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Nikon 18208133055 Digital Camera User Manual

1. Series R 70 125 Ton Air Cooled and Water Cooled Rotary Liquid Chillers Model RTAA 70 125 Ton RTWA 70 125 Ton RTUA 70 125 Ton August 2005 RLC SVD03A EN American Standard Inc 2005 NOTICE Warnings and Cautions appear at appropriate sections through out this literature 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 Important Read This First This manual is intended for experienced service personnel familiar with the proper use of electrical diagnostic instruments and all personal safety procedures when working on live electrical circuits This Manual is not intended for individuals who have not been properly trained in handling live electrical circuits Environmental Concerns Scientific research has shown that certain man made chemicals can affect the earth s naturally occurring stratospheric ozone layer when released to the atmosphere In particular several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine Fluorine and Carbon CFCs and those containing Hydrogen Chlorine Fluorine an
2. 115 HOT J6 3 KEY N C 46 4 NEUTRAL IPC 4 E NEUTRAL IPC IPC E3 COMPRESSOR MOTOR IPC WINDING THERMOST MANUF NO CONN HIGH PRESS SWITCH USE ONLY NO CONN CRANKCASE HEATER LOW PRESSURE SIG L LOCKOUT INPUT 115VAC HOT H o KEY N C KEY N C COMPRESSOR CONTCR TRANSITION KEY N C H COMPLETE INPUT 0 COMPRESSOR V L NOT USED TRANSITION OUTPUT 0 T KEY L A T G SATURATED STEP LOAD A E CONDENSER TEMP SOLENOID VALVE G E ENTERING SLIDE VALVE LOAD N OIL KEY TEMPERATURE SLIDE VALVE UNLOAD U P T PhA 115VAC FANS U COMPRESSOR PhA KEY N C T FAN RELAY 1 U CURRENTS PhB FAN RELAY 2 FAN RELAY 3 U P PhC FAN RELAY 4 T U P T U FAN VARIABLE FREQUENCY DRIVE FR NOT USED NOT USED Figure 22 Compressor Module MCSP 104 105 RLC SVDOS3A EN 77 Module Power and Miscellaneous I O Interprocessor Communication Bridge Module IPCB 1U7 The IPCB provides an extension of the IPC link to the Remote Clear Language Display See Figure 23 It prevents crashes of the IPC and UCM if the link to the RCLD is shorted or misapplied The IPCB receives and retransmits data to and from local to remote
3. 4 Service Philosoephy re ER Re be ec eos te DERE ROC oet oa deb ie 4 System DescriptiOH n tese Ree Re Ue RR RE HR Seed 5 System Level Components 5 Interprocessor Communications 8 IPG DiagriosticS s nag oro e EUR p be ERO Anas AG Rer eta 8 Troubleshooting Modules Using IPC Diagnostics 9 Troubleshooting Procedure 12 Temperature Sensor Checkout 15 Temperature Sensor Checkout Procedure 15 Compressor Operation 19 Restart s os roe Lee p PEU 19 Compressor Start Stop 20 Variable Speed Inverter Condenser Fan Control 21 Outdoor Air Temperature and Fan Control 22 YSF Inverter Baltes isa ta omo o 22 Current Transformer 23 CT and MCSP Compressor Current Input Checkout Procedure 24 Under Over Voltage Transformer 32 Under Over Voltage Transformer Checkout 32 Compressor Capacity 34 Checkout Procedure for MCSP Load Unload Outputs 35 Checkout Procedure for the Slide Valve and Load Unload S
4. Motor Overlad Fault The drive operated in current limit 110 of rated current for a period of 60 consecutive seconds If the motor current reduces to less than 110 and the motor reaches commanded speed the overload timer will begin to count down Low Bus Voltage Fault DC Bus Voltage is less than 200 VDC on a 200 230 VAC input unit or is less than 400 VDC on a 400 460 VAC input unit If the motor 15 already running this fault will not occur Instead the motor speed will be reduced to a speed that the proper voltage can be applied to the motor PWM Generator Fault The drive failed to switch a PWM output properly Logic Fault The Microcontroller in the drive executed an illegal instruction Stalled Motor Fault Motor failed to accelerate to the motor speed setpoint in 30 seconds Automatic Restart f the drive should fault the drive will automatically attempt one restart after a delay of 5 seconds If the drive faults a second time the drive will not attempt to restart and the fault must be cleared before the drive will run again Fault Clearing Drive Faults may be cleared by one of the following methods Removing and reapplying power to the controller Setting the speed control input duty cycle to less than 796 for 1 second RLC SVDOS3A EN 81 82 Variable Speed Fan System Troubleshooting Procedure A WARNING Live Electrical Components During installation testing servicing and troubleshooting of this pr
5. Loss of power to a module Improper connections on terminal J2 1 2 3 4 Internal module failure 5 6 High levels of EMI Electro Magnetic Interference 7 Module specific function selected without the Options Module These are discussed in more detail in the following paragraphs 1 Improperly set IPC address dip switches This could result in more than one module trying to talk at the same time or cause the mis addressed module to not talk at all Only the MCSP and the EXV modules have IPC address dip switches found in the upper left hand portion of the Module labeled as SW 1 The proper dip switch set ups are shown in Table 2 2 Opens or shorts in the twisted pair IPC wiring or connectors One or more modules may be affected by an open or a short in the IPC wiring depending on the location of the fault in the daisy chain The dia gram below shows the daisy chain order and is helpful in diagnosis of an open link Extreme care should be used in making any dip switch changes or when replacing MCSP modules Swapping of addresses on the MCSPs cannot be detected by the communication diagnostics discussed above and serious chiller misoperation will result Interprocessor Communication REMOTE CLD 1U2 and 108 are mutually exclusive options The Remote CLD is not available if the 108 option is installed Figure 1 IPC Link Order For 70 125 Ton RTAA 10 RLC SVDO3A EN Interprocessor Communication Table
6. Setpoint TB1 7 amp 8 The voltage measured at the terminals and the resulting setpoint as read on the CLD should agree with the Table 17 for Chilled Water Setpoint inputs and Table 18 for Current Limit Setpoints inputs Be sure to wait long enough when reading the display as the val ues are slew rate limited 3 Disconnect all wiring to these inputs The setpoints should slew back to the chiller s Front Panel settings 4 Disconnect all wiring and install fixed resistors of values near those shown in the following tables across TB 1 3 5 or TBI 6 8 The resulting set points should agree with the table values Table 17 Input Values vs External Chilled Water Setpoint INPUTS Resulting Chilled Resist ohms Current ma Voltage Vdc Water Setpt F 4F 94433 4 0 2 0 0 0 68609 5 2 2 6 5 0 52946 6 5 3 2 10 0 42434 77 3 9 15 0 34889 8 9 4 5 20 0 29212 0 2 5 1 25 0 24785 14 5 7 30 0 21236 2 6 6 3 35 0 18327 3 8 6 9 40 0 15900 5 1 76 45 0 13844 6 3 8 2 50 0 12080 75 8 8 55 0 10549 8 8 9 4 60 0 51 52 Module Power and Miscellaneous I O Table 18 Input Values vs External Current Limit Setpoint INPUTS Resulting Current Resist ohms Current ma Voltage Vdc Limit Setpt RLA 5 49000 4 0 2 0 40 29000 6 0 3 0 50 19000 8 0 4 0 60 13000 10 0 5 0 70 9000 12 0 6 0 80 6143 14 0 70 90 4010 16 0 8 0 100 2333 18 0 9 0 110 1000 20 0 10 0 120 Setpoint Priority
7. Solenoid valve mechanism bound Solenoid Coil exist No 14 15 wiring to valve OK p Check for open solenoid coil No 15 Repair and reverify Figure 6 Manual Slide Valve Diagnostic Flow Chart Checkout Procedure for MCSP Step Load Output The MCSP controls the step load solenoid valve on the respective compressor with a 115 VAC dry contact output relay This differs from the Load Unload solenoid output which is from a triac solid state relay Refer to the Chiller Control Wiring diagrams and the Component Layout Drawings for the following procedure 39 40 Compressor Capacity A 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 With a particular compressor running the relay may be checked under load as explained above by measuring the voltage from terminal J7 9 to the 115 VAC neutral The relay operates in the high side and switches power from J7 8 to J7 9 to move the step load valve to the loaded position When the CPM decides to load the compressor the step load solenoid is energized continuously To assure that l
8. The Compressors On menu item in the Chiller Report Group will indicate which compres sor started approximately five seconds after the contactor pulls in Note the diagnostic s that results then place the Chiller into the Stop mode by depressing the Stop button on the CLD RLC SVDO3A EN RLC SVDOS3A EN Current Transformer A 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 SVB06A EN or PROD SVBO6A FR 3 Forthe next portion of the procedure pull the unit s disconnect and inter rupt all high voltage power to the control panel Locate the torroid dough nut current transformers encircling the compressor power wiring and branching to the compressor contactors of the suspect compressorin the control panel Refer to the Component Location Drawing in the panel to identify the particular current transfo
9. diagnostics and control algorithms etc are made available to the CPM and the other modules for display and for input to higher level functions See Electronic Expansion Valve Module EXV 1U3 on page 58 for details General Information Options Module CSR 1U2 The CSR module is an optional part of the system and employs communica tions circuits for interface to Trane Building Automation Systems done through 1C17 The CSR also provides inputs for hard wired external setpoints and reset functions Included are low voltage analog and digital input circuits See Options Module CSR 1U2 on page 50 for details Clear Language Display CLD 1U6 The CLD Module provides an operator interface to the system through a two line 40 character alohanumeric display Three reports may be displayed and various operating parameters may be adjusted by depressing a minimal number of keys on the CLD Also chiller Start Stop functions may be performed at this keypad See Clear Language Display CLD 1U6 Keypad Overview on page 42 for details Interprocessor Communication Bridge IPCB 1U7 The IPCB module allows connection of a Remote Clear Language Display module to the UCM for distances of up to 1500 feet The Remote Clear Language Display communicates with the UCM utilizing the same IPC protocol and provides most of the same functions as the local CLD The IPCB then serves to protect the UCM s IPC if wires to the Remote CLD become shorted o
10. 2 Sor OMPRESSOR SUCTION MPERATURE CIRCUIT 2 ELECTRONIC KEY N C EXPANSION PHASE 1 VALVE CIRCUIT 1 PHASE 2 ELECTRONIC KEY N C EXPANSION PHASE 1 VALVE CIRCUIT 2 KEY N C HACVAC oHdcuouz Figure 20 SEO Electronic Expansion Valve Module 103 RLC SVDOS3A EN 24 VDC Peak only when the Phase is being stepped J6 1 115VAC HOT J6 2 115VAC HOT J6 3 KEY N C J6 4 NEUTRAL 6 5 NEUTRAL rO rIr 0 4 acuz 69 Sor NHACVAC OO 0 4 02 Figure 21 70 SEHI Valve Module MANUF USE ONLY LOW PRESSURE SIG SWITCH CIRCUIT 1 GND LOW PRESSURE SIG SWITCH CIRCUIT 2 GND SATURATED EVAPORATOR EMPE ELECTRO EXPANSI RAT MPRESSOR SUCTION RAT SATURATED EVAPORATOR RAT MPRESSOR SUCTION RAT IC ON VALVE CIRCU ELECTRO EXPANSI T 1 IC ON VALVE CIRCU 2 Module Power and Miscellaneous I O TP1 5V IPC IPC IPC IPC off NO CONN NO CONN KEY URE CIRCUIT 1 URE CIRCUIT 1 KEYING URE CIRCUIT 2 URE CIRCUIT 2 KEY N C KEY N C WHITE BLACK SEHI
11. 4 LIN 214 L Inv4 342 N21 38 INVHADO CONTROL WIRING INTERFACE TERMINALS USED ARE 156 MALE PINS Variable Speed Fan System 6 VDC If there is no voltage at either of these two test points check the incoming 115 VAC between pins J6 1 hot and J6 5 neutral and check fuse F1 mounted on the upper right hand corner of the circuit board If the fuse is OK and the voltage between J6 1 and J6 5 is 115 VDC but the TP1 and TP2 voltages are out of range replace the compressor module VARIABLE FREQUENCY POWER OUTPUT TO MOTOR 25 FEMALE INSULATED T3 Tl QUICK CONNECT 3 PLACES j POWER INPUT TERMINALS 25 MALE 0 4 PLACES SEE MOUNT CONTROL X13170290 01 amp 02 gt IN CONTROL PANEL WITH LARGE CAPACITORS LOCATED AT THE BOTTOM AS SHOWN Figure 25 Variable Speed Fan Inverter RLC SVDOS3A EN 7 Remove connector P9 P10 whichever applies from the inverter and place a jumper wire between terminals F and FR on the female connec tor See Figure 11 1 for the location of these wires This will prevent the control from reporting a fault diagnostic Restart the unit and carefully measure the DC voltage between wires and CR on the same female connector The voltage should be 2 to 10 VDC when the compres sor on the affected circuit is running At compressor start this voltage will
12. 5 5 15 150 160 240 320 440 640 80 120 5 41 160 170 255 340 468 680 85 127 5 5 67 170 180 270 360 495 720 90 135 5 94 180 190 285 380 523 760 95 142 5 6 20 190 200 300 400 550 800 100 150 6 46 200 210 315 420 578 840 105 157 5 6 72 210 220 330 440 605 880 110 165 6 99 220 230 345 460 632 920 15 72 5 725 230 240 360 480 660 960 120 180 7 51 240 250 375 500 687 1000 125 1875 777 250 260 390 520 715 1040 130 195 8 03 260 270 405 540 742 1080 135 202 5 8 29 270 280 420 560 770 1120 140 210 8 56 280 290 435 580 797 1160 145 2175 8 82 290 300 450 600 825 1200 150 225 9 08 300 30 RLC SVD03A EN RLC SVDOS3A EN Current Transformer Table 9 Overload Dip Switch Setting vs Internal Software Gain CPRSR RATED RLA OVERLOAD DP DECIMAL SOFTWARE AS A OF CT RATING SWITCH SETTING SETTING GAIN 66 00000 00 500000 67 00001 01 483870 68 00010 02 467743 69 00011 03 451613 70 00100 04 435483 71 00110 06 403226 72 00111 07 387097 73 01000 08 370969 74 01001 09 354839 75 01010 0 338709 76 01011 1 322580 77 01100 2 306452 78 01101 3 290323 79 01111 5 258065 80 01111 5 258065 81 10000 16 241936 82 0001 7 225806 83 10010 8 209678 84 0011 9 193549 85 10100 20 177419 86 10101 21 161291 87 10110 22 145162 88 10110 22 145162 89 10111 23 129032 90 11000 24 112903 91 001 25 096775 92 001 25 096775 93 11010 26 080645 94 01 27 064516
13. 9 2 162 8 0 67881 9 4 560 58 0 6150 5 3 558 08 0 4871 1 2 135 9 0 65790 2 4 547 59 0 5735 7 3 531 09 0 4765 0 2 108 0 0 63768 7 4 534 60 0 5332 9 3 504 10 0 4661 5 2 082 1 0 61815 3 4 521 61 0 4941 7 3 477 11 0 4560 6 2 055 2 0 599278 4 507 62 0 4561 9 3 450 12 0 4462 2 2 029 3 0 58103 1 4 494 63 0 4193 0 3 422 13 0 4366 3 2 003 4 0 56339 6 4 479 64 0 3834 6 3 394 14 0 4272 6 977 5 0 54634 7 4 465 65 0 3486 5 3 366 15 0 4181 3 951 6 0 52986 4 4 450 66 0 3148 3 3 338 16 0 4092 2 1 926 70 51392 6 4 435 670 2819 8 3 310 170 4005 3 901 8 0 49851 6 4 420 68 0 2500 5 3 282 18 0 3920 5 876 9 0 48360 9 4 404 69 0 2190 2 3 253 19 0 38377 851 20 0 46919 2 4 388 70 0 1888 7 3 225 20 0 3756 9 826 21 0 45524 6 4 372 71 0 1595 6 3 196 21 0 3678 1 802 22 0 44175 6 4 355 72 0 1310 7 3 167 22 0 3601 1 477 23 0 42870 3 4 338 73 0 1033 7 3 139 23 0 3526 5 1 754 24 0 416076 4 321 74 0 0764 4 3 110 24 0 3453 6 730 25 0 40385 3 4 303 75 0 0502 6 3 081 25 0 3382 4 1 707 26 0 39202 7 4 285 76 0 0248 0 3 051 26 0 3313 0 1 684 270 380579 4 266 770 0000 0 3 022 270 3245 1 661 28 0 36950 0 4 248 78 0 9759 6 2 993 28 0 3178 9 1 638 29 0 358774 4 229 79 0 9525 4 2 964 29 0 3114 2 1 615 30 0 34838 9 4 209 80 0 92975 2 935 30 0 3051 0 1 593 31 0 33833 3 4 190 81 0 9075 9 2 905 31 0 2989 2 1 571 32 0 32861 4 4 170 82 0 8860 2 2 876 32 0 2928 9 1 549 33 0 31935 3 4 150 83 0 8650 4 2 847 33 0 2870 0 1 528 34 0 31038 7 4 130 84 0 8446 2 2 817 34 0 2812 4 1 506 35 0 30170 5
14. Electronic Expansion Valve Module 1U3 1 0 terminals 24 VDC Peak only when the Phase is being stepped 6 1 115VAC HOT J6 2 115VAC HOT J6 3 KEY N C J6 4 NEUTRAL 46 5 NEUTRAL lt For the checkout of the I O refer to the block diagram of the EXV module in Table 21 and the Chiller Wiring Diagrams for both high and low voltage circuits All voltages are measured differently between terminal pairs RLC SVD03A EN Module Power and Miscellaneous I O specified unless otherwise indicated The first terminal in the pair is the positive or hot terminal Voltages given are nominals and may vary by 5 Unregulated Voltages unreg or 115 VAC voltages may vary by 15 Table 21 EXV Module Normal Terminal Voltages Terminal Description Normal Terminal Voltages Designation of Circuit for Various Conditions J1 4 to IPC Communications 19 2 kbaud serial data 5 volt signal level or J1 2 to 1 Refer to Interprocessor Communication Link IPC J2 2 1 Manufacturing 5 VDC No connection intended Address Use Only J3 9 8 Saturated Evap Refer to Temperature Sensor Checkout Rfrg Temp CKT 1 J3 7 6 Compressor Suct Refer to Temperature Sensor Checkout Rfrg Temp CKT 2 J3 4 3 Saturated Evap Refer to Temperature Sensor Checkout Rfrg Temp CKT 2 J3 2 1 Compressor Suct Re
15. However if the actual temperature is outside the allowable sensor tolerance range proceed to Step 4 Temperature Sensor Checkout 4 Again measure the temperature at the sensor with an accurate thermom eter record the temperature reading observed 5 Remove the sensor leads from the terminal strip or unplug the respective MTA Measure the resistance of the sensor directly or probe the MTA with a digital volt ohmmeter Record the resistance observed 6 Next with the sensor still disconnected from the module check the resistance from each of the sensor leads to the control panel chassis Both readings should be more than 1 Megohm If not the sensor or the wiring to the sensor is either shorted or leaking to chassis ground and must be repaired 7 Select the appropriate sensor table and locate the resistance value recorded in Step 5 Verify that the temperature corresponding to this resistance value matches i e within the tolerance range specified for that sensor the temperature measured in Step 4 8 If the sensor temperature is out of range the problem is either with the sensor wiring or the MTA connector if applicable If an MTA connector is used and the thermistor reads open first try cutting off the MTA strip ping a small amount of insulation from the sensor wire s end and repeat ing the measurement directly to the leads Once the fault has been isolated in this manner install a new sensor connector or both When r
16. IOM for the list of items found in the Service Setup Menu and Machine Configuration Menu Select Report Group and Select Settings Group Flowcharts Refer RTWA IOM for the display readouts found under each menu The first block of the flowchart is the header which is shown on the display after the menu key is pressed For example Press Chiller Report and the readout on the display will be CHILLER RPRT STATUS WTR TEMPS amp SETPTS PRESS NEXT PREVIOUS TO CONTINUE RLC SVDO3A EN Module Power and Miscellaneous I O Press Next to move down through the Chiller Report As shown in the figures the flowchart explains the conditions that the UCM looks at to determine which readout is to be displayed next For example Press Chiller Report to display the header Press Next to display MODE OPERATING MODE REQUESTED SETPOINT SOURCE SETPT SOURCE Press Next to display COMPRESSOR ON CIRCUITS LOCKED OUT Press Next to display ACTIVE ICE TERMINATION SETPOINT or ACTIVE CHILLED WATER SETPOINT The UCM will determine which screen will be displayed after looking at the current Operating Mode If the Operating Mode is Ice Making or Ice Making Complete ACTIVE ICE TERMINATION SETPOINT will be displayed Otherwise ACTIVE CHILLED WATER SETPOINT will be shown The flowcharts also list the setpoint ranges default options and a brief description of the item when necessary This information is shown in the lef
17. Normal Terminal Voltages for Options Module 1U2 Terminal Description Normal Terminal Voltages Designation of Circuit for Various Conditions J1 4 to 3 IPC Communications 19 2 kbaud serial data 5 volt signal level or J1 2 to 1 Refer to Interprocessor Communication Link IPC 92 2 1 Manufacturing 5 VDC No connection intended Address Use Only TB1 3 5V Source for use with 5VDC open circuit with respect to chassis ground Resistor programming of CW setpoint TB1 3 5 Ext Chilled Water Setpoint Refer to External Setpoint Inputs 4 20ma 2 10VDC on page 50 Resistive option 1 4 5 Ext Chilled Water Setpoint Refer to External Setpoint Inputs 4 20ma 2 10VDC on page 50 Current or Voltage option TB1 6 5V Source for use with 5VDC open circuit Resistor programming of CL setpoint TB1 6 8 Ext Current Limit Setpoint Refer to External Setpoint Inputs 4 20ma 2 10VDC on page 50 Resistive option TB1 7 8 Ext Current Limit Setpoint Refer to External Setpoint Inputs 4 20ma 2 10VDC on page 50 Current or Voltage option TB1 9 10 Unused TB2A 1 2 Serial Comm nput Refer to Section 2 ICS Communications or TB2B 3 4 J6 1 or 2 Input Power 115 VAC Refer to Power Supply on page 41 to J6 4 or 5 Dip Switch External Chilled Water Setpoint Off for 2 10 VDC input SW1 1 Dip Switch On for 4 20 mA input Dip Switch External Current Off for 2 10 VDC input SW1 2 Limit Setpoint On for 4 20 mA input Dip Switch 56 RLC SVDO
18. RLC SVDOS3A EN Module Power and Miscellaneous I O SEHI Electronic Expansion Valve Servicing The procedures listed below are to be followed for proper disassembly inspection cleaning and reassembly to the valve The valve does not need to be removed from the refrigerant piping before servicing If the motor is found to be defective the entire motor assembly must be replaced 1 Before disassembly of the valve be sure the refrigerant pressure in the system has been reduced to a safe level 0 psig on both sides of valve See RTAA SB 10 for preferred refrigerant handling in this area A 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 SVBO6A EN or PROD SVBO6A FR 2 Disconnect all the line voltage to the power supply of this unit Refer to the exploded view in Figure 19 while performing the remaining i
19. There are many ways in which the Chilled Water and Current Limit setpoints can be adjusted or reset when the Options Module is present in the Chiller control system The following flow charts show how these methods are prior itized and arbitrated under normal operating conditions When abnormal conditions are present such as loss of Tracer communications or out of range values on external setpoint inputs the system will default to other methods RLC SVD03A EN Module Power and Miscellaneous I O START LOCAL OR Local EXCEPT FOR CHILLED WATER USE ALL OTHER FRONT PANEL SETPOINTS EXTERNAL SETPOINTS INPUT ENABLED No SETPOINTS INPUT Tracer EXCEPT FOR CHILLED WATER USE ALL OTHER FRONT PANEL SETPOINTS EXTERNAL ENABLED Yes LOCAL Yes Yes LOCAL ICE MODE ICE MODE CMND CMND No No ANY No ANY No ANY No TYPE RESET ENABLED TYPE RESET ENABLED PERFORM RESET ON FRONT PANEL CW SETPOINT ICE MODE LOCAL TERMINATION SETPOINT PERFORM RESET ON EXTERNAL CW SETPOINT USE FRONT PANEL CHILLED WATER SETPOINT USE EXTERNAL CHILLED WATER SETPOINT TYPE RESET ENABLED ICE MODE TRACER TERMINATION SETPOINT PERFORM RESET ON TRACER CW SETPOINT USE TRACER CHILLED WATER SETPOINT TRACER implies Trane Integrated Comfort System remote device ICS using the digital communication link EXTERNAL implies generic building a
20. approximately 10 seconds but only if the compressor has been running over 5 minutes or longer prior to shutting down on temperature Otherwise it is the remaining portion of the 5 minutes Restart Inhibit Timer If compressor operation is interrupted by an extended not momentary loss of power or a manual reset there will be a two minute delay between the power up or manual reset and the start of a compressor assuming there is a call for cooling The timer is factory set at 2 minutes but can be field adjusted from 30 seconds to two minutes in the Service Settings Group 19 Compressor Start Stop To start a compressor after either a normal shutdown a Diagnostic reset or poweron reset the following sequence will occur 1 On a call for a compressor the Restart Inhibit Timer will time out if any time remains The EXV is positioned to the initial closed start position At the same time the unload solenoid is energized and the load solenoid is de ener gized Timing is determined by the time required to position the EXV After the EXV is positioned the compressor is turned on the compressor heater is de energized the saturated evaporator ref temp cutout ignore time is set based on the saturated condenser temperature Prior to start the condenser tem perature approximates the ambient temperature the fan control algorithm is executed To stop a compressor due to either the Stop button on the CLD or an External Rem
21. circuit you wish to pumpdown by selecting and Enabling it in the Service Tests Group The CLD will then be displaying an Operating Code for Service 4 The UCM shall then begin the start sequence without restart inhibit and turn on the selected compressor once the EXV has opened to its pre position The compressor shall run for a period of 1 minute at its mini mum load and the condenser fans will stage under normal fan control The UCM will automatically shut off the compressor and condenser fans close the EXV and return the chiller to the normal stop mode once the 1 minute timer has expired The pumpdown sequence cannot be repeated again without a UCM power down reset NOTE The unload solenoid is always kept energized for approximately 1 hour after any compressor shutdown and the oil sump heater is continuously energized 5 Manually close the discharge line shutoff valve and the oil line shutoff valve 6 Remove all power to the chiller and service as required RLC SVDOS3A EN 85 86 Other Service Features A 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 V
22. is called the Auto Lead Lag and can be found in the Service Settings Group under the Balanced CPRSR Starts and Hours menu When this function is disabled the UCM always starts compressor first When this function is enabled the following occurs The UCM equalizes operating starts and hours This will cause the compressor with the least amount of starts to be started first When a compressor starts it is always started unloaded When a compressor is stopped it shuts down in an unloaded state unless taken out by a manual reset diagnostic When the first compressor is brought on line it attempts to meet the load by staging on the step load solenoid and by pulsing the male slide valve load solenoid If one compressor cannot meet the load demand the second compressor is brought on line It also attempts to meet the load demand by staging on its step load solenoid and by pulsing its male slide valve solenoid When both compressors are running and both of their step load solenoids are energized the male load and unload solenoids on both compressors are pulsed thus modulating their respective slide valves to balance the load The UCM attempts to distribute the load evenly between the two compressors When the load drops off the compressor with the most hours will always be the first to unload and turn off The anti recycle timer is approximately 5 minutes from start to start The minimum time between compressor shutdown and restart is
23. less between pins J9 4 and J9 3 an inverter fault diagnostic for the affected circuit should not be displayed But if the variable speed fan in still not working check these two interconnecting wires from the compressor module to the inverter to be sure they are not shorted The inverter cannot send the compressor module a fault signal if these two wires are shorted together 9 If all settings and voltages through Step 8 are acceptable and the fan does not operate replace the variable speed fan inverter RLC SVDO3A EN Other Service Features Service Pumpdown The UCM provides for a onetime Service Pumpdown mode in which a service technician can direct a particular compressor to start and run for one minute to accomplish pumpdown of the low side of the refrigeration system evaporator and EXV To aid in accomplishing this pumpdown certain noncritical diagnostics will be ignored or disabled during this mode Critical diagnostics such as those associated with motor protection high pressure and chilled water flow will still be enforced and may prevent or terminate the sequence Service Pumpdown Procedure 1 Place the Chiller in the Stop Mode using the Stop Button on the CLD and allow the Chiller if currently running to go through its shutdown sequence 2 Manually close the liquid line shutoff valve on the circuit to be pumped down 3 Use the CPM s Operator Interface to begin the mode specifically for the compressor
24. links Therefore the data is available on either link SW1 should be set per the label on the IPCB LEDs RXA TXA RXB and TXB should be constantly blinking synchronously in normal operation 24 VAC From IPC Link Remote CLD SW1 IPCB Nominal Terminal Voltages J1 1 2 or J1 3 4 Local IPC 19 2K Baud 5 V signal level J2 1 2 or J2 3 4 Power 18 30 VAC neither side grounded J3 1 2 or J3 3 4 Remote IPC 19 2K Baud 5 V signal level Figure23 Nominal Terminal Voltages 78 RLC SVD03A EN Module Power and Miscellaneous I O LonTalk Communications Interface Chillers Module LCI C 1U8 The Tracer LCI C interface acts as a translator between Trane s IPC Inter Processor Communication and Echelon s LonTalk communications protocol ANSI EIA CEA 709 1 This allows the chiller to communicate with building automation systems which also communicate using the LonTalk protocol The LonTalk communications protocol also allows for peer to peer commu nications between controllers so they can share information Communicated setpoints have priority over locally wired inputs to the controller unless the controller is set to the Local control mode The LCI C module provides connectivity to Trane s Rover service tool for proper configuration of the LCI C module Note LonTalk amp communication links are not polarity sensitive 24 VAC From IPC Link To BAS LCI C Nominal Terminal Voltages J1 1 2 or J1
25. output switching devices associated with the compressor motor controlling function are contained in this module The outputs of this module control one compressor motor stop start contactor one compressor motor transition contactor one oil heater three solenoid valves compressor load compressor unload step loader and up to four fan motor contactors or groups of contactors Refer to the chiller s line wiring diagrams for details Dip switches are provided for redundant programming of the compressor current overload gains and for unique IPC address identification during operation Inputs to this module include motor temperature thermostats thermisters and safety switches See Compressor Module MCSP 1U4 AND 1U5 on page 72 for details Expansion Valve Module EXV 1U3 The EXV module provides power and control to the stepper motor driving the electronic expansion valves of the chiller Each module handles two valves one in each refrigeration circuit Input to the EXV Module is provided by four temperature sensors two per refrigeration circuit The sensors are located in the respective refrigeration circuits of the chiller and sense Saturated Evaporator and Suction tempera tures and calculate the superheat temperatures High level operational commands as well as superheat setpoints are received by the EXV Module over the IPC from the CPM module to modulate the EXV s RLC SVDOS3A EN RLC SVDOS3A EN Real time data for temperatures
26. side grounded Figure 9 CLD Module 1U6 46 LEDs There are four LEDs located to the right of TB1 of the CLD module See Figure 9 The ST LED should be on continuously If it blinks it indicates the processor is repeatedly being reset The 5 VDC LED should also be on continuously It will go out if power drops below normal operating voltage The TX LED should blink every second or two as the CLD transmits on the IPC The RX LED should blink continuously indicating that other modules are communicating Chiller Module CPM 1U1 A 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 RLC SVD03A EN RLC SVDOS3A EN Module Power and Miscellaneous I O Test Points There are two test points associated with the CPM module They are easily read with a DC voltmeter by probing the PC board solder pads found in the upper left hand corner of the module The positive meter lead should be connected to the pad while referencing the negative meter lead to the board edge ground plane NOTE Don t use the aluminum module enclosure as a refe
27. speed fan and the remaining constant speed fans per the VSF Control Algorithm If VSF Control is disabled for a given circuit but Fan Control is enabled for the machine the circuit will perform normal constant speed fan control The VSF is enabled and operational the control attempts to provide a 70 x 5 psid between the Condenser Pressure and the Evaporator Pressure as derived from the temperature sensor measurements High Differential Pressure Lockout Area Diagnostic Occurs when Delta P is gt 320 PSID and integral exceeds 60 PSI minutes 191 Additional Fans 148 if available are 145 immediately started Start Up Fan State Anticipatory Fan Control Function L442 at each condenser 9077 4 Fans VSF min speed temperature shown 11 0 In this area start a fan with 105 1 compressor step but Operating take no action with unstep Pressure 95 4 Differential 90 In this area always start PSID 854 or stop a fan with a 80 compressor step or unstop 139 d od 34 Y Var Spd Fan only min speed 0 10 20 30 40 50 60 VSF PID Increasing Fan Speed Evap Leaving Water Temp F VSF PID Decreasing Fan Speed 15 sec Stage on
28. start at approximately 2 VDC and gradually ramp up to about 10 VDC This voltage level is directly proportional to fan speed At 5 VDC the fan should be running at 50 of full speed and at 7 VDC the fan should be running at 70 of full speed NOTE The output from the compressor module is a pulse width modulated signal 10 volt peak and 10 Hz fundamental It s average value can be read with a DC voltmeter 8 Remove the jumper wire and reconnect connector or P10 While the inverter is still powered measure the DC voltage between pins J9 4 and J9 3 on the compressor module The connector must be plugged 83 84 Variable Speed Fan System on at both ends while measuring this voltage If the reading is between 11 5 and 12 5 VDC two problems may exist e inverter indicates that it has a fault by opening a semiconductor switch within the inverter The inverter will send a fault signal to the UCM when thas gone through a self shutdown One cause of this could be high line voltage A 1096 high line voltage could cause a diagnos tic trip The output frequency of the inverter is being internally limited to a less than 50 of the signal speed commanded by the UCM Excessive fan motor current high temperature or internal inverter failures could cause this to occur e There is an open circuit in the fault signal wiring somewhere between the inverter and the compressor module If the reading is 2 VDC or
29. the factory using unshielded 18 gauge twisted pair cable terminated into a 4 position MTA type connector orange color code This connector is plugged onto the 4 pin IPC connection jack designated as J1 located in the upper left corner of the PC board edge on all of the modules The 4 pins actually represent 2 pairs of communications terminals J1 1 4 internally connected to J1 3 and J1 2 internally connected to J1 4 to allow for easy daisy chaining of the bus IPC Diagnostics The modules in order to work together to control the chiller must constantly receive information from each other over the IPC Failure of certain modules to communicate or degradation of the communication link could potentially result in chiller misoperation To prevent this situation each module monitors how often it is receiving information from designated other modules If a module fails to receive certain other module s transmitted data over a 15 second time period it will 1 Onits own take specific action to safely shut down or to default its con trolled loads 2 Reporta diagnostic to the CPM over the IPC link The CPM if it properly receives such will then report and display the diagnostic on the Clear Language Display accordingly The diagnostic will e identify which module is reporting the communication problem and e identify which module was to have sent the missing information The CPM itself will then send out further commands to
30. unload solenoid should be on continuously Checking the load solenoid is more difficult Shortly after a start the compressor will usually start loading If however water temperature is dropping rapidly enough it will stay unloaded It may take a while to begin seeing load pulses Refer to on page 36 for a more detailed procedure on how to accomplish the load unload solenoid and slide valve check on the MCSP and associated compressor RLC SVDOS3A EN Module Power and Miscellaneous I O 1 Terminals For the checkout of the I O refer to the block diagram of the module in Figure 22 and the Chiller Wiring Diagrams for both high and low voltage circuits All voltages are measured differentially between terminal pairs specified unless otherwise indicated The first terminal in the pair is the positive or hot terminal Voltages given are nominals and may vary by 5 Unregulated Voltages unreg 115 VAC voltages may vary by 1596 Table 22 Compressor Module Normal Terminal Voltages 1 U4 and 1 U5 Terminal Description Normal Terminal Voltages Designation of Circuit for Various Conditions J1 4 to IPC Communications 19 2 kbaud serial data 5 volt signal level or J1 2 to 1 Refer to Interprocessor Communication Interface J2 2 1 Manufacturing Address Use 5 VDC No connection intended Only J3 7 6 External Circuit Lockout Open 12 VDC ckt lockout Clos
31. 2 IPC Address Dip Switch SW1 Settings for MCSP an EXV Modules MODULE DESIG CONTROLLING DIP SWITCH SETTING SW1 1 SW1 2 MCSP A 104 COMPRESSOR MCSP B 1U5 COMPRESSOR B OFF ON EXV 1U3 CKTS 1 amp 2 OFF OFF 3 Loss of power to a module Generally a power loss to a particular module will only affect communica tions with that module The module can usually be identified by analysis of the IPC diagnostics When the display is blank check power at the CLD Loss of power can most directly be diagnosed by measuring the AC voltage at the top of the fuse with respect to the neutral of the power connection pins 4 or 5 on the terminal just below the fuse UPPER RIGHT CORNER OF MODULE fused side H FUSE unswitched side 115 VAC To Check Fuse i H we H 115 VAC Power a N Connection NEUTRAL 5 N N Figure 2 Module Fuse and Power Connection Except CLD 4 Internal module failure Internal module failures usually result only in communication loss to the failed module but could in some cases affect all the modules because the failed module may lock the IPC bus and prevent all communica tions The former can be identified by analyzing all of the active IPC diag nostics The latter can be identified in a process of elimination whereby each module in turn is taken out of the IPC link and a jumper installed in its place See Figure 3
32. 3 4 Local IPC 19 2K Baud 5 V signal level J2 1 2 or J2 3 4 Power 18 30 VAC neither side grounded J3 1 2 or J3 3 4 BAS 19 2K Baud 5 V signal level Figure 24 LCI C Nominal Terminal Voltages RLC SVDOS3A EN 79 80 Variable Speed Fan System The purpose of this troubleshooting guide is to help technicians determine if the variable speed fan inverter the compressor module the variable speed fan inverter contactor the fan motor or the interconnecting wiring is faulty A 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 SVBO6A EN or PROD SVBO6A FR In this troubleshooting procedure the components will be referred to by the descriptions below Description Circuit 1 Circuit 2 Compressor Module 104 105 Variable Soeed Fan Motor 3B2 4B2 Variable Speed Fan Inverter 6U9 6U10 Variable Speed Fan Inverter Contac
33. 30 seconds through contactor control and then re powered If the fault still remains or occurs again within one minute an IFW diagnostic occurs The UCM will remove power from the Inverter and attempt to run the remaining constant speed fans using normal constant speed Fan Control Algorithm See page 80 for step by step troubleshooting procedure RLC SVDO3A EN RLC SVDOS3A EN Current Transformer Each compressor motor has all three of its line currents monitored by torroid doughnut current transformers While the MCSP utilizes all three of the signals it only displays the maximum phase at any given time These currents are normalized with respect to the Rated Load Amps of the respective compressor and thus are expressed in terms of 96 percent RLA The currents are normalized thru the proper selection of the Current Trans former the setting of the Compressor Current Overload dip switch SW2 on the MCSPs and the redundant programming of the decimal equivalent of these settings in the Service Settings Group of the CLD The term Compressor Current Overload setting is actually a misnomer Instead the setting should be thought of as an internal software gain that normalizes the currents to a 96 RLA for a given CT and compressor rating The true nominal steady state overload setting is fixed at 13296 Refer to Tables 5 thru 9 for setup details The current transformers provide the input for six basic functions of the MCSP 1 Mo
34. 3A EN Sor acuz Figure 13 Module Power and Miscellaneous I O MANUF NO CONN USE ONLY RESET ICE MAKING EXTERNAL CHILLED 5V WATER 4 20mA 2 10V SETPOINT COM EXTERNAL CHILLED 5V LIMIT 4 20mA 2 10V SETPOINT COM HPO CSR Options Module 102 RLC SVDOS3A EN 9 TP1 5V J6 1 TP2 6V TP2 12V J6 3 J6 4 oes J1 3 J1 2 J1 1 J2 2 J2 1 ES 1 2 3 4 5 6 7 8 9 10 O 57 rO r acuz Module Power and Miscellaneous I O Electronic Expansion Valve Module EXV 1U3 A 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 Valve Operation The electronic expansion valve is an electronic flow device that replaces the thermostatically controlled expansion valve and liquid line solenoid A sectional view of the valve is shown in Figure 16 and Figure 17 The control method uses two sensors that measure the temperature difference between the inle
35. 4 109 85 0 82475 2 788 35 0 2756 2 1 485 36 0 29329 5 4 088 86 0 8054 1 2 759 36 0 2701 2 1 464 370 28515 0 4 067 870 7865 8 2 730 370 26475 1 444 38 0 27725 9 4 045 88 0 7682 5 2 700 38 0 2595 0 1 423 39 0 26961 4 4 024 89 0 7504 2 2 671 39 0 2543 7 1 403 40 0 26220 8 4 002 90 0 7330 5 2 642 40 0 2493 6 383 41 0 25503 0 3 979 91 0 7161 4 2 613 41 0 2444 6 364 42 0 248075 3 957 92 0 6996 7 2 584 42 0 2396 7 1 344 43 0 24133 3 3 934 93 0 6836 3 2 555 43 0 2349 9 325 44 0 23479 7 3 910 94 0 6680 1 2 526 44 0 2304 1 306 45 0 22846 1 3 887 95 0 6528 0 2 498 45 0 2259 2 287 46 0 22231 9 3 863 96 0 6379 8 2 469 46 0 2216 0 269 470 21636 2 3 839 970 6235 5 2 440 470 2172 8 1 250 48 0 21058 7 3 815 98 0 6094 8 2 412 48 0 2131 6 232 49 0 20498 4 3 790 99 0 59578 2 384 49 0 2090 4 1 215 50 0 2051 2 197 1 Overall accuracy for the sensor is at least 2 F over the range shown 2 As you compare a thermistor resistance or input voltage reading with the actual temperature indicated by the thermometer be sure to consider the location and precision of the thermometer when you decide whether or not the thermistor is out of specified accuracy The thermistor resistances given do not account for the self heating effects that are present when connected to the UCM A connected operating thermistor will read a slightly lower less than 1 resistance w 18 RLC SVD03A EN RLC SVDOS3A EN Compressor Operation This feature
36. 6 5 0 74609 7 3 901 55 0 7471 6 2 271 05 0 5205 9 0 996 6 0 72288 8 3 872 56 0 7018 0 2 236 06 0 5091 5 0 977 70 700474 3 848 570 65778 2 207 070 4979 9 0 962 8 0 67881 9 3 818 58 0 6150 5 2 173 08 0 4871 1 0 942 9 0 65790 2 3 789 59 0 5735 7 2 144 09 0 4765 0 0 928 0 0 63768 7 3 760 60 0 5332 9 2 109 0 0 4661 5 0 913 1 0 61815 3 3 730 61 0 14941 7 2 080 111 0 4560 6 0 894 2 0 599278 3 701 62 0 14561 9 2 046 112 0 4462 2 0 879 3 0 58103 1 3 672 63 0 4193 0 2 017 3 0 4366 3 0 864 4 0 56339 6 3 643 64 0 3834 6 987 4 0 4272 6 0 850 5 0 54634 7 3 608 65 0 3486 5 958 5 0 4181 3 0 835 6 0 52986 4 3 579 66 0 13148 3 924 116 0 4092 2 0 820 70 51392 6 3 550 670 12819 8 895 70 4005 3 0 806 8 0 49851 6 3 516 68 0 12500 5 865 118 0 3920 5 0 791 9 0 48360 9 3 486 69 0 12190 2 836 119 0 38377 0 776 20 0 46919 2 3 452 70 0 11888 7 1 807 120 0 3756 9 0 762 21 0 45524 6 3 418 71 0 11595 6 477 121 0 3678 1 0 747 22 0 44175 6 3 389 72 0 11310 7 753 122 0 3601 1 0 732 23 0 42870 3 3 354 73 0 11033 7 724 123 0 3526 5 0 723 24 0 416076 3 320 74 0 10764 4 694 124 0 3453 6 0 708 25 0 40385 3 3 286 75 0 10502 6 670 125 0 3382 4 0 698 26 0 39202 7 3 257 76 0 10248 0 641 126 0 3313 0 0 684 270 380579 3 223 770 10000 4 616 1270 3245 1 0 674 28 0 36950 0 3 188 78 0 9759 6 587 128 0 3178 9 0 659 29 0 358774 3 154 79 0 9525 4 563 129 0 3114 2 0 649 130 0 3051 0 0 635 1 Overall accuracy for any of the sensors is at least 2 F over the range shown Accura
37. 95 11100 28 048387 96 11100 28 048387 97 1110 29 032258 98 11110 30 016128 99 11110 30 016128 100 11 31 000000 31 32 Under Over Voltage Transformer The hardware required for the Under Over voltage sensing function of the UCM is standard on the 70 125 Ton RTAA chiller This feature must be Enabled in the Service Settings Menu for it to be active A custom designed transformer whose primary is connected across the Line Voltage phases A to B provides a stepped down and isolated AC voltage to the CPM at input J4 This secondary voltage is directly proportional to the line voltage applied to the primary The Chiller Report on the CLD can directly display the Line Voltage and when so enabled can cause automatically reset MAR diagnostics for High and Low Line condition The Line Voltage Is internally calculated by dividing the selected nominal voltage rating only certain discrete values are selectable in the Service Settings Group by the actual line voltage as read and processed by the CPM With the UnderOver Voltage Protection Function enabled an Over Voltage diagnostic will occur if the calculated Line Voltage equals or exceeds 114 or an Under Voltage diagnostic will occur if it equals or falls below 87 for 15 continuous seconds Reset differential is set at 3 Under Over Voltage Transformer Checkout A WARNING Live Electrical Components During installation testing servicing and troubles
38. CSP B and EXV Suspect an open early in the IPC link between the CPM and MCSP B There are a large number of possible combinations of diagnostics One must deduce what is causing the problem using all available information If the CLD Comm link to the CPM is broken the message is No Communication Data Not Valid RLC SVDO3A EN RLC SVDOS3A EN Temperature Sensor Checkout With the exception of the thermostats located in the motor windings of the screw compressors all the temperature sensors used on the UCMs are negative temperature coefficient NTC thermistors The thermistors employed all have a base resistance of 10 Kohms at 77F 25C and display a decreasing resistance with an increasing temperature The UCMs read the temperature by measuring the voltage developed across the thermistors in a voltage divider arrangement with a fixed internal resistance The value of this pull up resistor is different depending on the temperature range where the most accuracy is desired The voltage source for this measurement is a closely regulated 5 0 VDC supply An open or shorted sensor will cause the UCM to indicate the appropriate diagnostic In most cases an open or short will cause a CMR or MMR diagnostic that will result in a machine or circuit shutdown Open or shorts on less critical Outdoor Air or Zone Temperature sensors will result in an Informational Warning Diagnostics and the use of default values for that parameter Temper
39. Communications Chiller Mod Indicating Cprsr B Communications The CPM is reporting that it cannot talk to any of the other modules Suspect a shorted IPC bus or a module locking up the bus The CPM could also be bad and not be sending recognizable tokens Discriminating between these possi bilities is done by disconnecting the link or jumping out modules in the link at various places Refer to Item 4 in Troubleshooting Modules Troubleshooting Modules Using IPC Diagnostics on page 9 for the procedure and the IPC Jumper for bypassing the Modules Diagnostics present Chiller Mod Indicating Cprsr B Communications EXV Mod Indicating Cprsr B Communications The CPM and EXV have both detected a communication loss with MCSP B Suspect the address switch on MCSP B or a power fuse problem Diagnostics present Chiller Mod Indicating Cprsr A Communications Chiller Mod Indicating Cprsr B Communications EXV Mod Indicating Cprsr A Communications EXV Mod Indicating Cprsr B Communications The CPM and EXV have both detected a communication loss with MCSP A and MCSP B Suspect that the address switches on both modules are set to the same address Wiring is probably OK since the EXV can talk to the CPM Diagnostics present Chiller Mod Indicating Cprsr B Communications Chiller Mod Indicating Cprsr A Communications Chiller Mod Indicating EXV Mod Communications Interprocessor Communication The CPM has detected loss of communications with MCSP A M
40. Display in order to insure proper unit operation It is helpful to include with the return of a module a brief explanation of the problem sales office job name and a contact person for possible follow up The note can be slipped into the module enclosure Early and timely processing of Field Returns allows for real measurements of our product quality and reliability providing valuable information for product improvement and possible design changes RLC SVD03A EN RLC SVDOS3A EN General Information System Description The CPM is the master module and coordinates operation of the entire system One is used per chiller The MCSP is a compressor protection module with one being used for each of the compressors in the chiller The EXV is the expansion valve controller module which controls two Electronic Expansion Valves There is one valve on each of the two refrigeration circuits The CLD is a two line 40 character alphanumeric interface to the system It allows the operator to read operating and diagnostic information as well as change control parameters The Interprocessor Communications Bridge IPCB provides an extension of the IPC link to the Remote Clear Language Display while protecting the integrity of the IPC communications link between the local modules The CSR is an optional communications module which allows for communica tions between the chiller and a remote building automation system i e Tracer Tracer Summit G
41. External Current Limit Setpoint and Tracer Summit Communications Troubleshooting Procedure 1 Place the CPM in Stop Record the active IPC diagnostics as shown the Diagnostics Report of the CLD The communication failure diagnos tics and their meanings are shown in IPC Diagnostics of the 4 4 manual Determine which modules are not talking These modules must be affected by one of the previously stated problems If there is a group of modules not talking suspect a wiring problem early in the daisy chain link If only one module is not talking suspect a loss of power or blown fuse RLC SVDOS3A EN RLC SVDOS3A EN Interprocessor Communication 3 Determine which modules are still talking Wiring up to these is likely to be OK 4 Try disconnecting the link or jumping out modules in the link at various places use Figure 1 Reset the diagnostics and note which diagnostics reappear Here are some examples of IPC diagnostics Diagnostics present Chiller Mod Indicating EXV Mod Communications Cprsr A Indicating EXV Mod Communications Cprsr B Indicating EXV Mod Communications The CPM and both MCSP modules are detecting a loss of communications with the EXV Suspect power to the EXV or its fuse or a wiring problem downstream of the MCSP A and B modules Diagnostics present Chiller Mod Indicating Options Mod Communications Chiller Mod Indicating EXV Mod Communications Chiller Mod Indicating Cprsr A
42. The CPM can then be reset and the new IPC diag nostics that result can be analyzed RLC SVDOS3A EN 11 Interprocessor Communication J1 1 AMP 156 c c header 045 pins or equiv Wire 4 jumpers soldered or wrapped into pins Figure 3 IPC Jumper For Bypassing Modules to be inserted into MTA connector in place of module 5 Improper connections to terminal J2 Jack J2 present on all modules except CLD should have no connections This input is for manufacturing test purposes only and any connections shorts etc will potentially cause the module to not respond respond to the wrong address or in the case of the CPM fail to initiate any commu nications and thus fail the entire IPC High levels of Electro Magnetic Interference The modules and the IPC have been qualified under severe EMI both radiated and conducted and the system was determined to be immune to all but extremely high noise levels Always be sure to close and latch the control panel cabinet doors as the panel enclosure provides signifi cant shielding and is integral in the overall noise immunity of the control system Module specific function selected without the Options Module If any of the functions on the Options Module are selected but the Options Module is not present the UCM will look for this module and generate an error The Options Module functions include Chilled Water Reset Ice Machine Control External Chilled Water Setpoint
43. Tracer always set the chiller setpoint source to the Tracer mode The setpoint source can be found in the Operator Settings Menu These inputs accept either an isolated 4 20mA or 2 10VDC signal from an external controller or programming resistor connected to an internal 5V source The switches SW1 1 and SW1 2 are used to select either the voltage or current option for External Chilled Water Setpoint and External Current Setpoint respectively See Test Points above Alternately either input may be used with a resistor or potentiometer NOTE Note For proper operation the 4 20mA 2 10VDC inputs are required to be used with a current or voltage source that 1 Is isolated floats with respect to ground or RLC SVDO3A EN RLC SVDOS3A EN Module Power and Miscellaneous I O 2 Has its negative terminal tied to chassis ground If the intended source does not meet the above requirement an isolation module must be used The 4 20mA 2 10VDC inputs may be tested in the following ways 1 Enable External Chilled Water Setpoint and or External Current Limit Set point in the Operator Settings Menu Advance display to Active Chilled Water Setpoint or Active Current Limit Setpoint to observe the respective setpoint in the Chiller Report 2 With all wiring in place apply an external voltage or current to the Exter nal Chilled Water Setpoint inputs TB 1 4 amp 5 or the External Current Limit
44. agrams for the specifics on the power wiring Generally a power loss to a particular module will first be noticed as a communications loss with that module The module can be identified by analysis of the IPC diagnostics as displayed by the CPM Refer to Section 2 Interprocessor Communication for more information about Communication IPC diagnostics If the CLD s display is blank 24 VAC power should be checked at the CLD 41 Module Power and Miscellaneous I O UPPER RIGHT CORNER OF MODULE fused side FUSE unswitched side 115 VAC Power Connection NEUTRAL Figure 7 AC Power Connection To Modules 42 Clear Language Display CLD 106 Keypad Overview Local operator interface with the system is accomplished using the 16 keys on the front of the Clear Language Display panel The readout screen is a two line 40 character liquid crystal display with a backlight The backlight allows the operator to read the display in low light conditions The depression of any key will activate the backlight The backlight will stay activated for 10 minutes after the last key 15 pressed At 10 F or below the backlight will stay activated continuously The keys are grouped on the keyboard by the following functions refer to Figure 8 Select Report Group Select Settings Group Selection Keys Stop amp Auto Keys RLC SVD03A EN Module Power and Miscellaneous I O Ae EE Bua 420F Figure8 Operator Interface Adaptive C
45. alve will be stepped closed again for a full 25 seconds Since the valve should have started from the full open position the time to stroke closed should be noted and it should be approximately the same as the opening time above If both opening and closing stroke times are correct to within x5 seconds of the time specified no further testing is required If any valve fails this test the service technician should perform the EXV Valve Winding Resistance Check steps 8 thru 10 below SEO EXV Valve Winding Resistance Check 1 Disconnect the appropriate EXV valve from the pin header of the EXV module 2 With a digital ohm meter check the resistance of the valve windings associated leads connector by measuring the resistance of pin pairs at the connector plug Pin pairs are 5 and 3 5 and 2 and 5 and 1 for Circuit 1 Pin numbers are indicated by corresponding position on the board or by the raised numbers of the connector block The resistances should all be 40 ohms 4 ohms at 75F winding temperature At a valve winding temp of 148F the resistance would be no more than 54 ohms at a valve winding temp of 32F the resistance would be no less than 33 ohms RLC SVDO3A EN Module Power and Miscellaneous I O 3 Check the resistance from each of the three phase pins J4 3 J4 2 and J4 1 to the board edge GND with the connector unplugged This resis tance should be between 100K and 200K ohms If the valve wiring connector
46. ansion Valve General Information High Pressure Cutout Switch Low Pressure Cutout Switch Variable Speed Fan Drive Motor Temperature Thermostats Slide Valve Load Unload Solenoids Step Load Solenoid Valve Chiller Module CPM 101 The CPM module performs machine chiller level control and protection functions Only one CPM is present in the chiller control system The CPM acts as the master controller to the other modules running top level machine control algorithms initiating and controlling all inte module communication over the IPC and providing parameters and operational requests i e loading and unloading starting and stopping to the other modules in the system via the IPC The CPM also contains nonvolatile memory which allows it to remember configuration and set up values setpoints historical diagnostics etc for an indefinite period of time following a power loss Direct hard wired associated with the CPM includes low voltage analog inputs low voltage binary inputs 115 VAC binary inputs and 115 VAC rated relay outputs See Chiller Module CPM 1U1 on page 46 for further details Compressor Module MCSP 1U4 and 1U5 The MCSP module employs the input and output circuits associated with a particular compressor and refrigeration circuit Two MCSP modules are used in the UCM system one for each compressor Included are low voltage analog and digital circuits 115 VAC input and 115 VAC output switching devices The
47. ature Sensor Checkout Procedure A 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 1 Measure the temperature at the sensor using an accurate thermometer Record the temperature reading observed 2 With the sensor leads connected to the UCM and the UCM powered measure the DC voltage across the sensor leads at the terminal or probe the back of the MTA plug NOTE Always use a digital volt ohmmeter with 10 megohm or greater input impedance to avoid loading down the voltage divider Failure to do so will result in erroneously high temperature calculations 3 Locate the appropriate sensor table Table 3 Evaporator Water and Refrigerant Temperature Sensors Table 4 Saturated Condenser Refriger ant and Entering Oil Temperature Sensors Then compare the tempera ture in the table corresponding to the voltage reading recorded in Step 2 with the actual temperature observed in Step 1 If the actual temperature measured falls within the allowable tolerance range both the sensor and the UCM s temperature input circuits are operating properly
48. ber RLC SVDOS3A EN 29 Current Transformer Table 8 Compressor Phase Current vs AC Input Voltage at MCSP ACTUAL COMPRESSOR PHASE AMPS THRU CT TERMINAL EXT EXT EXT EXT EXT EXT EXT VOLTAGE OF CT 01 02 03 04 05 09 10 V RMS RATING 0 0 0 0 0 0 0 0 00 0 5 8 10 14 20 2 5 3 75 1 19 5 10 15 20 28 40 5 75 1 37 10 15 23 30 41 60 7 5 11 25 1 53 15 20 30 40 55 80 10 15 1 67 20 25 38 50 69 100 12 5 18 75 1 81 25 30 45 60 83 120 15 22 5 1 95 30 35 53 70 96 140 175 26 25 2 09 35 40 60 80 10 160 20 30 2 23 40 45 68 90 24 180 22 5 33 75 2 36 45 50 75 100 38 200 25 37 5 2 50 50 55 83 110 51 220 275 41 25 2 63 55 60 90 120 65 240 30 45 2 77 60 65 98 130 79 260 32 5 48 75 2 90 65 70 105 140 93 280 35 52 5 3 03 70 75 113 150 206 300 375 56 25 3 17 75 80 120 160 220 320 40 60 3 30 80 85 128 170 234 340 42 5 63 75 3 43 85 90 135 180 248 360 45 675 3 57 90 95 143 190 261 380 475 71 25 3 70 95 100 50 200 275 400 50 75 3 83 100 105 58 210 289 420 52 5 78 75 3 96 105 110 65 220 303 440 55 82 5 4 10 110 115 173 230 316 460 575 86 25 4 23 115 120 180 240 330 480 60 90 4 36 120 125 188 250 344 500 62 5 93 75 4 49 125 130 195 260 358 520 65 97 75 4 62 130 135 203 270 371 540 675 101 25 4 75 135 140 210 280 385 560 70 105 4 88 140 145 218 290 399 580 72 5 08 75 5 02 145 150 225 300 413 600 75 112
49. ce of the trans former s by probing the appropriate pair s of receptacles within the MTA The receptacle pairs of the MTA are most easily measured by using meter leads with pointed probes and contacting the exposed metal of the connector through either the top or the side of the MTA It may be nec 25 26 Current Transformer 10 11 essary to remove a cap over the top of the connector to gain access to the connector conductors Refer to Table 7 which lists the normal resistance range for each exten sion of current transformer Check the measured resistance against the value listed per transformer extension If the resistance is within toler ance the transformer and MTA can be considered good Go on to step 8 If the resistance reading above is out of tolerance the problem is either with the transformer its wiring or the MTA connector First double check the schematic to be sure you are working the proper lead pair Then cut the leads to the particular transformer near the MTA connector and repeat the resistance measurement by stripping insulation from the wire s end Once the fault has been isolated in this manner reconnect leads or install a new transformer or connector More than one current transformer is terminated to a single MTA When replacing take care to note the proper positions of the respective trans former wire terminations on the MTA for the re termination The current transformers are NOT polarity or d
50. ckout TB3 2 1 Chilled Water open 115VAC No Flow Flow Switch Input closed 5VAC Flow Software imposes a 6 second delay to respond to opening or closing TB3 3 4 Chilled Water Demand Switch and open 115 Stop External Auto Stop closed lt 5VAC Auto TB4 1 2 Chiller Alarm or Alarm Ckt 1 Dry SPDT Contact closes on Alarm intended for 115 VAC N O Contact customer control circuit TB4 1 3 Chiller Alarm or Alarm Ckt 1 Dry SPDT Contact opens on Alarm intended for 115 VAC N O Contact customer control circuit TB4 4 5 Unit Running Alarm Ckt 2 or Dry SPDT Contact closes on Unit Running Ckt 1 Running Alarm Ckt 2 or Ckt 1 Running intended for N O Contact 115 VAC customer control circuit TB4 6 7 aximum Capacity or Ckt 2 Running Dry SPDT Contact closes on Maximum Capacity or Ckt 2 N O Contact Running intended for 115 VAC customer control circuit TB4 8 9 Chilled Water Pump Starter Dry SPST Contact closes when Chilled Water N O Contact Demand Switch is closed opens after time delay specified in UCM 115 VAC customer control circuit TB4 10 11 Spare Relay Dry SPST contact 115 VAC customer control circuit O Contact RLC SVDOS3A EN 49 50 Module Power and Miscellaneous I O Options Module CSR 1U2 A 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 quali
51. combination fails the above tests suspect the connector or the wiring first At the valve for circuit 1 wire color black corre sponds to pin 5 red to pin 3 white to 2 and green to 1 For circuit 2 black to pin 6 red to pin 4 white to 2 and green to pin 1 Refer to Table 20 and use the pass fail results above to determine the prescribed action SEHI EXV Valve Winding Resistance Check 1 Disconnect the appropriate EXV valve from the pin header of the EXV module 2 With a digital ohm meter check the resistance of the valve windings associated leads connector by measuring the resistance of pin pairs at the connector plug Pin pairs are 5 and 4 2 and 1 for Circuit 1 and 6 and 5 and 2 and 1 for Circuit 2 Pin numbers are indicated by corre sponding position on the board or by the raised numbers of the connec tor block The resistances should all be 75 ohms 10 ohms 3 Check the resistance from each lead to the board edge GND with the connector unplugged This resistance should be greater than 1 meg ohms If the valve wiring connector combination fails the above tests suspect the connector or the wiring first At the valve for circuit 1 wire color black corre sponds to pin 1 red to pin 5 white to 2 and green to 4 For circuit 2 black to pin 1 red to pin 6 white to 2 and green to pin 5 Refer to Table 20 and use the pass fail results above to determine the prescribed action Table 20 Tes
52. cy of matched sensors is 1 F over specific ranges 2 As you compare a thermistor resistance or input voltage reading with the actual temperature indicated by the thermometer be sure to consider the precision and location of the thermometer when you decide whether or not the thermistor is out of specified accuracy 3 The thermistor resistances given do not account for the self heating effects that are present when connected to the UCM A connected operating thermistor will read a slightly lower less than 196 resistance RLC SVDOS3A EN Temperature Sensor Checkout Table 4 Sensor Conversion Data Saturated Condenser and Entering Oil Temperature Matched Pairs 6RT12 3B1RT1 6RT13 4B1RT2 Actual Actual Thermistor Actual Actual Thermistor Actual Actual Thermistor Temp Resistance Voltage Temp Resistance Voltage Temp Resistance Voltage F Ohms Volts DC F Ohms Volts DC F Ohms Volts DC vo 875103 4651 500 199550 3 65 1000 58243 2000 1 0 84745 9 4 641 51 0 94279 3 740 01 0 5694 2 2 327 2 0 82072 1 4 630 52 0 8916 5 3 715 02 0 55674 2 300 3 0 79500 1 4 619 53 0 8420 3 3 689 03 0 5443 8 2 272 4 0 77012 3 4 608 54 0 7938 8 3 664 04 0 5323 3 2 244 5 0 74609 7 4 596 55 0 7471 6 3 638 05 0 5205 9 2 217 6 0 72288 8 4 584 56 0 7018 0 3 611 06 0 5091 5 2 189 70 700474 4 572 570 65778 3 585 070 4979
53. d Carbon HCFCs Not all refrigerants containing these compounds have the same potential impact to the environment Trane advocates the responsible handling of all refrigerants including industry replacements for CFCs such as and HCFCs and HFCs Responsible Refrigerant Practices Trane believes that responsible refrigerant practices are important to the environment our customers and the air conditioning industry All technicians who handle refrigerants must be certified The Federal Clean Air Act Section 608 sets forth the requirements for handling reclaiming recovering and recycling of certain refrigerants and the equipment that is used in these service procedures In addition some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants Know the applicable laws and follow them A WARNING Contains Refrigerant System contains oil and refrigerant under high 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 RLC SVD03A EN RLC SVD03A EN Contents General Information
54. dized surface with insulating properties The DC voltage shall be within the tolerance specified below If not replace the module TP1 5 volts DC 5 EXV Test The EXV module has a built in test which is designed to allow the service technician to confirm a problem with the EXV control system and to identify which of the components of the system the Valve Stepper Motor assembly the EXV Module or the interconnecting wiring is at fault The directions to perform this test are given below EXV Test Procedure 1 Place the Chiller in the STOP mode using the Stop Button on the CLD 2 Determine which refrigeration circuit is associated with the EXV valve you want to test Advance to the EXV TEST display in the Service Tests Menu 3 Press the A or N7 keys to change the displayed d to an which will enable or initiate the preprogrammed procedure Display will auto matically return the item to disabled when the test is completed Electrical Integrity Test 4 Initially the UCM will perform an Electrical Integrity test on the valve s stepper motor phases and associated wiring If a failure is detected it will report a diagnostic indicating EXV Elect Drive CKT at this time This 61 62 Module Power and Miscellaneous I O diagnostic suggests that there is a problem with the valve or the valve wiring To confirm this it is necessary to continue the procedure The Electrical Integrity test will be completed in ab
55. e Three measurements can be made 1 With the probe connected the voltage across the input terminals may be measured The voltage should agree with the table values in the Temper ature Sensor Checkout Procedure on page 15 2 The probe may be disconnected from the module and its resistance mea sured It should agree with the table values 3 With the probe disconnected the terminal voltage may be measured with a high impedance voltmeter It should be between 4 975 and 5 025 Vdc If the meter loads the input a slightly lower voltage may be expected Refer to Temperature Sensor Checkout for more details Current Inputs The following tests may be used to check a current input circuit 1 With the compressor off the AC voltage across the terminals with the current transformer connected should read 0 V The corresponding cur rent as read on the CPM display should read O 2 With the compressor on the AC voltage across the terminals should agree with the data of Table 8 The RLA read on the CPM display will depend on the setting of the gain switch If the gain switch is set to 11111 the percent CT rating values should agree with the display For any other switch setting the gain factor as found in Table 9 must be taken into account using one of the following procedures e Start with the displayed RLA Multiply by 67 and divide by the gain where the gain is found in Table 16 The result is the percent CT rating Use this and th
56. e Table 8 to find the corresponding terminal voltage e Start with an actual current measurement such as from a clamp on ammeter Determine which CTs are being used and use the Table 8 to find the corresponding terminal voltage and percent CT rating Multiply the percent CT rating by the gain and divide by 67 to find the RLA that should be displayed NOTE lf the gain switch and CPM gain setting do not agree diagnostic will be generated and the MCSP will continue operating using a default gain setting of 00000 max gain This will result in the MCSP thinking 73 74 Module Power and Miscellaneous I O the currents are higher than actual and will show up as an error in the RLA displayed by the CPM The compressor will operate safely but may unload due to the current limit function Refer to Current Transformers and Current Inputs for more details on operation and troubleshooting Isolated Binary Input Winding Temperature This input may be checked by disconnecting all wiring from the terminals and measuring the open circuit voltage It should read between 10 and 15 Vac A Winding Temp Cprsr A or diagnostic should appear on the CPM s display depending on which compressor module it is A jumper may then be placed across the input to short it out After clearing diagnostics the diagnostic should no longer be present It a diagnostic continues to occur the module needs replacement Relay Outputs Compres
57. e discussed in terms of chiller operation This should help the serviceman determine when and how they should function Certain inputs have been presented in greater detail in earlier sections and these are referenced where applicable Power Supply All of the modules are powered from 115 VAC 50 60hz Control Power except the CLD and the IPCB which are powered by 24 VAC This power is provided by either a control power transformer or is customer supplied With the exception of the CLD LCI C and the IPCB modules the other modules have incoming power connected to the uppermost terminal on the right hand side of the module just below the fuse The terminal is arranged with two hot pins 1 and 2 a keying pin 3 and two neutral pins 4 and 5 for ease of daisy chaining power from one module to another Incoming power can be verified by measuring the voltage between the fuse bottom hot side and the connector s neutral pins 4 or 5 The voltage should read between 978 to 132 2 volts AC rms Refer to Figure 7 The 15 voltage criteria is most important for the EXV module s operation as the Electronic Expansion Valve s available torque is directly related to this value The fuses can be checked by looking for the supply voltage at the top of the fuse fused side with respect to the connector neutral If some modules have power and some do not the daisy chain wiring or power connections should be suspected Refer to the Unit Wiring di
58. ed 0 VDC normal ckt lockout only if feature is enabled in Service Settings Must be jumpered if this feature is not used J3 4 3 Transition Complete Open 12 VDC pre transition Closed 0 VDC transition complete only used with reduced voltage starters J3 2 1 Not Used Must be jumpered J4 5 4 Saturated Condenser Refer to Temperature Sensor Checkout Refrigerant Temp J4 3 1 Entering Oil Temperature Refer to Temperature Sensor Checkout J5 7 6 Phase A Current Input for 100 400 0 1 Ratio CT using digital VOM Transformer Input in diode test mode open circuit input should read between 1 0 to 1 5 Volts Refer to Current Transformer Checkout J5 5 4 Phase B Current Same as above Transformer Input J5 2 1 Phase C Current Same as above Transformer Input J6 1 or 2 Input Power 115 VAC Refer to Power Supply in Module to J6 4 or 5 Power and Miscellaneous O E4 Compressor Motor Internally powered Isolated input Winding Temp Open 16 Vac high temp Thermostat Closed 0 Vac Ok temp E5 to High Pressure Externally powered isolation transformer input J6 4 or 5 Cutout Input 2 VA 115 Vac 115 volts input normal O volts trip J7 3 Compressor Contactor Normally open contact closes for compressor start Output Uses same power input as High Pressure Cutout input above J7 1 E6 Crankcase Heater Output Normally closed contact powers crankcase heater when compressor is off J7 5 6 Transition Command Output Normally open contact clos
59. efrigeration control system intended for use with Trane 70 125 ton helical rotor chillers Six types of modules are used and throughout this publication will be referred to by their abbreviations or their Line Wiring Drawing Designations see Table 1 Table 1 Unit Control Module Designations Line Drawing Controller Name Abbrev Designation Chiller Module CPM 1U2 Options Module CSR 1U3 Expansion Valve Module EXV 104 amp 105 Compressor Module MCSPA amp B 1U6 Clear Language Display CLD 1U7 Interprocessor IPCB Communications Bridge Remote Display Buffer Service Philosophy With the exception of the fuses no other parts on or within the modules are serviceable The intent of the troubleshooting is to determine which module is potentially at fault and then to confirm a module problem This is done either through voltage or resistance measurements at the suspected input or output terminals or by checking related wiring and external control devices connectors sensors transformers contactors etc in a process of elimi nation Once a problem has been traced to a module the module can be easily replaced using only basic tools In general all dip switch settings of the replaced modules should be copied onto the replacement module s dip switches before applying control power CPM replacement is more involved as there are numerous configuration and set up items that must be programmed at the Clear Language
60. eneric BAS All modules in the system communicate with each other over a serial inter processor communications bus IPC consisting of a twisted wire pair daisy chain link and RS485 type signal levels and drive capability Multiple modules of the same type i e MCSPs in an operating system are differentiated by address dip switches All the modules operate from 115VAC 50 or 60Hz power and each have their own internal step down transformer and power supply Each is individually fused with a replaceable fuse The modules also are designed to segregate their high and low voltage terminals by placing the high voltage on the right side of the module and the low voltage on the left When stacked segre gation is maintained In addition to the modules there are a number of system level compo nents that are closely associated with the modules These components were specifically designed and or characterized for operation with the modules For this reason the exact Trane part must be used in replacement System Level Components Description The following is a list of all the components that may be found connected to the various modules Transformer Under Over voltage Current Transformer Compressor Evap EntlL vg Water Temp Sensor Pair Sat Evap Cprsr Suc Rfgt Temp Sensor Pair Sat Cond RfgtlOil Temp Sensor Pair Outdoor Air Temperature Sensor Zone Temp Sensor Connector UCM mating connectors Connector Keying Plug Electronic Exp
61. eplacing a sensor it is easiest to cut the sensor wire near the MTA end and splice on a new sensor using wire nuts 9 A decade box can be substituted for the sensor and any sensor table value used to relate resistance to temperature By removing the MTA plug and applying the resistance to the proper pin terminals the tempera ture as sensed by the UCM can be confirmed Using the CLD menu dis plays scroll to the display of the temperature of interest NOTE All displayed temperatures are slew rate limited and only accurate within a specified normal range It is therefore important to be certain that the temperature readings are stable and that adequate time up to 1 minute is allowed after step changes in resistance inputs are made 10 In all instances where module replacement is indicated first perform the power supply fuse check according to the information in the section Module Power and Miscellaneous I O starting on page 41 RLC SVDOS3A EN Temperature Sensor Checkout Table 3 Sensor Conversion Data Outdoor Air 6RT3 Entering and Leaving Evap Water Temp Matched Pairs 6RT7 6RT8 and Saturated Evap and Comp Suction Refrigeration Temp 6RT9 3B1RT5 6RT10 4B1RT6 Actual Actual Thermistor Actual Actual Thermistor Actual Actual Thermistor Temp Resistance Voltage Temp Resi
62. erify 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 SVBO6A FR NOTE If it is necessary to service the circuit compressor while allowing the opposite circuit to start and run first temporarily disconnect all power to the chiller and then disconnect all control power connections to the compressor and associated controls by pulling off all the control power voltage connectors on the right hand side of the associated MCSP module Control power to the associated contactor should also be disconnected as should the power lead s to the high pressure switch at the control power terminal block Repower the chiller and lockout the circuit you are servicing by entering the Service Tests Menu and enabling CIRCUIT LOCKOUT for the desired circuit Placing the chiller switch into the Auto mode will then allow the opposite circuit to run 7 Return all valves to their normal position temporarily remove all power and reconnect all wiring when servicing is completed 8 Reset the chiller to clear diagnostics and diagnostic history if desired to resume normal operation COMPRESSOR TEST The UCM provides for a Compressor Test feature which is designed to allow a service technician to direct a particular compressor to be t
63. es 7 Does Magnetic Field on Solenoid valve mechanism bound Solenoid Coil exist or unloader valve stuck open No 8 15 wiring to valve OK p Check for open solenoid coil No 9 Repair and reverify Figure 5 Manual Slide Valve Diagnostic Flow Chart Load Unload NOTE The following assumes that the compressor s slide valve is already at some loaded position and RLA is higher than the minimum noted in step 1 1 Manually close the Unload toggle switch to continuously energize the Unload Solenoid Valve 2 Ifthe RLA decreases then the Unload Valve and Slide Valve are operat ing properly 3 If the RLA does not decrease observe the cylinder cavity pressure reading 4 lf cylinder cavity pressure reading decreases to approximately the suction RLC SVDO3A EN RLC SVDOS3A EN Compressor Capacity pressure then the Slide Valve is bound 5 If cylinder cavity pressure does not decrease or is at suction pressure before the Unload toggle switch was closed the problem lies with either the solenoid coil or valve 6 Check coil 7 If coil checks out change the valve NOTE Refer to the Flow Chart in Figure 6 Unload 10 Manually unload compressor in short increments Yes Good 11 Does RLA Decrease 9 Check UCM 2 3 Stop ue Bad Replace Yes 12 Does Cavity Press Slide valve mechanism bound decrease to a level close to suct pressure No 13 Does Magnetic Field
64. es to initiate Wye to Delta Starter transition if configured for Reduced Voltage start RLC SVDOS3A EN 75 Module Power and Miscellaneous I O Table 22 Compressor Module Normal Terminal Voltages 1 U4 and 1 U5 Terminal Description Designation of Circuit Normal Terminal Voltages for Various Conditions J7 8 9 Step Load Solenoid Normally open contact closes to energize the Step Load Solenoid Valve J7 1 E7 Slide Valve Open Triac Output Refer to Checkout Procedure for MCSP Load Unload Load Solenoid Output Outputs J7 1 E8 Slide Valve Close Triac Output Refer to Checkout Procedure for MCSP Load Unload Unload Solenoid Output Outputs J8 1 3 Fan Relay 1 Output Normally open contact for Variable Speed Fan contactor control J8 1 4 Fan Relay 2 Output Normally open contact for fan contactor s control J8 1 5 Fan Relay 3 Output Same as above J8 1 6 Fan Relay 4 Output Same as above J9 6 5 Variable Frequency 10 Volt Peak 10 Hz fundamental Its average value can be read with a DC Fan Output PWM voltmeter Refer to Section 11 Variable Speed Fan System Trouble shooting J9 4 3 Variable Frequency Fault 11 V connector plugged on Fan Fault Signa No Fault 0 VDC connector plugged on Refer to Section 11 Variable Speed Fan System Troubleshooting J9 2 1 Not Used N A 76 RLC SVDO3A EN Module Power and Miscellaneous I O P1 5V 46 1 115 HOT P2 12V 46 2
65. essed the display will wrap around to the last item Select Settings Group The first three keys on the second row Operator Settings Service Settings and Service Tests allow the operator to adjust various setpoints and perform various tests Certain items in these groups are password protected Refer to the Password section for additional information When a setpoint key is pressed a header will be displayed The setpoint headers identify the available items and setpoint functions The Next and Previous keys function in the same manner as that described in Selected Report Group above Setpoint values are incremented by pressing the Plus A key and decre mented by pressing the Minus key Once a setpoint is changed the Enter key must be pressed to save the new setpoint If the Cancel key is pressed the setpoint value on the display will be ignored and the original setpoint will remain Passwords Passwords are needed to enter into the Service Setup Menu and the Machine Configuration Menu Both of these menus are accessed through the Service Settings key If access into these menus is necessary follow the list of steps below 1 Press Service Settings 2 Press Next until the readout in the display is Password Required For Further Access Please enter Password 3 To enter into the Service Setup Menu press A WAKA A Enter 4 To enter into the Machine Configuration Menu press ANNA Enter Refer to RTAA or RTWA
66. essors the phase rotation is detected by the current transformers immediately at start up If improper phasing is detected within 1 second of startup the MCSP will trip out the compres sor The Phase Rotation diagnostics will be displayed This function is not sensitive to the current transformer s polarity 5 Phase Unbalance The MCSP will shut down the compressor if a phase current unbalance is detected by the current transformers while the com pressor is running A 15 unbalance if protection is enabled will cause the MCSP to trip out the compressor The Phase Unbalance diagnostics 23 24 Current Transformer will be displayed If this protection is disabled a 30 phase unbalance will still be in effect with the diagnostic code Severe Phase Imbalance being displayed 6 Current Limit The MCSP will begin to unload its compressor as the RLA exceeds 120 Further the CPM will cause the compressors to automatically unload when the Chiller Current Limit Setpoint is reached The Current Limit Setpoint is set in the Service Setting Group Individual compressor phase currents are averaged and added together to compare to the Chiller Current Limit which is in terms of Total of all of the Compressor RLNs NOTE The current transformers are NOT polarity or directionally sensitive CT and MCSP Compressor Current Input Checkout Procedure A WARNING Live Electrical Components During installation testing servicing and troubles
67. eter and the voltage developed at the respective cur rent transformer s termination at the MCSP using a digital volt meter on a 0 20 VAC scale Refer to Table 8 for the compressor phase current to output voltage relationship for each extension current transformer Using Table 8 look up to current that corresponds to the output voltage read by the voltmeter and compare to ammeter reading Assuming relatively accurate meters the values should agree to within 596 If the measured current and the output voltage from the CT agree within the tolerance specified the CT is good If diagnostics overload trips or other problems potentially involving current sensing continue to occur RLC SVDO3A EN with all phase currents to the compressors verified to be within their nor mal range then the problem is either with the CT selection MCSP Com pressor Overload Dip Switch Setting or the MCSP s current input analog to digital A D or dip switch input circuitry Since the first two items were verified in Step 2 using Table 5 that leaves only the MCSP circuitry as an issue It is advisable to replace the MCSP module at this point However if verification of the MCSP Current sensing operation is desired go to step 12 below 12 There are two ways that the MCSP s current sensing can be checked Both methods use the CLD display of the RLA from each MCSP Com pressor Report for indication of the sensed current The first is straight forward equatio
68. fer to Temperature Sensor Checkout Rfrg Temp CKT2 J4 5 EXV CKT1 GND OVDC GND J4 3 EXV CKT1 Phase 1 Between 0 and 1 VDC when the phase is not being stepped When the valve is being stepped this signal is actually a 24 221796 VDC J4 2 EXV CKT1 Ph 2 1 E ii peak square wave with a period of 60 msec and a 1 3 duty cycle J4 1 EXV CKT1 Phase 3 low On and 2 3 duty cycle high Off An averaging DC voltmeter can be used to measure this voltage The meter will show fluctua tions but the average should be approximately 8 volts J5 6 EXV CKT2 GND OVDC GND J5 4 EXV CKT2 Phase 1 Same a CKT 1 J5 2 EXV CKT2 Phase 2 Same as above J5 1 EXV CKT2 Phase 3 Same as above 44 1 2 4 5 EXV CKT 1 10 12 VDC J4 1 2 5 6 EXV CKT2 10 12 VDC J6 1 or 2 Input Power 115 VAC Refer to Power Supply on page 41 to J6 4 or 5 J7 5 4 Low Pressure Open 12 VDC Low Pressure Cutout Switch Circuit 1 Closed 0 VDC Normal J7 2 1 Low Pressure Open 12 VDC Low Pressure Cutout Switch Circuit 2 Closed 0 VDC Normal Note On a power up or a front panel reset the valve will always be driven closed for approximately 1000 steps During this time approximately 40 seconds an alternating audible clicking sound can be observed on the valves 1SEO Valve 2SEHI Valve RLC SVDOS3A EN 71 72 Module Power and Miscellaneous I O Compressor Module MCSP 1U4 AND 1U5 A WARNING Live Electrical Components During installation testing ser
69. fied 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 Test Points There are three test points associated with the CSR module They are easily read with a DC voltmeter by probing the PC board solder pads found in the upper left hand corner of the module The positive meter lead should be connected to the pad while referencing the negative meter lead to the board edge ground plane Note don t use the aluminum module enclosure as a reference as it has an anodized surface with insulating properties The DC voltages shall be within the tolerance specified below If not replace the module TP1 5 volts DC 5 TP2 6 volts DC 5 TP3 12 volts DC 25 Switch SW 1 Switch SW1 is used to configure the External Chilled Water Setpoint input and the External Current Limit Setpoint input for either a 2 10VDC or a 4 20ma signal With the respective switch closed on a shunt resistor is switched into the input circuit to provide a fixed low value input impedance 499 ohms for current loop operation With the switch off the input impedance is differentially 40Kohms External Setpoint Inputs 4 20ma 2 10VDC The chiller setpoint source should always be set to LOCAL when using any external inputs except a Tracer When using a
70. h 1 ON O OFF The decimal value should be set in the compressor overload setting menu of the UCM If the DIP switch value does not match the decimal value entered into the UCM the related compressor s will continue to run but a diagnostic will be initiated both settings will be ignored and the UCM will use the lowest possible trip setting value 28 RLC SVD03A EN Current Transformer Table 6 Trip Times Vs Current MOTOR CURRENT TRIP TIME SEC RATED RLA MINIMUM NOMINAL MAXIMUM 132 0 272 No Trip No Trip 132 1 272 30 08 No Trip 140 0 must trip pt 22 8 25 28 28 09 150 0 18 8 20 48 22 89 160 0 16 0 1728 9 29 170 0 14 0 15 28 6 89 180 0 12 4 13 28 4 89 190 0 11 2 12 08 3 29 200 0 10 4 10 88 2 09 210 0 9 6 10 08 0 89 220 0 8 8 9 28 0 09 230 0 8 0 8 48 9 69 240 0 76 8 08 8 89 250 0 72 768 8 49 260 0 6 8 6 88 7 69 270 0 6 4 6 88 7 29 280 0 6 0 6 48 6 89 290 0 5 6 6 08 6 89 300 0 4 0 5 68 6 49 300 1 4 0 4 08 6 49 310 2 or above 4 0 4 08 4 49 Table 7 Current Transformers Ratings and Resistance RATING RESISTANCE EXT USABLE RANGE OHMS 10 01 100A 66 67 100A 23 5 02 150A 100 150A 35 0 03 200A 134 200A 46 0 04 275A 184 275A 670 05 400A 267 400A 68 0 09 50A 33 37 50A 11 5 10 75A 50 75A 170 The current transformer base part number is X13580253 The numbers in this column are suffixes of the base part num
71. he first 30 seconds after a start the unload solenoid should be on continuously Checking the load solenoid is more difficult 30 seconds after a start the compressor will usually start loading until water temperatures are satisfied Remember however that under certain limit conditions the MCSP may 35 36 Compressor Capacity prevent a compressor from loading even if the chilled water setpoint is not satisfied Refer to the RTAA IOM 4 for discussion on condenser evaporator and current limiting functions and setpoints Refer to the Mode display under the Chiller Report on the CLD for an indication of the current running mode Checkout Procedure for the Slide Valve and Load Unload Solenoids Make sure unit is off and there is no power in the control panel before beginning this procedure Setup 1 Identify the MCSP Module associated with the compressor to be tested 104 or 105 Disconnect the stake on terminals for the Load and Unload Solenoid Valves at the MCSP UCM E7 and E8 respectively but take care to identify the wires so as to prevent crosswiring when reconnecting A 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 literatu
72. he next compressor to stage on run and modulate This allows the temporary override of the lead lag sequencing currently in effect and relieves the technician from forcing staging of compressors thru load or setpoint changes It is important to note that invoking this feature does not put the chiller into any kind of override mode and no action is required to return to normal operation The chiller will continue to run normally and the current lead lag sequence will again be in effect once the selected compressor has started This feature is used in the Slide Valve Checkout Procedure detailed in Slide Valve Checkout Procedure Invoking Compressor Test 1 With the Chiller in the Auto Mode regardless of whether or not other compressors are currently running use the CLD to enter the Service Tests Menu and enable the COMPRESSOR TEST for the appropriate compressor The selected compressor will automatically stage on once the anti recycle or restart inhibit timer is satisfied and the EXV is preposi RLC SVDO3A EN Other Service Features tioned if not already controlling Most often the stage on will be accom panied by a controlled stage off of an already running compressor Since normal operation is in effect a constant load or setpoint change may be required to keep the compressor from staging off later Circuit Lockout The UCM provides for a circuit lockout feature which prevents the compressor s of the selected refrigeration c
73. hooting 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 1 Check incoming 3 phase power for voltage within 10 of nominal Chiller nameplate 2 Interrogate the CPM for all of the presently active diagnostic codes or the historic diagnostic codes in the Diagnostics Menu Narrow the problem down to a particular compressor or contactor as noted above Write down all of the diagnostic codes stored in the diagnostic registers If there is any question as to which compressor or current transformer is causing a problem or simply to verify and witness the problem an attempt should be made to restart the chiller after clearing diagnostics The diagnostics can be cleared by entering the Diagnostics Menu and stepping to the CLEAR DIAGNOSTICS display It is possible to force certain compressors to be the first or next com pressor to stage on using the Compressor Test feature in the Service Tests Menu The Leaving Water Temperature must however be above the Chilled Water Setpoint by more than the differential to start setting in order to stage on the first compressor At startup verify the appropriate contactor s pull in
74. hooting 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 1 Locate the Under Over Voltage Transformer 1T2 in the panel by referring to the Component Location Drawing Carefully measure the primary volt age across the Transformer Line Voltage Phase A to B and note the value in Vac rms 2 Next disconnect the transformers secondary from J4 on the CPM Using voltmeter probes measure and note the unloaded secondary voltage Vac rms low voltage class 2 less than 32 Vac 3 The ratio of the primary or line voltage to the open circuity secondary voltage should be 20 to 1 If the unloaded turns ratio is not within 2 of this value replace the transformer 4 Reconnect the secondary back to J4 and remeasure the loaded con nected secondary voltage The new loaded ratio should be approximately 20 2 to 1 If not within 2 of this ratio the transformer s secondary should be disconnected from the CPM and a 1 Kohm resistor connected across the secondary Measuring the voltage across the 1 Kohm resistor should give us a voltage ratio of 20 17 Ratios more than 2 in error sug gest a bad transformer If the 1 Kohm loaded ratio is within t
75. in J8 3 25 to 30 seconds prior to compressor start If this voltage is read but the contactor does not pullin check for an open circuit in the contactor coil or an open circuit in the interconnecting wiring to the contactor 4 Check the fan motor by completely bypassing the inverter Disconnect power from the unit and remove the three phase power wiring from the inverter Connect it to the three phase power wiring of the fan motor using splice wires with 1 4 inch male quick connects on both ends Re apply power to the unit and reset the circuit being tested Twenty five or thirty seconds before the compressor starts the contactor that would normally apply power to the inverter should pull in and the fan should run If the fan does not run check the line fuses and contactor contacts 5 Disconnect power from the unit and reconnect the inverter module At the same time check for damaged wiring or loose quick connects on the inverter 6 Re apply power to the chiller and check the compressor module power supply by reading the DC voltage levels from TP1 to the circuit board edge ground and from TP2 to the circuit board edge ground TP1 and TP2 are found on the upper lefthand side of the compressor module The volt age at TP1 should be 5 25 VDC The voltage at TP2 should be 12 RLC SVD03A EN WHEN MOUNTING CONTROL TO BACK PANEL NOTE LOCATION OF 22 CUT OUT AREA REQUIRED FOR CLEARANCE OF HEAT SINK 2 INVWNWDO NHLLO3NNDO ON
76. ircuit s from starting or running If currently running the compressor s and circuit will go through a controlled shutdown This lockout can be initiated with either an external hardware interlock on either MCSP of a given circuit or can be invoked through the CLD Invoking Circuit Lockout To invoke circuit lockout manually simply enter the Service Tests Menu and move to the CIRCUIT LOCKOUT display and enable the circuit lockout for the appropriate circuit Circuit Lockout can then be verified in the Chiller Report under Circuits Locked Out The circuit will remain locked out until manually disabled at the same place in the menu To use an external hardwired interlock to accomplish lockout refer to the IOM or system wiring diagrams for the field installed interlock connections The external interlock feature must also be enabled in the Service Settings Menu Open normal and closed locked out Circuit Diagnostic Reset The UCM provides for a Circuit Diagnostic Reset feature which unlike the Chiller Reset does not require a complete chiller shutdown to clear CMR diagnostics By using this feature it is possible to service and restart a circuit that has been latched out on a circuit diagnostic while allowing the alternate circuit to remain on line making chilled water Invoking Circuit Diagnostic Reset ae Using the CLD enter the Diagnostic Menu and enable circuit reset on the appropriate circuit This will clear all la
77. irection RLC SVD03A EN Module Power and Miscellaneous I O A FLAG stop is located at either end of the threaded portion of the motor shaft The stops interfere with the milled flag on the drive coupling restricting rotation of the motor shaft and producing a clicking sound when the valve is driven fully OPEN or CLOSED Raintight Flex Connector n Motor Cap Bi Motor Cap Nut Motor Aluminum Housing Drive Coupling Stops Pushrod Bonnet Extended Copper Fittings 2 SS N 4 Valve Body Brass Flow SS SS Piston Y RY Y 3 S Bottom Cap Spring Figure 14 SEO 70 100 Electronic Expansion Valve Cut Away View RLC SVDOS3A EN SEHI 100 Valve The valve is a steppermotor type direct acting valve It uses a two phase motor with each phase having 75 ohms of resistance The supply voltage 12 VDC is switched on and off to each phase to step the valve open or closed Each step is 0 00007 of stroke with a full stroke of 6376 steps The step motor used in the SEHI valve is a permanent magnet rotor type Each step creates a 3 6 rotation of the rotor This rotation is increased in torque and reduced in speed by a 12 25 1 gear train Final rotation is converted to linear motion by the use of a lead screw and threaded drive coupling Forward motion of the motor extends the drive coupling and pin which moves the valve
78. irectionally sensitive The transformer lead wiring is 22 AWG UL 1015 600V and the proper MTA connector red color code must be used to ensure a reliable connection If the fault can be isolated to the current transformer or its wiring apart from the con nector the connector can be reused by cutting off the bad transformer and splicing in a new transformer using wire nuts If the transformer connector resistance proves accurate recheck the resistance with the connector held at different angles and with a light lead pull less than 5 Ib to test for an intermittent condition To perform the following test you will need to use a digital voltmeter with a diode test function With the transformer MTA disconnected and the power off to the MCSP perform a diode test across the corresponding pair of current transformer input pins on the MCSP header J5 The meter should read from 1 0 to 1 5 volts for each current transformer input Repeat using the opposite polarity The same reading should result Extreme errors suggest a defective MCSP module If the diode voltage drops prove accurate reconnect the transformers to the MCSP and repower the unit With the CT s reconnected to the MCSP attempt a restart of the chiller As the given compressor is started and the inrush locked rotor transient has passed locked rotor transient should last less than one second simultaneously monitor the actual compressor phase current s using a clamp on type amm
79. l also cause constant speed fans to stage On and Off when the inverter is commanded to full speed and minimum speed respectively The stage On or Off of a constant speed fan will occur if the inverter speed command is at max or min for three consecutive intervals 15 seconds Outdoor Air Temperature and Fan Control Outdoor air temperature is used to provide a reasonable startup state Using this temperature the algorithm automatically determines the number of constant speed fans to turn on immediately at compressor start The outdoor air temperature sensor is also used to anticipate new states during normal running to minimize pressure upsets This anticipation is based on the staging and unstaging of compressor steps at given leaving water temperatures In this way precise airflow can be maintained allowing for stable differential pressures under part load and low ambient conditions VSF Inverter Fault A fault signal will be sent to the UCM from the Inverter when it has gone through a self shutdown or if the output frequency of the Inverter is being limited to less than 5096 of the signal speed commanded by the UCM Upon receipt of the fault signal the UCM shall attempt to reset the fault by sending a 0 PWM command to the Inverter for a total of five seconds The fault signal will again be checked and repeated if still in fault If four faults are detected within one minute of each other the power to the Inverter will be cycled off for
80. l steady state overload setting is fixed at 13296 The setting of the dip switch SW2 on each of the MCSP modules should match those of Table 18 for each compressor Switch position SW2 1 is the Most Significant Bit The decimal equivalent of this setting should also be verified in the Service Settings Menu in the CLD display If the programmed value does not agree with the dip switch setting for each of the MCSP s an informational diagnostic will result The compressors will be allowed to run but default settings the most sensitive possible will be used for the internal software compressor current gains Refer to Section 7 Current Transformer and Current Input Checkout for more details RLC SVD03A EN RLC SVDOS3A EN Module Power and Miscellaneous I O Binary Inputs The binary inputs shown in Table 22 all use the same basic circuit A pullup resistor to the 12V power supply is connected to the higher numbered input pin The lower numbered pin is connected to ground The voltage between the two pins is sensed by the microprocessor To check the input measure the voltage between the two associated pins With the external switch open approximately 12 Vdc should be measured With the switch closed 0 Vdc should be measured Temperature Inputs These inputs use Trane s standard thermistor an NTC device giving 10 000 ohms at 25 C 75 F Refer to Temperature Sensor Checkout Table 4 for a table of temperature vs resistance vs voltag
81. llowed for proper disassembly inspection cleaning and reassembly to the valve The valve does not need to be removed from the refrigerant piping before servicing 1 Before disassembly of the valve be sure the refrigerant pressure in the system has been reduced to a safe level 0 psig on both sides of valve See RTAA SB 10 for preferred refrigerant handling in this area A 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 SVB06A EN or PROD SVBO6A FR RLC SVDOS3A EN RLC SVDOS3A EN Module Power and Miscellaneous I O 2 Disconnect all the line voltage to the power supply of this unit 3 Refer to the exploded view in Figure 18 while performing the remaining instructions CAUTION Prevent Injury Refer to Figure 18 The pushrod is under spring pressure and will be accelerated out of the top or b
82. n and assumes that the proper Compressor Overload dip Switch setting and current transformer have been selected Current Transformer Measured Compr amps of max phase 0 DC R tou Nameplate Compressor RLA To check the displayed 96 RLA as a function of the output voltage from the current transformers as connected at the MCSP Tables 8 and 9 are utilized In Table 8 look up or interpolate the 96 of CT rating corresponding to the maximum of the three CT Input Voltages VAC rms as read at the MCSP The table is necessary because the voltage developed at the MCSP is not linear with the CT s secondary current Next check the Compressor Current Overload setting of switch SW2 on the MCSP and find the corresponding SOFTWARE GAIN in Table 9 The 96 RLA displayed by the CPM should be RLA 96 CT Rating X SOFTWARE GAIN The preceding equations should only be applied during steady state current draws after transition Inrush transient currents and associated CT output voltages can be expected to be from 3 to 6 times the steady state values and the displayed value only reads up to 25596 RLA The accuracy of the displayed value should be within x 596 of that predicted using the Input voltage However the end to end accuracy of the displayed value compared to the actual RLA max phase current is 3 396 over the range of 50 to 150 of CT rating 13 If no phase currents are meas
83. next Constant speed speed Fan due to VSF E Constan at max Speed VSF at max speed lage on next Constant Inverter Fan Max Ramp P 45 speed Fan due to VSF rate is 24Hz sec a p at max Speed DeadBand 5 PSID BN Stage on next Fan Stage off Fan due to Compressor load Step See Anticipatory Begin Per Start Up Fan State 5 due to Compressor 5 See inset above Decrease speed of VSF load Step See Anticipatory Fan Control inset above to make up for added fan Fan Control inset above Low Differential Pressure Lockout Area Diagnostic Occurs if Delta P is lt 40 PSID for 2 minutes TIME Figure 4 Variable Speed Fan VSF and Fan Staging Control RLC SVDOS3A EN The VSF Inverter is commanded to a given speed by the UCM using a PWM Pulse Width Modulated signal 10V 15mA 10 Hz Fundamental with a duty cycle proportional to the desired voltage and frequency from the Inverter The UCM also controls power to the Inverter through a contactor The Inverter Contactor for the respective circuit is energized approximately 20 seconds prior to compressor start on that circuit The VSF Control algorithm runs on a 5 second interval and is limited to a commanded rate of change of no greater than 4096 of full speed per interval The same algorithm that controls the 21 22 Variable Speed Inverter Condenser Fan Control speed wil
84. nstructions Unplug valve Using the appropriate wrenches or a vice to properly support the valve body remove the motor assembly from the valve body by loosening the lock nut To prevent permanent damage to the motor DO NOT attempt to disassemble the motor housing NOTE Regardless of whether the valve is in the system or in a vise care must be taken to prevent distorting the valve parts when tight ening 6 Verify that the new motor assembly is in the OPEN position 7 Lightly oil the threads and knife edge on the new motor adapter Carefully seat the adapter on the valve body 8 Engage and tighten the lock nut One eighth turn more than hand tight is sufficient to achieve a leak proof seal 9 Pressurize the system and check for leaks 67 68 Module Power and Miscellaneous I O 22 Ss 25 Motor Adaptor Assembly Piston Assembly Body Assembly Figure 19 SEHI Electronic Expansion Valve Exploded View RLC SVD03A EN Module Power and Miscellaneous I O SEO Valve Module TP1 5V IPC IPC IPC IPC off MANUF NO CONN USE ONLY NO CONN LOW PRESSURE SIG SWITCH CIRCUIT 1 GND KEY LOW PRESSURE SIG SWITCH CIRCUIT 2 GND SATURATED EVAPORATOR TEMPERATURE CIRCUIT 1 COMPRESSOR SUCTION TEMPERATURE CIRCUIT 1 KEYING SATURATED EVAPORATOR TEMPERATURE CIRCUIT
85. oading and unloading is occurring may be necessary to make slight adjustments to the chilled water setpoints to force action Checkout Procedure for Step Load Solenoid Valve and Piston Prior to a compressor start connect a pressure gauge to the Schrader port near the step load solenoid valve This port is connected to the back side of the step load piston and therefore will allow direct measurement of the pressure that actuates the step load valve Observe the pressure gauge during a compressor start either from a manual compressor test or a normal call for cooling Initially the pressure should drop to the suction pressure and when the MCSP calls for compressor loading the solenoid will actuate and supply discharge pressure to the piston If after verifying that 115 VAC has been applied to the step load solenoid the pressure does not increase to discharge pressure the step load solenoid coil and or valve must be replaced Also when the solenoid valve is energized and the piston pressure 15 near discharge pressure the percent RLA of the compressor as seen in the Compressor Report should increase If the percent RLA does not increase the step load valve is stuck and should be repaired RLC SVD03A EN RLC SVDOS3A EN Module Power and Miscellaneous I O This section will detail the normal voltage levels present on each of the modules inputs and outputs under various conditions or states Typical operation of the I O will b
86. oduct 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 1 Go into the Machine Configuration Menu by performing the following keystrokes Service Settings Previous Enter Check this menu to be sure that Fan Control and Variable Speed Fan are Enabled for both circuits The Fan Control menu item was replaced with Unit on units built after September 1 1994 SN 94 and later Set Unit to RTA or RTU which ever applies Be sure that Variable Speed Fan is Enabled for both circuits 2 Verify that all inverter power and control signal wiring is correct for the affected circuit using Figure 11 1 and Trane wiring diagram 2307 3328 The wiring diagram is found in the Unit Wiring Section of RTAA IOM 4 or on the inside of the unit control panel door 3 Attempt to start the compressor on the affected circuit Twenty five or thirty seconds prior to compressor start the variable speed fan inverter contactor is energized Be sure that this is heard If not heard attach an AC voltmeter from pin J8 3 to ground on the compressor module Reset the control and look for a 115 volts reading on the voltmeter at p
87. olenoids 2 rro t n t RPG m A e Ies 36 Checkout Procedure MCSP Step Load Output 39 Checkout Procedure for Step Load Solenoid Valve AaNCPIStONy Du 4 iua ee eb tU mede d ati pado AS d d tt 40 Module Power and Miscellaneous I O 41 rito sa soy Mik DD ARR Ue des 41 Clear Language Display CLD 106 Keypad Overview 42 Chiller Module CPM 1 01 i eter e eer ERR e REN SERRE 46 Options Module 1U2 fsck geen kem ehe ma p TREE AVES 50 Electronic Expansion Valve Module EXV 103 58 Compressor Module MCSP 104 AND 105 72 Interprocessor Communication Bridge Module IPCB 1U7 78 LonTalk amp Communications Interface Chillers Module GTEC UNIS DC PCIE IH 79 Variable Speed Fan System 80 Inverter Diagnostics 80 Troubleshooting Procedure 82 Other Service Features 85 ServiGe PuropdOWLn usus cesa qu was DE eed Se peedia saad 85 Circuit LOCKOUT sra no etes eeu ed poa oed Pi et ME 87 Circuit DiagRostic Reset s cua y rese Ae Gee ASS en RETE A 87 General Information The Unit Control Modules UCMs described in this troubleshooting guide provide a microprocessor based r
88. olerance but the CPM connected ratio is out of tolerance suspect a bad CPM Before RLC SVDO3A EN Under Over Voltage Transformer replacing the CPM double check the Under Over Voltage Function s Nominal Line Voltage Setup in the Service Settings Group 5 If the UnderOver Voltage Protection function continues to misoperate and all of the above measured ratios are within tolerance and all CLD Under Over Voltage setups have been verified replace the CPM It is a good idea before replacing the CPM however to copy down all of setup data This data will be very helpful in making the necessary setup on the replacement CPM RLC SVDOS3A EN 33 Compressor Capacity The 35 to 60 ton helical rotary screw compressors are loaded and unloaded by means of an internal slide valve and a female unloader valve In simple terms these valves can regulate the amount of bite of the compressor rotors as they turn at relatively constant speeds The slide valve is moved by a hydraulic cylinder and piston internal to the compressor the hydraulic fluid is oil from the refrigerant system The movement of the cylinder is controlled by the load and unload solenoid valves which either add oil at compressor discharge pressures or withdraw oil to suction pressures The female unloader valve is moved to either the On or Off position by using internal suction and discharge gas pressure The movement of this valve is controlled by the female unloade
89. ontrol RLC SVDOS3A EN Select Report Group This group of four keys allows the operator to select and view the following reports Custom Report Chiller Report Refrigerant Report Compressor Report The Custom Report is the only report of the four that is defined by the operator Any display under the other three reports can be added to the Custom Report by pressing the plus A key while the desired read out is on the display A maximum of 20 entries can be contained under the Custom Report Items can be deleted from the Custom Report by pressing the minus key when the desired read out is on the display The operator must be in the Custom Report menu to delete the desired item The Chiller Report Refrigerant Report and Compressor Report are informa tional reports that give current status Each report and its contents are discussed in detail on the following pages 43 44 Module Power and Miscellaneous I O When any of the four report keys are pressed the first readout on the display will be the header The header identifies the title of the report and summa rizes the items in the report The Next key and Previous key allow the operator to scroll up and down through the display items listed under the report menus When the last item of a report is displayed and the Next key is pressed the display will wrap around to the header of the report When the first item of a report is displayed and the Previous key is pr
90. or as well as the operation of the Slide Valve modulating unloader Lastly the female unloader valve and solenoid will be discussed RLC SVDOS3A EN 34 RLC SVDOS3A EN Checkout Procedure for MCSP Load Unload Outputs A 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 Compressor Capacity The MCSP controls the Load and Unload Solenoid valves on the respective compressor with 115 V triacs solid state relays Unlike mechanical relays however a triac has a rather high leakage current when off comparatively speaking While this leakage is not nearly enough to actuate a solenoid valve it may under no load conditions as would be experienced when a solenoid coil failed open look like it was stuck on when using a voltmeter to test it Thus it is important to verify that the solenoid coil is continuous and providing a normal load or to connect a known good load such as a low wattage 115 Volt lamp to the terminals when testing the outputs Refer to the Chiller Control Wiring diagrams and Component Location Drawings for the following
91. ort pulses Each load pulse should be approxi mately one second in duration with approximately 10 seconds between pulses NOTE Loading the compressor faster than this rate could cause control instability and possible diagnostics Leave the toggle switch open i e valve de energized 3 If the RLA or the current and pressure increases then the Load Sole noid and Slide Valve are operating properly 4 Ifthe RLA or current does not increase read the pressure at the cylin der cavity Pressure increases to approximately condenser pressure condenser pressure read via the CLD without an increase in 96 RLA unless already fully loaded indicate the Slide Valve is bound 5 If cylinder cavity pressure does not increase check the coil of the Load Solenoid 6 If the coil checks out then one of two problems exist Either the Load Solenoid Valve is malfunctioning or the Unload Valve is stuck open NOTE Refer to the flow chart shown in Figure 5 RLC SVDOS3A EN 37 38 Compressor Capacity 1 Install toggle switches across load and unload solenoid 2 Install Pressure Gage on slide valve piston cylinder cavity Schrader valve 3 Start Unit Load 4 Manually load compressor in short increments Yes 5 Does RLA increase M Check UCM Repeat procedure No Bad for unload Replace 6 Does Cavity Press _ gt Slide valve mechanism bound increase to a level close to discharge pressure No que Y
92. ote STOP the sequence shall be as follows 1 5 The unload solenoid is energized for 20 seconds and the load solenoid is de energized The compressor continues to run for the remaining 20 sec onds This is defined as the RUN UNLOAD mode The compressor and the fans are turned off The crankcase heater is energized The unload solenoid remains energized for 60 minutes after the compres sor stops The load solenoid is de energized The EXV is closed Closing begins at maximum speed when the com pressor is turned off Max speed is 25 steps per second full stroke is 757 steps After 60 minutes the unload solenoid de energizes The RUN UNLOAD mode is also used to stop a compressor due to normal LWT control Low Ambient Run Inhibit or Freeze Avoidance A compressor stop due to any diagnostic will skip step 1 above and go directly to step 2 20 RLC SVD03A EN 350 340 330 320 310 300 OPERATING PRESSURE DIFFERENTIAL PSID 110 100 90 80 Non Adjustable 70 Diff Press Setpoint 60 50 40 30 Load Step CMPR STATE Min Load Off Panic Fan Adds mur Variable Speed Inverter Condenser Fan Control When Fan Control and Variable Speed Fan VSF are set to Enable in the Machine Configuration Menu the UCM will control both the variable
93. ottom of the valve body assembly if the activator assembly or bottom cap is removed When unscrewing either the activator assembly or bottom cap make sure these assemblies are kept in line with the valve body and moved away from the valve body very slowly in the vertical direction until you feel the pressure is relieved from the pushrod At this time hold the pushrod with one hand and then move the activator or bottom cap away from the valve body Do not try to remove either the activator assembly or bottom cap under any system pressure System pressure must be at 0 psig on both sides of the valve before attempting any disassembly of this valve Failure to slowly relieve spring pressure may result in minor to moderate injury 4 Remove the actuator assembly from the valve body using large hex nut to turn 5 Remove pushrod and check for excessive wear or scratches The pushrod must move freely in the valve body 6 Remove the bottom cap spring and piston Inspect these parts for for eign matter and physical damage 7 Clean all parts with a suitable solvent and blow dry with clean com pressed air 8 Toreassemble carefully install the piston spring and bottom cap Be sure that the piston nose guides are on the inside diameter of the port The seating surface may be damaged if the piston is improperly installed 9 Check that the sealing surfaces are free of foreign material or nicks that may prevent a leak tight joint Tighten
94. out 2 seconds Regardless of whether or not a diagnostic occurs the UCM will proceed with the stroke timing portion of the test Stroke Timing Test 5 At this time the UCM will drive the valve closed Thus the total closing time will be 25 seconds Due to mechanical characteristics of the valve it will make a clicking sound when it reaches its end stops either full open or full closed In most cases the valve will already be closed when this test is initiated so a normally operating valve will exhibit the clicking for approximately 25 seconds NOTE The loudness of the clicking varies from one valve to another and ambient noise can muffle the clicking sound Therefore it may be necessary to use a tool to aid in the hearing of the clicking such as a screwdriver held between the EXV and the ear 6 Following the 25 seconds of closing the valve will immediately be stepped open for the same period of time 25 seconds As soon as the valve begins its opening movement the clicking should stop while it moves through its stroke The service technician would then note the time between when the clicking stopped until the time it restarts This would give an indication of the opening stroke time NOTE f the valve and switching circuitry is operating properly the silent valve movement should last for approximately 15 seconds End of stroke clicking should then be heard for 10 seconds 7 module will then reverse direction and the v
95. procedure With the particular compressor running the triacs may be checked under load as explained above by measuring the voltage from terminals E7 or E8 to 115 neutral The triacs operate in the high side and switch 115 Vac power from J7 1 to either E7 load solenoid or E8 unload solenoid to move the slide valve in the appropriate direction Except during compressor starts and stops in normal operation the solenoid valves can only be energized for a period of between 40 and 400 milliseconds once every 10 seconds Often if the chilled water setpoint is being met under steady state conditions they may not energize at all To assure loading and unloading is occurring it may be necessary to make slight adjustments to the chilled water setpoints to force action As the pulsed on time is potentially short it may be difficult to see especially if using a meter movement type voltmeter Use of a low wattage 115 Vac test lamp may be of some help for a visual indication of output triac operation When a triac is off about O Vac should be measured on its terminal with the solenoid load connected When it is on the voltage should be close to 115 Vac the drop across the triac is about 1 2 volts The best time to check the unload solenoid is immediately after a powerup reset of the MCSP For the first 30 seconds after applying power the unload solenoid should be on continuously The next best time to check it is after the compressor starts For t
96. r broken See Section 2 and on page 75 for details Interprocessor Communications The respective modules communicate with each other via an InterProcessor Communication link IPC The IPC allows the modules to work in a coordi nated manner with the CPM directing overall chiller operation while each module handles specific subfunctions This IPC link is integral and necessary to the operation of the Unit Controls and should not be confused with the Optional ICS Integrated Comfort System communication In the IPC communication protocol scheme the CPM acts as the initiator and the arbitrator of all module communication The CPM essentially requests all the possible packets of information from each module in turn including itself in a predefined serial sequence The other modules act as responders only and cannot initiate communication Modules which are not currently responding to a specific request can listen to the data and thus indirectly they communicate with each other It is helpful to remember when troubleshooting that a module must be able to hear a request for its infor mation from the CPM or it will not talk The link is non isolated which means that a good common ground between all the modules is necessary for trouble free operation provided by the module enclosures mounting using star washers Also the link requires consistent polarity on all of the module interconnections Connections between modules are made at
97. r the proper ICS address in the Service Settings Menu and com pare to the address programmed at the ICS device 3 Check for proper termination of the twisted pair communication link wir ing to terminals TB2 1 and TB2 2 TB2 3 and 2 4 4 Check for a diagnostic at the display indicating loss of IPC communica tions with the Options module This could indicate IPC bus problems or a dead Options module See Options Module CSR 1U2 on page 50 The Options module needs to receive 4 good packets of data from the CPM before it will talk on the ICS link 5 Check power to the Options module and the condition of the fuse See Power Supply on page 41 6 Check the Test Point voltages on the module See Test Points on page 47 NOTE The LED on the module blinks each time a proper message or query is received from the Remote ICS device Terminals For the checkout of the I O refer to the block diagram of the module on the following page and the Chiller Wiring Diagrams for low and high voltage circuits All voltages are measured differentially between terminal pairs specified unless otherwise indicated The first terminal in the pair is the positive or hot terminal Voltages given are nominals and may vary by 5 Unregulated Voltages unreg may vary by 25 and 115 VAC voltages may vary by 15 RLC SVDOS3A EN 55 Module Power and Miscellaneous I O Table 19 CSR
98. r valve solenoid These solenoid valves are electrically controlled by the MCSP module to handle compressor startup and shutdown maintain chilled water temperature setpoints and limit current condenser pressures and evaporator temperatures etc Although the solenoids are an on off device effective modulation and high resolution of the slide valve under steady state conditions is possible by pulsing on and off the solenoid valves and varying the displaced volume of the cylinder piston When a given compressor is operating the MCSP will energize apply 115 VAC either the load or the unload solenoid if necessary for a period of between 40 and 400 milliseconds once every 10 seconds to control water temperature or limit conditions The female unloader valve solenoid receives a constant signal from the UCM as the first step in compressor loading and the last step in compressor unloading Just prior to and just after a compressor start and just before a compressor stop the MCSP will continuously energize the unload solenoid for 20 to 30 seconds to assure unloaded starts After a compressor stop the unload solenoid valve will remain energized for approximately one hour to prevent slide valve movement due to changing cylinder compressor pressures The first procedure below will allow the checkout of the MCSP load and unload outputs The next procedure will allow the checkout of the Load and Unload Solenoid valves located on the compress
99. re 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 SVBO6A FR 2 Install a toggle switch between Control Power HOT 1TB3 8 or 9 and the Load and Unload Solenoid Valve leads previously connected to E7 and E8 Initially make sure that the Load toggle switch is open and the Unload toggle switch is closed 3 Install a pressure gauge with a refrigerant hose hose should be long enough to read the gauge from the control panel to the slide valve pis ton cylinder cavity Schrader valve located near the load unload solenoids 4 Reapply power to the unit and place the chiller in the Stop mode Using the CLD select and enable the Compressor Test in the Service Tests Menu for the compressor that is to be run Additionally to prevent the opposite refrigeration circuit from running if desired the circuit can be locked out through the CIRCUIT LOCKOUT display in the Service Tests Menu for the appropriate circuit Next place the Chiller into the Auto mode and provide all necessary interlocks and a load or adjust chilled water setpoint to start the chiller The selected compressor will be the first to stage on after the restart inhibit timer has expi
100. red RLC SVDO3A EN NOTE Enabling the Compressor Test only affects which compressor will be cycled on next and is not an override mode The chiller will continue to operate normally not withstanding circuit lockout and will stage compressors on and off as well as attempt to modulate running compressors to maintain chilled water setpoint Be aware that during manual control of the load unload solenoids as explained in item 6 below other compressors may stage and or attempt to modulate and thus will affect the leaving chilled water temperature However all diagnostics are still active No specific action other than reconnecting the solenoid valves to their respective outputs on the MCSP is required to return the Chiller to normal operation Compressor Capacity 5 Allow the compressor to start and monitor compressor currents either in the Compressor Report display maximum phase 96 RLA or with a clamp on type ammeter Load 1 Once the compressor has started allow the Unload Solenoid Valve to remain energized for approximately 30 seconds then open the Unload toggle switch to de energize the valve Verify that at least one condenser fan is on before continuing with the checkout as low differential refriger ant pressures will preclude proper Slide Valve operation Record the cylin der cavity pressure and the compressor currents 2 Manually close and open the Load toggle switch to energize the Load Solenoid in 4 or 5 sh
101. rence as it has an anodized surface with insulating properties The DC voltages shall be within the tolerance specified below If not replace the module TP1 5 volts DC 5 TP2 12 volts DC 5 47 48 Module Power and Miscellaneous I O P1 5V J5 1 115V H P2 12V x 115V H J5 3 KEY IPC J1 4 J5 4 115V IPC J1 3 E 115V IPC J12 IPC 1 1 TB3 1 CHILLED H MANUF J2 2 WATER FLOW 1 USE ONLY J2 1 TB3 22 SWITCH G H OUTDOOR AIR TB1 1 TEMP TB1 2 EXTERNAL V AUTO STOP 0 EMERGENCY 1 3 INPUT L STOP 1814 L A 0 5 4 TB1 5 COM ALARM G NNS 1 6 NO RELAY E NC V NOT USED TB2 1 0 TB2 2 L COM COMPR P T NOT USED CLWT 2 3 NO RUN U A CLWT TB2 4 RELAY T G 5 EVAP ENTERING 3 5 WATER TEMP 3 4 MAX CAPACITY 0 RELAY U N KEY T P COM EVAP PUMP P U EVAP LEAVING NO RELAY U T WATER TEMP T 5 COM SPARE 5 AUX TEMP NO RELAY KEY N C AUX TEMP U O VOLT TRANSF KEY U O VOLT TRANSF Figure 10 CPM Chiller Module 1U1 1 terminals For the checkout of the I O refer to the block diagram of the module in Figure 10 and the Chiller Wiring Diagrams for both high and low voltage circuits All voltages are measured differentially between terminal pairs specified unles
102. rmer s of interest Locate the part number UL tag on the transformer leads and note the Trane part number which identifies the transformers Note all compressors of a given ton nage should have the same transformer extension number Verify the proper current transformer using Table 5 in this section Also check the setting of the dip switch SW2 on each of the modules and verify these against Table 5 for each compressor Switch position SW2 1 is the Most Significant Bit The decimal equivalent of this setting should also be verified in the Service Setting Group under the CURRENT OVRLD SETTINGS display If the programmed value does not agree with the dip switch setting for each of the MCSP s an informational diagnostic will result The compressors will be allowed to run but default settings the most sensitive possible will be used for the internal software compres Sor current gains 4 Utilizing the Schematic Wiring Diagram locate the termination of the transformer s wiring into the MTA plug at the appropriate MCSP module at pin header J5 Pull off the appropriate MTA connector from the pin header on the MCSP Current Transformers can be damaged and high voltages can result due to running the compressors without a suitable burden load for the CTs This load is provided by the MCSP input Take care to properly reconnect the CT s MTA prior to attempted start of the compressors 5 Using a digital volt ohmmeter measure the resistan
103. s otherwise indicated The first terminal in the pair is the positive or hot terminal Voltages given are nominals and may vary by 5 Unregulated Voltages unreg 115 VAC voltages may vary by 415 RLC SVD03A EN Table 16 Terminal Designation J1 4 to 3 to CLD J1 2 to 1 to 1U5 Module Power and Miscellaneous I O Description of Circuit IPC Communications CPM Chiller Nominal Terminal Input and Output 1U1 Normal Terminal Voltages for Various Conditions 19 2 kbaud serial data 5 volt signal level Refer to Interprocessor Communication PC 42 2 1 Manufacturing Address Use Only 5 VDC No connection intended TB1 1 2 Outdoor Air Temperature Refer to Temperature Sensor Checkout TB1 3 4 Emergency Stop open 20 6 VDC unreg Stopped closed 0 VDC Normal Must be jumpered if this feature is not used TB1 5 6 NNS Not Used open 20 6 Vdc unreg Normal closed 0 VDC Setback TB2 1 2 ECWT Not Used N A TB2 3 4 LCWT Not Used N A J3 5 4 Entering Evaporator Water Temper Refer to Temperature Sensor Checkout ature J3 2 1 Leaving Evaporator Refer to Temperature Sensor Checkout Water Temperature J4 3 1 Under Over Voltage Refer to Under Over Voltage Transformer Transformer Input Checkout Procedure J5 1 or 2 Input Power 115 VAC Power Supply on page 41 to J5 A or 5 J6 3 1 Auxiliary Temp Input Refer to Temperature Sensor Che
104. sor and Fan Control relays may be checked by measuring the voltage drop across the contacts 115 Vac should be seen when the relay is off 0 Vac should be seen when the relay is on Before condemning a module for bad relays make sure to check all diagnostics power to the module communica tions and the state of the high pressure cutout Refer to the units schematic wiring diagram for the control circuitry Triac Outputs The Load Unload triacs may be checked by measuring the voltage from terminals E7 or E8 to 115 V neutral with a load connected The triacs operate in the high side and switch 115 Vac power from J7 1 to either E7 or E8 to turn on the appropriate slide valve solenoid When a triac is off about 0 Vac should be measured on its terminal with the solenoid load connected When it is on the voltage should be close to 115 Vac the drop across the triac is about 1 2 volts Except during a start or stop the triacs normally pulse on for short durations as low as 40mS once every 10 seconds If chiller load is satisfied the triacs may not pulse Because of this it may be difficult to see the pulses on a meter A low wattage 115 Vac test lamp may be of help The best time to check the unload solenoid is immediately after a powerup reset For the first 30 seconds after applying power the unload solenoid should be on continuously The next best time to check it is after the compressor starts For the first 30 seconds after a start the
105. stance Voltage Temp Resistance Voltage F Ohms Volts DC F Ohms Volts DC F Ohms Volts DC 20 0 70040 3 4 448 30 0 34838 9 3 120 80 0 92975 533 19 0 64313 4 4 434 31 0 33833 3 3 086 81 0 9075 9 509 18 0 58796 5 4 414 32 0 32861 4 3 047 82 0 8860 2 484 170 53482 9 4 395 33 0 31935 3 3 018 83 0 8650 4 460 16 0 48365 0 4 380 34 0 31038 7 2 983 84 0 8446 2 436 15 0 43432 2 4 360 35 0 30170 5 2 949 85 0 82475 411 14 0 38679 6 4 341 36 0 29329 5 2 910 86 0 8054 1 387 13 0 34098 6 4 321 37 0 28515 0 2 876 87 0 7865 8 362 12 0 29684 9 4 302 38 0 27725 9 2 842 88 0 7682 5 343 11 0 25428 5 4 282 39 0 26961 4 2 808 89 0 7504 2 318 10 0 21326 1 4 263 40 0 26220 8 2 773 90 0 7330 5 294 9 0 17369 6 4 238 41 0 25503 0 2 739 91 0 7161 4 274 8 0 13554 9 4 219 42 0 248075 2 705 92 0 6996 7 1 250 70 09876 5 4 194 43 0 24133 3 2 671 93 0 6836 3 230 6 0 06328 1 4 175 44 0 23479 7 2 637 94 0 6680 1 211 5 0 02904 9 4 150 45 0 22846 1 2 603 95 0 6528 0 187 4 0 99602 3 4 126 46 0 22231 9 2 568 96 0 6379 8 167 3 0 964161 4 106 470 21636 2 2 534 970 6235 5 1 147 2 0 93341 6 4 082 48 0 21058 7 2 505 98 0 6094 8 128 1 0 90374 2 4 058 49 0 20498 4 2 471 99 0 59578 108 0 0 87510 3 4 033 50 0 9955 0 2 437 100 0 5824 3 1 089 1 0 84745 9 4 004 51 0 194279 2 402 101 0 5694 2 1 069 2 0 820771 3 979 52 0 8916 5 2 368 02 0 55674 1 050 3 0 79500 5 3 955 53 0 8420 3 2 334 103 0 5443 8 030 4 0 77012 3 3 926 54 0 17938 8 2 305 104 0 5323 3 01
106. t Results Logic Table ELECT INTEGRITY TEST STROKE TIMING RESISTANCE PRESCRIBED ACTION PASS PASS NOT REQ VALVE BOARD ARE WORKING PROPERLY NO ACTION REQ PASS FAIL PASS VALVE IS MECHANICALLY STUCK REPLACE REPAIR VALVE PASS FAIL FAIL HIGHLY UNLIKELY CONDITION RETESFREPLACE MODULE FAIL PASS PASS HIGHLY UNLIKELY CONDITION RETESFENO ACTION REQ FAIL FAIL PASS CHECK CONNECTION AT MODULE RETESFREPLACE MODULE FAIL FAIL FAIL SUSPECT WIRING PLUG OR VALVE REPLACE REPAIR SAME INDICATION OF PASS OR FAIL OF THIS TEST IS DISPLAYED AT THE CLD IN THE DIAGNOSTICS MENU RLC SVDOS3A EN Solder Techniques for Installation It is not necessary to disassemble the valve when soldering to the connecting lines Most commonly used types of solder eg Sil Fos Easy Flow PhosCopper or equivalent are satisfactory Regardless of the solder 63 64 Module Power and Miscellaneous I O used it is important to direct the flame away from the valve body See Figure 17 A wet cloth should be wrapped around the body during soldering to provide extra protection This will help prevent overheating and damage to the synthetic seals and subsequent degradation in valve performance Valves are shipped in the full open position to allow for the flow of inert gas while soldering Figure 17 Electronic Expansion Valve Soldering SEO Electronic Expansion Valve Servicing The procedures listed below are to be fo
107. t and outlet evaporator refrigerant temperature This enables the system to control the temperature difference and maintain superheat The SEO 70 and SEO 100 valves were used on units until November 1 2003 All units built after that date will have a SEHI 100 valve installed The module for the SEHI is different because the new valve uses a two coil instead of three The locations of the keying pins are different on the module Design Sequence Information digit 10 11 of the unit model number RTWAVUA EO SEO Valve RTWA UA FO and later SEHI Valve AO PO SEO Valve RTAA and later SEHI Valve NOTE For units with remote evaporator use 16 AWG wire SEO 70 and SEO 100 Valve The valve is a steppermotor type direct acting valve It uses a three phase motor not to be confused with3 phase AC with each phase having 40 ohms of resistance The supply voltage 24 VDC is switched on and off to each phase to step the valve open or closed Each step is 0 0003 of stroke with a full stroke of 757 steps The motor s rotary motion is translated into linear movement through a lead screw and drive coupling arrangement A clockwise rotation of the motor shaft creates a downward movement of the drive coupling This presses the pushrod and piston against the return spring opening the valve A counter clockwise rotation of the motor shaft retracts the drive coupling The return spring moves the piston and pushrod in the closing d
108. tching diagnostics for that circuit but will not remove them from the historical list Clearing the History list can be accomplished when compressors are running by entering the Diagnostic Menu and scrolling to the CLEAR DIAGNOSTIC HISTORY display Press Enter to clear the historical diagnostics RLC SVDOS3A EN 87 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 RLC SVD03A EN File Number SV RF RLC SVD03A EN 0805 Supersedes RTAA SB 9 Stocking Location Inland Trane has a policy of continuous product data and product 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 bulletin
109. thand column of the page adjacent to the appropriate display Auto Stop Keys The chiller will go through a STOPPING mode when the Stop key is pressed if a compressor is running This key has a red background color surrounding it to distinguish it from the others If the chiller is in the Stop mode pressing the Auto key will cause the UCM to go into the Auto Local or Auto Remote mode depending on the Setpoint Source setting The Auto key has a green back ground color When either the Auto or Stop key is pressed Chiller Operating Mode Chiller Report Menu will be shown on the display Power Up When power is first applied to the control panel the Clear Language Display goes through a self test For approximately five seconds the readout on the display will be SELF TEST IN PROGRESS During the self test the backlight will not be energized When the tests are successfully complete the readout on the display will be 6200 TYPE configuration Updating Unit Data Please Wait RLC SVDOS3A EN 45 Module Power and Miscellaneous I O When updating is successfully completed the system will default to the first display after the Chiller Report header MODE OPERATING MODE REQUESTED SETPOINT SOURCE SETPT SOURCE and the backlight will be activated 1 1 2 IPC Communications 19 2K Baud serial data 5 V signal level Refer to Interprocessor Communication IPC TB2 1 2 24 VAC Power 18 30 VAC neither
110. the bottom cap approximately 1 8 turn past hand tight to seal the knife edge joint 10 Place the pushrod in the valve body Press the pushrod down to open the valve and insure proper piston installation Approximately 8 ft lbs are required to open the valve If the valve cannot be opened repeat steps 9 and 10 Clean with a suitable solvent blow dry with clean compressed air and replace the pushrod in the valve body 11 Before replacing the actuator assembly be sure that all sealing surfaces are free of foreign material or nicks that may prevent a leak tight joint Carefully install the pushrod bonnet and thread the actuator assembly on 65 Module Power and Miscellaneous I O to the valve body until the sealing surfaces make contact Tighten the actuator approximately 1 8 turn to seal the knife edge joint 12 The motor cap quad ring may be replaced by removing the ferrule motor cap nut Be sure that the motor cap does not rotate with the motor cap nut The wires internal to the motor can be damaged 13 When reassembling be sure that the internal wires do not get crimped between the motor cap and motor housing 14 Pressurize the system and check for leaks Motor Cap d Motor Cap Nut v n AT NOOO b n Dim 4 Motor Aluminum Housing Activator Assembly Motor Adapter Assembly 4 w Pushrod Bonnet T Pushrod Figure 18 SEO Electronic Expansion Valve Exploded View 66 RLC SVD03A EN
111. the other modules to shutdown or take default actions as the particular case may warrant All IPC diagnostics are displayed in the Clear Language Display s diagnostics section For example Chiller Mod indicating Options Mod Comm Failure indicates that the CPM Module has detected a loss of IPC communication RLC SVDOS3A EN RLC SVDOS3A EN Interprocessor Communication from the Options Module When some problem exists with the IPC link or a module fails it is not uncommon for more than one of these IPC diagnostics to be displayed Note that only those diagnostics that are indicated to be active currently exist All other historic diagnostics should be disregarded for the purpose of the following troubleshooting discussion See RTAA IOM 4 for a complete listing of diagnostics Troubleshooting Modules Using IPC Diagnostics A 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 Communication problems can result from any of the following Improperly set IPC address dip switches Opens or shorts in the twisted pair IPC wiring or connectors
112. to the closed position Backward rotation of the motor retracts the drive coupling and pin modulating the valve in the opening direction Full forward or backward travel while the valve is assembled is limited by the valve seat in the closed position or an upper stop in the open direction A slight clicking sound may be heard at either of these two positions and does no harm to the valve or drive mechanism 59 Module Power and Miscellaneous I O Motor Cap Motor Drive Assembly Push Rod Valve Body Extended Copper Fittings Figure 15 SHEI Valve Electronic Expansion Valve Location The valve should be installed with the motor in a vertical position or no greater than 45 from vertical as shown in Figure 16 This will prevent oil logging and the possibility of contamination reaching the motor cavity The valve should also be installed as close to the evaporator as possible 60 RLC SVD03A EN RLC SVDOS3A EN Module Power and Miscellaneous I O Figure 16 Electronic Expansion Valve Location Test Points There is only one test point associated with the EXV module It is easily read with a DC voltmeter by probing the PC board solder pad found in the upper left hand corner of the module The positive meter lead should be connected to the pad while referencing the negative meter lead to the board edge ground plane NOTE Don t use the aluminum module enclosure as a reference as it has an ano
113. tor 1 9 1K13 Variable Speed Fan Inverter Fuses 1F18 1F20 1F21 1F23 Inverter Diagnostics The Inverter has two LED s for diagnostic purposes They are Power On LED This green LED is illuminated any time that more than 50 VDC is present on the DC Bus Capacitors Typically when power is removed from the TRANE AC INVERTER this LED will remain illuminated for up to 60 seconds while the DC Bus Capacitor Voltage discharges This LED also indicates that the 5 VDC Supply Voltage on the TRANE AC INVERTER control board is present Alarm LED When this red LED is illuminated constantly it indicates that the motor is overloaded and the drive is about to fault on a motor overload When the Alarm LED is flashing it indicates the drive is faulted By counting the number of times the Alarm LED flashes the cause of the fault can be deter mined The following table lists the possible fault conditions for the TRANE AC INVERTERS and the number of times the Alarm LED will flash Fault Condition Number of Alarm LED flashes Bus Overcurrent Fault 1 RLC SVDO3A EN Variable Speed Fan System Bus Overvoltage Fault Motor Overload Fault Low Bus Voltage Fault Generator Fault Logic Fault Stalled Motor Fault 01 B WN Fault Descriptions Bus Overcurrent Fault DC Bus Current exceeds the drive rated peak current Bus Overvoltage Fault DC Bus Voltage exceeds 400 VDC on 200 230 VAC input units or exceeds 800 VDC on 400 460 VAC input units
114. tor overload protection using a programmed 96 RLA versus time to trip characteristic Refer to Table 6 for details The steady state must trip value is 14096 RLA and the must hold value is 12596 RLA The MCSP will trip out the compressor The appropriate diagnostic descrip tions are then displayed in the CLD diagnostic section 2 Verifying contactor drop out If currents corresponding to less than 12 7 RLA are not detected on all three of the monitored compressor phases within approximately 5 seconds after an attempted contactor drop out the compressor will continue to be commanded Off the Unload solenoid will be pulsed the EXV will be opened to its fullest position and the fans will continue to be controlled This condition will exist until the diagnostic is manually reset 3 Loss of Phase Current If the detection of any or all of the three motor phase currents falls below 12 7 RLA for 2 1 seconds while the branch circuit should be energized the will trip out the compres sor The Phase Loss diagnostic or the Power Loss diagnostic will be dis played Failure of a contactor to pull in will cause the Phase Loss diagnostic However when reduced voltage starting is employed it may take an additional 3 seconds to detect a phase loss at startup as phase loss protection is not active during the 3 second transition time 4 Phase Rotation Screw compressors cannot be allowed to run in reverse direction To protect the compr
115. ured with the amprobe on any or all of the legs to a given compressor immediately following the attempted staging of that compressor by the MCSP the problem lies either with the contactor motor circuit or the MCSP relay outputs Refer to MCSP Checkout Procedure in Compressor Module MCSP 1U4 AND 1U5 on page 72 RLC SVDOS3A EN 27 Current Transformer Table 5 Compressor Overload DIP Switch Settings Primary Turns Current Overload Setting Compressor Through Current Transformer Dip Sw Decimal Tons Volts Hz RLA Transformer Extension 12345 35 200 60 115 02 01011 11 230 60 100 01 11111 31 346 50 58 10 01100 12 380 60 61 10 10000 16 400 50 50 10 00000 0 460 60 50 10 00000 0 575 60 40 01 01111 15 40 200 60 142 02 11011 27 230 60 124 02 10001 17 346 50 72 01 00111 7 380 60 75 01 01010 10 400 50 62 10 10001 17 460 60 62 10 10001 17 575 60 50 01 11111 31 50 200 60 192 03 11100 28 230 60 167 03 10010 18 346 50 96 01 11100 28 380 60 101 02 00001 1 400 50 84 01 10011 19 460 60 84 01 10011 19 575 60 67 02 10111 23 60 200 60 233 04 10011 19 230 60 203 04 01000 8 346 50 117 02 01101 13 380 60 123 02 10001 17 400 50 101 02 00001 1 460 60 101 02 00001 1 575 60 81 03 10000 16 The current transformer base part number is X13580253 The numbers in this column are suffixes of the base part number On the DIP switc
116. utomation system or process controller interface using a 4 20ma loop or a 2 10 VDC analog signal Figure 11 Chilled Water Setpoint Arbitration RLC SVDOS3A EN 53 Module Power and Miscellaneous I O START EXTERNAL CURRENT LIMIT INPUT ENABLED Yes LOCAL OR TRACER Tracer USE EXTERNAL USE FRONT PANEL USE TRACER USE FRONT CURRENT LIMIT CURRENT LIMIT CURRENT LIMIT PANEL SETPOINT SETPOINT SETPOINT CURRENT LIMIT SETPOINT TRACER implies Trane Integrated Comfort System remote device ICS using the digital communication link EXTERNAL implies generic building automation system or process controller interface using a 420ma loop or a 2 10 VDC analog signal Figure 12 Current Limit Setpoint Arbitration 54 RLC SVD03A EN Module Power and Miscellaneous I O ICS Communications ICS Tracer communication is handled the same as on previous products using the Trane proprietary Comms standard 1200 baud isolated serial communication link The following are some things to check when experi encing loss of ICS communications 1 If ICS control is desired check that Tracer has been selected in Set point Source of the Operator Settings Menu In any case the Tracer should be able to communicate to the chiller for monitoring purposes regardless of the Setpoint Source selection Refer to Figure 11 fora description of the normal operation of setpoint and setpoint reset arbitra tion 2 Check fo
117. vicing 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 Test Points There are two test points associated with the MCSP module They are easily read with a DC voltmeter by probing the PC board solder pads found in the upper left hand corner of the module The positive meter lead should be connected to the pad while referencing the negative meter lead to the board edge ground plane NOTE Don t use the aluminum module enclosure as a reference as it has an anodized surface with insulating properties The DC voltage shall be within the tolerance specified below If not replace the module TP1 5 volts DC 5 TP2 12 volts DC 5 IPC Address Switch SW1 Refer to Troubleshooting Modules Using IPC Diagnostics on page 9 Current Gain or Overload Dip Switch SW2 The Compressor phase current inputs on the individual MCSP modules are normalized thru the proper setting on this switch The term Compressor Current Overload setting is actually a misnomer Instead the setting should be thought of as an internal software gain that normalizes the currents to a 96 RLA for a given CT and compressor rating The true nomina

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