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American Standard CH530 User's Manual

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1. 1 CenTraVac Chiller motor connection remote starters __ In place and piped Do not insulate CenTraVac or Chilled water pump connected and tested adjacent piping The contractor is responsible for Condenser water pump connected and tested c any foreign material left in the unit s Cooling tower fan rotation checked 2 Piping Heat recovery condenser water Chilled water piping connected to pump as applicable CenTraVac tt Power available for Service tools 115 VAC Air handling units s All controls installed and connected n C PUMPS s All magnetic starters installed and connected Condenser and heat recovery condenser as applicable piping connected to Note Do not make final remote starter to compressor CenTraVaC t motor connections until requested to do so by the Pumps P Trane Service representative Cooling tower s Heating loop as applicable 6 Testing Make up water connected to cooling tower Dry nitrogen available for pressure testing __ Water supply connected to filling system _ C Trace gas amounts of Refrigerant 22 or R 134a
2. o pe8OS9E LX PIL SNOUYDINDWWOD 1 10 SY99 vNOLLdO lo 8 FTF Lo D O O 0 0 0 O 1455 ool Y8 o o INL fe o o ais o aus T m 1 T o o 9 TWNOLdO o m a o o svi o wes n o p E g WNOILdO i El TO s o o mm o ais g 1052 woiowossanos o a lol o o 0000 2232232229323 ZLOS9EIX anani nin 1052 NOlLdO SIVI IWNOlLdO SLINA 5 1 19253 LINDYID 53 1 53 32IA3Q ASSY TANVd 1O8 LNO2 O SHD 53 CDHF SVU01C EN e TRANE Control System Components Control Panel Devices Standard Devices Cont
3. Evacuation and charging Evacuation leak test When vacuum has been drawn down to 500 microns to 1000 micons secure the vacuum pump Wait for 12 hours for a valid vacuum leak test If the rise in vacuum is less than 500 microns per 12 hours start up may proceed Charge refrigerant MAKE SURE THE CHILLED WATER IS FLOWING TRHOUGH THE EVAPORATOR Charge the prescribed amount of refrigerant through the liquid charging valve at the liquid inlet to the evaporator Check that all drums contain a full amount of refrigerant Amount charged Igs and kg Electrical Disconnect all temporary power cords replace all fuses connect motor leads make final electrical inspection Power up the motor starter Check for control voltage at control panel terminals 1X1 1 and 1X1 17 Volts Check current to the oil sump heater Amperes As the oil heats up finish any operations not yet completed in preparation for starting the unit CDHF SVU01C EN e TRANE C Chiller Start up 1 Make all preliminary checks L Oil temp oil level chilled water flow chilled water load available cooling units on etc Start the unit If the phase rotation of the electrical power has not been positively confirmed the actual rotation of the motor must be checked Observe the rotation of the motor shaft through the sight glass on the end of the motor at the momen
4. Temperature 4 Front Panel Current Limit Setpt XXX 4 Percent RLA 5 Front Panel Base Load Cmd On Auto enum 6 Front Panel Base Load Setpt XXX Percent 7 Front Panel Ice Build On Auto Enum 8 Front Panel Ice Termn Setpt XXX X Temperature 9 Ice to Normal Cool Timer Setpt 0 10 5 min Minutes 10 Differential to Start XXX X Temperature 11 Differential to Stop XXX X Temperature 12 Setpoint Source BAS Ext FP Ext Front Panel Front Panel BAS xt FP Default Enum Follows hierarchy of selection from left to right except for ice building which is OR logic Feature Settings Description Resolution or Enumerations Default Units 1 Chilled Water Reset Constant Outdoor Return Disable Disable Enum 2 Return Reset Ratio XXX Percent 3 Return Start Reset XXXX Temperature 4 Return Maximum Reset XXX X Temperature 5 Outdoor Reset Ratio XXX Percent 6 Outdoor Start Reset XXXX Temperature 7 Outdoor Maximum Reset XXX X Temperature 8 Ext Chilled Water Setpoint Enable Disable Disable Enum 9 Ext Current Limit Setpoint Enable Disable Disable Enum 10 Ice Building Feature Enable Enable Disable Disable Enum 11 Ext Base Loading Setpoint Enable Disable Disable Enum 44 CDHF SVU01C EN e TRANE Operator Interface System Mode Overrides Description Resolution or Enumerations Default Units Monitor Value 1 Compressor
5. Latching MMR require corrective action and manual reset Non Latching MAR will restart automatically when condition corrects itself There are over 200 potential messages too numerous to incorporate in this manual Up to ten active diagnostics can be displayed if required CDHF SVU01C EN Operator Interface e TRANE The reason for all diagnostics must be determined and corrected Do not reset and restart the chiller as this can cause a repeat failure Contact local Trane Service for assistance as necessary After corrective action the chiller can be reset and or restarted In the case of Unit Shutdown Reset Required diagnostic types the chiller will have to be manually reset through the Diagnostics alarm menu When reset they become historic and viewable via the service tool TechView Performing a Reset All Active Diagnostics will reset all active diagnostics regardless of type machine or refrigerant circuit A Manual Override indicator shares space with the Alarms key alerts the operator to the presence of a manual override An Alarm will take precedence over any manual override until the reset of active alarms at which point the Manual indicator would reappear if such an override exists Temperature settings can be expressed in F or C depending on Display Units settings Dashes appearing in a temperature or pressure report indicates that the value is inval
6. Auto Manual 0 100 Auto Enum IGV Open Control Signal Evap LWT AFD Freq 2 Evap Water Pump Auto On Auto Enum 1 Evap Flow status 2 Override Tim e Remaining 3 Cond Water Pump Auto On Auto Enum 1 Cond Flow status 2 Override Time Remaining Circuit Mode Overrides Description Resolution or Enumerations Default Units Monitor Value 1 Oil Pump Auto On Auto Enum 1 Diff press 2 Override Time Remaining 2 Clear Restart Inhibit Timer 3 Purge Exhaust Circuit Test Off On Off Enum none 4 Purge Regen Cycle Off On Off Enum Carbon Temp 5 Front Panel Ckt Lockout Not Locked Out Locked Out Not Locked Out Enum Purge Description Resolution or Enumerations Default Units 1 Purge Operating Mode Auto On Adaptive Stop Adaptive Enum 2 Daily Pumpout Limit XXX Minutes 3 Disable Daily Pumpout Limit 0 to disable 0 XX Hours 4 Purge Liquid Temp Inhibit Enable Disable Enable Enum 5 Purge Liquid Temp Limit XXX X Temperature Display Settings Description Resolution or Enumerations Default Units 1 Date Format mmm dd yyy dd mmm yyyy mmm dd yyy Enum 2 Date 3 Time Format 12 hour 24 hour 12 hour Enum 4 Time of Day 5 Keypad Display Lockout Enable Disable Disable Enum 6 Display Units SI English English Enum 7 Pressure Units Gauge Absolute Absolute Enum 8 Language English Selection 2 Selection 3 English 2 Enum 1 Temperatures will be adjustable to 0 1
7. Algorithm Flow Compe CDHF SVU01C EN 115 e TRANE Trane A business of American Standard Companies www trane com For more information contact your local district office or e mail us at comfort trane com Literature Order Number CDHF SVU01C EN File Number SV RF CTV CDHF SVU01C EN 405 Supersedes CDHF SVU01B EN 604 Stocking Location La Crosse Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice Only qualified technicians should perform the installation and servicing of equipment referred to in this publication
8. N M3SN3QNOO 40 MIA dOL THIN OL 7HNvd 1OMINOO LINN 30 INANOD ONMOOD 3384 CLNY TBNvd 10MINOO 39uNd SSWdA SVD 10H SW NO pu AInQNOO 9NTI000 3344 ZIN ise Z LINGNOD NYL 710 2 m 7OMINOO 394nd 31 LINGNOD YILYVLS 5 0 LINN 393nd 0 E SSVdAB SVD ISt MO E S3HOLIMS ONMOOD 3384 CINY P ZINY S3HOLIMS MOTI N3IVM 28 7 18 3015 H G3sIno38 4 Sam NOLLVOINQWWOO 5 JYNSSIYd _LNVYIIIY43Y N3SN3ONOO zo MI NOUVOINGINMOO Sui ze 3Hnive3dW3l INVH39l443H 39MVHOSIQ oLar 7 OMIH GNOD dW3l HIM 9 1 7 INI Si 9 via O JYNLVYJAWAL LNVYI9IY43Y QILVYNLYS 14 3univs3dW3l INVYZOISY dvA3 3univH3dW3l YALVM 9NIAY31 6uv 1 N3lVM ONOO guy 3univu3dW3l 9NIAv31 dv 3 Luv TAR NONO Wo 3univu3dW3L dvA3 1 WO Suy 3unss3ud dWns 10 vut 3unss3ud dnd 10 Suy 3univsadWal Z ON 10 9NhV38 zur 3MnuvW3dW3l ON 10 SNI4v38 lay 3univsadW3L ONIGNIM YOLOW YOLWNLOY 3NVA 39 15 ANZ YOLOW 399315 4 MOLOA 10 YOLYNLOV INVA NOLON N3ddils AVI MilNNIS dWnd 10 Sur W3lV3H XNVL LYH 10 Noiovavo 0018 IXE FINGOW ive NOILVN9IS3Q NOlLdlM2S3Q 3ol 3a 65 CDHF SVU01C EN e TRANE Control System Components CDHF SVU01C
9. 4 Z5 Um BERE b vars TOR i 3 oe Temi atiu DOM comun soem NT cpi covey PER oi CDHF SVUO1C EN 23 e TRANE Base Loading Control Algorithm This feature allows an external controller to directly modulate the capacity of the chiller It is typically used in applications where virtually infinite sources of evaporator load and condenser capacity are available and it is desirable to control the loading of the chiller Two examples are industrial process applications and cogeneration plants Industrial process applications might use this feature to impose a specific load on the facility s elecrical system Cogeneration plants might use this feature to balance the system s heating cooling and electrical generation All chiller safeties and adaptive control functions are in full effect when Base Loading control is enabled If the chiller approaches full current the evaporator temperature drops too low or the condenser pressure rises too high Tracer CH530 Adaptive Control logic limits the loading of the chiller to prevent the chiller from shutting down ona safety limit These limits may prevent the chiller from reaching the load requested by the Base Loading signal Base Loading Control is basically a variation of the current limit algorithm During base loading the leaving water control algorithm provides load command every 5 seconds The current
10. I E copper 0 035 wall 0 75 C S B copper 0 028 wall 0 75 O D D S B copper 0 035 wall 0 75 O D I E copper 0 028 wall 1 0 F copper 0 035 wall 1 0 22 d 0 Not Assigned 23 B Evaporator Waterbox 150 psig 1 pass marine B 300 psig 1 pass marine C 150 psig 1 pass non marine D 300 psig 1 pass non marine O D O D 24 2 Evaporator Waterbox Connection 1 Victaulic 2 Flanged 25 0 Not Assigned 26 3 Condenser Tube Bundle Size 12 2100 nominal ton condenser 2 2300 nominal ton condenser 3 2500 nominal ton condenser 4 1610 nominal ton condenser 5 1760 nominal ton condenser 6 1900 nominal ton condenser 27 B Condenser Tubes I copper 0 028 wall 0 75 O D B I E copper 0 035 wall 0 75 C S B copper 0 028 wall 0 75 O D D S B copper 0 035 wall 0 75 O D E I E copper 0 028 wall 1 0 O D F copper 0 035 wall 1 0 O D I 90 10 CU NI 0 035 wall 0 75 O D 28 0 Not Assigned 29 Condenser Waterboxes 150 psig 1 pass marine B 300 psig 1 pass marine C 150 psig 1 pass non marine D 300 psig 1 pass non marine 30 2 Condenser Waterbox Connection 1 Victaulic 2 Flanged 31 0 2 Not Assigned 32 K Orifice Size LH Circuit 33 J Orifice Size RH Circuit Orifice Nominal Tons A 710 790 880 D 990 1100 1265 140
11. is fast and keeps the chiller online whenever possible Smart sensors collect three rounds of data per second 55 times the data collection speed of its predecessor Each device a sensor has its own microprocessor that simultaneously converts and accurately calibrates its own readings from analog to digital Because all devices are communicating digitally with the DynaView main processor there is no need for the main processor to convert each analog signal one at a time This distributed logic allows the main processor to focus on responding to changing conditions in the load the machine its ancillary equipment or its power supply Tracer CH530 constantly receives information about key data parameters temperatures and CDHF SVU01C EN Unit Control Panel UCP e TRANE current Every five seconds then a multiple objective algorithm compares each parameter to its programmed limit The chiller s Adaptive Control capabilities maintain overall system performance by keeping its peak efficiency Whenever the controller senses a situation that might trigger a protective shutdown it focuses on bringing the critical parameter back into control When the parameter is no longer critical the controller switches its objective back to controlling the chilled water temperature or to another more critical parameter should it exist Variable water flow through the evaporator Chilled water systems that vary water
12. e TRANE How many Degrees of Reset will there be Degrees of Reset Reset Ratio Start Reset TWE TWL Degrees of Reset 5 25 65 45 Degrees of Reset 2 5 If Reset Ratio 70 Start Reset 20 TWE 60 TWL 53 Maximum Reset 14 How many Degrees of Reset will there be Degrees of Reset Reset Ratio Start Reset TWE TWL Degrees of Reset 7 20 60 53 Degrees of Reset 9 1 87 e TRANE Machine Protection and Adaptive Control Figure 35 Return CWR Return CWR Dagresa of Pasa m m tf 15 B 3 Figure 36 Constant CWR Constant CWR 10 Degree Design Delta Temp Degrees of Reset 10 9 8 7 6 5 4 3 2 1 0 TWE TWL 88 CDHF SVU01C EN Unit Start Up Procedures Daily Unit Start Up 1 Verify the chilled water pump and condenser water pump starter are in ON or AUTO 2 Verify the cooling tower is in ON or AUTO 3 Check both oil tank oil level s the level must be visible in or above the lower sight glass Also be sure to check the oil tank temperature normal oil tank temperature before start up is 140 F to 145 F 60 to 63 C 4 Note Each oil heater is energized during the compressor off cycle During unit operation the oil tank heater is de energized 5 Check the chilled water setpoint and readjust it if necessary
13. CDHF2100AA0BC2552613C0B203B0 B20KJAC1GW40C111340A010 Digit Description 1 2 CD CenTraVac Duplex 2 compressors 3 Direct Drive 4 F Development Sequence F 2 Stage G 3 Stage 58 2100 Nominal total compressor tonnage 9 A Unit Voltage A 380V 60Hz 3Ph 440V 60Hz 3Ph 460V 60Hz 3Ph D 480V 60Hz 3Ph E 575V 60Hz 3Ph F 600V 60Hz 3Ph G 2300V 60Hz 3Ph H 2400V 60Hz 3Ph J 3300V 60Hz 3Ph K 4160V 60Hz 3Ph L 6600V 60Hz 3Ph 380V 50Hz 3Ph 400V 50Hz 3Ph 415V 50Hz 3Ph R 3300V 50Hz 3Ph T 6000V 50Hz 3Ph U 6600V 50Hz 3Ph 10 11 AO Design Sequence 12 B Compressor Motor Power LH Circuit 13 C Compressor Motor Power RH Circuit Compressor Motor codes A 588KW 653 KW 745 KW 856 KW 957 KW F 1062 KW 1228 KW 433 KW J 489 KW 548 KW L 621 KW CDHF SVU01C EN General Information e TRANE M 716 KW N 799 KW 892 KW R 403 KW 5 453 KW T 512 KW U 301 KW V 337 KW W 379 KW X 1340 KW 14 16 255 Compressor Impeller Diameter LH Circuit 17 19 261 Compressor Impeller Diameter RH Circuit 20 3 Evaporator Tube Bundle Size 12 2100 nominal ton evaporator 2 2300 nominal ton evaporator 3 2500 nominal ton evaporator 4 1610 nominal ton evaporator 5 1850 nominal ton evaporator 21 Evaporator Tubes copper 0 028 wall 0 75 O D
14. Fused at 3 amps FUS01513 CDHF SVU01C EN Relay 1 J2 1 NO J2 2 NC J2 3 common Relay 2 J2 4 NO J2 5 NC J2 6 common Relay Outputs at 120 VAC 7 2 Amps resistive 2 88 Amps pilot duty 1 3 HP 7 2 FLA at 240 VAC 5 Amps general purpose 14 26 AWG with a maximum of two 14 AWG Power 24 10 percent VDC 60 mA maximum Trane IPC3 protocol J1 1 24VDC J1 2 Ground J1 3 COMM J1 4 COMM Binary Input Signal 1 J2 1 to 2 Binary Input Signal 2 J3 1 to 2 High Voltage Binary Input Off Voltage 0 to 40 VAC RMS On Voltage 70 to 276 VAC RMS Input is not polarity sensitive Hot and neutral can be switched Input impedance 130K to 280K ohms 14 26 AWG with a maximum of two 14 AWG Power 24 10 percent VDC 20 mA maximum Trane IPC3 protocol J1 1 24VDC J1 2 Ground J1 3 COMM J1 4 COMM 1A7 High Power Output Module Relay contacts at 120 VAC 16 amps resistive 6 4 amps pilot duty 1 HP J2 14 26 awg witha maximum of two 14 awg J2 1 J2 2 no J2 3 NC J2 4 com 61 e TRANE 62 Control System Components 1A8 1A9 1A11 1A12 Quad Relay Output Status Relay 1 J2 1 NO J2 2 NC J2 common Relay 2 J2 4 NO J2 5 NC J2 6 common Relay 3 J2 7 NO J2 8 NC J2 9 common Relay 4 J2 10 NO J2 11 NC J2 12 common Relay Outputs at 120 VAC 7 2 Amps resistive 2 88 Amps pilot duty 1 3 HP 7 2 FLA at 240 VAC 5 Amps general purpose 14 26 AWG two 14 AWG Maximum Power 2
15. Operation Maintenance Duplex CDHF CDHG Water Cooled CenTraVac With CH530 X39640670030 CDHF SVU01C EN e TRANE Warnings and Cautions Warnings and Cautions death while cautions are designed to Notice that warnings and cautions alert personnel to conditions that appear at appropriate intervals could result in equipment damage throughout this manual Warnings are provided to alert installing contractors to potential hazards that could result in personal injury or Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions NOTICE Warnings and Cautions appear at appropriate sections throughout this manual Read these carefully A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices CAUTION Indicates a situation that may result in equipment or property damage only accidents 2005 American Standard All rights reserved CDHF SVU01C EN CDHF SVU01C EN Contents Warnings and Cautions General Information Unit Control Panel UCP Operator Interface Chilled Water Setpoint Inter Processor Communication IPC Control System Components Controls Sequence of Operation Machine Protection and Adaptive Cont
16. button on the DynaView display and initiates a chiller shutdown a window will now appear that displays the Unit Stop Information Screen as shown below TechView service tool is utilized to enable this feature Wait trip Pefoswaat o s Previous Screen Will Ertur in ADAPTIVE CONTROL CDHF SVU01C EN e TRANE Operator Interface Figure 22 The machine operating mode indicates the operational status of the chiller A subscreen with additional mode summary information will be provided When the user scrolls down the screen the Machine Operation Mode will remain stationary On DynaView the user will be presented with a single line of text that represents the top level operating state of the machine These top level modes are shown in the table below Additional information if it exists regarding the machine operating state will be available to the user by selecting the additional information button double right arrow next to the top level operating mode These sub level modes are shown in the table at left The TOP LEVEL is the text seen on the single top level chiller system operating mode line The SUB LEVEL MODE is the text seen on the operating mode sub menu The operating mode sub menu may have up to six 6 lines of text displayed The BAS CODE is the code that will be sent via COMMA to the Tracer Summit system as the chiller syste
17. 1 Chilled water reset with outdoor air temperature sensor S Special 43 1 Control Operating Status 0 None 1 Operating Status 44 1 2 Gas Powered Chiller 0 No 1 Yes 45 3 Compressor Motor Frame Size LH Circuit 46 4 Compressor Motor Frame Size RH Circuit FRAME SIZE CODES 3 440E 4 5000 5 5800 6 5800L S Special 47 0 Unit Insulation 0 None 1 Insulation package 48 A Spring Isolators 0 No A Yes 49 0 Not Assigned 0 Not assigned 50 1 Evaporator amp Condenser Size 1 2 2100 2100 2 250D 2500 3 250X 2500 4 250M 2500 51 0 Special Options 0 None S Special Option CDHF SVU01C EN Commonly Used Acronyms For convenience a number of acronyms are used throughout this manual These acronyms are listed alphabetically below along with the translation of each AFD Adaptive Frequency Drive ASME American Society of Mechanical Engineers ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers BAS Building Automation System CABS Auxiliary Condenser Tube Bundle S CDBS Condenser Bundle Size CDSZ Condenser Shell Size CH530 Tracer CH530 Controller DV DynaView Clear Language Display also know as the Main Processor MP CWR Chilled Water Reset CWR Chilled Water Reset Prime DTFL Design Delta T at Full Load i e the difference between entering and leaving chilled w
18. 4 Chiller Running Indicator J2 10 NO J2 11 NC Output Status J2 12 common 1 9 Optional Quad Relay OPST Relay 1 Chiller Maximum Capacity J2 1 NO J2 2 NC Output Status J2 3 common 1 9 Optional Quad Relay OPST Relay 2 Chiller Head J2 4 NO J2 5 NC Output Status Relief Request J2 6 common 1 9 Optional Quad Relay OPST Relay 3 Circuit 2 J2 4 NO J2 5 NC Output Status Purge Alarm to J2 6 common 1 9 Optional Quad Relay OPST Relay 4 Circuit 1 J2 1 NO J2 2 NC Output Status Purge Alarm to J2 3 common Head Relief Request Output When the chiller is running in Condenser Limit Mode or in Surge Mode the head relief request relay on the 1A9 J2 6 to J2 4 will be energized 1 minute default and can be used to control or signal for a reduction in the entering condenser water temperature Designed to prevent high refrigerant pressure trip outs during critical periods of chiller operation If the unit is not equipped with the CDPR Enhanced Condenser Limit Option the unit will use the condenser refrigerant temperature sensor input converted to saturated refrigerant pressure to perform the Standard Condenser Limit function CDHF SVU01C EN without the head relief request relay by limiting inlet guide vane stroke and chiller capacity Keep in mind that Condenser Limit Control supplements the protection provided by the condenser pressure high pressure cutout switch 3S1 Motor Temperature sensor module The motor temperature module 1A
19. a net oil pressure of 18 to 22 psid It is then filtered and sent to the oil cooler located in the economizer and on to the bearings From the bearings the oil drains back to the manifold under the motor and then on to the oil tank WARNING Surface Temperatures MAY EXCEED 150 Use caution while working on certain areas of the unit failure to do so may result in death or personal injury 22 General Information To ensure proper lubrication and prevent refrigerant from condensing in the oil tank a 750 watt heater is immersed in the oil tank and is used to warm the oil while the unit is off When the unit starts the oil heater is de energized This heater energizes as needed to maintain 140 to 145 F 60 63 C when the chiller is not running When the chiller is operating the temperature of the oil tank is typically 115 to 160 F 46 72 C The oil return lines from the thrust and journal bearings transport oil and some seal leakage refrigerant The oil return lines are routed into a manifold under the motor Gas flow exits the top of the manifold and is vented to the Evaporator Note A vent line solenoid is not needed with the refrigerant pump Oil exits the bottom of the manifold and returns to the tank Separation of the seal leakage gas in the manifold keeps this gas out of the tank A dual eductor system is used to reclaim oil from the suction cover and the evaporator and deposit it back
20. bearing problems or replacement later Once every six months the chiller oil pump must be started and the compressor motor bump started to rotate the shaft Contact a qualified service organization to perform this task If the compressor motor cannot be bump started then the shaft must be rotated manually by a qualified service organization 11 Obtain an oil analysis initially after six months of storage and once each succeeding year If no oil breakdown is evident do not change the oil If breakdown is evident the oil must be replaced 12 If the unit is stored for more than five years and the storage is expected to be indefinite the unit should be examined for leaks every five years from the initial storage date 13 When the unit is to be returned to service the services of a qualified service organization should be obtained to conduct all activities associated with the startup of a new chiller 103 e TRANE CenTraVac Annual Inspection Check List and Report Compressor Motor Motor Continuity check Good Open Check and tighten motor terminals Meg Motor Phase 1 Phase 2 Phase 3 Check nameplate rating Amps Starter Check condition of starter contacts Good Fair Replace Check tighten if necessary all connections per manufactures specs Oil Sump Change oil If oil analysis refer to progr
21. flow through chiller evaporators have caught the attention of engineers contractors building owners and operators Varying the water flow reduces the energy consumed by pumps while requiring no extra energy for the chiller This strategy can be a significant source of energy savings depending on the application With its faster and more intelligent response to changing conditions Tracer CH530 water flow sensing option accommodates variable evaporator water flow and its effect on the chilled water temperature These improvements keep chilled water flowing at a temperature closer to its setpoint User defined language support DynaView is capable of displaying English text or one of the two alternate languages that are stored in DynaView at one time Switching languages is simply accomplished from a settings menu Similarly TechView accommodates a primary and a secondary language from the same list of available languages 29 e TRANE Figure 21 Dyna View main processor The DynaView DV Operator Interface contains the Main Processor MP and is mounted on the unit control panel front door where it communicates commands to other modules collecting data status and diagnostic information from the other modules over the IPC Inter Processor Communications link The Main Processor MP software controls water flows by starting pumps and sensing flow inputs establishes a need to heat or cool pe
22. setpoint listing Upon selecting a Settings list i e Chiller Circuit 1 Purge System Mode Override etc a listing of all setpoints available to change along with their current value will appear The operator selects a setpoint to change by touching either the verbal description or setpoint value Doing this causes the screen to switch to either the Analog Settings Subscreen or the Enumerated Settings Subscreen Header Screen To aid in comparing circuit level setpoints the heading on the Settings list have buttons as indicated in the table above i e Ckt1 and Ckt2 The selected button is darkened presented in reverse video to indicate it is the selected choice CDHF SVU01C EN Operator Interface Settings screen for standard CTV Main Settings 1 Chiller bb 2 Feature Settings bb 3 Mode Overrides bb 4 Purge bb 5 Display Settings b gt Q Auto Stop Setpoint Menu standard CTV lt Back y v Auto Stop Settings Screen A e TRANE e TRANE Operator Interface Chiller Description Resolution or Enumerations Default Units 1 Front Panel Control Type Chilled Water Hot Water Chilled Water Enum 2 Front Panel Chilled Water Setpt 3 or Temperature 3 Front Panel Hot Water Setpt 3
23. takes for the chiller to reach full load Some process applications need the chiller to start and generate capacity as fast as possible This method will start both compressors slightly staggered to prevent doubling of the current inrush but will generally control the chiller as if there were only one compressor If the chiller is in the Auto mode and all interlocks have been satisfied compressor 1 will be started based on the leaving water temperature rising above the Differential to Start setting When compressor 1 is at speed compressor 2 will start Both compressors will run until water temperature falls below the differential to stop at that time both compressors will be shut down Figure 15 CDHF G sequence of operation combined start Eve WT fada Cs Pye ital Deeg AT Acum Aerar i V Bia Coan Cones Sarl Pus ierra Praet Conger CDHF SVU01C EN CDHF SVU01C EN General Information e TRANE Compressor Load Balancing Duplex chillers with CH530 control will balance the compressor load by giving each compressor the same load command The load command will be converted to IGV position that will be the same on each compressor Balancing compressor load results in the best overall efficiency and with both circuits operating with nearly the same refrigerant pressures When both compressors are running the overall chiller load command will be split evenly betw
24. the completed logs can be reviewed to identify any developing trends in the chiller s operating conditions For example if the machine operator notices a gradual increase in condensing pressure during a month s time he can systematically check then correct the possible cause s of this condition fouled condenser tubes noncondensable in the system etcetera Daily Maintenance and Checks Check the chiller s evaporator and condenser pressures oil tank pressure differential oil pressure and discharge oil pressure Compare the readings with the values provided in the Normal Chiller Operating Characteristics table IMPORTANT IT IS HIGHLY RECOMMENDED THAT THE OPERATING LOG BE COMPLETED ON A DAILY BASIS CAUTION Moisture Contamination IF FREQUENT PURGING IS REQUIRED MONITOR PURGE PUMPOUT RATE IDENTIFY AND CORRECT SOURCE OF AIR OR WATER LEAK AS SOON AS POSSIBLE Failure to do so can shorten chiller life expectancy due to moisture contamination caused by leakage 1 Check the oil level in the chiller oil sump using the two sight glasses provided in the oil sump head When the unit is operating the oil level should be visible in the lower sight glass CDHF SVU01C EN Periodic Maintenance e TRANE AN WARNING Hazardous Voltage w Capacitors Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power cannot be inad
25. 2 0 VDC Figure 25 Condenser pressure based output 10 vde T 2vdc 0 PSIA 0 Percent PSIG HPC inPSIA 100 Percent Value is equal to the High Pressure Cutout Setting CDHF SVU01C EN B Refrigerant Differential Pressure Indication Output A 2to 10 VDC analog output is provided instead of the previous condenser pressure output signal This signal corresponds to a predetermined minimum and maximum pressure settings setup at commissioning of this feature This relationship can be altered using the service tool if required Control System Components e TRANE The Minimum Delta Pressure is typically set to 0 psi and will then correspond to 2 vdc The Maximum Delta Pressure is typically set to 30 psi and corresponds to 10 vdc The Minimum Delta Pressure Calibration setting has a range of 0 400 psid 0 2758 kPa in increments of 1 psid 1kPa The Maximum Delta Pressure Calibration setting has a range of 1 400 psid 7 2758 kPa in Figure 26 Delta pressure setting differential pressure based output Defaults shown 10 vdc 2 vdc Min Delta Pressure Setting Default O psi Delta Pressure Settin Default 30 psi Note In this example 2 vdc corresponds to OPSI differential and 10 vdc corresponds to 30 psi differential The minimum value of 0 psi and maximum value of 30 psi are individually adjustable via the service tool CDHF SVU01C
26. 414 12 6 Note the above table is for copper conductors only Analog Input The analog input can be software switched between a voltage input or a current input When used as a current input a 200 Ohm load resistor is switched in 2 10 Vdc or 4 24 mA Analog Inputs UCP accepts either a 2 10 Vdc or 4 20 analog input suitable for customer external control The type is determined at unit commissioning during feature installation J2 14 26 AWG with a maximum of two 14 AWG J2 2 Input 1 to J2 3 Ground J2 5 Input 2 to J2 6 Ground Power 24 10 percent VDC 60 mA maximum Trane IPC3 protocol 63 e TRANE Unit mounted devices Vane Actuator Control The Stepper Module within the stepper vane actuator 4M2 and 4M4 extended capacity pulses a DC voltage to the windings of the Stepper Motor Actuator s to control inlet guide vane position While operation of this stepper motor is automatic manual control is possible by going to the Mode Overrides settings menu within the DynaView Compressor Control Signal allow the operator to manually increase or decrease the compressor load by adjusting the compressor control signal Note If the chiller is operating in a limit mode current limit condenser limit evaporator limit etcetera The limit operation has priority over all DynaView manual modes of operation On each UCP power up the inlet guide vanes are driven full closed to recalibrate the
27. CH530 Controller TECHVIEW SETTINGS RECORDS comgendonves cmt ____ View Setting Configuartion View Setting a3 jComm4Trmeerlterae 1 UntType Comm Tracer Interface CH3530 Tab 13 3 33 lCSAddresComnd 2 Control Sequenc 38 KSAMmsComns 3 Unit Capacit 37 Purge Control A Starter Type 3R Compressor Power Source Line Voltage Sensin Max Delta Rigi Press 3 bap Delay Time Contractor Interupt Failure ECLSMaximum 1 150 CTMeerscale 18 keBulding 3h amp 51 jCumentUnbalame Trip Point raure 52 Current Unbalance Grace Period 3 Maximam Acceleration Setting I di _ Second Condenser Voliam s i Cal ECWS Maximum Temperature ee ee EP i Enhanced Oil Temp Pro 28 High Pressure Cutout O O 29 Impeller Diameter 6 Surge Se 30 GV Actuators Power Loss Reset Timed Rela x irem 71 T Relays 114 CDHF SVU01C EN e TRANE STARTUP Chiller Report Water Cooled CenTraVac With CH530 Controller seromrviWw cuer 0 0 0 0 0 0 0 Front Panel Chilled WaerSepoi T01_ Check OW Fitter 65 Front Panel Lint 10 Cheek Oa Filer Sepo J ig Mode 03 Restart Inhibit FreeSans 0
28. Chiller Report Water Cooled CenTraVac With CH530 Controller TU EvapPD _ Cond PD Secondary f present Secondary if present leslie AMSamp PSIG Leak Test Vacuum lisi NEN Ss alter Unit Reperat Chage E n Unit Refrigerant Re High Pressure 112 CDHF SVU01C EN CDHF SVU01C EN S rane STARTUP Chiller Report Water Cooled CenTraVac With CH530 Controller Dyna View LII Entering Leaving Saad Flow Sw status 0 Flow Sw status Re m Ao Condenser 0 O Entering 0 0 0 0 Saturated _Refrig Press Approach Compressor 0 000000 o Stans OOO O Running Time CHI Tank Press Dichg Press ws Cil Tank Tem Position _ REA LI L2 L3 Volis AB BC Load i u Chil V Winding temp O O O 3 Winding 2temp O O O O Winding amp 31emp 5 bor Press WIAFD onl Freg 5 8 O AFDSped Pore Enteri Time Unril ze Run i PA _ parts oat N Dally Pumpoui 24 hrs Daily P Av 0 7 Daily Limit Alarm Chiller CHT 7 da Purngusat Li E E 8 BA 8 113 e TRANE STARTUP Chiller Report Water Cooled CenTraVac With
29. EN Electrical Sequence This section will acquaint the operator with the control logic governing CDHF CDHG chillers equipped with Tracer CH530 UCP based control systems When reviewing the step by step electrical sequences of operation refer to the typical wiring schematics for Unit mounted Wye Delta starter shown in the installation manual shipped with the chiller Note The typical wiring diagrams are representative of standard units and are provided only for general reference They may not reflect the actual wiring of your unit For specific electrical schematic and connection information always refer to the wiring diagrams that shipped with the chiller With the supply power disconnect switch or circuit breaker 201 or 2K3 closed 115 volt control power transformer 2T5 and a 40 amp starter panel fuse 2F4 to terminal 2X1 1 starter panel to terminal 1X1 1 in the control panel From this point control voltage flows to CDHF SVU01C EN Control Sequence of Operation e TRANE 1 Circuit Breaker 101 which provides power to the starter module 2A1 relay outputs and the High Pressure Cutout switch 3S1 2 Circuit Breaker 102 which provides power to the Purge circuitry 3 Circuit Breaker 103 which provides power to Transformer 1T1 which steps down the 115 Vac to 24 Vac This 24 Vac then powers the 24 Vdc power supply 1A1 and 1A2 if present The 24 vdc is then connected to all modules via the Interpr
30. Er ont Pane Hot Weer Scpobt f Restart bt Stat Sen 68 From Panel Base Loading Command _ 105_ Restart Inhibit Diagnostic _ 9 Front Panel Base Load Setpoim 16 F Time Permined ar Minis 770 _ Front Panel Free Cooling Command 107 H E LI Front Panel Ice Building Command mrIMsme et ae Teton Set FIO High Discharg i2 16 Source 113 Start Sequence Type L7 PowetpSatDeay Evaporator Pump Off Dek r cm Evaporator Desi n Delta Temp Evaporator qm Water Temp Cutout _ ee or eee 83 Inlet Guide Vane Max Steps First Stage 18 Return Max Reset us Guide Vane Max Steps Second 119 Outdoor Reset Ration ru Tie Rates Tent E B6 Condenser Limit Setpoim 12 Outdoor Max Reset 87 Evaporator Water Flow 1722 External Current Limit Setpoint Enable _ 88 Evaporator Pressure Drop 123 lce Building Feature Enable 89 Evaporator WaterFlow2 124 How Gas Bypass Feature 2 a rs Hot Gas Bypass Maximum Timer Enable a Evaporator Low Water Flow Warning us us Hot Gas mm Valve Travel Time Setpoint 94 Condenser Water Flow 1 128 perl Base Loading Enable 93_ Condenser Pressure Drop Ma Tine Sr Comi ___ c disabled Low Differential Oil Pressure bei Cutout
31. HGBP Hot Gas Bypass and EPRO Enhanced Protection Figure 24 illustrates the Control Panel Components Layout LLID Modules 1A1 143 1 4 1A5 146 1A7 and 1A13 are standard and present in all configurations Other Modules vary depending on machine optional devices 51 Control System Components e TRANE CDHF SVU01C EN ZO LE Z 9108 6089 1 vs I3Nvd QBVONVIS NO o 009118 WOSN3S 38niss3uid YILYM 441A Za C 5 dois ISN YOOGLNO nm siii Adi ois ain EINE o ers a o WWOD 38IM Z 68M o WNolLdo IWNOLLdO vivL lo o D ol o m ais o peii NOLO 1 o SLVL o lo Nodo WNOLLdO lo a 9171 LINGNOD W31SAS NOILYDIYANT Hi
32. Ratio Start Reset TOD Degrees of Reset 35 80 65 Degrees of Reset 5 25 Figure 32 Outdoor air temperature versus degrees of reset Reset Ratio 10 30 50 4 12 0 20 3 6 108 18 If Reset Ratio 70 percent Start Reset 90 TOD 100 Maximum Reset 17 How many Degrees of Reset will there be Degrees of Reset Reset Ratio Start Reset TOD Degrees of Reset 7 90 100 Degrees of Reset 7 multiply Outdoor Air Temp vs Degrees of Reset 3 2 9 6 16 28 84 14 o 24 72 12 oc 2 0 60 10 o 16 48 8 12 36 6 a 8 24 4 4 1 2 2 0 0 0 CDHF SVU01C EN 87 100 Degree Start Reset 80 5 74 67 5 61 54 5 48 41 5 OutdoorAir Temp F 85 e TRANE Machine Protection and Adaptive Control Figure 33 Reset function for return CWR Degrees of Reset vs Outdoor Air Temp 7 Wegte Reset Ratio MR Maximum Reset SR Start Reset RR Reset Ratio Figure 34 Reset function for return CWR Reset Ratio Wi deg Suri Feel 30 50 70 6 10 14 12 6 11 2 EE 84 42 28 1 4 Note This graph assumes Maximum Reset is set to 20 degrees 86 CDHF SVUO1C EN Example of Calculating Return Reset If Reset Ratio 50 Start Reset 25 TWE 65 TWL 45 Maximum Reset 8 CDHF SVU01C EN Machine Protection and Adaptive Control
33. Setpoint ECWS The External Chilled Water Setpoint allows the chilled water setpoint to be changed from a remote location The External Chilled Water Setpoint is found on 1A16 J2 5 to J2 6 Ground 2 10 vde and 4 20 ma corresponds to a default 34 F to 65 F 17 8 to 18 3 C adjustable via service tool WPSR WFC Water Pressure Sensing Option External Current Limit Setpoint The External Current Limit is an option that allows the current limit setpoint to be changed from a remote location The External Limit Setpoint is found on 1A16 J2 2 to J2 3 ground 2 10 vdc and 4 20 ma each correspond to a 40 to 100 percent RLA range UCP limits the maximum ECLS to 100 percent Default 40 to 10096 adjustable via service tool 1A21 Optional Dual Analog Input or output Module 1A21 Optional Dual Analog Input or output WPSR WFC Signal 1 WPSR WFC Signal 2 Evaporator Differential Water Pressure Condenser Differential Water Pressure Not for field use Not for field use Module Module Characteristics 1A3 1A5 1A10 Dual Relay Output 1A4 1A6 Dual High Voltage Binary 1A1 1A2 Power Supply modules input module Unit Control Power Supply Module Converts 27 vac to 24 vde Power Input Voltage 23VRMS minimum 27VRMS Nominal 30VRMS maximum Frequency 50 60 Hz Current Full load 27 VAC 4 30 A RMS Inrush 27 VAC RMS 30A RMS Power Output Class II Voltage 24 VDC Rated Current 2 44 Amps
34. TRANE The following equations and parameters apply for CWR Return Water CWS CWS RATIO START RESET TWE TWL and CWS gt or CWS and CWS CWS lt or Maximum Reset Outdoor Air Temperature CWS CWS RATIO START RESET TOD and CWS gt or CWS and CWS CWS lt or Maximum Reset Where CWS is the new chilled water setpoint CWS is the active chilled water setpoint before any reset has occurred RESET RATIO is a user adjustable gain START RESET is a user adjustable reference TOD is the Temperature Outdoor Sensor TWE is entering evaporator water temperature TWL is the Leaving Evaporator Temperature MAXIMUM RESET is a user adjustable limit providing the maximum amount of reset For all types of reset CWS CWS lt or Maximum Reset Both Return and Outdoor Reset do not apply to Heating Mode where the UCP is controlling the Leaving Condensing Hot Water Temperature Constant Return Reset will reset the leaving water temperature setpoint so as to provide a constant entering water temperature The Constant Return Reset equation is the same as the Return Reset equation except on selection of Constant Return Reset the UCP shall automatically set RATIO START RESET and MAXIMUM RESET to the following The RATIO 100 percent The START RESET Design Delta Temperature The MAXIMUM RESET Design Delta Temperature The equation for Constant Return is as foll
35. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water or saline or brackish water See Figure 38 which shows a Typical Chemical Cleaning Setup Figure 38 Typical chemical cleaning setup CDHF SVU01C EN Condenser tube fouling is indicated when the approach temperature the difference between the condensing refrigerant temperature and the leaving condenser water temperature is higher than predicted If the annual condenser tube inspection indicates that the tubes are fouled two cleaning methods mechanical and chemical can be used to rid the tubes of contaminants Use the mechanical cleaning method to remove sludge and loose material from smooth bore tubes To clean other types of tubes including internally enhanced types consult a qualified service organization for recommendations 1 Remove the retaining nuts and bolts from the water box covers at each end of the condenser Use a hoist to lift the covers off the water box A threaded connection is provided on each water box cover to allow insertion of an eyebolt 2 Work a round nylon or brass bristled brush attached to a rod in and out of each of the condenser water tubes to loosen the sludge 3 Thoroughly flush the condenser water tubes with clean water Scale deposits are best removed by chemical means Be sure to consult any qualified chemical house in the area one familiar with the loc
36. allowed one start every 20 minutes The start to start time is the time from when the motor was commanded to energize to when the next command to enter prestart is given Clear Restart Inhibit A Clear Restart Inhibit button is provided within Settings Manual Override on the DynaView display This provides a way for an operator to allow a compressor start when there is a currently active Restart Inhibit that is prohibiting such a start The button press will have no other function than to remove the restart inhibit if there is one active It does not change the count of any internal restart inhibit timers or accumulators The restart inhibit function setpoints and clear features exist for each compressor and operate independently of other compressors on that chiller During the time the start is inhibited due to the start to start timer the DynaView shall display the mode Restart Inhibit and the also display the time remaining in the restart inhibit A Restart Inhibit Invoked warning diagnostic will exist when the attempted restart of a compressor is inhibited 21 e TRANE Oil and Refrigerant Pump Compressor Lubrication System A schematic diagram of the compressor lubrication system is illustrated in Figure 16 This can be applied to circuit 1 or 2 Oil is pumped from the oil tank by a pump and motor located within the tank through an oil pressure regulating valve designed to maintain
37. and functional IDs to a LLID Binding is a simple process 1 Service selecting the LLID with a magnet 2 Assigning functional IDs to that LLID with TechView Functional Identification When each LLID on the bus is bound its inputs and outputs are givena functional ID The Frame LLIDS have only one functional ID but most Panel LLIDs have more than one functional ID A dual high voltage binary input will have two functional IDs a quad relay output has four functional IDs The DynaView Main Processor with its IPC3 Bus communicates to the control panel devices unit mounted devices and any remote devices on the IPC3 bus network The various devices are discussed in the upcoming sections Control Panel Internally mounted devices For visual identification Internal Control Panel mounted devices are identified by their respective schematic designation number Control panel items are marked on the inner back panel in the control panel Figure 24 illustrated below identifies these devices The Control Panel Devices table corresponds to the same device designators see right hand column Optional controls are present when a specific optional controls package is specified as listed in the second column Optional controls packages are OPST Operating Status GBAS Generic Building Systems EXOP Extended operation CDRP Condenser Pressure TRMM Tracer communications WPSR Water Flow Pressure sensing FRCL Free Cooling
38. degree F or C The Main Processor provides the minimum and maximum allowable value 2 Adjustable to the nearest whole number percent The Main Processor provides the minimum and maximum allowable value 3 Terminates with 10 minutes if inactivity 4 The Date and Time setup screen formats deviate slightly from the standard screens defined above See the time and date section for further details 5 Enables a DynaView Lockout screen All other screens timeout in 30 minutes to this screen when enabled The DynaView Lockout Screen displays a 0 9 keypad to permit the user to exit the lockout with a fixed password 1 5 9 Enter See lockout setion for further details 6 Language choices are dependent on what has been setup in the Main Processor Language selections will include English and qty 2 alternate as loaded by TechView Language shall always be the last setting listed on the Display Settings menu This will allow a user to find language selection if looking at an unrecognizable language 7 Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation This is not active during Stop mode CDHF SVU01C EN 45 e TRANE 46 Operator Interface Each Settings Sub screen consists of a setpoints list and the current value The operator selects a setpoint to change by touching either the description or setpoint value Doing this causes the screen to switch to the A
39. limit routine may limit the loading when the current is below setpoint When the current is within the deadband of the setpoint the current limit algorithm holds against this loading command 24 General Information If the current exceeds the setpoint the current limit algorithm unloads The Capacity Limited By High Current message normally displayed while the current limit routine is active is suppressed while base loading Base loading can occur via Tracer External signal or front panel Tracer Base Loading Current Setpoint Range 20 100 percent RLA Requires Tracer and Optional Tracer Communications Module LLID The Tracer commands the chiller to enter the base load mode by sending the base load mode request If the chiller is not running it will start regardless of the differential to start either chilled water or hot water If the chiller is already running it will continue to run regardless of the differential to stop either chilled water or hot water using the base load control algorithm While the unit is running in base loading it will report that status back to the Tracer by setting Base Load Status true in the Tracer Status Byte When the Tracer removes the base load mode request sets the bit to 0 The unit will continue to run using the normal chilled or hot water control algorithm and will turn off only when the differential to stop has been satisfied External Bas
40. need to pass all gaseous refrigerant through three stages of compression See Figure 3 Notice that some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice plates thus further cooling the liquid refrigerant This flash gas is then drawn directly from the first Chamber A and second Chamber B stages of the economizer into the third and second stage impellers of the compressor respectively All remaining liquid refrigerant flows through another orifice plate C to the evaporator Compressor 1 or 2 2 Stage Compressed gas from the first stage impeller is discharged through the second stage variable guide vanes and into the second stage impeller Here the refrigerant gas is again compressed and then discharged into the condenser Baffles within the condenser shell distribute the compressed refrigerant gas evenly across the condenser tube bundle Cooling tower water circulated through the condenser tubes absorbs heat from the refrigerant causing it to condense The liquid refrigerant then flows out of the bottom of the condenser passing through an orifice plate and into the economizer The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant through both stages of compression See Figure 6 Notice that some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice pla
41. not for field use Purge System Branch Circuit 103 Standard Circuit Breaker not for field use Module LLID Power Supply Branch Circuit 104 Standard Circuit Breaker not for field use Oil System Control Branch Circuit 105 Standard Oil Pump Motor Branch not for field use Circuit protection 1X1 Terminal Block Standard Control Panel Terminal Block 1X1 5 Chilled water flow Flow switch connections flow switch input 1X1 6 Condenser water flow switch input 54 CDHF SVU01C EN Chilled and Condenser Water Flow Interlock Circuits Proof of chilled water flow for the evaporator is made by the closure of flow switch 5S1 and the closure of OPST Operation Status Option Control System Components e TRANE auxiliary contacts 5K1 on terminals 1X1 5 and 1A6 J3 2 Proof of condenser water flow for the condenser is made by the closure of flow switch 5S2 and the closure of auxiliary contacts 5K2 on terminals 1X1 6 and 1A6 J2 2 Relay output modules 1A8 and 1A9 provide relay defaults shown For other selections see Installation Manual 1A8 Optional Quad Relay OPST Relay 1 Chiller Non Latching Alarm J2 1 NO J2 2 NC Output Status J2 3 common 1A8 Optional Quad Relay OPST Relay 2 Chiller Limit J2 4 NO J2 5 NC Output Status Mode Indicator J2 6 common 1A8 Optional Quad Relay OPST Relay 3 Chiller Latching J2 7 NO J2 8 NC Output Status Alarm Indicator J2 9 common 1A8 Optional Quad Relay OPST Relay
42. of the chiller because it has the advantage of leaving the chilled water temperature control logic in effect The chilled water temperature control logic responds quicker to dramatic system changes and can limit the chiller loading prior to reaching an Adaptive Control limit point CDHF SVU01C EN e TRANE General Information Figure 17 Base loading with external mA input and with external voltage input Bana Loading alih Eararnal AA legs i E a 5 a a bo CDHF SVU01C EN 25 e TRANE Ice Machine Control UCP provides a service level Enable or Disable menu entry for the Ice Building feature when the Ice Building option is installed Ice Building can be entered from Front Panel or if hardware is specified the UCP will accept either an isolated contact closure 1A19 Terminals J2 1 and J2 2 Ground or a remote communicated input Tracer to initiate the ice building mode where the unit runs fully loaded at all times Ice building will be terminated either by opening the contact or based on entering evaporator fluid temperature UCP will not permit the Ice Building mode to be entered again until the unit is switched to the Non ice building mode and back into the ice building mode It is not acceptable to reset the chilled water setpoint low to achieve a fully loaded compressor When entering ice building the compressor will be loaded at its maximum rate and when leaving ice buildin
43. on the 5 read out is outside this 4 degree tolerance range replace the sensor Note If the sensor is exposed to temperature extremes outside its normal operating range 0 F to 90 F 18 C to 32 C check its accuracy at six month intervals CDHF SVU01C EN Compressor Oil Change It is recommended to change the oil and oil filter After the first 1000 hours of chiller operation For a chiller operated continuously this oil and oil filter change may be performed as soon as 1 5 months after first start up for a chiller operated intermittently it may be 4 or 6 months after first start up Again at the first scheduled annual mainenance preferably within 6 to 12 months of the first oil change Note Use only Trane OILOO022 A full oil change is 9 gallons of OILOO022 Beyond the first year recommendations are to subscribe to an annual oil analysis program rather than automatically change the oil as part of scheduled maintenance Change the oil only if indicated by the oil analysis Use of an oil analysis program will reduce the chillers overall lifetime waste oil CDHF SVU01C EN Oil Maintenance e TRANE generation and minimize refrigerant emissions The oil analysis should be performed by a qualified laboratory that is experienced in refrigerant and oil chemistry and in the servicing of Trane centrifugal chillers In conjunction with other diagnostics performed by a qualified service technic
44. opening the system See unit nameplate for refrigerant type Do not use non approved refrigerants refrigerant substitutes or refrigerant additives Failure to follow proper procedures or the use of non approved refrigerants refrigerant substitutes or refrigerant additives could result in death or serious injury or equipment damage 2 After the liquid refrigerant is removed using a recovery or recycle unit or vacuum pump pull a vacuum to remove remaining refrigerant vapor from the unit 3 After all traces of refrigerant are out of the unit a positive nitrogen charge should be put into the unit 6 to 8 psig This positive pressure must be checked monthly to insure no noncondensables get into the unit Use a pressure gage on the evaporator shell to verify that the 6 to 8 psig dry nitrogen holding charge is still in the chiller If this charge has escaped contact a qualified service organization and the Trane sales engineer that handled the order 4 The refrigerant charge should be stored in proper refrigerant containers Due to possible leakage do not store in used drums 5 Maintain control power to the control panel This will maintain oil temperature in the oil sump and the capability of the control panel to present report information The Chiller Reports should be viewed once a week for normal readings Any abnormal observation must be reported to the Trane Sales Engineer that handled the order CDHF SVU0
45. percent The filtering time is default set to 10 minutes 0 120 minutes however these can be altered via the service tool This filtered setpoint allows for stable control if the Current Limit setpoint is adjusted during a run The Current Limit Setpoint CLS can be changed from Front Panel External Analog input with GBAS external option or Tracer Tracer option However If present Tracer current setpoint has the highest priority unless disabled in the DynaView Setpoint source override menu The External CLS has second priority and will be used if Tracer is disabled or not installed The Front Panel Setpoint has the lowest priority and will be used if Tracer and the External CLS are both disabled Phase Loss Protection Loss of phase detection protects the chiller motor from damage due to a single phasing condition The controls will shut down the chiller if any of the three phase currents feeding the motor are lost The shutdown will result in a latching diagnostic indicating the failure The motor is protected from over current during a single phase condition by the Current Overload Protection feature Phase Loss Protection provides redundant protection and a diagnostic that more accurately describes the fault Reverse Rotation Protection This function protects the compressor from being driven in the reverse direction Incorrect phase rotation detection results in a manually resettable diagnostic Phase R
46. setpoints in the Main menu 39 e TRANE 40 Operator Interface Reports L Main Reports Settings Evaporator Condenser Compressor Motor Purge Ashrae Guideline Log Syyyy O Auto Stop To aid in comparing the status of both circuits the heading on the Reports list screen has buttons as indicated in the table above i e System Ckt1 and Ckt2 The selected button is darkened presented in reverse video or some how changed to indicate it is the selected choice When a report screen is selected the appropriate circuit is displayed in the screen heading as shown in the sample evaporator screen below Back Evap Sat Rfgt Temp 403 F Evap Rfgt Pressure 9 7 psia Evap Approach 66 F e Auto Stop e Report Menu Description Heading Buttons 1 Evaporator System Ckt 1 Ckt 2 2 Condenser System Ckt 1 Ckt 2 3 Compressor Ckt 1 Ckt 2 4 Motor Ckt 1 Ckt 2 5 Purge Ckt 1 Ckt 2 6 ASHRAE Chiller Log System Ckt 1 Ckt 2 CDHF SVU01C EN e TRANE Operator Interface Report name System Evaporator Description Resolution Units Dependencies 1 Evap Entering Water Temp or XXX X Temperature 2 Evap Leaving Water Temp or XXX X Temperature 3 Evap Water Flow Switch Status Flow No Flow 4 E
47. the refrigerant Maximum Acceleration Timer Setting by Starter Type Wye Delta 27 Seconds Auto Transformer 16 Primary Reactor 16 Across the Line 6 Solid State 15 AFD 30 pump starter relay 4K8 to the start windings of the refrigerant pump When motor 4 first starts current draw is high This causes current sensing relay 4K8 to close its normally open contacts and pull in of pump Capacitor 4C1 Increasing motor speed and related decreasing current through the main winding and relay coil reduce the magnetic force and the armature Drops out to open the start contacts and disconnect the start windings and capacitor Current now flows only to the Run windings of the oil pump motor or refrigerant and oil pump motor 71 e TRANE Momentary Power Loss MPL Protection Improved power measurement and protection algorithms allow the unit to accommodate more power anomalies than ever If the chiller must shut down faster restarts get the machine up and running as soon as possible Momentary power loss MPL detects the existence of a power loss to the compressor motor and responds by initiating the disconnection of the compressor motor from the power source Power interruptions of less than 30 line cycles are defined as momentary power losses Tests have shown that these short term power Machine Protection and Adaptive Control interruptions can be damaging to the motor and compres
48. then use the up or down arrows to adjust Adjusting hours will also adjust am and pm 4 Back Press Enter To Save Change Press Cancel To Ignore Change Time hh mm am pm Hour Minute Enter Cancel A Press Arrows to Change O Auto Sto Note The 24 hour format setpoint screen is similar with the am and pm not shown 49 e TRANE 50 Operator Interface The DynaView Display Touch Screen Lock screen is shown below This screen is used if the Display and Touch Screen Lock feature is Enabled 30 minutes after the last key stroke this screen will be displayed and the Display and Touch Screen will be locked out until 159enter is entered Until the proper password is entered there will be no access to the DynaView screens including all reports all setpoints and Auto and Stop and Alarms and Interlocks The password 159 is not programmable from either DynaView or TechView DISPLAY AND TOUCH SCREEN ARE LOCKED ENTER PASSWORD TO UNLOCK 1 2 3 3 5 6 7 8 9 Enter Co Cancel If the Display and Touch Screen Lock feature is Disabled the following screen will be automatically shown if the MP temperature is below 32 F 0 C and it has been 30 minutes after the last key stroke Note the main processor is equipped with an on board temperature sensor which enables the ice protection
49. timed out after compressor shut down If the Immediate Stop is initiated a panic stop occurs which follows the same stop sequence as pressing the STOP key once except the inlet guide vanes are not sequence closed and the compressor motor is immediately turned off 69 e TRANE Control Sequence of Operation Figure 24 Test and start timing sequence Closed Start G Open Closed E Stop Open 1 t1 Open Closed Open Short gt E K EMEN K F Transition Closed Open Closed Transition Don t Care Complete Open gt B Input A lt gt H gt LK Timing requirements to operate the Stop Start Short YV Transition and Run contact closure outputs are shown below Maximum Phase Current Prior to closing the Short contact the transition complete input shall be verified to be open otherwise an MMR diagnostic shall be generated Steps A to F Starter Integrity Test Steps G to N Starter Timing Interval Minimum Maximum Units Actual Design A Test for transition complete input open 160 to 240 milliseconds B Just delay time 20 milliseconds C Close 1M 2K1 Contactor and test for no current Starter integrity test 500 mil
50. zero position Steps of the Stepper motor vane actuator Temperature sensors Evaporator sensors 4R6 and 4R7 and condenser sensors 4R8 4R9 entering and leaving bearing temperature sensors 4R1 4R2 oil temperature sensor 4R5 outdoor air temperature 4R13 and evaporator 4810 and condenser 4R11 saturated refrigerant temperature sensors Probe Operating Temperature Range 40 to 250 F 40 to 121 C Accuracy 0 25 C over the range 4 to 122 F 20 to 50 C 0 50 C over the range 40 to 250 F 40 to 121 C Power and Communications and Terminations Power 24 10 VDC 20 mA maximum Trane IPC3 protocol Communications Control System Components Pressure sensors Oil tank sump 4R4 and oil pump discharge 4R3 evaporator and condenser refrigerant pressure 4R22 Working Pressure Range 0 to 50 Psia Accuracy 0 3 of full scale output at 68 F 20 C Power and Communications and Terminations Power 24 10 VDC 20 mA maximum Communications RS485 Physical Layer 19 2 Kbaud Trane IPC3 protocol Starter Module In the hierarchy of modules the Starter module 2A1 1A23 when customer supplied starter specified is second only to the DynaView The starter module is present in all starter selections except AFD This includes Wye Delta Across the Line Solid State whether remote unit mounted or supplied by others The starter module provides the logic to provide the motor protection for Curre
51. 0 1540 1810 J 1660 L 1970 2150 N 1045 1185 1335 1605 U 1735 e TRANE General Information V 1890 40 Control Condenser W 2060 Refrigerant Pressure X 1475 0 Nore C with Z 560 3 stage 935 2 stage Y 500 3 stage 835 2 stage 1 630 3 stage 2245 2 stage 2 800 3 stage 2345 2 stage 3 900 3 stage 2450 2 stage 4 1000 3 stage 2560 2 stage 5 1120 stage 2675 2 stage 6 1250 7 1600 8 1800 9 750 34 Starter Type Star Delta Unit Mounted C Star Delta Remote Mounted E X Line Full Volt Remote Mounted F Autotransformer Remote Mounted G Primary Reactor Remote Mounted H X Line Full Volt Unit Mounted J Autotransformer Unit Mounted K Primary Reactor Unit Mounted L Solid State Unit Mounted M Solid State Floor Mounted N Solid State Wall Mounted P Adaptive Freq Drive Unit Mounted R Customer Supplied 35 C Control Enclosure C Standard S Special 36 1 Control Enhanced Protection 0 None 1 Enhanced protection 37 G Control Generic BAS 0 None G Generic BAS 38 W Water Flow Control 0 None W Water flow control 39 4 Tracer Comm Interface 0 None 4 COMM 4 5 COMM 5 S Special 41 1 Control Extended Operation 0 None 1 Extended operation 42 1 Chilled Water Reset Outdoor Air Temperature Sensor 0 None
52. 1C EN AN WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury 6 Remove the factory installed jumper or the field installed wiring on terminals in the unit control panel This will prevent unwanted chiller operation 7 Setthe purge operating mode to OFF on UCP chillers 8 The oil can be left in the unit 9 The water side should not cause a problem if shut down and drained There may be slight scaling inside the tubes but not enough to cause a problem The customer should inspect and clean tubes before the unit is returned to service CDHF SVU01C EN Maintenance e TRANE IMPORTANT DO NOT USE UNTREATED OR IMPROPERLY TREATED WATER OR EQUIPMENT DAMAGE MAY OCCUR IMPORTANT SCALE DEPOSITS ARE BEST REMOVED BY CHEMICAL MEANS BE SURE TO CONSULT ANY QUALIFIED CHEMICAL HOUSE IN THE AREA ONE FAMILIAR WITH THE LOCAL WATER SUPPLY S CHEMICAL MINERAL CONTENT FOR A RECOMMENDED CLEANING SOLUTION SUITABLE FOR THE JOB 10 Motor bearings If the motor sits for a long time the bearings could take a set and cause
53. 26 connects via unit wiring to the three motor winding temperature sensors This module is located in the control panel where the module is connected to the IPC bus Default status relay selections are shown Selections can be altered using service tool Other choices are Circuit 1 Running Circuit 2 Running Chiller Alarm Circuit 1 Alarm Circuit 2 Alarm and Purge Alarm Maximum Capacity Relay When the chiller has been operating at maximum capacity for 10 minutes TechView adjustable this relay will activate Also upon being less than maximum capacity for 10 minutes this relay will deactivate Compressor Running Relay Relay activates while compressor is running Machine Shutdown Manual Reset MIVIR Limit warning machine shutdown auto reset relays will activate with such conditions for remote status indication 55 e TRANE Control System Components EXOP Extended Operation Option The following modules 1A17 1A18 and 1A19 are provide when this control package is specified 1A5 Ouad Relay EXOP Relay 4 Ice Building Relay J2 10 NO J2 11 NC Output module J2 12 common 1A17 Optional Dual Analog EXOP Signal 1 External Base Loading J2 1 Output 1 Input Output Module Setpoint input J2 3 Ground 1A17 Optional Dual Analog EXOP Signal 2 Refrigerant monitor inputs J2 4 Output 2 Input Output Module J2 6 Ground 1A18 Optional Dual LV EXOP Signal 1 External Base Loading J2 1 Binary Input Signal 1 Bin
54. 4 10 percent VDC 100 ma maximum Trane IPC3 protocol 1A13 1A18 1A19 1A20 Dual Binary input module J2 1 Binary Input Signal 1 J2 2 Ground J2 3 Binary Input Signal 2 J2 4 Ground Binary Input Looks for a dry contact closure Low Voltage 24V 12 mA 14 26 AWG with a maximum of two 14 AWG Power 24 10 percent VDC 40 mA maximum Trane IPC3 protocol 1A14 Communication interface Module Power 24 10 percent VDC 50 mA maximum Trane IPC3 protocol J1 1 24 VDC J2 1 COMM 11 1 24 VDC J1 2 Ground J2 2 COMM J11 2 Ground J13 COMM J2 3 COMM J11 3 COMM J14 COMM J2 4 COMM J11 4 COMM CDHF SVU01C EN CDHF SVU01C EN e TRANE Control System Components 1A15 1A16 1A17 1A21 Dual Analog UCP provides a 2 10 Vdc analog Input output Module signals as Outputs The Output s Analog Output The Analog Output is maximum source capability is 22mA a voltage only signal 2 10 Vdc at The maximum recommended length 22mA to run this signal is included in the J2 14 26 AWG with a maximum of table below two 14 AWG J2 1 Output 1 to J2 3 Ground J2 4 Output 2 to J2 6 Ground Recommended Length to Run external Output signals Gauge Ohms per Feet Length Feet Maximum Length Meters 14 0 00 2823 1062 7 324 16 0 004489 668 3 203 8 18 0 007138 420 3 128 1 20 0 01135 264 3 80 6 22 0 01805 166 3 7 24 0 0287 104 5 31 9 26 0 04563 65 7 20 28 0 07255
55. 7J2 4 and J2 2 t J Check the correctness of the power connections from the starter to the motor Check the wiring to the starter for size voltage and correct phase rotation A L1 B L2 amp C L3 t J Check the equal phase representation in each power wiring conduit b Control Panel terminals tightened Wiring free from abrasion kinks and sharp corners Low voltage wires are isolated from high voltage wires Panel is free of dust debris etc Power Up the control panel Non AFD Starters 1 Starter disconnect locked open 2 Fuse 2F4 must be removed from the starter 3 Connect auxiliary 115VAC power cord to Terminals 1X1 5 L1 and 1X1 17 L2 in the control panel MAKE SURE OF THE POLARITY THE HOT SIDE MUST BE CONNECTED TO TERMINAL 1X1 5 L1 AND THE NEUTRAL SIDE DO 1X1 17 L2 4 Plug in cord to 115VAC power source Control panel is now energized Record the configuration and setpoints of the CH530 control system using Service Tool Using the unit nameplate data and the order specification double check and reset if required the settings of RLA amp STMS using Service Tool If Evaporator and condenser water pumps are controlled by the UCP use the DynaView or Service Tool manual override menu to manually start and test the control of the pumps CDHF SVU01C EN 109 e TRANE Check the setting of the oil pressure regulati
56. EN increments of 1 psid 1kPa The condenser refrigerant pressure is based on the Condenser Refrigerant Temperature sensor if the Condenser Pressure Option is selected as Not Installed at the display The evaporator refrigerant pressure is based on the Saturated Evaporator Refrigerant Temperature Sensor See CTV PRBO0O6 EN for additional information about condenser water temperature control 59 e TRANE Control System Components GBAS Generic Building Automation System 1A15 Optional Dual GBAS Signal 1 Percent RLA Compressor Output Analog Input output Module J2 1 Output 1 J2 3 Ground 1A16 Optional Dual GBAS Signal 1 External Current limit Setpoint Analog Input output Module J2 2 Input 1 J2 3 Ground 1A16 Optional Dual GBAS SignalZ2 Chilled Water Reset input Analog Input or External Chiller Water Setpoint output Module J2 5 Input 2 J2 6 Ground Percent RLA Output 2 to 10 corresponding to 0 to 120 RLA With a resolution of 0 146 The Percent RLA Output connections are on the terminals 1A15 J2 1 to J2 3 Ground The Percent RLA Output is polarity sensitive The following graph illustrates the output Figure 27 Voltage versus percent RLA Voltage vs Percent RLA 120_ 100 80 60 RLA 40 20 60 CDHF SVU01C EN Control System Components e TRANE External Chilled Water
57. Systems filled innn L available for leak testing if necessary E Pumps run air bled from system sl Strainers cleaned C 7 Refrigerant On Job Site 555555056062056 3 Flow Balancing Valves Installed 8 Systems Can Be Operated Under Leaving chilled water Load ss Leaving condenser water ss Heat recovery condenser leaving water ow 9 Electrical Control Man and Contractor s Representative Are Available to Evacuate 4 Gauges Thermometers and Air Vents Charge and Test the CenTraVac under Installed on both sides of evaporator Serviceman s Supervision i Installed on both sides of condenser and heat recover condenser as applicable 10 Equipment Room Does the equipment room have a refrigerant 5 Wiring monitor sensor capable of monitoring and Compressor motor starter has been furnished alarming within the allowable exposure level by or approved by Trane La Crosse Wl Of the refirgerant2 cccmmusssiuuiiuee Full Power available Does the installation have properly placed and Interconnecting wiring starter to panel as req d operating audible and visual refrigerant External interlocks flow swtch pumps aux etc alarms ttt Continued on next CDHF SVUOTC EN 105 e TRANE 10 Equipment Room continued 11 Owner Awareness Does the equipment room have proper Has the owner been fully instructed o
58. TV machine The DynaView enclosure is 9 75 wide 8 high and 1 6 deep The DynaView display is approximately 4 wide by 3 high Features of the display include a touch screen and long life LED backlight This device is capable of operating in 0 95 percent relative humidity non condensing and is designed and tested with UV considerations consistent with an outdoor application in direct sunlight The enclosure includes a weather tight connection means for the RS232 service tool connection Touch screen key functions are determined completely in the software and change depending upon the subject matter currently being displayed The user operates the touch sensitive buttons by touching the button of choice The selected button is darkened to indicate it is the selected choice The advantage of touch sensitive buttons is that the full range of possible choices as well as the current choice is always in view CDHF SVU01C EN Operator Interface e TRANE Spin values up or down are a graphical user interface model used to allow a continuously variable setpoint such as leaving water setpoint to be changed The value changes by touching the increment or decrement arrows Action buttons are buttons that appear temporarily and provide the operator with a choice such as Enter or Cancel The operator indicates his choice by touching the button of choice The system then takes the appropriate action and the butto
59. acts H After the compressor motor has accelerated and the maximum phase current has dropped below 85 percent of the chiller nameplate RLA for 1 5 seconds the starter transition to the Delta configuration is initiated J The transition contactor 2K4 is closed through relay 2A1 J2 placing the transition resistors 2R1 2R2 and 2R3 in parallel with the compressor motor windings K The shorting contactor 2K3 is opened through the opening of relay 2A1 J4 100 msec after the closure of the transition relay 2A1 J2 L The run contactor 2K2 is closed through relay 2A1 J6 shorting out the transition resistors 260 milliseconds after the opening of the shorting relay 2A1 J4 This places the compressor motor in the Delta configuration and the starter module waits to look for this transition for 2 35 seconds through the closure of the transition complete contacts 2K2 Aux at module 2A1 J12 input M The starter module must now confirm closure of the transition complete contact 2K2 AUX within 2 32 to 2 38 seconds after the run relay 2A1 J6 is closed Finally the transition relay 2A1 J2 is opened de energizing the transition contactor 2K4 and the compressor motor starting sequence is complete An MMR diagnostic will be generated if the transition complete contacts 2K2 AUX do not close A diagram of this test or start sequence is shown in Figure 24 CDHF SVU01C EN Now that the compressor motor 4M 1 is
60. al water supply s chemical mineral content for a recommended cleaning solution suitable for the job Remember a standard condenser water circuit is composed solely of copper cast iron and steel CDHF SVU01C EN Maintenance e TRANE CAUTION Unit Corrosion Damage Proper procedures must be followed when using corrosive chemicals to clean water side of unit It is recommended that the services of a qualified chemical cleaning firm be used Proper personal protective equipment as recommended by the chemical manufacturer should be used Refer to the chemicals MSDS sheet for proper safety procedures Failure to follow proper procedures could result in corrosion damage to the unit and tubes IMPORTANT ALL OF THE MATERIALS USED IN THE EXTERNAL CIRCULATION SYSTEM THE QUANTITY OF THE SOLUTION THE DURATION OF THE CLEANING PERIOD AND ANY REQUIRED SAFETY PRECAUTIONS SHOULD BE APPROVED BY THE COMPANY FURNISHING THE MATERIALS OR PERFORMING THE CLEANING REMEMBER HOWEVER THAT WHENEVER THE CHEMICAL TUBE CLEANING METHOD IS USED IT MUST BE FOLLOWED UP WITH MECHANICAL TUBE CLEANING FLUSHING AND INSPECTION Cleaning the Evaporator Since the evaporator is typically part of aclosed circuit it does not accumulate appreciable amounts of scale or sludge Normally cleaning every 3 years is sufficient However on open evaporator systems such as air washers periodic inspection and cleaning is recommended Control Set
61. am chillers refrigerant temperature and the leaving water temperature after the down stream chillers circuit Therefore the approach ofthe upstream circuit will be a negative number in many instances when both compressors are operating CDHF SVU01C EN 41 e TRANE Operator Interface Report name System ASHRAE Chiller Log Description Resolution Units Dependencies 1 Current Time Date XX XX mmm dd yyyy Date Time 2 Chiller Mode Enum 3 Active Chilled Water Setpoint XXX X Temperature 4 Active Current Limit Setpoint XXX 96 RLA 5 Refrigerant Type Enum 6 Refrigerant Monitor XXX X PPM If option installed 7 Evap Entering Water Temp XXXX Temperature 8 Evap Leaving Water Temp XXXX Temperature 9 Evap Water Flow Switch Status Enum If option not installed 10 Evap Differential Wtr Press XXXX Diff Pressure If option installed 11 Approx Evap Water Flow XXXX GPM LPM If option installed 12 Approx Chiller Capacity XXXX Capacity If option installed 13 Cond Entering Water Temp XXX Temperature 14 Cond Leaving Water Temp XXX X Temperature 15 Cond Water Flow Switch Status Enum If option not installed 16 Cond Differential Wtr Press XXXX Pressure 17 Approx Cond Water Flow XXXX Flow If option installed Report name Circuit ASHRAE Chiller Log Description Resolution Units Dependencies 1 Ci
62. am procedure Gallons 9 required _ Refrigerant Oil pump motor ground check Good Open Check motor terminal Change oil filter Condenser Visually inspect for scaling in tubes not findings and make recommendations Comments Recommendations 104 Control Circuits _ Low refrigerant temperature sensor check Fsetpoint F trip point ice water Leaving Evaporator water temperature sensor check out setpoint F trip point ice water Condenser High Pressure Switch check out psig set point psig trip point _ Check Net Oil Pressure Check adjustment and operation of inlet guide vane actuator stepper motor Note each machine is unique and must have the full open position number of steps input Leak Test Chiller L Refrigerant and oil analysis for acid content _ Sample refrigerant and oil for laboratory analysis attach a copy of analysis to next monthly inspection report Purge Unit Review the purge operation maintenance manual and follow maintenance and or inspection items identified CDHF SVU01C EN e TRANE CenTraVac Checksheet and Request for Serviceman To Trane Service Company 8 0 No LL Serial s Job Project Name Address The following items are being installed and will be completed by Check boxes if the task is complete or if the answer is yes
63. ary input module Enable or Disable input points J2 2 Ground 1A18 Optional Dual LV EXOP Signal 2 External Hot Water Control J2 3 Binary Input Signal 2 Binary input module Enable or Disable input J2 4 Ground 1A19 Optional Dual LV EXOP Signal 1 Ice Building Control J2 1 Binary Input Signal 1 Binary input module Enable or Disable input point J2 2 Ground Refrigerant Monitor Input 1A17 Analog type input 4 20ma input signal to the 1A17 J2 4 to J2 6 ground This represents 0 100 ppm 56 CDHF SVUO1C EN e TRANE Control System Components TRMM TRMA Tracer Comm 4 interface 1A14 Optional TRM4 Tracer Communications J2 1 COMM J2 2 COMM J2 3 Communication or COMM J2 4 COMM Interface Module LCI C CDRP Condenser Refrigerant Pressure Output 1A15 Optional Dual Analog CDRP Signal 2 Condenser Refrigerant J2 4 Output 2 J2 6 Ground Input output Module Pressure output EPRO Enhanced Protection 4R22 EPRO Condenser Refrigerant Pressure Transducer 4R16 EPRO Compressor Discharge Refrigerant Temperature Sensor This is also included with HGBP 4R1 EPRO Inboard Bearing Temperature Sensor 4R2 EPRO Outboard Bearing Temperature Sensor CDHF SVU01C EN 57 e TRANE CDRP Refrigerant Pressure Output Option 1A15 Refrigerant Pressure Output can be configured at commissioning to correspond to either A the absolute condenser pressure or B the differential pressure of the evaporator to condenser pre
64. ated a latching diagnostic indicating the condition is displayed The Low Evaporator Refrigerant Temperature Diagnostic is active in both the Running and Stopped modes The Low Evaporator Refrigerant Cutout Setpoint is factory set to 36 F This can be altered via the service tool A Service Tool adjustable setpoint that should be based on the percentage of antifreeze used in the customer s water loop The Service tool will display a warning message such as Warning Adequate Antifreeze required for any Evaporator Refrigerant Temperature Cutout below 28 F and any Leaving Water Temperature Cutout below 35 F The percent of antifreeze required is a function of the leaving water temperature setpoint and the worse case lowest permitted water flow approach temperatures of the chiller s evaporator design Head Relief Relay Surge condenser limit and certain conditions in ice mode can energize the head relief relay Note There is a TechView programmable head relief relay filter time setpoint The default is 1 minute 77 e TRANE Machine Protection and Adaptive Control Figure 31 Cutout strategy Cutout Strategy Wolar Seipcent Differential bs Siop 2 d ye F 1 1 C Lering Woler Terme Cutout integrate in Tria whan below ee ee Rigi Temp Cutout integrata da Trip when below minu Limit Loading The potential to limit loading i
65. ater temperatures ELWT Evaporator Leaving Water Temperature ENT Entering Chilled Water Temperature GPM Gallons per minute HGBP Hot Gas Bypass CDHF SVU01C EN General Information e TRANE HVAC Heating Ventilating and Air Conditioning IE Internally Enhanced Tubes IPC Interprocessor Communication LBU La Crosse Business Unit LCD Liquid Crystal Display LED Light Emitting Diode MAR Machine Shutdown Auto Restart Non Latching where chiller will restart when condition corrects itself MMR Machine Shutdown Manual Restart Latching where chiller must be manually reset MP Main Processor PFCC Power Factor Correction Capacitor PSID Pounds per Square Inch differential pressure PSIG Pounds per Square Inch gauge pressure UCP Unit Control Panel LLID Low Level Intelligent Device Sensor Pressure Transducer or Input output UCP module RLA Rated Load Amps RTD Resistive Temperature Device Tracer CH530 Tracer CH530 controller TOD Temperature Outdoor Control Optional Packages OPST Operating Status Control GBAS Generic Building Automation Interface EXOP Extended Operation CDRP Condenser Pressure Transducer TRMM Tracer Communications WPSR Water pressure sensing EPRO Enhanced Protection CWR Chiller Water reset outdoor e TRANE General Information Overview Compressors and Motor 1 Left hand and 2 Right hand CDHP CDHG Econ
66. attention to the shutdown diagnostic condition Blinking is defined as normal versus reverse video Pressing on the Alarms button takes you to the corresponding screen Persistent keys horizontal at the bottom of the display are those keys that must be available for operation regardless of the screen currently being displayed These keys are critical for machine operation The Auto and Stop keys will be presented as radio buttons within the persistent key display area The 32 Operator Interface selected key will be dark The chiller will stop when the Stop key is touched entering the stop sequence Pressing the Immediate Stop button will cause the chiller to stop immediately The AUTO and STOP take precedence over the ENTER and CANCEL keys While a setting is being changed AUTO and STOP keys are recognized even if ENTER or CANCEL has not been pressed Selecting the Auto key will enable the chiller for active cooling if no diagnostic is present Chiller Stop Prevention Inhibit Feature A new chiller Stop prevention inhibit feature allows a user to prevent an inadvertent chiller stop from the DynaView screen for those chillers which are solely controlled by the CH530 How It Works This new feature will be activated after the service tech sets a variable shut down timer in TechView to be greater that 0 seconds and up to 20 seconds i e 0 lt Timer 20 Then when the user presses the STOP
67. cked out in restart inhibit or generally not ready to start the available compressor will be started Note The following description assumes compressor 1 is the down stream compressor CDHF SVU01C EN General Information e TRANE Fixed Sequence Compressor 1 Compressor 2 Default mode If the chiller is in the Auto mode and all interlocks have been satisfied compressor 1 will be started based on the leaving water temperature rising above the Differential to Start setting Compressors 2 will stage on when the overall chiller average capacity exceeds Stage ON Load point for 30 seconds The stage on load point is adjustable via service tool up to 5096 The default is 4096 which means that a single compressor would have to load to 8096 the average would be 4096 before the second compressor starts Both compressors will run until chiller average capacity drops below Stage off Load point for 30 seconds The Stage OFF load point is also adjustable via service tool default 30 range from 0 to 50 Compressor 2 will be shut down and compressor 1 will run until water temperature drops below the differential to stop Before shutting down compressor 2 will be unloaded and compressor 1 will be loaded to maintain the same average capacity command When running chilled water temperature at selected conditions the downstream compressor usually will be the most efficient compressor to operate at part load beca
68. correct and complete CDHF SVU01C EN e TRANE Evaporator pump s run 24 hrs System and strainers properly cleaned and or flushed Evaporator water strainer in close proximity to entering connection of evaproator Provisions installed to properly maintain water treatment additives Initial water treatment added to system Flow or differential pressure switch installed and where possible wired in series with auxiliary of pump motor starter Verify correct operation of flow proving circuit Evaporator water flow balanced PSID design PSID actual GPM design GPM actual Electrical and Controls a Motor Starter Panel All terminals tightened __ Wiring free from abrasion kinks and sharp corners L Contactors and relays have freedom of movement All contacts are free of corrosion or dirt Panel is free of dust debris etc t J Check the ratio of the current transformers Record the part numbers on the start up log _ Use only twisted shielded pair for the IPC circuit between the starter and the UCP on remote starters Recommended wire is Belden 8760 18 AWG Polarity is critical The low voltage IPC link __30 volts must be in separate conduit from the 115 volt wiring IPC link routing within the starter panel must stay a minimum of 6 inches from higher voltages t JRemote starter to UCP connections are complete and comply with Trane requirements Verify oil pump interlock circuit to 1A
69. e o o o o LINGNOD 1 o m L LINANOD 9 9 ac WNOLLdO E o SHOSN3S dW HOLOW O J DULY u LWE ZuLWe 3 m o zSMd o lo SELOSSEUX SYOSNAS 3unssaid YILYM 2310 cn 5 svi o o nom zm Zab 8 Lae 8 O a wi wi 8 WNOLL4O m lo lo loj WNOLLdO o EZYL E NOLLISNVEL ANIT WWOO AD SAM O nonus D an KU maz als ovi E TO g tut d ais Eri 8 6 INIT WWOD YIM 7 9 Land lo TWNOLLdO NOWWOD 1431 8 aiso Lol LLL 5 B eis 105 o FE m 1 1052 WWOD o NOWWOD LHD ZIM co Bc R SLINN X41dNG DHGD 4HGD SNOILdlId2S3G LINDYID SNOLLVNDIS3G ADIAIG ASSV TANVd O SHD Figure 24 Control panel components layout 52 e TRANE Control System Components ANIT WWOD 3HIMcc 68M N3dO N3dO LINGNOD WALSAS NOLLVDINEN1 ALINGNOD Y3LYYLS LINGNOD SYOSNAS dWAL ONIGNIM HOLOIW 8 1 CHLWE NddO ANNT WWOO 38IW t ADI SEM WWOD NOWWOO 1331 8M ANT WWOD 38IA E NOWWOD LHI Z8M ZO LE 4 910106059 1 Z060S9E1X
70. e oil heater is energized in an attempt to raise the oil temperature over this inhibit temperature setpoint The compressor is inhibited from starting until the oil temperature is raised 5 or more degrees above this setpoint The Low Oil Temperature Start Inhibit is tested on every start unless a quick restart is being performed during post lube If the Enhanced Oil Temperature Protection setting is enabled the Low Oil Temperature Start Inhibit value is the greater of 100 F 37 8 C or the Saturated Evaporator Refrigerant Temperature 30 F 16 7 C If the Enhanced Oil Temperature Protection setting is not enabled the Low Oil Temperature Start Inhibit value is settable with the Low Oil Temperature Start Inhibit Setpoint via the service tool 81 e TRANE 82 Machine Protection and Adaptive Control Oil Temperature Control The oil heater is used to maintain the oil temperature within 2 5 F 1 4 C of the oil temperature control setpoint The oil heater is commanded off when the oil pump is commanded on If the oil temperature is at or below the Low Oil Temperature Cutout setpoint this diagnostic will be issued and stops the compressor This diagnostic is ignored for the first 10 minutes of compressor run After that if the oil temperature falls below this cutout temperature for more than 60 consecutive seconds this diagnostic is issued High Oil Temperature Cutout Name High Oil Temperature Cut
71. e Loading Current Setpoint Range 20 100 percent RLA The UCP accepts 2 inputs to work with external base loading The binary input is at 1A18 Terminals J2 1 and J2 2 Ground which acts as a switch closure input to enter the base loading mode The second input an analog input is at 1A17 terminals J2 1 and Ground which sets the external base loading setpoint and can be controlled by either a 2 10Vdc or 4 20ma Signal At startup the input type is configured The graphs in Figure 13 show the relationship between input and percent RLA While in base loading the active current limit setpoint is set to the Tracer or external base load setpoint providing that the base load setpoint is not equal to 0 or out of range If it is out of range the front panel current limit setpoint is used During base loading all limits are enforced with the exception of current limit The human interface displays the message Unit is Running Base Loaded Hot Gas Bypass is not run during base loading If base loading and ice making are commanded simultaneously ice making takes precedence An alternative and less radical approach to Base Loading indirectly controls chiller capacity Artifically load the chiller by setting the chilled water setpoint lower than it is capable of achieving Then modify the chiller s load by adjusting the current limit setpoint This method provides greater safety and control stability in the operation
72. e performed by qualified Trane service technicians Note During extended shutdown be sure to operate the purge unit for a 2 hour period every two weeks This will prevent the accumulation of air and noncompensable in the machine To start the purge change the purge mode to ON in the DynaView Settings Purge Menu Remember to turn the purge mode to AUTO after the 2 hour run time Trouble Analysis If the ALARM indicator on the control panel is flashing an MMR diagnostic has occurred Refer to Diagnostic section for trouble shooting information 91 e TRANE Overview This section describes the basic chiller preventive maintenance procedures and recommends the intervals at which these procedures should be performed Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a CenTraVac chiller Recommended purge maintenance procedures for the EarthWise Purge unit are covered by PRGD SVU01A EN or the latest revision which can be obtained at the nearest Trane office Record Keeping Forms An important aspect of the chiller maintenance program is the regular completion of records Provided at the end of this manual are copies of the Annual Inspection Check List and Report CenTraVac Commissioning Checklist and a Start Up Report with a TechView settings record When filled out 92 Periodic Maintenance accurately by the machine operator
73. easy access to pertinent and appropriate information CDHF SVU01C EN General Information e TRANE DynaView Human Interface For the operator Day to day operational information is presented at the panel Up to seven lines of data English or SI units are simultaneously displayed on the VGA touch sensitive screen Logically organized groups of information chiller modes of operation active diagnostics settings and reports put information conveniently at your fingertips See Operator Interface Section for details TechView Chiller Service Tool For the service technician or advanced operator All chiller status machine configuration settings customizable limits and up to 60 active or historic diagnostics are displayed through the service tool interface Without changing any hardware we give you access to the latest and greatest version of Tracer CH530 A new level of serviceability using the innovative TechView chiller service tool A technician can interact with an individual device or a group of devices for advanced troubleshooting LED lights and their respective TechView indicators visually confirm the viability of each device Any PC that meets the system requirements may download the service interface software and Tracer CH530 updates For more information on TechView visit your local Trane Service company or The Trane Company s website at www trane com 13 e TRANE CTV D
74. een the two compressors unless limit control overrides balancing When transitioning between one compressor operation and two compressor operation the load commands will be actively balanced at a rate slow enough to minimize capacity control disturbances Restart Inhibit The purpose of restart inhibit feature is to provide short cycling protection for the motor and starter The operation of the restart inhibit function is dependent upon two setpoints The Restart Inhibit Free Starts 1 5 3 default and the Restart Inhibit Start to Start Timer 10 30min 20 default These settings are adjustable via the service tool Restart Inhibit Free Starts This setting will allow a number of rapid restarts equal to its value If the number of free starts is set to 1 this will allow only one start within the time period set by the Start to Start Time Setting The next start will be allowed only after the start to start timer has expired If the number of free starts is programmed to 3 the control will allow three starts in rapid succession but thereafter it would hold off on a compressor start until the Start to Start timer expired Restart Inhibit Start to Start Time Setting This setting defines the shortest chiller cycle period possible after the free starts have been used If the number of free starts is programmed to 1 and the Start to Start Time Setting is programmed to 20 minutes then the compressor will be
75. ess of installation or enabling those optional items In the second column will be shown if that option is Not Installed otherwise the current setpoint from that source will be shown The Back button provides navigation back to the chiller screen CDHF SVU01C EN CDHF SVU01C EN Operator Interface e TRANE 4 Back Active Current Limit Setpoint Arbitration Front Panel 100 Active Blank BAS 80 96 Active Blank External 70 96 Active Blank Active Current Limit Setpoint 100 O Auto Stop Q The active current limit setpoint is the current limit setpoint that is currently in use It will be displayed in percent RLA Touching the double arrow to the left of the Active Current Limit Setpoint will take the user to the active current limit setpoint sub screen The active current limit setpoint is that setpoint to which the unit is currently controlling It is the result of arbitration between the front panel BAS and external setpoints The left column text Front Panel BAS External and Active Current Limit Setpoint will always be present regardless of installation or enabling those optional items In the second column will be shown if that option is Not Installed otherwise the current setpoint from that source will be shown The Back button provides navigation back to the chiller screen Note This is the same for other
76. ety control that protects the chiller from damage caused by water freezing in the evaporator The cutout setpoint is factory set however is adjustable with the Service tool The Leaving Water Temperature Cutout Setpoint is independently adjustable from the chilled water setpoint and factory set Shutdown of the compressor due to violation of the Leaving Water Temperature Cutout results in an automatically resettable diagnostic MAR The DynaView Operating Mode indicates when the Leaving Water Temperature Cutout Setpoint conflicts with the chilled water temperature setpoint by a message on the display The Leaving Water Temperature Cutout Setpoint and chilled water setpoint both active and front panel are separated by a minimum of 1 7 F See Cutout Strategy Figure 27 When either difference is violated the UCP does not permit the above differences to be violated and the display exhibits a message to that effect and remains at the last valid setpoint After violation of the Leaving Water Temperature Cutout Setpoint for 30 F seconds the chiller will shutdown and indicate a diagnostic CDHF SVU01C EN CDHF SVU01C EN Machine Protection and Adaptive Control e TRANE Low Refrigerant Temperature Cutout The purpose of the low evaporator refrigerant temperature protection is to prevent water in the evaporator from freezing When the Low Evaporator Refrigerant Temperature Cutout LRTC trip point is viol
77. eversal protection is default to Enable however can be disabled via the service tool CDHF SVU01C EN Differential to Start or Stop The Differential to Start setpoint is adjustable from 1 to 10 F 0 55 to 5 55 C and the Differential to Stop setpoint adjustable from 1 to 10 F 0 55 to 5 55 C Both setpoints are with respect to the Active Chilled Water Setpoint When the chiller is running and the LWT Leaving Water Temperature reaches the Differential to Stop setpoint the chiller will go through its shutdown sequence to AUTO Refer to Figure 10 SoftLoading Softloading stabilizes the startup control during the initial chiller pulldown Soft loading is used to bring the building loop temperature from its start value to the Chilled Water or Hot Water Setpoint in a controlled manner Without soft loading the chiller controls will load the chiller rapidly and use the full chiller capacity to bring the loop temperature to setpoint Although the start temperature of loop may have been high the actual system load may be low Thus when the setpoint is met the chiller must unload quickly to the system load value If it is not able to unload quickly enough the supply water temperature will CDHF SVU01C EN Machine Protection and Adaptive Control e TRANE drop below setpoint and may even cause the chiller to cycle off Soft loading prevents the chiller from going to full capacity during the pulldown period After
78. ew value is assumed Mode Override for Enumerated Settings is shown below Override Screen Title Setting Value Radio 1 Button Selections Radio 2 Monitor Value Text Here Dependent on Setting XXX X Press Button To Select O Auto Stop CDHF SVU01C EN 47 e TRANE Operator Interface The mode override analog setting subscreen is similar but offers an Auto or Manual radio button and value setting An Auto or Manual selection is necessary set to the mode to override An Enter and Cancel Key will allow the user to Enter or Cancel the entry Mode Override for Analog Settings is shown below 4 Back Override Screen Title Text Monitor Value actual name Ckt 2 Setting Value Enter Cancel ext here XX X units O Auto Stop The date setpoint screen for setting up the is shown below The user must select Day Month or Year and then use the up or down arrows to adjust lt Back Date dd mmm yyyy Day Month Year Enter Cancel A VW Press Arrows to Change Press Enter To Save Change Press Cancel To Ignore Change Q Auto Stop o CDHF SVU01C EN CDHF SVU01C EN Operator Interface e TRANE The time setpoint screen with a 12 hour format is shown below The user must select Hour or Minute and
79. feature CDHF SVU01C EN Inter Processor Communications IPC3 When using Tracer CH530 you will not be required to know all the details about the structure of the IPC3 bus However this page gives detailed information about the system for those of you that are really interested in how it works The IPC3 protocol is based on RS485 signal technology IPC3 was designed to be very efficient It communicates at 19 2 Kbaud IPC3 Definitions Bus Management The DynaView provides the bus management having the task of restarting the link or filling in for missing nodes when the normal communication has been degraded This involves reassigning node addresses and filling in for nodes that are off line The DynaView always has a node number of 01 Node Assignment When a unit is factory commissioned the Low Level Intelligent Device LLID or module must have their node addresses assigned to them for storage in non volatile memory The node addresses are normally assigned sequentially during factory commissioning Node Zero CDHF SVU01C EN Interprocessor Communication e TRANE Node number zero is is a special node assignment that is reserved for devices that are service selected A LLID communicating on node address zero will also communicate on an assigned node address A LLID will only communicate on node address zero if it is service selected Binding Binding is the process of assigning a node number
80. frigerant compatible hoses or copper tubing with self sealing connections or shut off valves CDHF SVU01C EN Maintenance e TRANE 3 Transfer the refrigerant using one of the following listed in order of preference a An approved Trane low pressure refrigerant recovery and recycle unit b The available pressure differential c Gravity Use a return vent line to refrigerant drums to equalize pressure 5 Do not use dry nitrogen to push refrigerant into the chiller as was common practice in the past This will contaminate the charge and require excessive purging which will result in unnecessary release of refrigerant 6 Weigh in the proper charge 7 Use recovery and recyle unit or vacuum pump to evacuate hoses discharge outdoors 8 If refrigerant is supplied in new returnable cylinders be sure and refer to General Service Bulletin CVHE SB 48B for information on returning cylinders This service bulletin is available at the nearest Trane office Depending on the chiller duty contact a qualified service organization to determine when to conduct a complete examination of the unit to discern the condition of the compressor and internal components Note If your chiller is covered by a Trane extended warranty the terms of that warranty may require that the procedures listed in the Periodic Maintenance section of this manual be followed for your extended warranty to remain in force The ter
81. g has been replaced by Loctite 515 applied at a minimum film thickness of 010 applied across the width of the flange The current jack bolt holes remain for disassembly CAUTION Oil Supply System Problems Plugging of oil supply system could lead to bearing failure Failure to use care could result in Loctite getting into the chiller which may cause problems with the Oil supply system and eductor system Inspect the condenser tubes for fouling clean if necessary AX WARNING Hazardous Voltage w Capacitors Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Note For additional information regarding the safe discharge of capacitors see PROD SVBOGA EN or PROD SVBO06A FR CDHF SVU01C EN Maintenance e TRANE Measure the compressor motor winding resistance to ground a qualified service technician should conduct this check to ensure that the findings are properly interpreted Contact a qualified
82. g the compressor will be unloaded at its maximum rate While loading and unloading the compressor all surge detection will be ignored While in the ice building mode current limit setpoints less than the maximum will be ignored Ice Building can be terminated by one of the following means 1 Front panel disable 2 Opening the external Ice Contacts Remote communicated input Tracer 3 Satisfying an evaporator entering fluid temperature setpoint Default is 27 F 4 Surging for 7 minutes at full open IGV 26 General Information Figure 18 Sequence of operation ice making running to ice making Lessing E Cell d Mem Dees a p xs a Bey ee eee Figure 19 Sequence of operation ice making stopped to ice to ice building complete lew To Meera Timer Water Temp ion Making Command Fal Beles tha Without 3 Pret Paral Evap LWT Rising v Above DP io Steg dowhcrpsa Lnag eee Kursen bioos Daph E CDHF SVU01C EN Hot Water control Occasionally CTV chillers are selected to provide heating as a primary mission With hot water temperature control the chiller can be used as a heating source or cooling source This feature provides greater application flexibility In this case the operator selects a hot water temperature and the chiller capacity is modulated to maintain the hot water setpoint Heating is the primary mission and cooling is a waste product or is a seconda
83. grammed to 10 minutes then the compressor will be allowed one start every 10 minutes The start to start time is the time from when the motor was commanded to energize to when the next command to enter prestart is given Clear Restart Inhibit A Clear Restart Inhibit button is provided within Settings Manual Override on the DynaView display This provides a way for an operator to allow a compressor start when there is a currently active Restart Inhibit that is prohibiting such a start The button press will have no other function than to remove the restart inhibit if there is one active It does not change the count of any internal restart inhibit timers or accumulators The restart inhibit function setpoints and clear features exist for each compressor and operate independently of other compressors on that chiller During the time the start is inhibited due to the start to start timer the DynaView shall display the mode Restart Inhibit and the also display the time remaining in the restart inhibit A Restart Inhibit Invoked warning diagnostic will exist when the attempted restart of a compressor is inhibited If all three motor winding temperatures are less than the Restart Inhibit Temperature Setpoint default 165 F 74 C then restart is allowed Restart inhibit mode exist when at least one of the three motor winding temperatures is greater than or equal to the Restart Inhibit Temperature Setpoint bu
84. he normal cooling mode In the hot water temperature control mode the differential to start and differential to stop setpoints are used with respect to the hot water setpoint instead of with the chilled water setpoint UCP provides a separate entry at the DV to set the hot waiter setpoint Tracer is also able to set the hot water setpoint In the hot water mode the external chilled water setpoint is the external hot water setpoint that is a single analog input is shared at the 1A16 J2 1 to J2 3 ground An external binary input to select external hot water control mode is on the EXOP OPTIONAL module 1A18 terminals J2 3 to J2 4 ground Tracer also has a binary input to select chilled water control or hot water temperature control There is no additional leaving hot water temperature cutout the HPC and condenser limit provide for high temperature and pressure protection In hot water temperature control the softloading pulldown rate limit operates as a softloading pullup rate limit The setpoint for setting the temperature rate limit is the same setpoint for normal cooling as it is for hot water temperature control The hot water temperature control feature is not designed to run with or ice making The factory set PID tuning values for the leaving water temperature control are the same settings for both normal cooling and hot water temperature control 27 e TRANE 28 Unit Control Pane
85. ian oil analyses can provide valuable information on the performance of the chiller to help minimize operating and maintenance costs and maximize it s operating life A drain fitting is installed in the oil filter top after the oil filter for obtaining oil samples Oil Change Procedure When oil analysis indicates the need to change compressor oil use the following procedure for removing oil CAUTION Heater Damage The oil sump heater must be deenergized before draining the sump Failure to do so could possibly burn out the oil sump heater 1 Draw the oil from the chiller through the oil charging valve on the chiller oil sump into an approved evacuated tank or Pump the oil from the chiller through the oil charging valve into an airtight resealable container using a magnetically driven auxiliary pump Forcing the oil from the oil sump by pressurizing the chiller by raising chiller temperature or adding nitrogen is not recommended Refrigerant dissolved in the oil can be removed and returned to the chiller by using an appropriate deep vacuum recovery unit and heating and agitating the oil container Follow all Federal State and Local regulations with regard to disposal of waste oil 95 e TRANE 96 Oil Maintenance Replacing Oil Filter Replace oil filter 1 annually 2 at each oil change 3 or if erratic oil pressure is experienced during chiller operation Oil Filter Replace
86. id or not applicable The languages for DynaView will reside in the main processor The main processor will hold three languages English and two alternate languages The service tool TechView will load the main processor with user selected languages from a list of available translations Whenever possible complete words will be used on the persistent keys as described 37 e TRANE 38 Operator Interface 4 Active Chilled Water Setpoint Arbitration Front Panel 44 0 F BAS 48 0 F External 42 0 F Chilled Water Reset Active Blank Active Blank n Active Blank Return Constant Return Outdoor None Active Chilled Water Setpoint 44 0 F O Auto Stop The active chilled water setpoint is the setpoint that is currently in use It will be displayed to 0 1 degrees Fahrenheit or Celsius Touching the double arrow to the left of the Active Chilled Water Setpoint will take the user to the active chilled water setpoint arbitration sub screen The Active Chilled Water Setpoint the result of arbitration between the front panel BAS and external setpoints The chilled water reset status area in the right most column will display one of the following messages Return Constant Return Outdoor None The left column text Front Panel BAS External Chilled Water Reset and Active Chilled Water Setpoint will always be present regardl
87. in the Chiller Settings menu 6 If necessary readjust the current limit setpoint in the Chiller Setpoints menu 7 Press AUTO CDHF SVU01C EN Unit Startup e TRANE The UCP also checks compressor motor winding temperature and a minimum restart time is initiated if the winding temperature is less than 265 F The chilled water pump relay is energized and evaporator water flow is proven Next the UCP checks the leaving evaporator water temperature and compares it to the chilled water setpoint If the difference between these values is less than the start differential setpoint cooling is not needed If the UCP determines that the difference between the evaporator leaving water temperature and chilled water setpoint exceeds the start differential setpoint the unit enters the initiate Start Mode and the oil pump and Refrigerant pump and the condenser water pump are started If condenser water flow is not proven flow switch 5S3 does not close within 4 minutes 15 seconds the unit is locked out on a MMR Diagnostic Oil pressure must be verified within 3 minutes or a MMR diagnostic is generated When less than 5 seconds remain on the restart inhibit the pre start starter test is conducted on Y Delta starters If faults are detected the unit s compressor will not start and a MMIR Diagnostic will be generated If the compressor motor starts and accelerates successfully Unit is Running appears o
88. ing mode The Condenser Limit Setpoint is factory set 93 percent of HPC however can be altered via the service tool 79 e TRANE Restart Inhibit This function provides short cycle protection for the motor and indirectly also short cycling protection for the starter since the starter is designed to operate the motor under all the conditions of motor performance The operation of the restart inhibit function is dependent upon two setpoints The Restart Inhibit Free Starts 1 5 3 default and the Restart Inhibit Start to Start Timer 10 30min 20 default These settings are adjustable via the service tool Restart Inhibit Free Starts This setting will allow a number of rapid restarts equal to its value If the number of free starts is set to 1 this will allow only one start within the time period set by the Start to Start Time Setting The next start will be allowed only after the start to start timer has expired If the number of free starts is programmed to 3 the control will allow three starts in rapid succession but thereafter it would hold off on a compressor start until the Start to Start timer expired 80 Machine Protection and Adaptive Control Restart Inhibit Start to Start Time Setting This setting defines the shortest chiller cycle period possible after the free starts have been used If the number of free starts is programmed to 1 and the Start to Start Time Setting is pro
89. into the oil tank These eductors use high pressure condenser gas to draw the oil from the suction cover and evaporator to the eductors and then discharged into the oil tank The evaporator eductor line has a shut off valve mounted by the evaporator and ships closed Open two turns if necessary Liquid refrigerant is used to cool the oil supply to both the thrust bearing and journal bearings On refrigerant pump units the oil cooler is located inside the economizer and uses refrigerant passing from the condenser to evaporator to cool the oil Oil leaves the oil cooler and flows to both the thrust and journal bearings Motor Cooling System Compressor motors are cooled with liquid refrigerant see Figure 16 The refrigerant pump is located on the front of the oil tank motor inside the oil tank The refrigerant pump inlet is connected to the well at the bottom of the condenser The connection is on the side where a weir assures a preferential supply of liquid Refrigerant is delivered to the motor via the pump Motor refrigerant drain lines are routed to the condenser CDHF SVU01C EN General Information Figure 16 Oil refrigerant pump circuit 1 or 2 GENERAL Y CUI REFREGERATSOM SYSTEM BCEEMATIC wA Dona ee UE CDOmDDWRHE DES UR eem V Pp uu 3 a ic mee iia ni E EOE Een L E rT Lam Eau RAE utc Oe HIS euim UN
90. it to service Grease fittings are not vacuum tight and will become a leak path 9 Using a clean wooden dowel or other similar tool remove excess grease from the remaining open lubrication port 10 Clean and then lightly coat the threads of the plug with Rheolube grease and re install it into the lubrication port Tighten the plug to hand tight plus 1 4 to 1 2 turn 11 Before reconnecting the vane linkage grasp the tang operator arm and manually operate the vane assembly If it is now difficult to move then the tang operator may have become hydraulically locked because of excess grease in the assembly This situation could cause damage to the o rings of the assembly If this occurs then remove one of the lubrication plugs remove some of the grease then re install the plug 12 Reconnect the linkage to the tang operator arm Ensure the spacer washers between the linkage and the arm are properly placed and that the assembly does not bind Re install any insulation that was cut or removed The unit may be restarted To service the 1st and 2nd stage tang operators on CDHF extended capacity chillers with 1470 or 1720 compressors The 1st and 2nd stage rotary inlet guide vane tang operators of the extended capacity chillers also require periodic lubrication at least annually with R123 compatible Rheolube grease These actuators have two 1 8 NPT plugs located 180 degrees apart with one on the top 98 Main
91. l UCP Control Panel Devices and Unit Mounted Devices Unit Control Panel UCP Safety and operating controls are housed in the unit control panel the starter panel and the purge control panel The UCP s operator interface and main processor is called the DynaView DV and is located on the UCP door See Operators interface section for detailed information Figure 20 Left control panel The UCP houses several other controls modules called panel mounted LLID Low Level Intelligent Device power supply terminal block fuse circuit breakers and transformer The IPC Interprocessor communication bus provides communication between LLID s and the main processor Unit mounted devices are called frame mounted LLID s and can be temperature sensors or pressure transducers vane actuator These and other functional switches provide analog and binary inputs to the control system STANDARD ENCLOSURE CDHF SVU01C EN Tracer CH530 Chiller Controller Revolutionary control of the chiller chilled water system and your entire building with unprecedented accuracy reliability efficiency and support for maintenance using the chiller s PC based service tool Chiller reliability is all about producing chilled water and keeping it flowing even when facing conditions that ordinarily would shut down the chiller conditions that often happen when you need cooling the most Tracer CH530 s Main Processor DynaView
92. liseconds D Hold 1M 2K1 Contactor and test for no current Starter integrity test 1 second E Open 1M 2K 1 Delay time 200 milliseconds F Close Shorting Contactor 2K3 and and test for no current then wait for Start command Starter integrity test 100 milliseconds 1 second Minimum G Close 1M 2K1 and 2K11 2 0 second 2 second H Wait 1 5 seconds after phase currents drop to 85 percent 1 2 second 1 5 second J Begin Transition sequence 35 100 milliseconds 100 milliseconds K Open S Shorting Contactor 250 300 milliseconds 260 milliseconds L Close 2M 2K2 Contactor 140 milliseconds M Wait to look for Transition complete milliseconds 2 32 to 2 38 second N Filtering time on Transition complete input milliseconds 160 to 240 milliseconds 70 CDHF SVU01C EN CDHF SVU01C EN Control Sequence of Operation e TRANE Current passing through circuit breaker 105 reaches 2 normally open parallel sets of contacts those of refrigerant and oil pump relay 1A7 J2 5 to 1 and the 2K11 interlocking relay Connected at module 1A7 J2 2 to 4 Note While the 1A7 J2 5 to 1 relay automatically is closed by the main processor 1A22 as a part of the start sequence It can also be closed manually by changing the oil pump status to ON in the manual over ride mode menu of DynaView Closure of the 1A7 J2 5 to 1 or 2K11 contacts also allows current to pass through the coil of
93. m mode Note that each top level mode A general description of the top level modes is show in the following table Top Level Mode Description may contain multiple sub level Stopped Unit inhibited from running and will require modes In general the BAS CODE user action to go to Auto will reflect the top level mode and not Run Inhibit Unit inhibited from running by Tracer the sub level mode External BAS or an Auto Reset diagnostic Auto Unit determining if there is a need to run Waiting To Start Unit waiting for tasks required prior to compressor start to be completed Starting Compressor Unit is starting compressor Running Compressor is running with no limits in effect Running Limit Compressor is running with limit in effect Preparing To Shutdown Unit is closing inlet guide vanes prior to compressor shutdown Shutting Down Compressor has been stopped and unit is performing shutdown tasks CDHF SVUOTCEEN 33 e TRANE Operator Interface Figure 23 Main Reports Settings Ww Chiller Mode Running b gt Circuit 1 Mode Running b gt Circuit 2 Mode Starting Compressor b gt Evap Ent Lvg Water Temp 54 0 44 0 F Cond Ent Lvg Water Temp 85 0 95 0 F Active Chilled Water Setpt 440 F Auto Stop Main Screen Duplex CTV Reference Top Level Mode Sub Level Mode BAS Code SYSTEM RESET Boot amp A
94. ment Use the following procedure to service the oil filter Refer to Figure 34 1 Run the oil pump for two to three minutes to insure that the oil filter is warmed up to the oil sump temperature 2 Turn the oil pump motor off 3 Pull the D handle on the rotary valve locking pin out of its detent and rotate the valve to the DRAIN position An offset pointer is located on top of the valve with wrench flats to allow turning The spring force on the locking pin should allow the pin to drop into a detent at this position 4 Allow at least 15 minutes for the oil to drain from the filter back into the oil sump 5 Pull the D handle to unlock the pin and rotate the valve to the Change Filter position This isolates the filter from the unit The locking pin should drop into a detent in this position 6 Remove and replace the filter as quickly as possible Tighten filter 2 3 to 3 4 turn per instructions written on the filter Place the used filter in a reusable container Follow all local state and federal regulations to dispose of the filter Pull the D handle to unlock the pin and rotate the valve to the RUN position The locking pin should drop into a detent in this position The chiller is now ready for operation 7 Purge unit 8 Check oil pressure 18 22 psi CDHF SVU01C EN Other Maintenance Requirements Compressors using new seal technology will not use O rings The O rin
95. ms may also require that the chiller be inspected by a Trane authorized warranty agent every 4 years or 40 000 operating hours whichever occurs first This inspection will include at a minimum a review of the annual inspection checklists and the daily operating logs as well as performance of a leak test and a general inspection of the chiller The owner is then required to follow the recommendations made as a result of this inspection at the owners expense 99 e TRANE 100 Maintenance Recovery and Recycle Connections To facilitate refrigerant removal and replacement newer design CDHF CDHG units are provided with a 3 4 inch vapor fitting with shutoff valve on the chiller suction and with a 3 4 inch liquid connection with shutoff valve at the bottom of the evaporator shell Refer to Refrigerant Handling Guidelines Leak Testing To leak test a chiller containing full refrigerant charge raise chiller pressure using a controlled hot water or electric resistance system to a maximum of 8 psig Do not use nitrogen which will cause excessive refrigerant discharge by the purge system Cleaning the Condenser CAUTION Proper Water Treatment The use of untreated or improperly treated water in a CenTraVac may result in scaling erosion corrosion algae or slime It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment if any is required
96. mum Triptime Sec amp Maximum Triptime The Maximum Acceleration Time Setting and Current Transformer Setting are factory set however can be set with the service tool Sec 73 e TRANE Current Limit Protection Current Limit Protections exist to avoid motor current overload and damage to the compressor motor during starting and running Compressor motor current is continuously monitored and current is controlled via a limit function that to prevent running into over current diagnostic trips The current limit control logic attempts to prevent the motor from shutting down on a diagnostic trip by limiting compressor current draw relative to an adjustable current limit DynaView Current Limit Setpoint This setpoint can also be lowered to provide electrical demand limiting on the unit as required This could also be set to allow the Chiller to continue to run at a lower load to avoid tripping off via a diagnostic 74 Machine Protection and Adaptive Control The Current Limit function uses a PID algorithm Similar to the Leaving Water Temperature control that allows the chiller to run at the Current Limit Setpoint At machine startup or with any setpoint change the new current limit setpoint reached after the is filtered setpoint time elapses The minimum current limit setpoint is default set to 40 percent RLA 20 100
97. n typically disappears DynaView consists of various screens each meant to serve a unique purpose of the machine being served Tabs are shown across the top of the display The user selects a screen of information by touching the appropriate tab The folder that is selected will be brought to the front so it s contents are visable The main body of the screen is used for description text data setpoints or keys touch sensitive areas The double up arrows cause a page by page scroll either up or down The single arrow causes a line by line scroll to occur At the end of the screen the appropriate scroll buttons will disappear Wrap around will not occur The bottom of the screen is the persistent area It is present in all screens and performs the following functions The left circular area is used to reduce the contrast and viewing angle of the display The right circular area is used to increase the contrast and viewing angle of the display The contrast control will be limited to avoid complete light or complete dark which would potentially confuse an unfamiliar user to thinking the display was malfunctioning 31 e TRANE The Auto and Stop keys are used to put the unit into the auto or stop modes Key selection is indicated by being darkened reverse video The Alarms button is to the right of the Stop key The Alarms button appears only when alarm information is present The alarm blinks to draw
98. n the mechanical ventilation proper use of refrigerant HCFC 123 If itis required by local code is a Does the owner have a copy of the MSDS for self contained breathing apparatus available refrigerant HCFC 123 a el Was the owner given a copy of the Refrigerant Handling Guidelines Note Additional time required to properly complete the start up and commissioning due to any incompleteness of the of the installation will be invoiced at prevailing rates This is to certify that the CenTraVac chiller s has have been properly and completely installed and that the applicable items listed above have been satisfactorily completed Checklist Completed By Signed Date In accordance with your quotation and our purchase order number We will therefore require the presence of Trane service on the site for the purpose of start up and commissioning by Date Note Advance notification is required to allow scheduling of the start up as close as possible to the requested date Additional Comments Instructions A copy of this completed form must be submitted to the Trane Service Agency that will be responsible for the start up of the chiller 106 CDHF SVU01C EN e TRANE CenTraVac Commissioning Checklist Job Location Model Sales Order Start up Date Note The Unit Installation Operation and Maintenance Manual
99. n the display At this time the purge unit will start operating on Automatic and will continue to operate as long as chiller compressor is running Note Whenever the UCP detects a MMIR diagnostic condition during start up unit operation is locked out and manual reset is required before the start up sequence can begin again If the fault condition has not cleared the UCP will not permit restart 89 e TRANE When the cooling requirement is satisfied the UCP originates a Shutting down signal The inlet guide vanes are driven closed for 50 seconds and the unit enters a 3 minute post lube period The compressor motor and condenser water pump starter are de energized immediately but the oil pump continues to run during this 3 minute interval the evaporator pump will continue to run Once the post lube cycle is done the unit returns to auto mode Seasonal Unit Start Up 1 Close all drain valves and re install the drain plugs in the evaporator and condenser headers N Service the auxiliary equipment according to the start up and maintenance instructions provided by the respective equipment manufacturers w Vent and fill the cooling tower if used as well as the condenser and piping At this point all air must be removed from the system including each pass Then close the vents in the condenser water boxes 90 Unit Startup 4 Open all of the valves in the evaporator chilled wa
100. nalog Settings Subscreen shown below Analog Settings Subscreen displays the current value of the chosen setpoint in the upper of the display It is displayed in a changeable format consistent with its type Binary setpoints are considered to be simple two state enumeration and will use buttons Analog setpoints are displayed as spin buttons The lower half of the screen is reserved for help screens To change the setpoint the ENTER key must be touched otherwise the new setting is cancelled 1 Setpoint Screen Title Text Setpoint Value Enter Cancel ZN VW Press Arrows to Change Press Enter To Save Change Press Cancel To Ignore Change O Auto Stop e Note Spin buttons used to change setpoint value CDHF SVU01C EN e TRANE Operator Interface Settings with buttons only screen has no cancel or enter key do accept the new selection immediately Back Setpoint Screen Title Setpoint Value Radio 1 Button Selections Radio 2 Note Radio 1 and Radio 2 refer to touch sensitive buttons The labels depend upon the setting being Press Button To Select controlled O Auto Stop e The analog setting subscreen is similar but offers an Auto Manual radio button and value setting An Auto Manual selection is necessary to set the mode to override Subsequently when an arrow key is depressed that n
101. ncreases as the saturated evaporator temperature approaches the evaporator limit setpoint Unload The potential to unload increases as the saturated evaporator temperature falls further below the evaporator limit setpoint Figure 31 illustrates these functions as follows chilled water setpoint top bold line evap leaving water temp cutout center bold line evap rfgt temp cutout bottom bold line 78 CDHF SVU01C EN CDHF SVU01C EN Machine Protection and Adaptive Control e TRANE Condenser Limit Condenser pressure is continuously monitored to provide a limit function that prevents High Pressure Cutout HPC trips This protection is called Condenser Refrigerant Pressure Limit or High Pressure Limit A fully loaded compressor operating at high Evaporator Leaving Water Temperature ELWT and high condenser temperatures causes high condenser pressures The purpose of this limit is to avoid High Pressure Cutout HPC trips by allowing the Chiller to continue to run at a lower load instead of tripping off via HPC The Condenser Limit will be based from a pressure conversion from the Condenser Refrigerant Temperature sensor unless there is a Condenser Refrigerant Pressure sensor installed CDRP option If the Condenser Refrigerant Pressure Sensor is installed then the limit will be based from the Pressure sensor When limited by this action Condenser Pressure Limit will be displayed as a sub operat
102. nd compressor is staged on The First and Second compressor will be determined by the type of duplex start selected CDHF SVU01C EN 15 e TRANE General information Staging Second Compressor Off This diagram shows the sequence of operations where there is no longer a need to run the Second compressor so it is staged off The First and Second compressor will be determined by the type of duplex start selected Figure 10 CDHE F G sequence of operation staging second compressor off Call lor Senor Chrous OF Satisfied Setpoint This diagram shows the sequence of operations where the setpoint has been satisfied and the last compressor is staged off Figure 11 CDHE CDHF and CDHG sequence of operation normal shutdown to stopped and run inhibit Evap LWT rnpa Below p Oo Siop 16 CDHF SVU01C EN Duplex Compressor Sequencing Four methods Two fixed sequence methods a balanced start and hour s method and a no staging method are provided for order of a compressor sequencing on CTV Duplex chillers The desired method is selectable at startup via the service tool The application can decide to either balance the wear burden among the unit s compressors to start the most efficient compressor or to simultaneously start and stop both compressors to minimize startup pull down time Each method has specific applications were it can be used advantageously If one compressor is lo
103. needs one compressor then the upstream compressor would be running closer to its selection point and will be the most efficient compressor to operate Figure 13 CDHE F G sequence of operation lead 2 lag 1 Evap L NT Fals Bira Herria Evig LAT Hitti Hiei CDHF SVU01C EN CDHF SVU01C EN e TRANE General Information Sequencing Balanced Starts and restart inhibit or a circuit diagnostic Hours then the other compressor will be When desired to balance the wear started The second compressor will between the compressors This stage on when chiller capacity method will extend the time between exceeds the Stage on Load point for maintenance on the lead compressor 30 seconds When chiller capacity When balanced starts and hours is falls below Stage off Load point for selected the compressor with the 30 seconds the compressor with the fewest starts will start If that most hours will be shut off compressor is unavailable to start due to a circuit lockout including Figure 14 CDHF G sequence of operation equalize starts and hours Evap LWT Paia Dill in ing Con wih Fw Irt dd Harij Carry Lena Binge Tum X Capicity Deia pru wan Geis are Dn Tera Casting 19 e TRANE 20 General Information Simultaneous Compressor Start Stop Both compressors will start in close succession to minimize the time it
104. neric BAS systems to start another chiller The minimum default at 0 percent and maximum default at 100 percent capacity are adjustable via the service tool 75 e TRANE Evaporator Limit Evaporator refrigerant temperature is continuously monitored to provide a limit function that prevents low refrigerant temperature trips which allows the chiller to continue to run at a reduced load instead of tripping off at the Low Evaporator Refrigerant Temperature Cutout Setpoint LRTC Evaporator limit could occur with an initial pull down of a loop where the Condenser is colder than the Evaporator Inverted Start the Evaporator refrigerant temperature may drop below the Low Refrigerant Temperature Cutout LRTC This limit prevents the unit from shutting down on a diagnostic during this type of pulldown Another example is a Chiller that is low on refrigerant charge will run with low Evaporator refrigerant temperatures This limit allows the chiller to continue to run at a reduced load 76 Machine Protection and Adaptive Control Evaporator Limit uses the Evaporator Refrigerant Temperature sensor in a PID algorithm Similar to the Leaving Water Temperature control that allows the chiller to run at the LRTC 2 degree F When actively limiting machine control Evaporator Temperature Limit will be displayed as a sub operating mode Leaving Water Temperature Cutout Leaving water temperature cutout is a saf
105. ng valve 1 Use the DynaView manual override of the UCP to manually start the oil pump 2 Proceed to the Compressor Report menu and observe the Differential Oil Pressure 3 Adjust the oil pressure regulating valve to maintain 18 to 22 psid The oil pressure regulating valve may require adjustment as the unit is started 4 This procedure also checks to ensure correct sensing of oil pressure The Oil Pressure Cutout setting is adjustable within via the CH530 Service Tool 5 Return Oil Pump control to Auto from within the DynaView Check vane operator and vanes Service Tool 1 Use the Service Tool manual override menu to manually override the vane control 2 Enter targets from 0 to 100 and observe vane operation At minimum and maximum travel the operator should not exert any force on the vane assembly adjust as required 3 Vane movement is smooth to open close 4 Vane movement is reported back to the UCP 5 Return Vane control to Auto Dry run the starter Service Tool 1 Make sure the starter disconnect is safety locked open 2 Use the Service Tool menu of the UCP to initiate the Starter Dry Run 3 Observe correct operation of starter contactors 4 Observe correct operation of transition complete signal if required 5 Disable Starter Dry Run when complete Remove Power Disconnect and remove temporary power cord B Preparation for Start up 110 1
106. nt overload phase reversal phase loss phase imbalance and momentary power loss These functions are discussed in the motor protection section of this manual EarthWise Purge Trane has also revolutionized its controller integrated purge which features an automatic regeneration system for high efficiency maintenance free refrigerant containment Air and noncondensables are pumped out faster and the lower temperature refrigeration system enhances the base purge efficiency See EarthWise purge operation and maintenance manual for details Unit mounted medium voltage starter Take advantage of Tracer CH530 s new starter and save space in your equipment room There is no need for a remote or floor mounted starter with our new exclusive unit mounted medium voltage starter from Cutler Hammer The following two figures illustrate the typical location of various standard and optional unit mounted control and sensor devices CDHF SVU01C EN e TRANE Control System Components ni ni i svi evi z B iL a 1 olay TOYLNOD LINN TOMINOO LINN i Z UNY 1 0 0333 10 0334 10 cup LINN 39Nnd 214 ONILNNON 39Nnd
107. ocessor communications Bus providing module power 103 also provides power to the external chiller water proof of flow device connected between terminal block 1X1 5 to 1A6 J3 2 and condenser water proof of flow device connected at 1X1 6 to 1A6 J2 2 4 Circuit Breaker 104 which provides power to the Oil Heater 4HR1 circuit and to circuit breaker 1O5 oil and refrigerant pump circuits 5 The DynaView display module 1A22 receives 24 vdc power from the IPC bus UCP and Wye Delta Starter Control Circuits Logic Circuits within the various modules will determine the starting running and stopping operation of the chiller When operation of the chiller is required the chiller mode is set at Auto Using customer supplied power the chilled water pump relay 5K1 is energized by the 1A5 Module output at 1A5 J2 4 and chilled water flow must be verified within 4 minutes 15 seconds by the 1A6 Module The main processors logic decides to start the chiller based on the differential to start setpoint With the differential to start criteria met module 1A5 then energizes condenser water pump relay 5K2 via customer supplied power at 1A5 J2 1 Based on the restart inhibit function and the differential to start setpoint oil and refrigerant pump 4M3 will be energized by 1A7 Module 1A7 J1 The oil pressure must be at least 9 Psid for 30 continuous seconds and condenser water flow verified within 4 minutes 15 seconds minutes f
108. omizers 1 LH and 2 RH See Figure 1 for General Unit Purge 1 LH and 2 RH components Each Chiller unit is Oil Tank Refrig Pump 1 LH and 2 composed of the following RH components as viewed when facing Control Panel 1 LH and 2 RH the control panel front side And when specified Unit mounted Common Evaporator and Common Starters 1 LH and 2 RH not Condenser shown Figure 1 General Duplex unit components front view COMPRESSOR 2 c 2 CONTROL PANEL 2 8 CDHF SVU01C EN General Information Figure 2 General Duplex unit components 2 stage compressor PIDEN fe CONDENSER Ay SN gt Purge 2 a CONDENSER N ECONOMIZER G 2 11 OIL TANK AND N RENEI EINI PUMP A gt n p gt w OIL TANK AND REFRIGERANT PUMP 2 Oran Q 9 EVAPORATOR CDHF SVU01C EN e TRANE Cooling Cycle Duplex Chillers have two refrigerant circuits that operate as their own independent circuits These circuits are discussed as individual chiller refrigeration units in the following discussion The sequence of operation of the two refrigeration circuits is discussed in a later section When in the cooling mode liquid refrigerant is distributed along the length of the evaporator and sprayed through small holes in a distributor i e running the entire length of the shell to unif
109. on eset AKIMA nerement ncrement actory Degrees of Reset Reset Ratio Start Reset English SI Units Default Reset TOD Range Units Value Return Oto 20 F 0 1 F 0 1 C The chiller will start at the Differential 0 0 to 11 11 C 2 78 C to Start value above a fully reset CWS Outdoor 0 to 20 F 0 1 F 0 1 C or CWS for both Return and Outdoor 0 2 to 11 11 C 2 78 C Reset The graph on the next page shows the reset function for Outdoor Air Temperature Note This graph assumes that Maximum Reset is set to 20 degrees Degrees of Reset Degrees of Reset Active CWS Front Panel CWS or Degrees of Reset CWS CWS To obtain Active CWS from Degrees of Reset Active CWS Degrees of Reset Front Panel CWS multiply CDHF SVU01C EN Reset Ratio The Reset Ratio is displayed as a percentage To use it in the above equation it must be converted to it s decimal form Reset Ratio percent 100 Reset Ratio decimal Example of converting Reset Ratio If the Reset Ratio displayed on the CLD is 50 percent then use 50 100 5 in the equation TOD Outdoor Air Temperature Machine Protection and Adaptive Control e TRANE Start Reset Outdoor Air Start Reset Example of Calculating Reset for Outdoor Air Temperature If Reset Ratio 35 percent Start Reset 80 TOD 65 Maximum Reset 10 5 How many Degrees of Reset will there be Degrees of Reset Reset
110. or the compressor start sequence to be initiated 67 e TRANE When less than 5 seconds remain before compressor start a starter test is conducted to verify contactor states prior to starting the compressor The following test or start sequence is conducted for Wye Delta starters Also refer to Figure 24 A Test for transition complete contact open 2A1 J12 2 160 to 240 msec An MMR diagnostic will be generated if the contact is closed B Delay time 20 msec C Close start contactor 2K 1 and check for no current 500 msec If currents are detected the MMR diagnostic Starter Fault Type is generated D Stop relay 2A1 J10 3 to 1 closes for one second for test C above E Delay time 200 msec Opens 2K1 F Close shorting contactor 2K3 and check for no current one second If currents are detected the MMR diagnostic Starter Fault Type II is generated Starter Integrity test 68 Control Sequence of Operation G If no diagnostics are generated in the above tests the Stop Relay 2A1 J10 is closed for 2 seconds and the Start Relay 2A1 J8 is closed to energize the start contactor 2K1 The shorting contactor 2K3 has already been energized from F above The compressor motor 4M1 starts in the Wye configuration an auxiliary contact 2K1 AUX locks in the start contactor 2K1 coil Additonally 2K11 pulls in to hold the oil pump on This is parallel to 1A7 cont
111. ormly coat each evaporator tube Here the liquid refrigerant absorbs enough heat from the system waiter circulating through the evaporator tubes to vaporize The gaseous refrigerant is then drawn through the eliminators which remove droplets of liquid refrigerant from the gas and first stage variable inlet guide vanes and into the first stage impeller Note Inlet guide vanes are designed to modulate the flow of gaseous refrigerant to meet system capacity requirements they also prerotate the gas allowing it to enter the impeller at an optimal angle that maximizes efficiency at all load conditions Compressor 1 or 2 3 Stage Compressed gas from the first stage impeller flows through the fixed second stage inlet vanes and into the second stage impeller 10 General Information Here the refrigerant gas is again compressed and then discharged through the third stage variable guide vanes and into the third stage impeller Once the gas is compressed a third time it is discharged into the condenser Baffles within the condenser shell distribute the compressed refrigerant gas evenly across the condenser tube bundle Cooling tower water circulated through the condenser tubes absorbs heat from the refrigerant causing it to condense The liquid refrigerant then passes through orifice plate and into the economizer The economizer reduces the energy requirements of the refrigerant cycle by eliminating the
112. out Type of Diagnostic Latching results in Immediate Shutdown Default Setpoint value 180 F 82 2 C Implemented to avoid overheating of the oil and the bearings If the oil temperature is at or above the High Oil Temperature Cutout setpoint this diagnostic will be issued which will stop the compressor If Oil Temperature violates this temperature cutout for more than 120 seconds this diagnostic is issued Manual Oil Pump Control The oil pump control accepts commands to turn on the oil pump The manual oil pump choices will be Auto or On When the oil pump is commanded On it will revert to Auto in 15 minutes CDHF SVU01C EN Controls Chilled Water Reset CWR Chilled water reset is designed for those applications where the design chilled water temperature is not required at partload In these cases the leaving chilled water temperature setpoint can be reset upward using the CWR features When the CWR function is based on return water temperature the CWR feature is standard When the CWR function is based on outdoor air temperature the CWR feature is an option requiring an outdoor temperature sensor module installed in the UCP panel and sensor installed outdoors The type of CWR is selected in the Operator Interface settings Menu along with the Reset Ratio Start Reset Setpoint and the Maximum Reset Setpoint CDHF SVU01C EN Machine Protection and Adaptive Control e
113. ows 83 e TRANE Machine Protection and Adaptive Control Table 3 Values for start reset types Constant Return The values for RESET TYPE are CWS CWS 100 percent Reset Outdoor Return Const Return Design Delta Temperature TWE Type Disable Air Reset Reset Reset TWL and CWS gt or CWS and CWS CWS lt or Maximum Reset The values for RESET RATIO for each of the reset types are Notice that Constant Return is Reset p nothing more than a specific case of Type ngis nits efault Return Reset offered for operator R 10 to 120 1 T t ee eturn to percent percen percen percen Outdoor 80to 80 percent 1 percent 1 percent 10 percent When any type of CWR is enabled the UCP will step the CWS toward The values for START RESET for each of the reset types are the desired CWS based on the above Reset Start Increment Increment Factory equations and setup parameters at a Type Reset English SI Units Default rate of 1 F every 5 minutes until the Range Units Value Active CWS equals the desired Return 410 30 F 0 1 F 0 1 C 10 F 56 CWS This applies when the chiller 2 2 to 16 7 C is running only Outdoor 50 to 130 F 0 1 F 0 1 C 90 F Using the Equation for calculating 10 to 54 44 C 32 22 C CWR for Outdoor Air Temperature The values for MAXIMUM RESET for each of the reset types are PAS R Maxi E Equati
114. pacity Control Soft Loading 74 Running Limit Current Limit 75 Running Limit Phase Unbalance Limit 75 Running Limit Condenser Pressure Limit 75 Running Limit Evaporator Temperature Limit 75 Running Limit Minimum Capacity Limit 75 Running Limit Maximum Capacity Limit 75 Preparing To Shutdown Closing IGV IGV Position 96 7E Shutting Down Post Lubrication Time MIN SEC 7E Shutting Down Evaporator Pump Off Delay MIN SEC 7E Shutting Down Condenser Pump Off Delay MIN SEC 7E CDHF SVU01C EN 35 e TRANE Operator Interface Main Screen The main screen is provides an overall view of the chiller performance in addition to the main and sub operating modes The table below indicates other items found when specified by options that can be scrolled to via the up or down arrows Main Screen Data Fields Table Description Units Resolution Dependencies 1 Chiller Mode gt gt submodes 2 Circuit 1 Mode gt gt submodes 3 Circuit 2 Mode gt gt submodes 4 Evap Ent Lvg Water Temp F C 0 1 5 Cond Ent Lvg Water Temp F C 0 1 6 Active Chilled Water Setpoint gt gt source F C 0 1 7 Active Hot Wtr Setpoint gt gt source F G 0 1 If in heat installed 8 Active Current Limit Setpoint gt gt source RLA 1 9 Active Base Loading Setpoint gt gt source 1 If enabled 10 Circuit 1 Purge Mode status i e on off See modes in Emum adaptive auto
115. pective DynaView screens during a power up of the main processor This process takes from 30 to 50 seconds depending on the number of installed Options On all power ups the software model always will transition through the Stopped Software state independent of the last mode If the last mode before power down was Auto the transition from Stopped to Starting occurs but it is not apparent to the user Software Operation Overview Diagram The Software Operation Overview is a diagram of the five possible software states This diagram can be thought of as a State Chart with the arrows and arrow text depicting the transitions between states The text in the circles are the internal software designations for each State The first line of text in the Circles are the visible top level operating modes that can be displayed on Dyna View The shading of each software state circle corresponds to the shading on the timelines that show the state that the chiller is in CDHF SVU01C EN e TRANE General Information Figure 8 CDHE F G sequence of operation auto to running This diagram shows the sequence of operations for a start of the first compressor on a duplex chiller The First compressor will be determined by the type of duplex start selected Staging Second Compressor On This diagram shows the sequence of operations where the First compressor is all ready running and the seco
116. pplication software part number self test and configuration validity screens will be present NA Stopped Local Stop 00 Stopped Panic Stop 00 Stopped Diagnostic Shutdown Manual Reset 00 Run Inhibit Ice Building Is Complete 100 Run Inhibit Tracer Inhibit 100 Run Inhibit External Source Inhibit 100 Run Inhibit Diagnostic Shutdown Auto Reset 100 Auto Waiting For Evaporator Water Flow 58 Auto Waiting For A Need To Cool 58 Auto Waiting For A Need To Heat 58 Auto Power Up Delay Inhibit MIN SEC 58 Waiting To Start Waiting For Condenser Water Flow 70 Waiting To Start Establishing Oil Pressure 70 Waiting To Start Pre Lubrication Time MIN SEC 70 34 CDHF SVU01C EN Operator Interface e TRANE Reference Top Level Mode Sub Level Mode BAS Code Waiting To Start Motor Temperature Inhibit Motor Temperature Inhibit Temperature 70 Waiting To Start Restart Time Inhibit MIN SEC 70 Waiting To Start High Vacuum Inhibit Oil Sump Press Inhibit Press 70 Waiting To Start Low Oil Temperature Inhibit Oil Temperature Inhibit Temperature 70 Waiting To Start Waiting For Starter To Start MIN SEC 70 Starting Compressor There is no sub mode displayed 72 Running There is no sub mode displayed 74 Running Hot Water Control 74 Running Surge 74 Running Base Loaded 74 Running Ice Building 74 Running Ice To Normal Transition 74 Running Current Control Soft Loading 74 Running Ca
117. purge manual 11 Circuit 2 Purge Mode status i e on off See modes in Enum adaptive auto purge manual 12 Approx Chiller Capacity Tons kW XXX If option installed 13 Active Ice Termination Setpoint gt gt source F C 0 1 If option installed 14 Software Version 0 XX Chiller Operating Mode The machine operating mode Circuit Operating Mode The circuit operating modes indicate indicates the operational status ofthe the operational status of the circuits chiller A subscreen with additional mode summary information will be provided by selection of an A subscreen with additional mode summary information will be provided by selection of an additional information icon gt gt The additional information icon gt gt The operating mode lines will remain operating mode lines will remain stationary while the remaining status stationary while the remaining status items scroll with the up down arrow items scroll with the up down arrow keys 36 keys CDHF SVU01C EN Diagnostic Screen The diagnostic screen is accessible by touching the Alarms enunciator When an alarm is present the alarm enunciator is present next to the Stop key A flashing alarm indicates a machine shutdown and a non flashing alarm indicates an informational message Machine shutdowns can be of two types Latching Machine Shutdown Manual Reset Required IVIMR or Non Latching Machine Shutdown Auto Reset
118. r exceeds 15 PSIG 103 4 Kpa A signifcant release of refrigerant into a confined space due to a rupture disk failure could displace available oxygen to breathe and cause possible asphyxiation Should a rupture disk fail evacuate the area immediately and contact the appropriate rescue or response authority Failure to take appropriate precautions or react properly to a potential hazard could reuslt in death or serious injury CDHF SVU01C EN CDHF SVU01C EN Unit Shutdown e TRANE Unit Shutdown Procedures Daily Unit Shutdown Note Refer to Start Run Shutdown sequence in General Information Overview Sequence of Operation 1 Press STOP 2 After compressor and water pumps shutdown turn Pump Contactors to OFF or open pump disconnects Seasonal Unit Shutdown CAUTION Oil Pump Heater Operation CONTROL POWER DISCONNECT SWITCH MUST REMAIN CLOSED TO ALLOW OIL SUMP HEATER OPERATION Failure to do this will allow refrigerant to condense in the oil pump 3 Open all disconnect switches except the control power disconnect switch 4 Drain the condenser piping and cooling tower if used Rinse with clean water 5 Remove the drain and vent plugs from the condenser headers to drain the condenser Air dry bundle of residual water 6 Once the unit is secured for winter the maintenance procedures described under Annual Maintenance in the Periodic Maintenance section of this manual should b
119. rators should be serviced annually with R123 compatible grease Use only Rheolube 734A available from Trane as LUB00033 160z standard grease gun cartridge or LUB00063 3oz mini grease gun cartridge To service the 1st stage tang operator of all units except CDHF extended capacity chillers with 1470 or 1720 compressors 1 The chiller must be off 2 Carefully remove any insulation that may have been placed over the two lubrication ports of the tang operator base This insulation will need to be replaced after the service is complete 3 Note the position of the tang operator arm note the placement of spacing washers etc then disconnect the linkage rod from the tang operator arm Manually move the tang operator arm and note the amount of effort required to operate the assembly 4 Loosen but DO NOT REMOVE the 1 16 NPT lubrication port plug that is highest on the assembly 5 Loosen and remove the remaining lower 1 16 NPT plug 6 Using a grease gun with an appropriate fitting insert ONLY Rheolube grease into the open port until clean grease is seen to appear around the threads of the plug in the opposite port 7 Tighten the plug that was loosened in step 4 Tighten the plug to hand tight plus 1 4 to 1 2 turn 8 Remove the grease fitting if used 97 e TRANE DO NOT LEAVE GREASE FITTINGS INSTALLED If grease fittings have been used for this procedure then they MUST BE REMOVED before returning the un
120. rcuit Operating Mode Enum 2 Amps L1L2L3 XXXX Amps XXX X if less than 1000 Amps 3 Volts AB BC CA XXXX Volts 4 Purge Daily Pumpout 24 Hrs XXXX Min 5 Purge Daily Pumpout Limit Alarm XXX Min 6 Purge Pumpout Life XXXXXX X Min 7 Purge Operating Mode Enum 8 Purge Status Enum 9 Compressor Starts XXXX Integer 10 Compressor Running Time XX XX Hours Minute 11 Compressor Rfgt Discharge Temp XXX X Temperature If option installed 12 Oil Pump Discharge Pressure XXXX Pressure 13 Oil Tank Pressure XXXX Pressure 14 Differential Oil Pressure XXXX Diff Pressure 15 Oil Tank Temp XXX Temperature 16 Inboard Bearing Temp XXX X Temperature If option installed 17 Outboard Bearing Temp XXX X Temperature If option installed 18 Evap Sat Refrigerant Temp XXXX Temperature 19 Evap Rfgt Pressure XXXX Pressure 20 Evap Approach Temp XXX X Temperature 21 Cond Sat Rfgt Temp XXX X Temperature 22 Cond Rfgt Pressure XXX X Pressure 23 Condenser Approach Temp XXX X Temperature Historic Diagnostics Log 1 to 20 Historic Diagnostics main processor 2 0 and later 42 CDHF SVU01C EN Setting Tab screens provides a user the ability to adjust settings justified to support daily tasks The layout provides a list of sub menus organized by typical subsystem To change chilled water setpoint first select the settings tab screen Chilled water setpoint to within the chiller sub menu See next page for
121. rforms pre lube performing post lube starts the compressor s performs water temperature control establishes limits and pre positions the inlet guide vanes 30 Operator Interface DynaView presents three menu tabs across the top which are labeled MAIN REPORTS and SETTINGS The Main screen provides an overall high level chiller status so the operator can quickly understand the mode of operation of the chiller The Chiller Operating Mode will present a top level indication of the chiller mode Auto Running Inhibit Run Inhibit etc The additional information icon arrow will present a subscreen that lists in further detail the subsystem modes See Machine Operating Modes Main screen content can be viewed by selecting the up or down arrow icons The Main screen is the default screen and after an idle time of 30 minutes The MP contains non volatile memory both checking for valid set points and retaining them on any power loss System data from modules LLID can be viewed at the DynaView operator interface Such as evaporator and condenser water temperatures outdoor air temperature evaporator and condenser water pump control status and alarm relays external auto stop emergency stop evaporator and condenser water pressure drops and evaporator and condenser water flow switches CDHF SVU01C EN DynaView DV is the operator interface of the Tracer CH530 control system utilized on the C
122. ring replacements parts or requesting service Note Unit mounted starters are identified by a separate number found on the starter Typical Product Description Block 3 Product Coding Block The CDHF and CDHG models are defined and built using the product definition and selection PDS system This system describes the product offerings in terms of a product coding block which is made up of feature categories and feature codes An example of a typical product code block is given on this page The coding block precisely identifies all characteristics of a unit 4 Identifies unit electrical requirements 5 Correct operating charges and type of refrigerant 6 Unit Test Pressures and Maximum Operating Pressures 7 Identifies unit Installation and Operation and Maintenance manuals 8 Drawing numbers for Unit Wiring Diagrams MODL CDHF DSEO 2R NTON 2500 VOLT 575 REF 123 HRTZ 60 TYPE SNGL CPKW 142 CPIM 222 TEST AIR EVTM IECU EVTH 28 EVSZ 032S EVBS 280 EVWC STD EVWP 2 EVWT NMAR EVPR 150 EVCO VICT EVWA LELE CDTM IECU CDTH 28 CDSZ 032S CDBS 250 CDWC STD CDWP 2 CDWTNMAR CDPR 150 CDCO VICT CDWA LELE CDTY STD TSTY STD ECTY WEOR ORSZ 230 PURG PURE WCNM SNMP SPKGDOM OPTI CPDW HHOP NO GENR NO GNSL NO SOPT SPSH ACCY ISLS HGBP WO LUBE SNGL AGLT CUL CNIF UCP SRTY USTR SRRL 207 PNCO TERM CDHF SVU01C EN Model Number An example of a typical duplex centrifugal chiller model number is
123. rol Unit Startup Unit Shutdown Periodic Maintenance Oil Maintenance Maintenance Forms 28 30 38 51 52 67 72 89 91 92 95 97 104 e TRANE Literature change Applicable to CDHF CDHG About this manual Operation and maintenance information for models CDHF CDHG are covered in this manual This includes both 50 and 60 Hz CDHF and CDHG centrifugal chillers equipped with the Tracer CH530 Chiller Controller system Please note that information pertains to all three chiller types unless differences exist in which case the sections are broken down by Chiller type as applicable and discussed separately By carefully reviewing this information and following the instructions given the owner or operator can successfully operate and maintain a CDHF or CDHG unit If mechanical problems do occur however contact a qualified service organization to ensure proper diagnosis and repair of the unit General Information Unit Nameplate The unit nameplate is located on the left side of the unit control panel The following information is provided on the unit nameplate 1 Serial Number The unit serial number provides the specific chiller identity Always provide this serial number when calling for service or during parts identification 2 Service Model Number The service model represents the unit as built for service purposes It identifies the selections of variable unit features required when orde
124. rols Field Connection Description Package Purpose Point Terminals 1A1 Power Supply Standard 1 Converts 24 vac to 24 vdc not for field use 1A2 Power Supply as required 2 Converts 24 vac to 24 vdc not for field use 1A3 Dual Relay Standard Relay 1 Oil Heater Relay not for field use Output modules 1A4 Dual High Standard High Pressure Cutout not for field use Voltage Input 1A5 Quad Relay Standard Relay 1 Chilled water pump J2 4 NO J2 5 NC Output modules Relay 1 J2 6 common 1A5 Quad Relay Standard Relay 2 Condenser water pump control J2 1 NO J2 2 NC Output modules relay 2 J2 3 common 1A6 Dual High Standard Input 1 Condenser Flow Input J2 2 Condenser water Voltage Input flow switch 1A6 Dual High Standard Input 2 Evaporator Flow Input J3 2 Chilled water Voltage Input flow switch 1A7 High Power Standard Oil Pump and not for field use Output Relay Refrigerant Pump 1A13 Dual LV Binary Standard Signal 1 External Auto Stop J2 1 Binary Input Signal 1 input module J2 2 Ground 1A13 Dual LV Binary Standard Signal 2 Emergency stop J2 3 Binary Input Signal 2 input module J2 4 Ground 1A26 Temp Sensor Standard Compressor Motor not for field use Input 1F1 Standard LLID Power Supply Transformer not for field use Primary Circuit protection 171 Standard Control Panel Power not for field use Transformer 120 24Vac 101 Standard Circuit Breaker Compressor not for field use Motor Controller Control Power Branch Circuit 102 Standard Circuit Breaker
125. running in the Delta configuration the inlet guide vanes will modulate opening and closing to the chiller load variation by operation of the stepper vane motor actuator 4M2 4M4 extended capacity to satisfy chilled water setpoint The chiller continues to run in its appropriate mode of operation Normal Softload Limit Mode etcetera As explained in the General Information section If the chilled water temperature drops below the chilled water set point by an amount set as the differential to stop setpoint a normal chiller stop sequence is initiated as follows Refer to Figure 10 1 The inlet guide vanes are driven closed for 50 seconds CDHF SVU01C EN Control Sequence of Operation e TRANE 2 After the 50 seconds has elapsed the stop relay 2A1 J10 and the condenser water pump relays 1A5 J2 open to turn off The oil and refrigerant pump motor 4B3 will continue to run for 3 minutes post lube while the compressor coasts to a stop The chilled water pump will continue to run while the Main processor module 1A22 monitors leaving chilled water temperature preparing for the next compressor motor start based on the differential to start setpoint If the STOP key is pressed on the operator interface the chiller will follow the same stop sequence as above except the chilled water pump relay 1A5 J2 will also open and stop the chilled water pump after the chilled water pump delay timer has
126. ry mission This type of operation requires an endless source of evaporator load heat such as well or lake water The chiller has only one condenser Note Hot water temperature control mode does not convert the chiller to a heat pump Heat pump refers to the capability to change from a cooling driven application to a heating driven application by changing the refrigerant path on the chiller This is impractical for centrifugal chillers as it would be much easier to switch over the water side This is NOT heat recovery Although this feature could be used to recover heat in some form there s not a second heat exchanger on the condenser side CDHF SVU01C EN General Information e TRANE The DynaView Main Processor provides the hot water temperature control mode as standard The leaving condenser water temperature is controlled to a hot water setpoint between 80 and 140 F 26 7 to 60 C The leaving evaporator water temperature is left to drift to satisfy the heating load of the condenser In this application the evaporator is normally piped into a lake well or other source of constant temperature water for the purpose of extracting heat In hot water temperature control mode all the limit modes and diagnostics operate as in normal cooling with one exception The leaving condenser water temperature sensor is an MMR diagnostic when in hot water temperature control mode It is an informational warning in t
127. s This overload protection logic is independent of the current limit The overload protection will ultimately shut the unit down anytime the highest of the three phase currents exceeds the time trip curve A manual reset diagnostic describing the failure will be displayed CDHF SVU01C EN Machine Protection and Adaptive Control e TRANE Overload protection for the motor starts based on the Maximum Time to Transition permitted for a particular motor Running Over Current Protection In the run mode a time to trip curve is looked at to determine if a diagnostic should be called The UCP continuously monitors compressor line currents to provide running over current and locked rotor protection Over current protection is based on the line with the highest current It triggers a manually resettable diagnostic shutting down the compressor when the current exceeds the specified time trip curve The compressor overload time trip curve is expressed as a percent of the Rated Load Amps of the compressor and is not adjustable Overload Must Hold 102 Percent RLA Overload Must Trip in 20 0 3 seconds 112 Percent RLA Note the above gives a nominal 20 second must trip point of 107 Percent RLA Overload Must Trip in 1 5 seconds 140 Percent RLA Nominal The linear time trip curve is as follows Figure 30 Overload trip time versus percent RLA Nominal Triptime Sec B Mini
128. s including Warning and Cautions Applicable Service Alerts and Bulletins Submittals and Design Specifications must be used in conjunction with this checklist 1 PRECOMMISSIONING PROCEDURES A Obtain Installation Check Sheet This must be prepared by installer for a particular unit verifying the unit is ready for commissioning B Obtain Design order Specification Data This indicates the design criteria of the particular unit A unit cannot be properly commissioned unless this data is known It is the responsibility of the selling office to furnish this data C Obtain Wiring Diagrams The as wired electrical diagram should be compatible with the recommended Trane submittals and diagrams Are customer added external remote control circuits compatible Yes No D General Installation Observations 1 Is there any apparent shipping or rigging damage Yes No 2 Record the unit pressure upon receipt psig If there is no pressure a leak test will have to be done before the unit can be evacuated and charged 3 Is the water piping correctly installed Flow Switches Yes No Pressure Gauges Yes No Isolations Valves Yes No Flow Balancing Valves Yes No Thermometer Wells Yes No Vent Cocks and Drains Yes No 4 Have proper clearances around the unit been maintained per submi
129. service organization to leak test the chiller this procedure is especially important if the system requires frequent purging 1 Use a nondestructive tube test to inspect the condenser and evaporator tubes at 3 year intervals Note It may be desirable to perform tube tests on these components at more frequent intervals depending upon chiller application This is especially true of critical process equipment 1 Depending on chiller duty contact a qualified service organization to determine when to conduct a complete examination of the unit to discern the condition of the compressor and internal components Note a Chronic air leaks which can cause acidic conditions in the compressor oil and result in premature bearing wear and b Evaporator or condenser water tube leaks Water mixed with the compressor oil can result in bearing pitting corrosion or excessive wear Submit a sample of the compressor oil to a Trane qualified laboratory for comprehensive analysis on an annual basis this analysis determines system moisture content acid level and wear metal content of the oil and can be used as a diagnostic tool Lubrication The only chiller component that requires periodic lubrication is the external vane linkage assembly and Rotary oil valve Lubricate the vane linkage shaft bearings and rod end bearings as needed with a few drops of light weight machine oil The CenTraVac inlet guide vane tang ope
130. sor if the chiller is reconnected to the line while the motor and line phases do not match The chiller will be shut down when a MPL is detected and will display a non latching diagnostic indicating the failure The oil pump will be run for the post lube time period when power returns The compressor and compressor motor are protected from damage from large torques and inrush currents resulting from reconnecting the compressor motor to the power source following a momentary loss of power MPL s greater than 2 or 3 cycles are detected resulting in unit shut down Disconnection from the line is initiated within 6 line cycles of the power loss MPL protection is active anytime the compressor is in the running mode The transition complete input has been satisfied MPL is enabled however can be disabled if required via the service tool Figure 29 Sequence of operation momentary power loss DynaView and starter module remain powered Running ee Momentary Power Loss Detected Shutting Down MPL Clenred and Hoed to Cool enis men t amor 72 Enforce Stop to Start Timer 5 to 200 Seconds 7 Sec is Default CDHF SVU01C EN Current Overload Protection Motor currents are continuously monitored for over current protection and locked rotor protection This protects the Chiller itself from damage due to current overload during starting and running modes but is allowed to reach full load amp
131. ssures This vde output is located at 1A15 J2 4 to J2 6 Ground The Voltage DC Output can source a maximum of 22 mA of current This output is Voltage DC only 4 20 mA is not supported A Condenser Pressure Output 2 to 10 corresponds to 0 Psia to the HPC in Psia setting Note CH530 control allows for Delta Pressure or condenser pressure but not both on one circuit 58 Control System Components Temperature based On standard machines the Percent Condenser Pressure Indication Output is based on the Saturated Condenser Refrigerant and a temperature to pressure conversion is made If the Condenser Saturated Temperature goes out of range due to an open or short a pressure sensor diagnostic will be called and the output will also go to the respective out of range value That is for an out of range low on the sensor the output will be limited to 2 0 VDC For an out of range high on the sensor the output will be limited to 10 0 VDC Pressure based With the Enhanced Protection EPRO option a condenser pressure transducer is installed and the pressure is measured If the Condenser Pressure sensor goes out of range due to either an open or short a pressure sensor diagnostic will be called and the output will go to end of range low That is for an out of range low on the sensor the output will be limited to 2 0 VDC For an out of range high on the sensor the output will be limited to
132. t less than 265 F 129 4 C Restart inhibit mode is entered until all three motor winding temperatures are less than the Restart Inhibit Temperature Setpoint Note When one of the three motor winding temperatures is 265 F 129 4 C or greater a High Motor Winding Temperature diagnostic will occur Note When the start is inhibited by the restart inhibit function the time remaining will be displayed along with the restart inhibit mode CDHF SVU01C EN CDHF SVU01C EN Machine Protection and Adaptive Control e TRANE High Vacuum Lockout The oil sump pressure is below the lockout setpoint Starting of compressor is inhibited as a result Low Oil Temperature Start Inhibit The oil temperature is at or below the low oil temperature start inhibit setpoint 143 F 61 7 C The heater is energized to raise the oil temperature Low oil temperature is indicative of refrigerant dilution in the oil Oil temperature is used to estimate this dilution since the oil temperature directly corresponds to amount of refrigeration dilution in the oil It is required that oil contains minimal refrigerant in it This is accomplished by boiling the refrigerant out of the oil by maintaining a high enough oil temperature If the oil temperature is at or below a given Low Oil Temperature Inhibit setting default 95 F 35 C the compressor cannot be started This is an inhibit mode and will be reported to the operator interface Th
133. t of start up Rotation must be CLOCKWISE If the phase sequence is incorrect confirmed by observation of the Phase Reversal diagnostic on the UCP then the incoming power leads to the stator must be adjusted by authorized personnel C As the unit starts and runs observe closely all operating conditions Adjust the oil pressure regulator if necessary to 18 to 22 psi net In the DynaView Purge Settings menu of the UCP place the Purge Operating Mode to on to allow the removal of non condensables It may also be necessary to disable the Purge Pumpout Limit timer found in the Purge Settings menu After the unit has the system down to design leaving chilled water temp and is under control and the purge is no longer relieving non condensables begin taking the start up test log Log the unit a minimum of 3 times at 15 minute intervals In the DynaView Purge Settings menu of the UCP return the purge operating mode to Adaptive Restart the chiller and carefully observed the starting and loading sequence Instructions to the Chiller Operator Instructions for starting operating and shutting down Instructions for logging the unit Instrucitons for periodic maintenance D After 2 weeks of operation International Units Only 1 Replace the oil filter with the spare oil filter included in the control panel at time of shipment E Comments and or Recommendations Service Technician Signature Date CDHF SVU01C EN 111 STARTUP
134. t the vacuum pump to start evacuation Use a 2 stage pump with at least 5 CFM capacity Connect to the evaporator charging valve with a hose no smaller than 3 4 inch ID a For the IT Cutler Hammer Solid State Starter it is necessary to shut off all power to the unit prior to evacuating the chiller The IT starter has terminals 4 5 amp 6 hot when the unit is off Failure to shut off power to the chiller with the vacuum pump hook up will cause a motor failure Condenser Isolation and flow valves installed Calibrated thermometers and pressure gauges installed in out condenser on machine side of any valve or elbow If condenser pump controlled by UCP is field wiring correct and complete Condenser pump s run system and strainers properly cleaned and or flushed Condenser water strainer in close proximity to entering connection of condenser Previsions installed to properly maintain water treatment additives Initial water treatment added to system Flow or differential pressure switch installed and where possible wired in series with auxiliary of pump motor starter Verify correct operation of flow proving circuit Condenser water flow balance PSIDdesign PSIDactual GPM design GPM actual Evaporator psig Must be positive pressure or leak test must be done Calibrated thermometers and pressure gauges installed in out of evaporator on machine side of any valve or elbow If evaporator pump controlled by UCP is field wiring
135. te thus further cooling the liquid refrigerant This flash gas is then drawn directly from the economizer into the second stage impellers of the compressor All remaining liquid refrigerant flows out of the economizer passes through another orifice plate and into the evaporator CDHF SVU01C EN General Information Figure 3 Pressure enthalpy curve 3 stage compressor CDHF SVU01C EN 11 e TRANE General information Figure 5 Pressure enthalpy curve 2 stage compressor Condenser P3 a Compressor 5 2 51 Economizer Compressor E 1st Stage Pi Figure 6 Single stage economizer 2 stage compressor Refrigerant Vapor To Compressor 2rd 5tage Ligand Foglrigerani In Economizer Liquid Aetigerand Liquid Refrigerant Orifice From Condenser Orifice Ta Evaporator Plate Plate 12 CDHF SVUO1C EN Overview Controls Operator Interface Information is tailored to operators service technicians and owners When operating a chiller there is specific information you need on a day to day basis setpoints limits diagnostic information and reports When servicing a chiller you need different information and a lot more of it historic and active diagnostics configuration settings and customizable control algorithms as well as operation settings By providing two different tools one for daily operation and one for periodic service everyone has
136. tenance and the other on the bottom of the operator base Use the same procedure as described above except that it will be necessary to temporarily disconnect the vane actuators from the tang operator arms in order to test for a hydraulically locked condition Figure 37 Rotary valve in drain position The oil valve block rotary valve uses dual O Rings to seal to atmosphere These should be manually lubricated by removing the pipe plug at the valve lubrication port and placing a few drops of Trane OILO0022 in the cavity Be sure to reinstall the pipe plug when lubrication is completed NOTE ROTARY VALVE SHOWN IN DRAIN POSITION VIEW Front View with Refrigere CDHF SVU01C EN Refrigerant Charge WARNING Contains Refrigerant System contains oil and refrigerant and may be under positive pressure Recover refrigerant to relieve pressure before opening the system See unit nameplate for refrigerant type Do not use non approved refrigerants refrigerant substitutes or refrigerant additives Failure to follow proper procedures or the use of non approved refrigerants refrigerant substitutes or refrigerant additives could result in death or serious injury or equipment damage The refrigerant charging procedure for Trane centrifugal chillers is 1 If water is present in the tubes break machine vacuum with refrigerant vapor or circulate water to avoid tube damage 2 Always use re
137. ter circuit e If the evaporator was previously drained vent and fill the evaporator and chilled water circuit When all air is removed from the system Including each pass close the vent valves in the evaporator water boxes 6 Lubricate the external vane control linkage as needed 7 Check the adjustment and operation of each safety and operating control eo Close all disconnect switches 9 Perform instructions listed in Daily Unit Start up section WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury A WARNING Toxic Hazards Do notrun evaporator water pump longer than 30 minutes after the chiller is shutdown Ensure that the evaporator is isolated from the hot water loop before changeover to heating mode Do not allow the chiller to increase above 110 F in temperature while unit is off Failure to prevent high chiller temperature will cause the inside pressure to rise The rupture disk is designed to relieve and discharge the refrigerant from the unit if the pressure in the evaporato
138. the compressor has been started the starting point of the filtered setpoint is initialized to the value of the Evaporator Leaving Water temperature and the percent RLA There are three independent Softload setpoints Capacity Control Softload Time default to 10 minutes 0 120 minutes This setting controls the time constant of the Filtered Chilled Water Setpoint Current Limit Control Softload Time default 10 minutes 0 120 minutes This Setting controls the time constant of the Filtered Current Limit Setpoint Current Limit Softload Starting Percent default is 40 percent RLA 20 100 percent This setting controls the Starting point of the Filtered Current Limit Setpoint Service tool provides access to these three setpoints if it is determined necessary to change from the defaults Softloading is not active during Ice Making or during the Ice To normal Transition Softloading will be enabled after the Ice to normal Transition timer has expired Minimum and Maximum Capacity Limit A Minimum Capacity can be set to limit the unloading ability of the compressor thus forcing differential to stop to be reached cycling the chillers Minimum capacity limit will be displayed when in this limit mode This indicates when the chiller is running fully unloaded Similarly a maximum capacity can be set to limit normal chilled water temperature control the maximum capacity relay is energized which is a signal used by ge
139. tings and Adjustments Time delays and safety control cutout settings need to be checked annually For control calibration and check out contact a Trane qualified service organization 101 e TRANE Purge System Because some sections of the chiller s refrigeration system operate at less than atmospheric pressure the possibility exists that air and moisture may leak into the system If allowed to accumulate these noncondensables become trapped in the condenser this increases condensing pressure and compressor power requirements and reduces the chiller s efficiency and cooling capacity The Trane EarthWise Purge is the only purge system available for the chiller The purge is designed to remove noncondensable gases and water from the refrigeration system EarthWise Purge unit operation maintenance and trouble shooting is covered by a separate operation and maintenance manual which may be obtained from the nearest Trane office Overview This section describes extended storage requirements for installed chillers to be removed from service for an undetermined length of time 102 Maintenance Unit Preparation The following steps are necessary in order to properly prepare a unit for storage 1 Remove all liquid refrigerant if the unit is charged WARNING Contains Refrigerant System contains oil and refrigerant and may be under positive pressure Recover refrigerant to relieve pressure before
140. ttal and or Installation Are there Manual guidelines available Yes No 5 Is power wiring of adequate ampacity and correct voltage Yes No 6 Is the unit base acceptable level and is the unit on isolators rubber as supplied by Trane or spring type Yes No C 7 Have the low voltage circuits been properly isolated from the higher voltage control and power circuits Yes No E Comments CDHF SVUO1CEN 107 e TRANE Il COMMISSIONING PROCEDURES A Pre start Operations 108 1 Holding Charge psig Must be positive pressure or leak test must be done Before relieving the holding charge calibrate the H P C high pressure control This is a check of pressure to the H P C as well as calibration of the control Disconnect and cap the flare Calibrate H P C and reconnect flare Relieve the holding charge Check and if necessary tighten all connections per proper specs Megohm the Motor 500 volt Meggar Compressor motor Megohms refer to temp resistance chart for acceptable values Remove surge suppressors before Megging Never Meg test with the unit in a vacuum T1 to Earth T4 to Earth T1 to T2 T1 to T4 T2 to Earth T5 to Earth T1 to T3 T2 to T5 T3 to Earth T6 to Earth T2 to T3 T3 to T6 Evacuation Connec
141. uplex Sequence Of Operation This section will provide basic information on chiller operation for common events With microelectronic controls ladder diagrams cannot show today s complex logic as the control functions are much more involved than older pneumatic or solid state controls Adaptive control algorithms can also complicate the exact sequence of operation This section and its diagrams attempt to illustrate common control sequences The Sequence of Events diagrams use the following KEY Software States Figure 7 There are five generic states that the software can be in 1 Power Up Stopped Starting Running Stopping Timeline Text Figures 8 11 General information The large timeline cylinder indicates the upper level operating mode as it would be viewed on DynaView Text in Parentheses indicates sub mode text as viewed on DynaView Text above the timeline cylinder is used to illustrate inputs to the Main Processor This may include User input to the DynaView Touch pad Control inputs from sensors or Control Inputs from a Generic BAS Boxes indicate Control actions such as Turning on Relays or moving the Inlet Guide Vanes Smaller cylinders indicate diagnostic checks Text indicates time based functions Solid double arrows indicate fixed timers Dashed double arrows indicate variable timers Figure 7 Sequence of operation overview 14 Power Up Diagram The Power up chart shows the res
142. use compressors on Duplex chillers are not sized exactly the same Figure 12 CDHF G sequence of operation lead 1 lag 2 Ewap LWT Fal inte Chi Capacity Laus fan 0 Ma Tener Delay Ep LAT Sree Saree Hieta flan 17 e TRANE Fixed Sequence Compressor 2 Compressor 1 If the chiller is in the Auto mode and all interlocks have been satisfied compressor 2 will be started based on the leaving water temperature rising above the Differential to Start setting Compressors 1 will stage on when the overall chiller average capacity exceeds Stage on Load point for 30 seconds The stage on load point is adjustable up to 5096 The default is 4096 which means that a single compressor would have to load to 8096 the average would be 40 before the second compressor 18 General Information starts Both compressors will run until chiller average capacity drops below Stage off Load point for 30 seconds The stage off load point is also adjustable Compressor 1 will be shut down and compressor 2 will run until water temperature drops below the differential to stop Before shutting down compressor 1 will be unloaded and compressor 2 will be loaded to maintain the same average capacity command If chilled water reset is used the upstream compressor usually will be the most efficient compressor to operate at part load If the leaving water temperature is reset and the chiller only
143. vap Differential Wtr Press XXX X Diff Pressure If option installed 5 Approx Evap Water Flow XXXX Flow If option installed 6 Approx Chiller Capacity XXXX Tons If option installed Report name Circuit Evaporator Description Resolution Units Dependencies 1 Evap Sat Rfgt Temp or XXX X Temperature 2 Evap Rfgt Pressure XXX X Pressure 3 Evap Approach Temp XXX X Temperature Report name System Condenser Description Resolution Units Dependencies 1 Cond Entering Water Temp XXX X Temperature 2 Cond Leaving Water Temp Temperature 3 Cond Water Flow Switch Status Flow No Flow 4 Cond Differential Wtr Press XXXX Diff Pressure If option installed 5 Approx Cond Water Flow XXXX Flow If option installed 6 Outdoor Air Temperature or Temperature If option installed Report name Circuit Condenser Description Resolution Units Dependencies 1 Cond Sat Rfgt Temp or Temperature 2 Cond Rfgt Pressure XXX Pressure 3 Cond Approach Temp or XXX X Temperature Note Approach temperatures shown are the mathematical difference between the chiller leaving water temperature and the corresponding saturated refrigerant temperature of same circuit When one compressor is operational the approach value will be similar to those values found on single compressor models However when both compressors are operating the upstream compressor circuits approach will be the mathematical difference of the upstre
144. vertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Note For additional information regarding the safe discharge of capacitors see PROD SVBO6A EN or PROD SVBO06A FR Weekly Maintenance Complete all recommended daily maintenance procedures and checks Complete logs on a daily basis Every 3 Months 1 Complete all recommended weekly maintenance procedures Refer to the previous sections for details Clean all water strainers in the CenTraVac water piping system Every 6 Months Normal Chiller Operating Characteristics Operating Characteristic Normal Reading Approx Evaporator Pressure 6to 9 PSIA 9 to 6 PSIG Approx Condenser Pressure See Notes 1 and 2 17 TO 27 PSIA 2 to 12 PSIG Standard Condensers Oil Sump Temperature Unit Not Running 140 F to 145 F 60 C to 63 C Unit Running 80 F to 162 F 26 6 C to 72 C Differential Oil Pressure 18 to 22 psid 93 e TRANE Complete all recommended quarterly maintenance procedures Lubricate the vane control linkage bearings ball joints and pi
145. vot points as needed a few drops of light machine oil SAE 20 is sufficient Lubricate vane operator tang o rings as described in the maintenance section 1 Lubricate the oil filter shutoff valve o rings by removing the pipe plug and adding several drops of Trane 00022 Replace plug Drain the contents of the rupture disc and purge discharge ventline drip leg into an evacuated waste 94 Periodic Maintenance container minimally and more often if the purge is operated excessively Also apply one or two drops of oil on the vane operator shaft and spread it into a very light film this will protect the shaft from moisture and rust Off Season Maintenance During those periods of time when the chiller is not operated be sure the control panel is energized This is to keep the purge operational the oil heater warm and will also keep air out of the machine Annual Maintenance Shut down the chiller once each year to check the items listed a more detailed inspection checklist is provided on the Annual Inspection Checklist and Report illustrated in this manual Perform the annual maintenance procedures referred to in the Maintenance Section of the purge manual Use an ice water bath to verify that the accuracy of the evaporator refrigerant temperature sensor 4R10 is still within tolerance or 2 0 at 32 F 1 at 0 C If the evaporator refrigerant temperature displayed

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