 ton unit must be elevatedand have recess opening to provideclearance for burner extension belowunit.

4. 1000 and 1100 ton units do not have tobe elevated since burner does notextend below unit.

5. Overall slab or rail size to bedetermined by customer.

6. Foundation finish to be flat andsmooth. Grade not to exceed .20" overlength of unit.

7. Use unit anchoring holes, as required,to meet local codes.

Unit Max. Weight PerNom. Anchoring BoltTons A B C D E F G H J (lbs)600 10'-6 3/8" 8'-10 7/8" 4'-1 1/2" 2'-9 3/8" * * * 6 6 Max. 9,400700 12'-11 1/8" 8'-10 7/8" 4'-1 1/2" 2'-9 3/8" * * * 6 6 Max. 8,900800 15'-7 7/8" 9'-5 3/8" 4'-8" 3'-4" 1'-10" 5 1/2" 2'-7 1/2" 6 1'-0" Min. 10,100900 15'-8 1/8" 9'-5 3/8" 4'-8" 3'-4" 2'-9" 5 1/2" 2'-7 1/2" 6 6 Min. 11,1001000 13'-2" 11'-1 1/8" 5'-4" 3'-6 3/8" * * * * * 12,7001100 14'-5" 11'-1 1/8" 5'-4" 3'-6 3/8" * * * * * 13,700

*= Not Applicable

Isolation Pad Placement By OthersUnit with 8 anchor brackets shown.Other units are similar

End ElevationRail Mounting Method

End ElevationSlab Mounting Method

Field Installation600 thru 1100 Tons

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JobsiteConnections Field Installation

ABS-PRC007-EN36

JobsiteConnections

Field InsulationRequirements

37ABS-PRC007-EN

JobsiteConnections

Field InsulationRequirements

Surface Area for Hot Insulation (Sq. Ft.) Surface Area for Cold Insulation (Sq. Ft.)Direct-Fired Vapor/Liquid Separator, Low Temp. Generator,Generator, Header for Heat Exchanger, Solution Piping, Evaporator,

Exhaust Gas Low Temp. Refrigerant Vapor Piping, Chilled/Hot Water Refrigerant Economizer Generator Float Valve Header Piping

Metal Surface TemperatureUnit 40 to 200°F

Nom. Tons 350°F Max. 350°F Max. 250°F Max. (Refer to Note 1b) 150°F Max.100 54 23 73 39 14120 59 23 80 44 13150 68 23 89 52 12180 76 29 122 59 12200 83 29 132 63 13240 89 29 153 73 14300 102 43 146 96 15350 112 43 172 108 16400 124 43 184 121 17450 135 48 216 131 18500 146 48 239 145 19550 159 48 302 157 20600 140 81 420 226 54700 194 102 484 269 54800 237 118 527 301 54900 258 129 581 334 65

1000 280 151 592 344 651100 301 172 603 344 65

Customer Notes:

1. Unit is painted with heat resistantmaterial. Customer must provide andinstall nonflammable insulationmaterials to prevent dew and burn,and to keep unit at high operatingefficiency. Refer to table for metaltemperatures of surfaces to beinsulated.a. Hot Insulation: Type and thickness of

insulation must be sufficient so thatouter skin temperature meets OSHAsafety requirements for personnelprotection.

b. Cold Insulation: Insulation should bewarranted to prevent sweating up toa dew point rating of 74°F andwithstand a temperature of 200°F(during heating).

2. Perform vacuum test prior toinsulation unit.

3. Make sure that unit cover plates andflange parts are easily detachable afterinsulating.

4. Make the insulation material on thetop and outside of the heat exchangerremovable. Do not connect it withother insulation parts using metalfasteners.

ABS-PRC007-EN38

JobsiteConnections

BurnerInstallation

39ABS-PRC007-EN

JobsiteConnections

BurnerInstallation

Customer Notes:

1. Burner is supplied with a separatecontrol panel, burner mountingrefractory frontplate, fuel supplysystem, insulating rope, and mountinghardware for installation by contractor.

2. Fuel supply system is furnished to suitfuel type ordered: (Refer to fuel supplysystem submittal)

Gas – A pre-piped and wired gastrain will be provided withcomponents that are selectedto meet local codes.(Mandatory to consult localcodes to verify gas trainrequirements.)

Oil – An oil pump system isprovided. Contractor tomount on unit base or otherconvenient location.

Gas/Oil –Includes both of the above.

3. Units 100 thru 900 nominal ton mustbe elevated or the housekeeping padmust provide clearance for the burnerwhich extends below the unit wheninstalled. (Refer to unit installationsubmittal for details.)

4. It may be necessary to remove asection of the unit base duringinstallation of the burner.

5. The electrical connections arefurnished and must be connected afterburner mounting is complete. (Refer tofield wiring submittal for details.)

6. Use table to determine riggingweights and size of components.Burner weights are for a combinationgas-oil dual fuel type burner

Table JC-1 – Burner SpecificationsUnit Component Weights (Approx. Lbs.)

Nom. Tons Burner (G/O) Frontplate Burner Control Panel Gas Train100 250120 275 60150 285180 295200 375 100240 400300 600350 700 150400 700 65 Varies With Code450 700 and Gas Flow500 1000 175550 1000600 1100 200700 1300800 1400 250900 1400

1000 1600 3001100 1600

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JobsiteConnections

Gas Fuel SupplySystem

Table JC-2 – Capacity of Pipe – Natural Gas (CFH)Table JC-3 – SpecificGravity Other than 0.60

Table JC-4 – PressureDrop Other Than 0.3"

Fuel Correction Factors for Table JC-2

41ABS-PRC007-EN

JobsiteConnections

Gas Fuel SupplySystem

ABS-PRC007-EN42

JobsiteConnections

Oil Fuel SupplySystem

43ABS-PRC007-EN

JobsiteConnections

Oil Fuel SupplySystem

Table JC-5 – High Pressure Pump Set Specifications For No. 2 Oil

Table JC-6 – Suction Line size and Maximum Length

Table JC-7 – Relation Between Vacuum and Vertical Lift 140 F API Oil at 60 F

ABS-PRC007-EN44

JobsiteConnections

ExhaustGas Duct

Flue Gas Duct Connection:The exhaust flue access duct is providedby factory for field installation. It has aninspection cover, condensate drain andpre-drilled flanges. This section shouldbe connected to the unit before otherductwork is attached. (Refer to unitsubmittal for duct dimensions).

Exhaust Gas Duct and Flue StackDesign:The flue exhaust duct and flue stackmust be designed of material incompliance with municipal, state andfederal regulations.

The duct and stack must be heat-resistant to accept temperatures up to675 F. The duct and stack sectional areasshould increase in diameter, avoidingsharp bends or steep changes whichmay cause eddy current and/or backpressure to the unit.

Avoid horizontal bends in the flue gasduct. However, if bends are inevitabledue to construction of building,determine the height of the stack withrespect to the length of the horizontalflue gas duct using the followingformula:

Stack Height = 0.6 ft. per ft. of horizontalflue gas duct length and 4 ft. for every 90bend, providing that the exhaust gaspressure at the unit outlet is 0 to -0.2”water gauge.

Note: Remember to provide cleaningaccess doors for removing soot frominside of the exhaust duct and flue stack.

Construction of Gas Duct and FlueStack:Penetrating duct or stack which ismounted through a wall, ceiling or otherbuilding constructions must be madewith heat-resistant material (concrete,plaster, mortar, or equivalentnonflammable material).

This duct must be insulated to preventrising ambient temperature in theequipment room or injury from beingburned. Comply with municipal, stateand federal codes. The use of zinc platedsteel plate or normal steel structure plateas thick as practical is recommended.

Provide a lightning rod or good groundto the flue stack.

Note: When designing support,remember to consider thermalexpansion.

Multiple Unit Installation:If using the same flue stack fordischarging exhaust from more than onesystem, it will be necessary to provide adamper preventing the back flow ofexhaust in the unused unit(s) and/orfluctuations in static pressure.

Flue Stack Opening:The outlet of the stack should bedesigned so that rain, wind and snowdoes not enter into the stack. This allowsa constant draft to be maintained.

Refer to ASHRAE Equipment Handbook,Chapter 26, for further information onchimneys and stack design.

Flue Stack Location:Considerations should be made whendetermining the location of the flue stackto the conditions of the atmosphere,roof, cooling tower(s), and other intakeand exhaust vents.

Airflow around buildings affects workersafety, process and building equipmentoperation, weather and pollutionprotection of inlets, and the ability tocontrol environmental factors oftemperature, humidity, air motion, andcontaminants. Wind causes surfacepressures that vary around buildings,changing intake and exhaust systemflow rates, natural ventilation, infiltrationand exfiltration, and interior pressure.The mean flow patterns and turbulenceof wind passing over a building cancause a recirculation of exhaust gases toair intakes.

To obtain information about evaluatingflow patterns, estimating windpressures, air intake contamination, andsolving problems caused by the effectsof wind on intakes, exhausts, andequipment, refer to the ASHRAEFundamentals Handbook, Chapter 14and Equipment Volume, Chapter 26—Design of Chimneys.

45ABS-PRC007-EN

JobsiteConnections

TypicalInstallations

ABS-PRC007-EN46

OptionalDisassembledShipment

Unit Evap/Abs/Cond/ Low Temp Conc. Section High Temp. SectionNominal Length Width Height Weight Length Width Height Weight

Tons L1 W1 H1 (lbs.) L2 W2 H2 (lbs.)600 19'-0 3/4" 8'-5 1/4" 10'-11 1/8" 40,800 12'-10 3/8" 3'-11 7/8" 10'-11 1/8" 8,200700 20'-9 3/8" 8'-5 1/4" 10'-11 1/8" 45,000 15'-3 1/8" 3'-11 7/8" 10'-11 1/8" 8,400800 24'-0 5/8" 8'-5 1/4" 10'-11 1/8" 50,100 15'-9" 4'-6 1/2" 10'-11 1/8" 9,800900 26'-1 7/8" 8'-5 1/4" 10'-11 1/8" 55,600 15'-8 1/8" 4'-6 1/2" 10'-11 1/8" 11,100

1999 22'-1 1/4" 9'-8 1/4" 12'-1" 67,800 15'-5 7/8" 4'-11 5/8" 12'-1" 11,7001100 23'-8" 9'-8 1/4" 12'-1" 68,400 16'-8 3/4" 4'-11 5/8" 12'-1" 12,400

47ABS-PRC007-EN

OptionalDisassembledShipment

ABS-PRC007-EN48

ConstructionEach unit is a complete chiller/heaterpackage. The package includes anevaporator/absorber section, condenser/low temperature generator section, ahigh temperature (direct-fired) generator/economizer section and burnerassembly. A unique reverse solutionflow cycle enhanced by an exhaust gaseconomizer provides a high efficiencydesign. All units require field mountingat the burner, burner control panel andfuel supply system, which shipindependently. All units are hermeticdesign, factory assembled and leaktested. Units that are factory charged arerun-tested prior to shipment. Thestandard method of shipment is byvessel to the USA and rail or truck to thejob location.

Units 550 nominal tons and smaller shipfully assembled and are run-tested priorto shipment. Shipping or installationconstraints on units 600-1100 nominaltons may require shipment andinstallation in sections. In this case, fieldassembly, charging and run-testing arerequired at the jobsite.

Standard waterside working pressureare 150 psig and are tested at 150percent of design pressure. All waterboxes have lifting lugs, gasketedremovable covers, drains and vents.

The low temperature generator head iswelded to the unit. Steel tubes areprovided. Solution heat exchangers arean efficient plate type design thatenhance the solution cycle.

MechanicalSpecifications

Shell and Tube BundlesThe shell material is carbon steel. Tubesheets are carbon steel, drilled, reamedand grooved to accommodate tubing.Tubes are individually replaceable andare mechanically expanded into thetubesheet. Evaporator, absorber andcondenser tubes are copper. Eliminatorsare positioned to insure efficientoperation by separating the absorberfrom the evaporator and the condenserfrom the low temperature generator. Arupture disc is provided on the generatorsection.

The shell side of the unit is leak-tested.The unit is both air proof tested and leakchecked. A helium mass spectrometertest is performed under vacuum toinsure hermetic integrity.

Motor and PumpThe unit has three motor/pumpassemblies. The pump is direct-coupledto the motor. Carbon bearings arelubricated and cooled by the fluid beingpumped. Stainless steel is usedthroughout the pump and motor. Themotor is a submersible type with therotor and stator protected by stainlesssteel liners. The motors are 3 phase 200V50/60 cycle as standard.

Electrical PowerUnit control panel control circuit is 200V1 phase. Burner control panel controlcircuit power is 115 V 1 phasetransformed from 200V 1 phase. Oil-firedunits require separate 115 V supply for oilpump.

49ABS-PRC007-EN

MechanicalSpecifications

Standard Control CapabilitiesThe unit control panel is integratedcircuit board based in a factory- mountedpackage that includes a full complementof controls to operate the chiller safelyand efficiently. Unit status and diagnosticcontrol monitor lights on the paneldefine status. The controls maintain aselected chilled water temperature over afull range of loads. The unit controlsmust be interconnected with jobsitesafety interlocks provided by others forproper unit operation.

Chiller control of chilled or hot water isaccomplished by metering the amountof heat introduced into the absorptioncycle from a Gordon-Piatt combustionburner assembly. The burner assembly isfired by natural gas, No. 2 fuel oil, LP gasor a combination burner that will handlemultiple fuels.

The UL listed Gordon-Piatt burner andcontrol assembly is supplied with flamesafeguard and other burner controlstand-alone safety functions that aredesigned for safe burner operation. Aseparate Gordon-Piatt burner controlpanel is provided.

The unit control assembly monitorsrefrigerant and lithium bromide solutiontemperatures. If an evaporator freezecondition or the lithium bromidesolution approaches an unsafecondition, automatic correction action isinitiated to maintain a safe condition. Theunit is shut down if the unsafe conditioncontinues. The panel features operatingstatus and diagnostic display.

The temperature of the chilled or hotwater leaving the evaporator section ofthe absorption unit is measured byfactory mounted sensors located in theevaporator water leaving the unit. Theunit is started and stopped atpredetermined set points which areactivated by sensor temperature. Theultimate burner firing rate is determinedby the cooling or heating requirement ofthe water circulating through theevaporator section.

With the unit panel switch in the coolingmode and design water flow through theevaporator and condenser circuit, theunit control will respond to a coolingrequirement by starting the chiller andburner in sequence. The burner ismodulated from 100 to 30 percent ofdesign as needed to control the leavingevaporator water temperature. Below 30percent of design, the burner is cycled toallow the chiller to reach a 10 percentminimum load. Upon turning the unitoff, a 15 minute dilution cycle is initiatedto dilute the lithium bromide solution.Heating operation is similar with thepanel switched to heating mode. Acooling/heating switch valve is alsomanually operated to accomplishchangeover. Hot system water isprovided in the evaporator circuit.During heating cycle operation thecooling water must be isolated anddrained from the unit.

Purge SystemThe purge is designed to removenoncondensable gas from the unitautomatically while the unit is operating.The purge system contains an isolationtank that has palladium cells attachedwhich remove gas collected by the purgeprocess. A mechanical pump is used toremove any air accumulation and isprovided as part of the machine asstandard.

Crystallization GuardA solenoid valve system is provided totransfer refrigerant into the lithiumbromide solution when an unsafecondition occurs such as low refrigeranttemperature or low solutiontemperature. Unit operation isautomatically terminated if thecrystallization guard activity does notcorrect the condition.

Flue Access DuctThe exhaust gas duct must beconstructed to provide an exhaust gaspressure of 0 to -0.2” water at the chilleroutlet. All units ship with either a flueaccess duct or an exhaust hood. This isbolted directly to the unit outlet and isused as an inspection port, for flue gassampling and for cleaning if necessary.This section must be bolted to the unitbefore the exhaust gas duct isconnected. Barometric dampers arerequired if the drafting ability of the stackexceeds 0.05” water/foot of stack height.Exhaust gas temperatures can reach 360F at full heating conditions. Exhaust gasduct and stack should be heat resistantto 675 F.

Since The Trane Company has a policy of continuous product and product data improvement, it reservesthe right to change design and specifications without notice.

Literature Order Number

File Number

Supersedes

Stocking LocationThe Trane Company

An American Standard Company

www.trane.com

For more information contactyour local sales office ore-mail us at [email protected]

ABS-PRC007-EN

PL-RF-ABS-000-PRC007-EN 1004

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La Crosse

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