cvhe-svu01f-en_04012011

cvhe-svu01f-en_04012011
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Operation and Maintenance
Water-Cooled CenTraVac™
with CH530
X39640712060
April 2011
CVHE-SVU01F-EN
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Warnings, Cautions and Notices
Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at
appropriate intervals throughout this manual. Warnings are provided to alert installing contractors
to potential hazards that could result in personal injury or death. Cautions are designed to alert
personnel to hazardous situations that could result in personal injury, while notices indicate a
situation that could result in equipment or property-damage-only accidents.
Your personal safety and the proper operation of this machine depend upon the strict observance
of these precautions.
ATTENTION: Warnings, Cautions and Notices appear at appropriate sections throughout this
literature. Read these carefully.

 CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
minor or moderate injury. It could also be used to alert against unsafe practices.
NOTICE: Indicates a situation that could result in equipment or property-damage-only accidents.
Important
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 and 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 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.
WARNING
Contains Refrigerant!
System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to
relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use
non-approved refrigerants, refrigerant substitutes, or refrigerant additives.
Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant
substitutes, or refrigerant additives could result in death or serious injury or equipment damage.
© 2011 Trane All rights reserved
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WARNING
Personal Protective Equipment (PPE) Required!
Installing/servicing this unit could result in exposure to electrical, mechanical and chemical
hazards.
•
Before installing/servicing this unit, technicians MUST put on all Personal Protective
Equipment (PPE) recommended for the work being undertaken. ALWAYS refer to appropriate
MSDS sheets and OSHA guidelines for proper PPE.
•
When working with or around hazardous chemicals, ALWAYS refer to the appropriate MSDS
sheets and OSHA guidelines for information on allowable personal exposure levels, proper
respiratory protection and handling recommendations.
•
If there is a risk of arc or flash, technicians MUST put on all Personal Protective Equipment (PPE)
in accordance with NFPA70E or other country-specific requirements for arc/flash protection
PRIOR to servicing the unit.
Failure to follow recommendations could result in death or serious injury.
Introduction
Literature change
Applicable to CVHE, CVHF, CVHG.
About this manual
Operation and maintenance information for models CVHE, CVHF, and CVHG are covered in this
manual. This includes both 50 and 60 Hz. CVHE, CVHF, and CVHG centrifugal chillers equipped with
the Tracer CH530 Chiller Controller system. Please note that information pertains to all three chiller
types unless differences exist in which case the sections are broken down by Chiller type as
applicable and discussed separately.
By carefully reviewing this information and following the instructions given, the owner or operator
can successfully operate and maintain a CVHE, CVHF, or CVHG unit.
If mechanical problems do occur, however, contact a qualified service organization to ensure
proper diagnosis and repair of the unit.
Trademarks
Adaptive Control, Adaptive Frequency, CenTraVac, DynaView, EarthWise, TechView, Trane, and the
Trane logo are trademarks of Trane in the United States and other countries. All trademarks
referenced in this document are the trademarks of their respective owners.
© 2011 Trane All rights reserved
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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Model Number Digit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Model Number Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commonly Used Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CVHE, CVHG, CVHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CVHE, CVHG, CVHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CVHE, CVHG Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CVHF Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Controls Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DynaView Human Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TechView Chiller Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil and Refrigeration Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Base Loading Control Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tracer Base Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
External Base Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ice Machine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Free Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Free Cooling FRCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hot Water Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Heat Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Auxiliary Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unit Control Panel (UCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Panel Devices and Unit Mounted Devices . . . . . . . . . . . . . . . . . . . . . 29
Unit Control Panel (UCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tracer CH530 Chiller Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Variable Water Flow through the Evaporator . . . . . . . . . . . . . . . . . . . . . . 30
User-Defined Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chiller Stop Prevention/Inhibit Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4
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Chilled Water Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Interprocessor Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inter Processor Communications IPC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
IPC3 Definitions: Bus Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Node Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Node Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
50
50
50
50
Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control Panel Internally Mounted Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chilled and Condenser Water Flow Interlock Circuits . . . . . . . . . . . . . . . . . . 54
Head Relief Request Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Compressor Motor Winding Temp Sensor Module . . . . . . . . . . . . . . . . . . . . 54
Maximum Capacity Relay (TechView adjustable) . . . . . . . . . . . . . . . . . . . . . . 54
Compressor Running Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Machine Shutdown Manual Reset (MMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Refrigerant Monitor Input 1A17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CDRP Refrigerant Pressure Output Option 1A15 . . . . . . . . . . . . . . . . . . . . . . . 56
A) Condenser Pressure Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
B) Refrigerant Differential Pressure Indication Output . . . . . . . . . . . . . . . 56
Percent RLA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
External Chilled Water Setpoint (ECWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
External Current Limit Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Module Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1A1, 1A2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A3, 1A5, 1A10 Dual Relay Output Modules . . . . . . . . . . . . . . . . . . . . . . .
1A4, 1A6 Dual High Voltage Binary Input Module . . . . . . . . . . . . . . . . . .
1A7 High Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A8, 1A9, 1A11, 1A12 Quad Relay Output Status . . . . . . . . . . . . . . . . . . .
1A13, 1A18, 1A19, 1A20 Dual Binary Input Module . . . . . . . . . . . . . . . . .
1A14 Communication Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . .
1A15, 1A16, 1A17, 1A21 Dual Analog Input/output Module . . . . . . . . . .
Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–12 Vdc or 4–20 mA Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
59
59
59
59
60
60
60
60
60
Unit Mounted Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Vane Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EarthWise Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit-Mounted Medium-Voltage Starter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adaptive Frequency Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CVHE-SVU01F-EN
61
61
61
61
61
62
62
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Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Electrical Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
UCP and Wye-Delta Starter Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Machine Protection and Adaptive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Momentary Power Loss (MPL) Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Current Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Running Over Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Current Limit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Phase Loss Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Reverse Rotation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Phase Imbalance Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Under and Over Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Differential to Start or Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Softloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Minimum and Maximum Capacity Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Evaporator Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Leaving Water Temperature Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
High Evaporator Leaving Water Temperature Cutout . . . . . . . . . . . . . . . . . . 71
(Main Processor Software Revision 6.0 and higher) . . . . . . . . . . . . . . . . 71
Low Refrigerant Temperature Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Head Relief Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Evaporator Variable Flow Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Condenser Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Restart Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Restart Inhibit Free Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Restart Inhibit Start to Start Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Clear Restart Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
High Vacuum Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Temperature Start Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Oil Temperature Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Oil Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
74
75
75
75
Controls Chilled Water Reset (CWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Constant Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Using the Equation for calculating CWR for Outdoor Air Temperature . 77
Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Unit Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Daily Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Seasonal Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6
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Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Unit Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Daily Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Seasonal Unit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Trouble Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Record Keeping Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Daily Maintenance and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 3 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off-Season Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
86
86
86
86
86
Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compressor Oil Change on CVHE, CVHF, CVHG . . . . . . . . . . . . . . . . . . . . . . . 87
Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Replacing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Other Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Recovery and Recycle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cleaning the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Control Settings and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Leak Checking Based on Purge Pump Out Time . . . . . . . . . . . . . . . . . . . . . . . 94
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Waterbox Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Waterbox Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Parts Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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Model Number Descriptions
Model Number
Digit
Identification
Digit 14—Control Enclosure
Digit 38
S
C
1
=
=
Special
Standard Control Enclosure
=
Control: Extended Operation
Digit 39
Digit 15
4
U
Digit 40
=
Compressor Motor Power (kw)
Digit 16, 17, 18
275 =
C
=
=
Compressor Imp Cutback
Tracer Communication Interface
Control: Condenser Refrigerant
Pressure
An example of a typical model
number is:
Digit 19
Digit 41
8
1
CVHF091NAL00ACU2758W7E8TB
C0000000K01G14C10W1A03B1
Digit 20
Digit 42
W =
0
Digit 1
Digit 21
Digit 43
C
7
W =
=
CenTraVac™ Hermetic
=
=
Evaporator Shell Size
Evaporator Tube Bundle
Evaporator Tubes
=
=
Control: Tracer IO
Special Options
Control: Water Flow Control
Digit 2
Digit 22
Digit 44
V
E
1
=
CenTraVac Hermetic
=
Evaporator Waterbox
=
Control: Chilled Water Reset
Digit 3
Digit 23
Digit 45
H
8
A
=
Direct Drive
=
Condenser Shell Size
Digit 4
Digit 24
F
T
=
Development Sequence
Digit 5, 6, 7
091 =
Nominal Compressor Tonnage
Digit 8
N
=
Unit Voltage
Digit 9—Unit Type
A
B
C
D
S
=
=
=
=
=
Cooling Condenser
Heat Recovery Condenser
Auxiliary Condenser
Free Cooling Option
Special
=
Design Sequence
B
Digit 47
=
Condenser Tubes
=
3
C
Digit 48
=
Condenser Waterboxes
=
Gas Powered Chiller
Digit 26
B
0
Digit 19
=
Heat Recovery Condenser Shell
Size
Digit 28
0
=
Heat Recovery Condenser Tube
Bundle
Digit 29
W =
0 =
S =
With HGB
Without HGB
Special
Digit 30
Digit 13—Starter Type
Digit 31
A
C
E
=
=
=
0
F
=
G
=
H
J
K
L
M
N
P
=
=
=
=
=
=
=
R
=
0
=
=
=
Heat Recovery Condenser Tubes
Heat Recovery Condenser
Waterboxes
Auxiliary Condenser Size and
Waterboxes
Digit 32
0
=
Auxiliary Condenser Tubes
Digit 33
0
=
1
=
Compressor Motor Frame Size
Digit 27
0
=
Volute Discharge Angle
Control: Operating Status
Digit 50—Industrial Chiller
Package (INDP)
0 =
W =
Without INDP
With INDP
Digit 51—Control Power
Transformer (CPTR)
0
1
S
=
=
=
Without CPTR
With CPTR
Special
Digit 52—Motor and Terminal
Board Configuration
A
B
C
S
=
=
=
=
Six Lead Low Voltage
Three Lead Medium Voltage
Six Lead Medium Voltage
Special
Orifice Size
Digit 34
K
=
Orifice Size
Digit 35
0
=
Unit Option
Digit 36
1
=
Control: Enhanced Protection
Digit 37
G
8
Digit 46
0
Digit 12—Hot Gas By-Pass
Star-Delta Unit Mounted
Star Delta—Remote Mounted
X-Line Full Volt—Remote
Mounted
Autotransformer—Remote
Mounted
Primary Reactor—Remote
Mounted
X-Line Full Volt—Unit Mounted
Autotransformer—Unit Mounted
Primary Reactor—Unit Mounted
Solid State—Unit Mounted
Solid State—Floor Mounted
Solid State—Wall Mounted
Adaptive Frequency Drive—Unit
Mounted
Customer Supplied
Control: Heat Recovery
Temperature Sensors
Digit 25
Digit 10, 11
L0 =
Condenser Tube Bundle
=
=
Control: Generic BAS
CVHE-SVU01F-EN
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General Information
Unit Nameplate
The unit nameplate is located on the left side of the unit control panel. The following
information is provided on the unit nameplate.
1. Serial Number
The unit serial number provides the specific chiller identity. Always provide this serial number
when calling for service or during parts identification.
2. Service Model Number
The service model represents the unit as built for service purposes . It identifies the selections
of variable unit features required when ordering replacements parts or requesting service.
Note: Unit-mounted starters are identified by a separate number found on the starter.
3. Product Coding Block
The CVHE, CVHF, and CVHG models are defined and built using the product definition and
selection (PDS) system. This system describes the product offerings in terms of a product
coding block which is made up of feature categories and feature codes. An example of a typical
product code block is given on this page. The coding block precisely identifies all characteristics
of a unit.
Typical product description block
MODL CVHE
DSEQ 2R
NTON 320
VOLT 575
REF 123
HRTZ 60
TYPE SNGL
CPKW 142
CPIM 222
TEST AIR
EVTM IECU
EVTH 28
EVSZ 032S
EVBS 280
EVWC STD
EVWP 2
EVWT NMAR
EVPR 150
EVCO VICT
EVWA LELE
CDTM IECU
CDTH 28
CDSZ 032S
CDBS 250
CDWC STD
CDWP 2
CDWT NMAR
CDPR 150
CDCO VICT
CDWA LELE
CDTY STD
TSTY STD
ECTY WEOR
ORSZ 230
PURG PURE
WCNM SNMP
SPKG DOM
OPTI CPDW
HHOP NO
GENR NO
GNSL NO
SOPT SPSH
ACCY ISLS
HGBP WO
LUBE SNGL
AGLT CUL
Note: The CH530 controller was first applied to CVHE with Design Sequence “3K”, and to CVHF
with Design Sequence “1W”.
4. Identifies unit electrical requirements
5. Correct operating charges and type of refrigerant
6. Unit Test Pressures and Maximum Operating Pressures
7.
Identifies unit Installation and Operation and Maintenance manuals
8. Drawing numbers for Unit Wiring Diagrams
Commonly Used Acronyms
For convenience, a number of acronyms are used throughout this manual. These acronyms are
listed alphabetically below, along with the “translation” of each:
AFD = Adaptive Frequency Drive
ASME = American Society of Mechanical Engineers
ASHRAE = American Society of Heating, Refrigerating and Air Conditioning Engineers
BAS = Building Automation System
CABS = Auxiliary Condenser Tube-Bundle S
CVHE-SVU01F-EN
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General Information
CDBS = Condenser Bundle Size
CDSZ = Condenser Shell Size
CH530 = Tracer CH530 Controller
DV = DynaView™ Clear Language Display, also know as the Main Processor (MP)
CWR = Chilled Water Reset
CWR’ = Chilled Water Reset Prime
DTFL = Design Delta-T at Full Load (i.e., the difference between entering and leaving chilled water
temperatures)
ELWT = Evaporator Leaving Water Temperature
ENT = Entering Chilled Water Temperature
FC = Free Cooling
GPM = Gallons-per-minute
HGBP = Hot Gas Bypass
HVAC = Heating, Ventilating, and Air Conditioning
IE = Internally-Enhanced Tubes
IPC = Interprocessor Communication
LBU = La Crosse Business Unit
LCD = Liquid Crystal Display
LED = Light Emitting Diode
MAR = Machine Shutdown Auto Restart (Non-Latching where chiller will restart when condition
corrects itself.)
MMR = Machine Shutdown Manual Restart (Latching where chiller must be manually reset.)
MP = Main Processor
PFCC = Power Factor Correction Capacitor
PSID = Pounds-per-Square-Inch (differential pressure)
PSIG = Pounds-per-Square-Inch (gauge pressure)
UCP = Unit Control Panel
LLID = Low Level Intelligent Device (Sensor, Pressure Transducer, or Input/output UCP module)
RLA = Rated Load Amps
RTD = Resistive Temperature Device
Tracer CH530 = Controls Platform utilized on this Chiller
TOD = Temperature Outdoor
Control optional packages
OPST = Operating Status Control
GBAS = Generic Building Automation Interface
EXOP = Extended Operation
CDRP = Condenser Pressure Transducer
TRMM = Tracer Communications
FRCL = Free Cooling
HGBP = Hot Gas Bypass
WPSR = Water pressure sensing
10
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General Information
EPRO = Enhanced Protection
ACOS = Auxiliary Condenser sensors
CWR = Chiller Water reset outdoor
Overview
CVHE, CVHG, CVHF
Each CVHE, CVHG, or CVHF unit is composed of five basic components.
•
the evaporator,
•
3-stage compressor on CVHE, CVHG or 2 stage compressor on CVHF,
•
2-stage economizer on CVHE, CVHG, or single economizer on CVHF,
See Figure 1 and Figure 2, p. 12 for Typical CVHE and CVHG, and Figure 3, p. 13 for Typical CVHF
major components.
A heat-recovery or auxiliary condenser can be factory-added to the basic unit assembly to provide
a heat-recovery cycle.
•
water-cooled condenser,
•
related interconnecting piping.
Figure 1. General CVHE and CVHG unit components
CVHE-SVU01F-EN
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General Information
Figure 2. General CVHE and CVHG unit components
Compressor
Suction
Elbow
Motor
Housing
Condenser
Economizer
Evaporator
Oil Tank and
Refrigerant Pump
12
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General Information
Figure 3. Illustrates the general component layout of a typical CVHF chiller
Compressor
Suction
Elbow
Motor
Housing
Condenser
Economizer
Evaporator
Oil
Tank and Refrigerant Pump
GENERAL ASSEMBLY OIL/REFRIGERATION SYSTEM SCHEMATIC
Compressor Lubrication System
Motor Coolant Return to Condenser
(2.125 OD)
Oil Tank Vent to Evap
Motor Cooling System
Oil Reclaim System
COMPRESSOR
Oil Separator and
Tank Vent Manifold
PURGE
Tank Vent Line
Oil Reclaim from Suction Cover
(1st Eductor) (0.25 OD)
CONDENSER
High Pressure
Condenser Gas to
Drive Oil Reclaim
Eductors (0.375 OD)
Liquid Refrigerant Motor Coolant Supply (1.125 OD)
Oil Return to Tank
Oil Supply to Bearings
(0.625 OD)
ECONOMIZER
Liquid Refrig.
to Pump
(1.625 OD)
OIL TANK
Liquid Refrig. to Econ
Oil Cooler within
Economizer (0.625 OD
Coiled Tubing)
CVHE-SVU01F-EN
Liquid Refrigerant
to Evap
EVAPORATOR
Oil Reclaim from Evaporator
(2nd Eductor) (0.25 OD)
13
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General Information
Cooling Cycle
CVHE, CVHG, CVHF
When in the cooling mode, liquid refrigerant is distributed along the length of the evaporator and
sprayed through small holes in a distributor (i.e., running the entire length of the shell) to uniformly
coat each evaporator tube. Here, the liquid refrigerant absorbs enough heat from the system water
circulating through the evaporator tubes to vaporize.
The gaseous refrigerant is then drawn through the eliminators (which remove droplets of liquid
refrigerant from the gas) and first-stage variable inlet guide vanes, and into the first stage impeller.
Note: Inlet guide vanes are designed to modulate the flow of gaseous refrigerant to meet system
capacity requirements; they also prerotate the gas, allowing it to enter the impeller at an
optimal angle that maximizes efficiency at all load conditions.
CVHE, CVHG Compressor
Compressed gas from the first-stage impeller flows through the fixed, second-stage inlet vanes and
into the second-stage impeller.
Here, the refrigerant gas is again compressed, and then discharged through the third-stage variable
guide vanes and into the third stage impeller.
Once the gas is compressed a third time, it is discharged into the condenser. Baffles within the
condenser shell distribute the compressed refrigerant gas evenly across the condenser tube
bundle. Cooling tower water circulated through the condenser tubes absorbs heat from the
refrigerant, causing it to condense. The liquid refrigerant then passes through orifice plate ‘‘A’’ and
into the economizer.
The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need
to pass all gaseous refrigerant through three stages of compression. See Figure 4, p. 15. Notice that
some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice
plates, thus further cooling the liquid refrigerant. This flash gas is then drawn directly from the first
(Chamber A) and second (Chamber B) stages of the economizer into the third-and second-stage
impellers of the compressor, respectively.
All remaining liquid refrigerant flows through another orifice plate ‘‘C’’ to the evaporator.
CVHF Compressor
Compressed gas from the first-stage impeller is discharged through the second-stage variable
guide vanes and into the second-stage impeller. Here, the refrigerant gas is again compressed, and
then discharged into the condenser.
Baffles within the condenser shell distribute the compressed refrigerant gas evenly across the
condenser tube bundle. Cooling tower water, circulated through the condenser tubes, absorbs heat
from the refrigerant, causing it to condense. The liquid refrigerant then flows out of the bottom of
the condenser, passing through an orifice plate and into the economizer.
The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need
to pass all gaseous refrigerant through both stages of compression. See Figure 7, p. 16. Notice that
some of the liquid refrigerant flashes to a gas because of the pressure drop created by the orifice
plate, thus further cooling the liquid refrigerant. This flash gas is then drawn directly from the
economizer into the second-stage impellers of the compressor.
All remaining liquid refrigerant flows out of the economizer, passes through another orifice plate
and into the evaporator.
14
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General Information
Figure 4. CVHE, CVHG Pressure enthalpy curve
Pressure (PSI)
Condenser
Compressor
(3rd Stage)
High-Side Economizer
Low-Size Economizer
Compressor
(2nd Stage)
Compressor
(1st Stage)
Evaporator
Enthalpy (BTU/LBM)
Figure 5. CVHE, CVHG Two-stage economizer
Refrigerant Gas Out to
3rd-Stage Compressor
Chamber A
Refrigerant Gas Out to
2nd-Stage Compressor
Chamber B
High-Side
Economizer
Refrigerant Vapor
Liquid from Motor
Cooling System
Low-Side
Economizer
Orifice
Plate A
Orifice Plate
C
Orifice
Plate B
Liquid Refrigerant
from Condenser
CVHE-SVU01F-EN
Liquid Refrigerant
Out to Evaporator
15
CVHE-SVU01_-EN.book Page 16 Friday, April 29, 2011 1:10 PM
General Information
Figure 6. CVHF Pressure enthalpy curve
Pressure (PSI)
Condenser
Economizer
Compressor
(1st Stage)
Evaporator
Figure 7.
Compressor
(2nd Stage)
CVHF Single-stage economizer
Refrigerant Vapor to
Compressor 2nd-Stage
Economizer
Liquid Refrigerant
in Economizer
Economizer
Outlet Pipe
Economizer
Inlet Pipe
Orifice
Plate
16
Liquid Refrigerant
from Condenser Orifice
Plate
Liquid Refrigerant
to Evaporator
CVHE-SVU01F-EN
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General Information
Overview
Controls Operator Interface
Information is tailored to operators, service technicians and owners.
When operating a chiller, there is specific information you need on a day-to-day basis—setpoints,
limits, diagnostic information, and reports.
When servicing a chiller, you need different information and a lot more of it—historic and active
diagnostics, configuration settings, and customizable control algorithms, as well as operation
settings.
By providing two different tools—one for daily operation and one for periodic service—everyone
has easy access to pertinent and appropriate information.
DynaView Human Interface
For the operator
Day-to-day operational information is presented at the panel. Up to seven lines of data (English or
SI units) are simultaneously displayed on the 1/4 VGA touch-sensitive screen. Logically organized
groups of information — chiller modes of operation, active diagnostics, settings and reports put
information conveniently at your fingertips. See “Operator Interface,” p. 31 for details.
TechView Chiller Service Tool
For the service technician or advanced operator
All chiller status, machine configuration settings, customizable limits, and up to 60 active or historic
diagnostics are displayed through the service tool interface. Without changing any hardware, we
give you access to the latest and greatest version of Tracer CH530! A new level of serviceability
using the innovative TechView™ chiller service tool, a technician can interact with an individual
device or a group of devices for advanced troubleshooting. LED lights and their respective
TechView indicators visually confirm the viability of each device. Any PC that meets the system
requirements may download the service interface software and Tracer CH530 updates. For more
information on TechView visit your local Trane Service company, or The Trane Company’s website
at www.trane.com.
CVHE-SVU01F-EN
17
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General Information
Figure 8. CVHE, CVHF, and CVHG Sequence of operation overview
Power
Up
Stopped
Stopped
Run Inhibit
d
me
fir wn
n
o
Co utd
Sh
Co Star
mm t
an
d
Di
ag
no
Re
s
s e tic
t
Fast Restart or Satisfied Setpoint
Stopping
Preparing to Shut Down
Shutting Down
Di
Stop Command or Diagnostic
Co Stop
mm
an
d
ag
n
os
tic
Starting
Auto
Waiting to Start
Starting Compressor
e
rm
n f i rt
o
a
C St
Running
d
Running
Running - Limit
Figure 9. CVHE, CVHF, and CVHG Sequence of operation: Power up to starting
Last Chiller Mode
Was Auto
Power
Applied
to
Controls
Auto
Call for Cooling
Waiting to Start
Enforce Start to Start
Timer (5 to 60 minutes)
CH530
Boot Time
(30 to 50
Sec)
Enforce Power Up Wait for Oil Temp to Rise
Above Sat Evap + 30°F
Start Delay Timer
and 100°F
(0 to 30 minutes)
Energize Evaporator
Water Pump Relay
Confirm Evaporator Water
Flow Within 4 mins 15
seconds (6 Sec Filter)
Waiting to Start
Starting
Compressor
Prelube (60 Seconds)
Overdrive IGV
Closed
Energize Condenser
Water Pump Relay
Confirm Condenser Water
Flow Within 4 mins 15
seconds (6 Sec Filter)
Energize Oil Pump
Relay
Confirm 12 PSID Oil
Pressure Within 3 mins
Enforce Stop to Start Timer Using Values
From Real Time Clock (5 to 200 seconds, 30
is Default)
18
Check for High Vacuum
Lockout
CVHE-SVU01F-EN
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General Information
Figure 10. CVHE, CVHF, and CVHG Sequence of operation: Running
Starter
Status is
‘Running’
Starting
Compressor
Limit Mode
Running
Modulate IGV/AFD
for LWT control
Exit Limit Mode
Running
Running - Limit
Modulate IGV/AFD
for Limit control
Running
Modulate IGV/AFD
for LWT control
Enforce All Running Mode Diagnostics
Figure 11. CVHE, CVHF, and CVHG Sequence of operation: Satisfied setpoint
Satisfied Setpoint
Running
Preparing to Shutdown
Close IGV (0–50 Seconds)
Command IGV
Closed
Shutting Down
Post Lube (3 Minutes)
De-Energize
Compressor
Shutting Down
Auto
De-Energize Oil
Pump
Confirm < 3 PSID Oil
Press 5 minutes after oil
pump is de-energized
Confirm No Compressor Currents
Within 0–30 Seconds
De-Energize Condenser
Water Pump Relay
Enforce All Running Mode
Diagnostics
CVHE-SVU01F-EN
19
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General Information
Figure 12. CVHE, CVHF, and CVHG Sequence of operation: Normal shutdown to stopped and run inhibit
External Auto-Stop
Tracer Stop
Stopped
Normal Non-Latching Diagnostic
Normal Latching Diagnostic
Local Stop
Run Inhibit
IGV Closed
Running
Shutting Down
Preparing to Shutdown
Close IGV (0–50 Seconds)
Command IGV
Closed
Post Lube (3 Minutes)
De-Energize Condenser
Water Pump Relay
Evap Pump Off Delay Time
(0–30 Minutes)
De-Energize
Compressor
Enforce All Running Mode
Diagnostics
Shutting Down
De-Energize Oil
Pump
Stopped
or
Run Inhibit
Evap Pump Off
Delay and Postlube
Complete
Confirm < 3 PSID Oil
Press 5 minutes after oil
pump is de-energized
De-Energize
Evaporator Water
Confirm No Compressor Currents
Within 8 Seconds
Oil and Refrigeration Pump
Compressor Lubrication System
A schematic diagram of the compressor lubrication system is illustrated in Figure 13, p. 21.
Oil is pumped from the oil tank (by a pump and motor located within the tank) through an oil
pressure-regulating valve designed to maintain a net oil pressure of 18 to 22 psid. It is then filtered
and sent to the oil cooler located in the economizer and on to the bearings. From the bearings, the
oil drains back to the manifold under the motor and then on to the oil tank.
NOTICE
Surface Temperatures!
MAY EXCEED 150°F. Use caution while working on certain areas of the unit, failure to do so may
result in minor or moderate injury.
To ensure proper lubrication and prevent refrigerant from condensing in the oil tank, a 750-Watt
heater is immersed in the oil tank and is used to warm the oil while the unit is off. When the unit
starts, the oil heater is de-energized. This heater energizes as needed to maintain 140°F to 145°F
(60°C to 63°C) when the chiller is not running.
When the chiller is operating, the temperature of the oil tank is typically 115°F to 160°F (46°C to
72°C). The oil return lines from the thrust and journal bearings transport oil and some seal leakage
refrigerant. The oil return lines are routed into a manifold under the motor. Gas flow exits the top
of the manifold and is vented to the Evaporator. A vent line solenoid is not needed with the
refrigerant pump. Oil exits the bottom of the manifold and returns to the tank. Separation of the
seal leakage gas in the manifold keeps this gas out of the tank.
A dual eductor system is used to reclaim oil from the suction cover and the evaporator, and deposit
it back into the oil tank. These eductors use high pressure condenser gas to draw the oil from the
20
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General Information
suction cover and evaporator to the eductors and then discharged into the oil tank. The evaporator
eductor line has a shut off valve mounted by the evaporator and ships closed. Open two turns if
necessary.
Liquid refrigerant is used to cool the oil supply to both the thrust bearing and journal bearings. On
refrigerant pump units the oil cooler is located inside the economizer and uses refrigerant passing
from the condenser to evaporator to cool the oil. Oil leaves the oil cooler and flows to both the
thrust and journal bearings.
Motor Cooling System
Compressor motors are cooled with liquid refrigerant, see Figure 13.
The refrigerant pump is located on the front of the oil tank (motor inside the oil tank). The refrigerant
pump inlet is connected to the well at the bottom of the condenser. The connection is on the side
where a weir assures a preferential supply of liquid. Refrigerant is delivered to the motor via the
pump. Motor refrigerant drain lines are routed to the condenser.
Figure 13. Oil refrigerant pump
GENERAL ASSEMBLY OIL/REFRIGERATION SYSTEM SCHEMATIC
Compressor Lubrication System
Motor Coolant Return to Condenser
(2.125 OD)
Oil Tank Vent to Evap
Motor Cooling System
Oil Reclaim System
COMPRESSOR
Oil Separator and
Tank Vent Manifold
PURGE
Tank Vent Line
Oil Reclaim from Suction Cover
(1st Eductor) (0.25 OD)
CONDENSER
High Pressure
Condenser Gas to
Drive Oil Reclaim
Eductors (0.375 OD)
Liquid Refrigerant Motor Coolant Supply (1.125 OD)
Oil Return to Tank
Oil Supply to Bearings
(0.625 OD)
ECONOMIZER
Liquid Refrig.
to Pump
(1.625 OD)
OIL TANK
Liquid Refrig. to Econ
Oil Cooler within
Economizer (0.625 OD
Coiled Tubing)
CVHE-SVU01F-EN
Liquid Refrigerant
to Evap
EVAPORATOR
Oil Reclaim from Evaporator
(2nd Eductor) (0.25 OD)
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General Information
Base Loading Control Algorithm
This feature allows an external controller to directly modulate the capacity of the chiller. It is
typically used in applications where virtually infinite sources of evaporator load and condenser
capacity are available and it is desirable to control the loading of the chiller. Two examples are
industrial process applications and cogeneration plants. Industrial process applications might
use this feature to impose a specific load on the facility’s electrical system. Cogeneration plants
might use this feature to balance the system’s heating, cooling and electrical generation.
All chiller safeties and adaptive control functions are in full effect when Base Loading control is
enabled. If the chiller approaches full current, the evaporator temperature drops too low, or the
condenser pressure rises too high, Tracer CH530 Adaptive Control logic limits the loading of the
chiller to prevent the chiller from shutting down on a safety limit. These limits may prevent the
chiller from reaching the load requested by the Base Loading signal.
Base Loading Control is basically a variation of the current limit algorithm. During base loading,
the leaving water control algorithm provides a load command every 5 seconds. The current limit
routine may limit the loading when the current is below setpoint. When the current is within the
deadband of the setpoint the current limit algorithm holds against this loading command. If the
current exceeds the setpoint, the current limit algorithm unloads. The “Capacity Limited By High
Current” message normally displayed while the current limit routine is active is suppressed while
base loading.
Base loading can occur via Tracer, External signal, or front panel.
Tracer Base Loading
Current Setpoint Range: (20–100) percent RLA
Requires Tracer and Optional Tracer Communications Module (LLID)
The Tracer commands the chiller to enter the base load mode by sending the base load mode
request. If the chiller is not running, it will start regardless of the differential to start (either chilled
water or hot water). If the chiller is already running, it will continue to run regardless of the
differential to stop (either chilled water or hot water), using the base load control algorithm. While
the unit is running in base loading, it will report that status back to the Tracer by setting “Base Load
Status = true” in the Tracer Status Byte. When the Tracer removes the base load mode request (sets
the bit to 0). The unit will continue to run, using the normal chilled or hot water control algorithm,
and will turn off, only when the differential to stop has been satisfied.
External Base Loading
Current Setpoint Range: (20–100) percent RLA
The UCP accepts 2 inputs to work with external base loading. The binary input is at 1A18 Terminals
J2-1 and J2-2 (Ground) which acts as a switch closure input to enter the base-loading mode. The
second input, an analog input, is at 1A17 terminals J2–1 and 3 (Ground) which sets the external
base loading setpoint, and can be controlled by either a 2–10 Vdc or 4–20 mA Signal. At startup the
input type is configured. The graphs in Figure 13 show the relationship between input and percent
RLA. While in base loading the active current limit setpoint is set to the Tracer or external base load
setpoint, providing that the base load setpoint is not equal to 0 (or out of range). If it is out of range,
the front panel current limit setpoint is used. During base loading, all limits are enforced with the
exception of current limit. The human interface displays the message “Unit is Running Base
Loaded”. Hot Gas Bypass is not run during base loading. If base loading and ice making are
commanded simultaneously, ice making takes precedence.
An alternative and less radical approach to Base Loading indirectly controls chiller capacity.
Artificially load the chiller by setting the chilled water setpoint lower than it is capable of achieving.
Then, modify the chiller’s load by adjusting the current limit setpoint. This method provides greater
safety and control stability in the operation of the chiller because it has the advantage of leaving
the chilled water temperature control logic in effect. The chilled water temperature control logic
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General Information
responds quicker to dramatic system changes, and can limit the chiller loading prior to reaching an
Adaptive Control limit point.
Figure 14. Base loading with external mA input and with voltage input
% RLA
Base Loading with External mA Input
% RLA
mA
% RLA
Base Loading using External Voltage Input
% RLA
Volts
Ice Machine Control
The control panel provides a service level “Enable or Disable” menu entry for the Ice Building
feature when the Ice Building option is installed. Ice Building can be entered 1) from the “Front
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General Information
Panel”, 2) if hardware is specified, will accept either an isolated contact closure (1A19 Terminals J2-1
and J2-2 [Ground]) 3), a remote communicated input (Tracer) to initiate the ice building mode
where the unit runs fully loaded at all times. Ice building will be terminated either by opening the
contact or based on entering evaporator fluid temperature. UCP will not permit the Ice Building
mode to be entered again until the unit is switched to the Non-ice building mode and back into the
ice building mode. It is not acceptable to reset the chilled water setpoint low to achieve a fully
loaded compressor. When entering ice-building the compressor will be loaded at its maximum rate
and when leaving ice building the compressor will be unloaded at its maximum rate. While loading
and unloading the compressor, all surge detection will be ignored. While in the ice building mode,
current limit setpoints less than the maximum will be ignored. Ice Building can be terminated by
one of the following means:
1. Front Panel Disable, or
2. Opening the external Ice. Contacts/Remote communicated input (Tracer), or
3. Satisfying an evaporator entering fluid temperature setpoint (Default to 27°F).
4. Surging for 7 minutes at full open IGV.
Figure 15. CVHE, CVHF, and CVHG Sequence of operation: Ice making: Running to ice making
Ice Making Command:
1. Front Panel
2. Tracer
3. External Input
Running
Running (Ice Building)
Open IGV at Max Rate/
Max AFD Frequency
Evap Entering
Water Temp
Falls Below the
Ice Termination
Setpoint
Running (Ice to Normal
Transition)
Ice to Normal Transition Timer
(0–10 Minutes)
Close IGV/Min AFD
Frequency
Ignore Softloading and
Set CLS = 100%
De-Energize Ice
Building Relay
Energize Ice
Building Relay
De-Energize Head
Relief Request Relay
Head Relief Request Relay
Delay (1 to 60 Mins)
Evap Leaving
Water Temp
Rises Above the
Diff to Stop
Running
Running
Modulate IGV/AFD
for LWT control
Energize Head Relief
Request Relay
Enforce All Limits and Running Mode Diagnostics
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General Information
Figure 16. CVHE, CVHF, and CVHG Sequence of operation: Ice making: Stopped to ice to ice building complete
Evap Entering
Water Temp
Falls Below the
Ice Termination
Setpoint
Ice Making Command:
1. Front Panel
2. Tracer
3. External Input
Auto
Starting
Compressor
Running
(Ice Building)
Running (Ice to
Normal
Transition)
Ice To Normal
Expires, Without
Evap LWT Rising
Above Diff to Stop
Preparing to
Shut Down
Shutting
Down
Auto (Ice
Building
Complete)
Ice to Normal Transition
Timer (0–10 Minutes)
Open IGV at Max Rate/
Max AFD Frequency
Close IGV/Min AFD
Frequency
Ignore Softloading and
Set CLS = 100%
De-Energize Ice
Building Relay
Energize Ice
Building Relay
De-Energize Head
Relief Request Relay
Head Relief Request Relay
Delay (1 to 60 Mins)
Energize Head Relief
Request Relay
Enforce All Limits and Running Mode Diagnostics
Free Cooling Cycle
Based on the principle that refrigerant migrates to the coldest area in the system, the free cooling
option adapts the basic chiller to function as a simple heat exchanger. However, it does not provide
control of the leaving chilled water temperature.
If condenser water is available at a temperature lower than the required leaving chilled water
temperature, the operator interface must remain in “AUTO” and the operator starts the free cooling
cycle by enabling the Free cooling mode in the “DynaView Feature Settings” group of the operator
interface, or by means of a Tracer request.
Several components must be factory-installed or field-installed to equip the unit for free cooling
operation:
•
a refrigerant gas line, and electrically-actuated shutoff valve, between the evaporator and
condenser;
•
a valve liquid return line, and electrically-actuated shutoff valve, between the condenser sump
and the evaporator;
•
a liquid refrigerant storage vessel (larger economizer); and,
•
additional refrigerant.
When the chiller is changed over to the free cooling mode, the compressor will shut down if
running, the shutoff valves in the liquid and gas lines open; unit control logic prevents the
compressor from energizing during free cooling. Liquid refrigerant then drains (by gravity) from
the storage tank into the evaporator and floods the tube bundle. Since the temperature and
pressure of the refrigerant in the evaporator are higher than in the condenser (i.e., because of the
difference in water temperature), the refrigerant in the evaporator vaporizes and travels to the
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General Information
condenser. Cooling tower water causes the refrigerant to condense, and it flows (again, by gravity)
back to the evaporator.
This compulsory refrigerant cycle is sustained as long as a temperature differential exists between
condenser and evaporator water. The actual cooling capacity provided by the free cooling cycle is
determined by the difference between these temperatures which, in turn, determines the rate of
refrigerant flow between the evaporator and condenser shells.
If the system load exceeds the available free cooling capacity, the operator must manually initiate
changeover to the mechanical cooling mode by disabling the free cooling mode of operation. The
gas and liquid line valves then close and compressor operation begins. (See Figure 9, p. 18
beginning at “Auto” mode.) Refrigerant gas is drawn out of the evaporator by the compressor,
where it is then compressed and discharged to the condenser. Most of the condensed refrigerant
initially follows the path of least resistance by flowing into the storage tank. This tank is vented to
the economizer sump through a small bleed line; when the storage tank is full, liquid refrigerant
must flow through the bleed line restriction. Because the pressure drop through the bleed line is
greater than that of the orifice flow control device, the liquid refrigerant flows normally from the
condenser through the orifice system and into the economizer.
Free Cooling FRCL
To enable Free Cooling Mode:
1. Free Cooling must first be installed and commissioned.
2. Enable the Free Cooling mode in the DynaView Settings Menu
3. Press “AUTO”, and if used, close the external binary input switch (connected to 1A20 J2-1 to 2)
while the chiller is in “AUTO”.
Free Cooling cannot be entered if the chiller is in “STOP”.
If the chiller is in “AUTO” and not running, the condenser water pump will start. After condenser
water flow is proven, Relay Module 1A11 will energize operating the Free Cooling Valves 4B12 and
4B13. The Free Cooling Valves End Switches must open within 3 minutes, or an MMR diagnostic
will be generated. Once the Free Cooling Valves End Switches open, the unit is in the Free Cooling
mode. If the chiller is in “AUTO” and running powered cooling, the chiller will do a friendly shut
down first, (Run: Unload, Post Lube, and drive vanes closed). After the vanes have been overdriven,
closed and condenser water proven, the Free Cooling relays will be energized. To disable Free
Cooling and return to Powered Cooling, either disable the Free Cooling Mode in the DynaView
settings menu if used to enable Free Cooling or “OPEN” the external binary input switch to the 1A20
Module if it was used to enable Free Cooling. Once Free Cooling is disabled, the Free Cooling relays
Relay Module 1A11 will de-energize allowing the Free Cooling valves to close. The Free Cooling
valves end switches must close within 3 minutes or an MMR diagnostic is generated. Once the end
switches close the chiller will return to “AUTO” and powered cooling will resume if there is a call
for cooling based on the differential to start.
Notes:
•
The manual control of the inlet guide vanes is disabled while in the Free Cooling Mode and the
compressor is prevented from starting by the control logic.
•
The relay at 1A11-J-2-4 to 6 is a FC auxiliary relay and can be used as required.
Hot Gas Bypass
The hot gas bypass (HGBP) control option is designed to minimize machine cycling by allowing the
chiller to operate stably under minimum load conditions. In these situations, the inlet guide vanes
are “locked” at a preset minimum position, and unit capacity is governed by the HGBP valve
actuator. Control circuitry is designed to allow both the inlet guide vanes and the HGBP valve to
close for unit shutdown.
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After a chiller starts and is running the inlet guide vanes will pass through the HGBP Cut-In-Vane
position as the chiller starts to load. As the chiller catches the load and starts to unload, the inlet
guide vanes will close to the HGBP Cut-In Vane position. At this point the movement of the inlet
guide vanes is frozen and further unloading of the chiller is controlled by the opening of the HGBP
Valve 4M5 and module modulates the HGBP valve at low loads. When the control algorithm
determines the chiller to be shut down, the inlet guide vanes will be driven fully closed, and the
HGBP valve will be driven closed. After the inlet guide vanes are fully closed the chiller will shut
down in the Friendly mode. Chillers with HGBP have a discharge temperature sensor (4R16)
monitoring the discharge gas temperature from the compressor. If this temperature exceeds 200°F,
the chiller will shut off on a MAR diagnostic. The chiller will reset automatically when this
temperature drops 50°F below the trip-point.
HGBP is enabled in the Features menu settings Group of the DV Menus by enabling the option. The
setting the HGBP Cut-In Vane Position is setup at unit commissioning via the service tool.
Hot Water Control
Occasionally CTV chillers are selected to provide heating as a primary mission. With hot water
temperature control, the chiller can be used as a heating source or cooling source. This feature
provides greater application flexibility. In this case the operator selects a hot water temperature and
the chiller capacity is modulated to maintain the hot water setpoint. Heating is the primary mission
and cooling is a waste product or is a secondary mission. This type of operation requires an endless
source of evaporator load (heat), such as well or lake water. The chiller has only one condenser.
Note: Hot water temperature control mode does not convert the chiller to a heat pump. Heat pump
refers to the capability to change from a cooling-driven application to a heating-driven
application by changing the refrigerant path on the chiller. This is impractical for centrifugal
chillers as it would be much easier to switch over the water side.
This is NOT heat recovery. Although this feature could be used to recover heat in some form, there
is a second heat exchanger on the condenser side.
The DynaView Main Processor provides the hot water temperature control mode as standard. The
leaving condenser water temperature is controlled to a hot water setpoint between 80°F and 140°F
(26.7°C to 60°C) The leaving evaporator water temperature is left to drift to satisfy the heating load
of the condenser. In this application the evaporator is normally piped into a lake, well, or other
source of constant temperature water for the purpose of extracting heat.
In hot water temperature control mode all the limit modes and diagnostics operate as in normal
cooling with one exception; The leaving condenser water temperature sensor is an MMR
diagnostic when in hot water temperature control mode. (It is an informational warning in the
normal cooling mode.)
In the hot water temperature control mode the differential-to-start and differential-to-stop setpoints
are used with respect to the hot water setpoint instead of with the chilled water setpoint.
UCP provides a separate entry at the DV to set the hot water setpoint. Tracer is also able to set the
hot water setpoint. In the hot water mode the external chilled water setpoint is the external hot
water setpoint; that is, a single analog input is shared at the 1A16–J2-1 to J2-3 (ground)
An external binary input to select external hot water control mode is on the EXOP OPTIONAL
module 1A18 terminals J2-3 to J2-4 (ground). Tracer also has a binary input to select chilled water
control or hot water temperature control.
There is no additional leaving hot water temperature cutout; the HPC and condenser limit provide
for high temperature and pressure protection.
In hot water temperature control the softloading pulldown rate limit operates as a softloading
pullup rate limit. The setpoint for setting the temperature rate limit is the same setpoint for normal
cooling as it is for hot water temperature control.
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General Information
The hot water temperature control feature is not designed to run with HGBP, AFD, free cooling, or
ice making.
The factory set PID tuning values for the leaving water temperature control are the same settings
for both normal cooling and hot water temperature control.
Heat Recovery Cycle
‘‘Heat recovery’’ is designed to salvage the heat that is normally rejected to the atmosphere through
the cooling tower, and put it to beneficial use. For example, a high-rise office building may require
simultaneous heating and cooling during the winter months. With the addition of a heat recovery
cycle, heat removed from the building cooling load can be transferred to areas of the building that
require heat. (Keep in mind that the heat recovery cycle is only possible if a cooling load exists to
act as a heat source.)
To provide a heat recovery cycle, a heat-recovery condenser is added to the unit; see Figure 3, p. 13.
Though physically identical to the standard cooling condenser, the heat-recovery condenser is
piped into a heat circuit rather than to the cooling tower. During the heat recovery cycle, the unit
operates just as it does in the ‘‘cooling only’’ mode except that the cooling load heat is rejected to
the heating water circuit rather than to the cooling tower water circuit. When hot water is required,
the heating water circuit pumps energize. Water circulated through the heat-recovery (or auxiliary)
condenser tube bundle by the pumps absorbs cooling-load from the compressed refrigerant gas
discharge by the compressor. The heated water is then used to satisfy heating requirements.
Auxiliary Condensers
Unlike the heat-recovery condenser (which is designed to satisfy comfort heating requirements),
the auxiliary condenser serves a preheat function only, and is used in those applications where hot
water is needed for use in kitchens, lavatories, etc. While the operation of the auxiliary condenser
is physically identical to that of the heat-recovery condenser, it is comparatively smaller in size, and
its heating capacity is not controlled.
Trane does not recommend operating the auxiliary condenser alone because of its small
size.
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Unit Control Panel (UCP)
Control Panel Devices and Unit Mounted Devices
Unit Control Panel (UCP)
Safety and operating controls are housed in the unit control panel, the starter panel and the purge
control panel. The UCP’s operator interface and main processor is called the DynaView (DV) and
is located on the UCP door. (See “Operator Interface,” p. 31 for detailed information.)
The UCP houses several other controls modules called panel mounted LLID (Low Level Intelligent
Device), power supply, terminal block, fuse, circuit breakers, and transformer. The IPC
(Interprocessor communication) bus allows the communications between LLID’s and the main
processor. Unit mounted devices are called frame mounted LLIDs and can be temperature sensors
or pressure transducers. These and other functional switches provide analog and binary inputs to
the control system.
Figure 17. Control panel and approximate dimensions
Standard Enclosure
Tracer CH530 Chiller Controller
Revolutionary control of the chiller, chilled water system, and your entire building with
unprecedented accuracy, reliability, efficiency, and support for maintenance using the chiller’s PCbased service tool. Chiller reliability is all about producing chilled water and keeping it flowing,
even when facing conditions that ordinarily would shut down the chiller — conditions that often
happen when you need cooling the most.
Tracer CH530’s Main Processor, DynaView, is fast and keeps the chiller online whenever possible.
Smart sensors collect three rounds of data per second, 55 times the data collection speed of its
predecessor. Each device (a sensor) has its own microprocessor that simultaneously converts and
accurately calibrates its own readings from analog to digital.
Because all devices are communicating digitally with the DynaView main processor, there is no
need for the main processor to convert each analog signal one at a time. This distributed logic
allows the main processor to focus on responding to changing conditions—in the load, the
machine, its ancillary equipment, or its power supply. Tracer CH530 constantly receives
information about key data parameters, temperatures and current. Every five seconds then a
multiple objective algorithm compares each parameter to its programmed limit. The chiller’s
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Unit Control Panel (UCP)
Adaptive Control™ capabilities maintain overall system performance by keeping its peak
efficiency. Whenever the controller senses a situation that might trigger a protective shutdown, it
focuses on bringing the critical parameter back into control. When the parameter is no longer
critical, the controller switches its objective back to controlling the chilled water temperature, or to
another more critical parameter should it exist.
Variable Water Flow through the Evaporator
Chilled-water systems that vary water flow through chiller evaporators have caught the attention
of engineers, contractors, building owners, and operators. Varying the water flow reduces the
energy consumed by pumps, while requiring no extra energy for the chiller. This strategy can be
a significant source of energy savings, depending on the application. With its faster and more
intelligent response to changing conditions, Tracer CH530 reliably accommodates variable
evaporator water flow and its effect on the chilled water temperature. These improvements keep
chilled water flowing at a temperature closer to its setpoint.
User-Defined Language Support
DynaView is capable of displaying English text or one of the two alternate languages that are stored
in DynaView at one time. Switching languages is simply accomplished from a settings menu.
Similarly, TechView accommodates a primary and a secondary language from the same list of
available languages.
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Operator Interface
The DynaView (DV) Operator Interface contains the “Main Processor (MP)” and is mounted on the
unit control panel front door where it communicates commands to other modules, collecting data,
status and diagnostic information from the other modules over the IPC (Inter Processor
Communications) link. The Main Processor (MP) software controls water flows by starting pumps
and sensing flow inputs, establishes a need to heat or cool, performs pre-lube, performing postlube, starts the compressor(s), performs water temperature control, establishes limits, and prepositions the inlet guide-vanes.
The MP contains non-volatile memory both checking for valid set points and retaining them on any
power loss. System data from modules (LLID) can be viewed at the DynaView operator interface.
Such as evaporator and condenser water temperatures, outdoor air temperature, evaporator and
condenser water pump control, status and alarm relays, external auto-stop, emergency stop,
evaporator and condenser water pressure drops and evaporator and condenser water flow
switches.
Figure 18. DynaView main processor
DynaView presents three menu tabs across the top which are labeled “MAIN,
REPORTS, and SETTINGS”
The Main screen provides an overall high level chiller status so the operator can quickly
understand the mode of operation of the chiller.
The Chiller Operating Mode will present a top level indication of the chiller mode (Auto, Running,
Inhibit, Run Inhibit, etc.) The “additional info” icon will present a subscreen that lists in further
detail the subsystem modes. (See Machine Operating Modes, p. 33.)
Main screen content can be viewed by selecting the up or down arrow icons. The Main screen is
the default screen and after an idle time of 30 minutes.
DynaView (DV) is the operator interface of the Tracer CH530 control system utilized on the CTV
machine. The DynaView enclosure is 9.75” wide, 8” high and 1.6” deep. The DynaView display is
approximately 4” wide by 3” high. Features of the display include a touch screen and long life LED
backlight. This device is capable of operating in 0 to 95 percent relative humidity (non-condensing),
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Operator Interface
and is designed and tested with UV considerations consistent with an outdoor application in direct
sunlight. The enclosure includes a weather tight connection means for the RS232 service tool
connection.
Touch screen key functions are determined completely in the software and change depending
upon the subject matter currently being displayed. The user operates the touch sensitive buttons
by touching the button of choice. The selected button is darkened to indicate it is the selected
choice. The advantage of touch sensitive buttons is that the full range of possible choices as well
as the current choice is always in view.
Spin values (up or down) are a graphical user interface model used to allow a continuously
variable setpoint, such as leaving water setpoint to be changed. The value changes by touching the
increment or decrement arrows.
Action buttons are buttons that appear temporarily and provide the operator with a choice such as
Enter or Cancel. The operator indicates his choice by touching the button of choice. The system
then takes the appropriate action and the button typically disappears.
DynaView consists of various screens, each meant to serve a unique purpose of the machine being
served. Tabs are shown row across the top of the display. The user selects a screen of information
by touching the appropriate tab. The folder that is selected will be brought to the front so its
contents are visible.
The main body of the screen is used for description text, data, setpoints, or keys (touch sensitive
areas) The double up arrows cause a page by page scroll either up or down. The single arrow
causes a line by line scroll to occur. At the end of the screen, the appropriate scroll buttons will
disappear. Wrap around will not occur.
The bottom of the screen is the persistent area. It is present in all screens and performs the
following functions. The left circular area is used to reduce the contrast and viewing angle of
the display. The right circular area is used to increase the contrast and viewing angle of the
display. The contrast control will be limited to avoid complete “light” or complete “dark”, which
would potentially confuse an unfamiliar user to thinking the display was malfunctioning.
The Auto and Stop keys are used to put the unit into the auto or stop modes. Key selection is
indicated by being darkened (reverse video).
The Alarms button is to the right of the Stop key. The Alarms button appears only when alarm
information is present. The alarm blinks to draw attention to the shutdown diagnostic condition.
Blinking is defined as normal versus reverse video. Pressing on the Alarms button takes you to
the corresponding screen.
Persistent keys, horizontal at the bottom of the display, are those keys that must be available for
operation regardless of the screen currently being displayed. These keys are critical for machine
operation. The Auto and Stop keys will be presented as radio buttons within the persistent key
display area. The selected key will be dark. The chiller will stop when the Stop key is touched,
entering the stop sequence. Pressing the “Immediate Stop” button will cause the chiller to stop
right away.
The AUTO and STOP, take precedence over the ENTER and CANCEL keys. (While a setting is being
changed, AUTO and STOP keys are recognized even if ENTER or CANCEL has not been pressed.
Selecting the Auto key will enable the chiller for active cooling ( if no diagnostic is present.)
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Operator Interface
Chiller Stop Prevention/Inhibit Feature
A new chiller “Stop prevention/inhibit” feature allows a user to prevent an inadvertent chiller stop
from the DynaView screen for those chillers which are solely controlled by the CH530.
How it works
This new feature will be activated after the service tech sets a variable shut down timer in TechView
to be greater that 0 seconds and up to 20 seconds (i.e. 0 < Timer ± 20). Then, when the user presses
the ‘STOP’ button on the DynaView display and initiates a chiller shutdown, a window will now
appear that displays the “Unit Stop Information Screen” as shown below.
TechView service tool is utilized to enable this feature.
The machine-operating mode indicates the operational status of the chiller. A subscreen with
additional mode summary information will be provided. When the user scrolls down the screen the
Machine Operation Mode will remain stationary
On DynaView, the user will be presented with a single line of text that represents the ‘top-level’
operating state of the machine. These top-level modes are shown in the table below. Additional
information (if it exists) regarding the machine operating state will be available to the user by
selecting the “additional information” button (double right arrow) next to the top-level operating
mode. These sub-level modes are shown in the table at left.
The TOP LEVEL MODE is the text seen on the single top level chiller system operating mode line.
The SUB LEVEL MODE is the text seen on the operating mode sub-menu. The operating mode submenu may have up to 6 lines of text displayed. The BAS CODE is the code that will be sent via
COMM4 to the Tracer Summit system as the chiller system mode. Note that each top level mode
may contain multiple sub level modes. In general, the BAS CODE will reflect the top level mode and
not the sub level mode.
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Operator Interface
Figure 19.
A general description of the top level modes is show in the following table:
34
Top Level Mode
Description
Stopped
Unit inhibited from running and will require user action to go to Auto.
Run Inhibit
Unit inhibited from running by Tracer, External BAS, or an Auto Reset diagnostic.
Auto
Unit determining if there is a need to run.
Waiting To Start
Unit waiting for tasks required prior to compressor start to be completed.
Starting Compressor
Unit is starting compressor.
Running
Compressor is running with no limits in effect.
Running – Limit
Compressor is running with limit in effect.
Preparing To Shutdown
Unit is closing inlet guide vanes prior to compressor shutdown.
Shutting Down
Compressor has been stopped and unit is performing shutdown tasks.
Free Cooling
Unit is in Free Cooling mode and will not run the compressor.
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Operator Interface
Figure 20.
Top Level Mode
Sub Level Mode
Reference
BAS Code
SYSTEM RESET
Boot & Application software part number, self-test, and configuration validity screens will be present.
NA
Stopped
Local Stop
0
Stopped
Panic Stop
0
Stopped
Diagnostic Shutdown – Manual Reset
0
Run Inhibit
Ice Building Is Complete
100
Run Inhibit
Tracer Inhibit
100
Run Inhibit
External Source Inhibit
100
Run Inhibit
Diagnostic Shutdown – Auto Reset
100
Auto
Waiting For Evaporator Water Flow
58
Auto
Waiting For A Need To Cool
58
Auto
Waiting For A Need To Heat
Auto
Power Up Delay Inhibit:
Waiting To Start
Waiting For Condenser Water Flow
70
Waiting To Start
Establishing Oil Pressure
70
Waiting To Start
Pre-Lubrication Time:
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58
MIN:SEC
MIN:SEC
58
70
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Operator Interface
Top Level Mode
Reference
BAS Code
Sub Level Mode
Waiting To Start
Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature
Waiting To Start
Restart Time Inhibit:
70
Waiting To Start
High Vacuum Inhibit: Oil Sump Press / Inhibit Press
70
Waiting To Start
Low Oil Temperature Inhibit: Oil Temperature / Inhibit Temperature
70
Waiting To Start
Waiting For Starter To Start:
MIN:SEC
MIN:SEC
70
70
Starting Compressor There is no sub mode displayed
72
Running
There is no sub mode displayed
74
Running
Hot Water Control
74
Running
Surge
74
Running
Base Loaded
74
Running
Hot Gas Bypass
74
Running
Ice Building
74
Running
Ice To Normal Transition
74
Running
Current Control Soft Loading
74
Running
Capacity Control Soft Loading
74
Running – Limit
Current Limit
75
Running – Limit
Phase Unbalance Limit
75
Running – Limit
Condenser Pressure Limit
75
Running – Limit
Evaporator Temperature Limit
75
Running – Limit
Minimum Capacity Limit
75
Running – Limit
Maximum Capacity Limit
75
Free Cooling
9
Free Cooling
Opening Free Cooling Valves
9
Free Cooling
Closing Free Cooling Valves
9
Preparing To
Shutdown
Closing IGV:
IGV Position %
Shutting Down
Post-Lubrication Time:
MIN:SEC
7E
7E
Shutting Down
Evaporator Pump Off Delay:
MIN:SEC
7E
Shutting Down
Condenser Pump Off Delay:
MIN:SEC
7E
Main Screen
The main screen is provides “an overall view“ of the chiller performance in addition to the main
and sub operating modes. The table below indicates other items found , when specified by options,
that can be scrolled to via the up or down arrows.
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Operator Interface
Description
Chiller Operating Mode (>>sub modes)
Evaporator Entering and Leaving Water Temperature
Condenser Entering and Leaving Water Temperature
Active Chilled Water Setpoint (>>source)
Active Hot Water Setpoint (>>source)
Active Current Limit Setpoint (>>source), If enabled
Active Base Loading Setpoint (>>source), If enabled
Purge Operating Mode
Purge Status
Average Line Current
Approximate Chiller Capacity, If option installed
Active Ice Termination Setpoint (>>source), If option installed
Software Version
Diagnostic Screen
The diagnostic screen is accessible by touching the Alarms enunciator.
When an alarm is present, the alarm enunciator is present next to the Stop key. A flashing “alarm”
indicates a machine shutdown and a non flashing “alarm” indicates an informational message.
Machine shutdowns can be of two types:
•
Latching - Machine Shutdown Manual Reset Required (MMR)
or
•
Non-Latching - Machine Shutdown Auto Reset (MAR)
Latching (MMR) require corrective action and manual reset.
Non-Latching (MAR) will restart automatically when condition corrects itself.
There are over 200 potential messages, too numerous to incorporate in this manual.
Up to ten active diagnostics can be displayed if required.
The reason for all diagnostic must be determined and corrected. Do not reset and restart the chiller
as this can cause a repeat failure. Contact local Trane Service for assistance as necessary.
After corrective action, the chiller can be reset and/or restarted. In the case of “Unit Shutdown Reset Required” diagnostic types, the chiller will have to be manually reset through the Diagnostics
alarm menu.
When reset they become historic and viewable via the service tool TechView.
Performing a Reset All Active Diagnostics will reset all active diagnostics regardless of type,
machine or refrigerant circuit.
A Manual Override indicator (shares space with the Alarms key) alerts the operator to the
presence of a manual override. An Alarm will take precedence of the Manual, until the reset of
active alarms, at which point the Manual indicator would reappear if such an override exists.
Temperature settings can be expressed in F or C, depending on Display Units settings.
Dashes (“- - - -”) appearing in a temperature or pressure report, indicates that the value is invalid
or not applicable.
The languages for DynaView will reside in the main processor. The main processor will hold three
languages, English, and two alternate languages. The service tool (TechView) will load the main
processor with user selected languages from a list of available translations. Whenever possible,
complete words will be used on the persistent keys as described.
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Operator Interface
The active chilled water setpoint is the setpoint that is currently in use. It will be displayed to
0.1 degrees Fahrenheit or Celsius. Touching the double arrow to the left of the Active Chilled Water
Setpoint will take the user to the active chilled water setpoint arbitration sub-screen.
The Active Chilled Water Setpoint the result of arbitration between the front panel, BAS, and
external setpoints,
The chilled water reset status area in the right most column will display one of the following
messages: Return, Constant Return, Outdoor, None
The left column text “Front Panel”, “BAS”, “External”, Chilled Water Reset, and “Active Chilled Water
Setpoint” will always be present regardless of installation or enabling those optional items. In the
second column “- - - -” will be shown if that option is Not Installed, otherwise the current setpoint
from that source will be shown.
The “Back” button provides navigation back to the chiller screen.
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Operator Interface
The active current limit setpoint is the current limit setpoint that is currently in use. It will be
displayed in percent RLA. Touching the double arrow to the left of the Active Current Limit Setpoint
will take the user to the active current limit setpoint sub-screen. The active current limit setpoint
is that setpoint to which the unit is currently controlling. It is the result of arbitration between the
front panel, BAS, and external setpoints.
The left column text “Front Panel”, “BAS”, “External”, and “Active Current Limit Setpoint” will always
be present regardless of installation or enabling those optional items. In the second column “- - - -”
will be shown if that option is Not Installed, otherwise the current setpoint from that source will be
shown. The “Back” button provides navigation back to the chiller screen.
Note: This is the same for other setpoints in the “Main” menu.
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Operator Interface
Reports
40
Evaporator Report items
Units
Evaporator Entering Water Temperature
°C or °F
Evaporator Leaving Water Temperature
°C or °F
Evaporator Saturated Refrigerant Temperature
°C or °F
Evaporator Refrigerant Pressure
Psia or kPa
Evaporator Approach
°C or °F
Evaporator Water Flow Switch Status
Flow or No Flow
Evaporator Differential Water Pressure, If installed
Psid
Approximately Evaporator Water Flow, If installed
Gpm or LPM
Approximate Chiller Capacity, If installed
Tons or kW
Condenser Report Items
Units
Condenser Entering Water Temperature
°C or °F
Condenser Leaving Water Temperature
°C or °F
Condenser Saturated Refrigerant Temperature
°C or °F
Evaporator Refrigerant Pressure Temperature
°C or °F
Condenser Refrigerant Pressure
Psia or kPa
Condenser Approach Temperature
°C or °F
Condenser Water Flow Switch Status
Open or closed
Condenser Differential Water Pressure, If installed
Psid or kPa
Approximate Condenser Water Flow, If installed
Gpm or LPM
Auxiliary Condenser or Heat Recovery Entering Water Temperature, If installed
°C or °F
Auxiliary Condenser or Recovery Leaving Water Temperature, If installed
°C or °F
Outdoor Air Temperature, If installed
°C or °F
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Operator Interface
Compressor Report Items
Units
Compressor Starts:
###
Compressor Running Time:
Hour and minute
Compressor Discharge Temperature; If installed
°C or °F
Oil Tank Pressure
Oil Discharge Pressure
Oil Differential Pressure
Oil Tank Temperature
°C or °F
Inboard Bearing Temperature, If installed
°C or °F
Outboard Bearing Temperature, If installed
°C or °F
Vanes Position
Percent open
Vanes Position Steps
Steps
Hot Gas Bypass Time, If installed
Hour and minute
Motor Report Items
Units
Percent RLA L1 L2 L3
Percent RLA
Amps L1 L2 L3
Amps
Volts AB, BC, CA
Vac
Power Consumption, If installed
xxx kW
Load Power Factory, If installed
xx
Winding Temperature A
°C or °F
Winding Temperature B
°C or °F
Winding Temperature C
°C or °F
Adaptive Frequency Drive Speed, If installed
Hz
Adaptive Frequency Drive Speed, If installed
RPM
Adaptive Frequency Drive Heat Sink Temperature, If installed
°C or °F
Purge Report Items
Units
Time Until Next Purge Run
Daily Pumpout – 24 Hours
CVHE-SVU01F-EN
Minute
Average Daily Pumpout – 7 Days
Minute
Daily Pumpout Limit and Alarm
Minute
Chiller On – 7 Days
Percent
Pumpout Chiller On – 7 Days
Percent
Pumpout Chiller Off – 7 Days
Percent
Pumpout - Life
Minute
Purge Refrigerant Compressor Suction Temperature
°C or °F
Purge Liquid Temperature
°C or °F
Carbon Tank Temperature
°C or °F
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Operator Interface
ASHRAE Chiller Log
Units
1
Current Time and Date Monitor
HH:MM xm
2
Operating Mode
3
Active Chilled Water Setpoint:
°C or °F
4
Active Current Limit Setpoint:
% RLA
5
Refrigerant Type:
6
Refrigerant Monitor: If installed
7
Purge Daily Pumpout – 24 Hours:
Minute
8
Purge Daily Pumpout Limit and Alarm
Minute
9
Purge Pumpout - Life
Minute
10
Purge Operating Mode:
Enum
11
Purge Status:
Enum
12
Compressor Starts:
13
Compressor Running Time:
14
Compressor Discharge Temperature; If option installed
°C or °F
15
Discharge Oil Pressure;
Psia or kPa
16
Oil Tank Pressure:
Psia or kPa
17
Differential Oil Pressure:
Psid or kPa
18
Oil Tank Temperature:
°C or °F
19
Inboard Bearing Temperature, If option installed
°C or °F
20
Outboard Bearing Temperature, If option installed
°C or °F
21
Evaporator Entering Water Temperature
°C or °F
22
Evaporator Leaving Water Temperature
°C or °F
23
Evaporator Saturated Refrigerant Temperature
°C or °F
24
Evaporator Refrigerant Press
Psia or kPa
25
Evaporator Approach
°C or °F
26
Evaporator Water Flow Switch Status:
Flow/No flow
27
Evaporator Differential Water Pressure, If installed
Psid or kPa
28
Approximately Evaporator Water Flow, If installed
GPM or LPM
29
Approximate Chiller Capacity, If installed
Tons or kW
30
Condenser Entering Water Temperature
°C or °F
31
Condenser Leaving Water Temperature
°C or °F
32
Saturated Condenser Refrigerant Temperature
°C or °F
33
Condenser Refrigerant Pressure
Psia or kPa
34
Condenser Approach
°C or °F
35
Condenser Water Flow Switch Status
Flow or No Flow
36
Condenser Differential Water Pressure
Psia or kPa
37
Approximate Condenser Water Flow, If installed
GPM or LPM
38
Second Condenser Entering Water Temperature, If installed
°C or °F
39
Second Condenser Leaving Water Temperature, If installed
°C or °F
PPM
Hours:Minutes
Historic Diagnostics Log
1 to 20 Historic Diagnostics (main processor software 6.0 and later)
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Operator Interface
Setting Tab screens provides a user the ability to adjust settings justified to support daily tasks.
The layout provides a list of sub-menus, organized by typical subsystem.
Figure 21. Settings screen for standard CTV
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Operator Interface
Chilled Water Setpoint
To change chilled water setpoint first select the settings tab screen. Chilled water setpoint is within
the chiller sub-menu. (See the following tables for setpoint listing.)
Chiller
Description
Units
1
(Chilled Water, Hot Water), Chilled Water default
Front Panel Control Type
Notes
2
Front Panel Chilled Water Setpoint
Temperature
1
3
Front Panel Hot Water Setpoint
Temperature
1
2
4
Front Panel Current Limit Setpoint
Percent
5
Front Panel Base Load Command
On or Auto
6
Front Panel Base Load Setpoint
Percent
7
Front Panel Free Cool Command
On or Auto
8
Front Panel Ice Building Command
On or Auto
9
Front Panel Ice Termination Setpoint
Temperature
10
Ice to Normal Cooling Timer
(0–10), 5 Minutes default
11
Differential to Start
Temperature
12
Differential to Stop
Temperature
13
Setpoint Source
(a)(BAS/EXT/FP,
EXT/FP, FP), none default
(a) Follows hierarchy of selection from left to right (except ice build which is “OR” logic).
Feature Settings
Description
Units
1
Chilled Water Reset
(Constant, Outdoor, Return, Disable), Disable
2
Return Reset Ratio
Percent
3
Return Start Reset
Temperature
4
Return Maximum Reset
Temperature
5
Outdoor Reset Ratio
Percent
6
Outdoor Start Reset
Temperature
7
Outdoor Maximum Reset
Temperature
8
External Chilled Water Setpoint
(Enable, Disable), Disable
9
External Current Limit Setpoint
(Enable, Disable), Disable
10
Ice Building Feature Enable
(Enable, Disable), Disable
11
External Base Loading Setpoint
(Enable, Disable), Disable
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Operator Interface
Mode Overrides
Description
Units
Default
Monitor Value
Notes
3
1
Compressor Control Signal
(Auto, Manual [0-100]),
Auto
Percent Vane Position
Evaporator Leaving Water
Temperature, AFD Frequency, if installed
2
Evaporator Water Pump
(Auto, On),
Auto
1) Evaporator Flow status
2) Override Time Remaining
4
3
Condenser Water Pump
(Auto, On),
Auto
1) Condenser Flow status
2) Override Time Remaining
4
4
Oil Pump
(Auto, On),
Auto
1) Differential pressure
2) Override Time Remaining
4
5
Purge Exhaust Circuit Test
(Off, On),
Off
6
Purge Regeneration Cycle
(Off, On),
Off
Carbon Temperature
Purge
Description
Units
Default
1
Purge Operating Mode
(Auto, On, Adaptive, Stop),
Adaptive
2
Daily Pumpout Limit
Minutes
3
Disable Daily Pumpout Limit
Hours
4
Purge Liquid Temperature Inhibit
(Enable, Disable),
5
Purge Liquid Temperature Limit
Temperature
Enable
Display Settings
Description
Units
1
Date Format
(“mmm dd, yyy”, “dd-mmm-yyyy”), “mmm dd, yyy”
2
Date
3
Time Format
Notes
5
(12-hour, 24-hour), 12-hour
4
Time of Day
5
Keypad and Display Lockout
(Enable, Disable), Disable
5
6
Display Units
(SI, English), English
7
Language
(English, Selection 2, Selection 3), English
6
7
Notes:
1. Temperatures will be adjustable to 0.1 degree F or C. The Main Processor provides the minimum and maximum allowable value.
2. Adjustable to the nearest whole number percent. The Main Processor provides the minimum and maximum allowable value.
3. Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation. This is not active
during Stop mode.
4. Terminates with 10 minutes if inactivity.
5. The Date and Time setup screen formats deviate slightly from the standard screens defined above. See the date and time sections, p. 47 and p. 48,
for further details.
6. Enables a DynaView Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView Lockout Screen displays a
0–9 keypad to permit the user to exit the lockout with a fixed password (1-5-9 + Enter). See lockout section, p. 48, for further details.
7. Language choices are dependent on what has been setup in the Main Processor. Language selections will include English and qty 2 alternate as loaded
by TechView. Language shall always be the last setting listed on the Display Settings menu. This will allow a user to find language selection if looking
at an unrecognizable language.
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Operator Interface
Each Settings Subscreen consists of a setpoints list and the current value. The operator selects a
setpoint to change by touching either the description or setpoint value. Doing this causes the
screen to switch to the Analog Settings Subscreen shown in the following figure.
{
Analog Settings Subscreen displays the current value of the chosen setpoint in the upper half of
the display. It is displayed in a changeable format consistent with its type. Binary setpoints are
considered to be simple two state enumeration and will use buttons. Analog setpoints are
displayed as spin buttons. The lower half of the screen is reserved for help screens. To change the
setpoint the ENTER key must be touched, otherwise the new setting is cancelled.
Note: Spin buttons used to
change setpoint value.
Settings with buttons only [screen has no cancel or enter key] do accept the new selection
immediately.
Note: Radio 1 and Radio 2 refer to “touch sensitive buttons.” The labels depend upon the setting
being controlled.
Mode Override for Enumerated Settings is shown in the following figure:
46
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Operator Interface
Figure 22. Mode override for enumerated settings
The mode override analog setting subscreen is similar but offers an Auto or Manual radio button
and value setting. An Auto or Manual selection is necessary set to the mode to override. An Enter
and Cancel Key will allow the user to Enter or Cancel the entry.
Mode Override for Analog Settings is shown in the following figure:
Figure 23. Mode override for analog settings
The date setpoint screen is shown in the following figure: The user must select Day, Month, or
Year and then use the up or down arrows to adjust.
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Operator Interface
The time setpoint screen with a 12-hour format is shown in the following figures: The user must
select Hour, or Minute and then use the up or down arrows to adjust. Adjusting hours will also
adjust am and pm.
Note: The 24-hour format setpoint screen is similar with the am and pm not shown.
The DynaView Display Touch Screen Lock screen is shown in Figure 24, p. 49. This screen is used
if the Display and Touch Screen Lock feature is Enabled. Thirty minutes after the last key stroke this
screen will be displayed and the Display and Touch Screen will be locked out until “159enter” is
entered.
Until the proper password is entered there will be no access to the DynaView screens including all
reports, all setpoints, and Auto and Stop and Alarms and Interlocks. The password “159” is not
programmable from either DynaView or TechView.
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Operator Interface
Figure 24. DynaView display touch screen lock screen
If the Display and Touch Screen Lock feature is Disabled, the following screen will be automatically
shown if the MP temperature is below 32°F (0°C) and it has been 30 minutes after the last key stroke.
Note: The main processor is equipped with an on-board temperature sensor which enables the
ice protection feature.
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Interprocessor Communication
Inter Processor Communications IPC3
When using Tracer CH530, you will not be required to know all the details about the structure of
the IPC3 bus. However this page gives detailed information about the system for those of you that
are really interested in how it works. The IPC3 protocol is based on RS485 signal technology. IPC3
was designed to be very efficient. It communicates at 19.2 Kbaud. This data rate will allow for three
rounds of data per second on a 64-device network. A typical CVHE control network will have less
than 50 devices. IPC3 allows for a maximum of 255 devices per network.
IPC3 Definitions: Bus Management
The DynaView provides the bus management having the task of restarting the link, or filling in for
missing nodes when the normal communication has been degraded. This involves reassigning
node addresses and filling in for nodes that are off-line. The DynaView always has a node number
of 01.
Node Assignment
When a unit is factory commissioned, the LLIDs must have their node addresses assigned to them
for storage in non-volatile memory. The node addresses are normally assigned sequentially during
factory commissioning.
Node Zero
Node number zero is is a special node assignment that is reserved for devices that are service
selected. An LLID communicating on node address zero will also communicate on an assigned
node address. An LLID will only communicate on node address zero if it is service selected.
Binding
Binding is the process of assigning a node number and functional IDs to a LLID. Binding is a simple
process:
1. Service selecting the LLID with a magnet.
2. Assigning functional IDs to that LLID with TechView.
Functional Identification
When each LLID on the bus is bound, its inputs and outputs are given a functional ID. The Frame
LLIDS have only one functional ID, but most Panel LLIDs have more than one functional ID. A dual
high voltage binary input will have two functional IDs, a quad relay output has four functional IDs.
The DynaView Main Processor with its IPC3 Bus communicates to the control panel devices, unit
mounted devices, and any remote devices on the IPC3 bus network. The various devices are
discussed in the upcoming sections.
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Control System Components
Control Panel Internally Mounted Devices
For visual identification Internal Control Panel mounted devices are identified by their respective
schematic designation number. Control panel items are marked on the inner back panel in the
control panel. Figure 25 identifies these devices. The Control Panel Devices table corresponds to
the same device designators (see right hand column). Optional controls are present when a specific
optional controls package is specified, as listed in the second column. Optional controls packages
are; OPST Operating Status, GBAS Generic Building Systems, EXOP Extended operation, CDRP
Condenser Pressure, TRMM Tracer communications, WPSR Water Flow Pressure sensing, FRCL
Free Cooling, HGBP Hot Gas Bypass, and EPRO Enhanced Protection
Figure 25 illustrates the Control Panel Components Layout.
Modules 1A1, 1A3, 1A4, 1A5, 1A6, 1A7, and 1A13 are standard and present in all configurations.
Other Modules vary depending on machine optional devices.
Figure 25. Control panel components layout and approximate dimensions
Standard Enclosure
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Control System Components
Figure 26. CH530 Main control panel assy device designations & circuit descriptions: CVHECVHF-CVHG Simplex units
52
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Control System Components
Control Panel Devices
Standard Devices
Description
Controls Package
1A1 Power Supply
Standard
#1
Purpose
Converts 24 Vac to 24 Vdc
Field Connection Point Terminals
not for field use
1A2 Power Supply
(as required)
#2
Converts 24 Vac to 24 Vdc
not for field use
1A3 Dual Relay
Standard
Relay #1
Oil Heater Relay
not for field use
High Pressure Cutout
not for field use
Chilled water pump
J2-4 NO, J2-5 NC, J2-6 common
Output modules
1A4 Dual High
Standard
Voltage Input
1A5 Quad Relay
Standard
Relay #1
Output modules
1A5 Quad Relay
(Relay #1)
Standard
Relay #2
Output modules
1A6 Dual High
Condenser water pump control
J2-1 NO, J2-2 NC, J2-3 common
(relay #2)
Standard
Input 1
Condenser Flow Input
J2-2 Condenser water flow switch
Standard
Input 2
Evaporator Flow Input
J3-2 Chilled water flow switch
Oil Pump and
not for field use
Voltage Input
1A6 Dual High
Voltage Input
1A7 High Power
Standard
Output Relay
1A13 Dual LV Binary
Refrigerant Pump
Standard
Signal #1
External Auto Stop
J2-1 Binary Input Signal #1, J2-2 Ground
Standard
Signal #2
Emergency stop
J2-3 Binary Input Signal #2, J2-4 Ground
Compressor Motor
not for field use
Input module
1A13 Dual LV Binary
Input module
1A26(a)
Standard
Winding Temp Sensor
1F1
Standard
LLID Power Supply Transformer
not for field use
Primary Circuit protection
1T1
Standard
Control Panel Power
not for field use
Transformer ; 120:24 Vac
1Q1
Standard
Circuit Breaker - Compressor
not for field use
Motor Controller Control Power
Branch Circuit
1Q2
Standard
1Q3
Standard
Circuit Breaker -
not for field use
Purge System Branch Circuit
Circuit Breaker – Module [- LLID]
not for field use
Power Supply Branch Circuit
1Q4
Standard
1Q5
Standard
Circuit Breaker - Oil System Control not for field use
Branch Circuit
Oil Pump Motor Branch
not for field use
Circuit protection
1X1 Terminal Block
Standard
Control Panel Terminal Block,
1X1-5 Chilled water flow flow switch input
Flow switch connections
1X1-6 Condenser water flow switch input
(a) Previously was located in Purge Control Panel.
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Control System Components
Chilled and Condenser Water Flow Interlock Circuits
Proof of chilled water flow for the evaporator is made by the closure of flow switch 5S1 and the
closure of auxiliary contacts 5K1 on terminals 1X1-5 and 1A6-J3-2. Proof of condenser water flow
for the condenser is made by the closure of flow switch 5S2 and the closure of auxiliary contacts
5K2 on terminals 1X1-6 and 1A6-J2-2.
OPST Operation Status Option
Relay output modules 1A8 and 1A9 provide relay outs as shown:
1A8 Optional Quad Relay Output Status
OPST
Relay #1
Compressor running relay
J2-10 NO, J2-11 NC, J2-12 common
1A8 Optional Quad Relay Output Status
OPST
Relay #2
MMR Alarm Relay (Latching)
J2-7 NO, J2-8 NC, J2-9 common
1A8 Optional Quad Relay Output Status
OPST
Relay #3
Limit Warning Relay
J2-4 NO, J2-5 NC, J2-6 common
1A8 Optional Quad Relay Output Status
OPST
Relay #4
MAR Alarm Relay (Non-Latching)
J2-1 NO, J2-2 NC, J2-3 common
1A9 Optional Quad Relay Output Status
OPST
Relay #2
Purge Alarm Relay
J2-7 NO, J2-8 NC, J2-9 common
1A9 Optional Quad Relay Output Status
OPST
Relay #3
Head Relief Request Relay
J2-4 NO, J2-5 NC to J2-6 common
1A9 Optional Quad Relay Output Status
OPST
Relay #4
Maximum Capacity Relay
J2-1 NO, J2-2 NC, to J2-3 common
Head Relief Request Output
When the chiller is running in Condenser Limit Mode or in Surge Mode, the head relief request relay
(1 minute default) on the 1A9-J2-6 to J2-4 will be energized and can be used to control or signal
for a reduction in the entering condenser water temperature. Designed to prevent high refrigerant
pressure trip-outs during critical periods of chiller operation.
If the unit is not equipped with the CDPR Enhanced Condenser Limit Option the unit will use the
condenser refrigerant temperature sensor (input converted to saturated refrigerant pressure) to
perform the Standard Condenser Limit function, without the head relief request relay, by limiting
inlet guide vane stroke and chiller capacity.
Keep in mind that Condenser Limit Control supplements the protection provided by the condenser
pressure high pressure cutout switch 3S1.
Compressor Motor Winding Temp Sensor Module
The motor temperature module 1A26 connects via unit wiring to the three motor winding
temperature sensors.
Maximum Capacity Relay (TechView adjustable)
When the chiller has been operating at maximum capacity for 10 minutes (TechView adjustable
1 to 60 minutes) this relay will activate. Also upon being less than maximum capacity for
10 minutes this relay will deactivate.
Compressor Running Relay
Relay activates while compressor is running.
Machine Shutdown Manual Reset (MMR)
Limit warning machine shutdown auto reset relays will activate with such conditions for remote
status indication.
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Control System Components
EXOP Extended Operation Option
The following modules (1A17, 1A18, and 1A19) are provide when this control package is specified.
1A5 Quad Relay
EXOP
Relay #4
Ice Building Relay
J2-10 NO, J2-11 NC, J2-12 common
EXOP
Signal #1
External Base Loading Setpoint input
J2-1 Output #1, J2-3 Ground
EXOP
Signal #2
Refrigerant monitor inputs
J2-4 Output #2, J2-6 Ground
EXOP
Signal #1
External Base Loading Enable or Disable input, points
J2-1 Binary Input Signal #1,
Output Modules(a)
1A17 Optional Dual Analog
Input/Output Module
1A17 Optional Dual Analog
Input/Output Module
1A18 Optional Dual LV
Binary Input Module
J2-2 Ground
1A18 Optional Dual LV
EXOP
Signal #2
External Hot Water Control Enable or Disable input
J2-3 Binary Input Signal #2,
EXOP
Signal #1
Ice Building Control Enable or Disable input point
J2-1 Binary Input Signal #1,
Binary Input Module
J2-4 Ground
1A19 Optional Dual LV
Binary Input Module
J2-2 Ground
(a) Previously was 1A10.
Refrigerant Monitor Input 1A17
Analog type input 4–20 mA input signal to the 1A17 J2-4 to J2-6 (ground). This represents 0 ppm–
100 ppm.
FRCL (Free Cooling Option)
1A11 Optional Quad Relay Output Status
FRCL
Relay #1
Free Cooling Relay 1
J2- 4 NO to J2-6 common
1A20 Optional Dual LV Binary Input Module
FRCL
Signal #1
External Free Cooling Switch
J2-1 Binary Input Signal #1, J2-2 Ground
1A20 Optional Dual LV Binary Input Module
FRCL
Signal #2
Free Cooling Valves closed
Not for field use
Hot Gas Bypass input
Not for field use
Auxiliary relays
Not for field use
Tracer Communications
J2-1 COMM+, J2-2 COMM -J2-3,
HGBP (Hot Gas Bypass Option)
1A7 Dual High Voltage Binary Input
HGBP
1A12 Optional Quad Relay Output Status
HGBP
#1
Relay #1
TRMM TRM4 (Tracer Comm 4 interface)
1A14 Optional Communication
TRM4 or LCI-C
Interface Module
COMM +J2-4, COMM -
CDRP (Condenser Refrigerant Pressure Output)(a)
1A15 Optional Dual Analog
CDRP or GBAS
Signal #2
Condenser Refrigerant Pressure output
J2-4 Output #2, J2-6 Ground
Input/Output Module
(a) See CTV-PRC006-EN for “Condenser Water Temperature Control”.
EPRO (Enhanced Protection)
4R22
EPRO
Condenser Refrigerant Pressure Transducer
4R16
EPRO
Compressor Discharge Refrigerant Temperature Sensor. (This is also included with H6BP).
4R1
EPRO
Inboard Bearing Temperature Sensor
4R2
EPRO
Outboard Bearing Temperature Sensor
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Control System Components
CDRP Refrigerant Pressure Output Option 1A15
Refrigerant Pressure Output can be configured at commissioning to correspond to either A) the
absolute condenser pressure, or B) the differential pressure of the evaporator to condenser
pressures.
This Vdc output is located at 1A15-J2-4 (+) to J2-6 (Ground)
The Voltage DC Output can source a maximum of 22 mA of current.
This output is Voltage DC only, 4–20 mA is not supported.
A) Condenser Pressure Output.
2 to 10 Vdc corresponds to 0 Psia to the HPC (in Psia) setting.
Note: Controls allow Delta Pressure or condenser pressure output, but not both.
Temperature based
On standard machines the Percent Condenser Pressure Indication Output is based on the Saturated
Condenser Refrigerant and a temperature to pressure conversion is made.
If the Condenser Saturated Temperature goes out of range due to an open or short, a pressure
sensor diagnostic will be called and the output will also go to the respective out of range value. That
is, for an out of range low on the sensor, the output will be limited to 2.0 Vdc. For an out of range
high on the sensor, the output will be limited to 10.0 Vdc.
Pressure based
With the Enhanced Protection EPRO option, a condenser pressure transducer is installed and the
pressure is measured.
If the Condenser Pressure sensor goes out of range due to either an open or short, a pressure
sensor diagnostic will be called and the output will go to end of range low. That is, for an out of
range low on the sensor, the output will be limited to 2.0 Vdc. For an out of range high on the sensor,
the output will be limited to 2.0 Vdc.
Figure 27. Condenser pressure based output
10 Vdc
2 Vdc
0 PSIA
0 percent
15 PSIG
HPC in PSIA
100 percent
(Value is equal to the
High Pressure
Cutout Setting)
15 PSIG Typical
B) Refrigerant Differential Pressure Indication Output
A 2 to 10 Vdc analog output is provided instead of the previous condenser pressure output signal.
This signal corresponds to a predetermined minimum and maximum pressure settings setup at
commissioning of this feature. This relationship can be altered using the service tool if required.
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Control System Components
The “Minimum Delta Pressure“ is typically set to 0 psi and will then correspond to 2 Vdc. The
“Maximum Delta Pressure“ is typically set to 30 psi and corresponds to 10 Vdc.
The Minimum Delta Pressure Calibration setting has a range of 0 psid–400 psid (0 kPA–2758 kPa)
in increments of 1 psid (1 kPa). The Maximum Delta Pressure Calibration setting has a range of
1 psid–400 psid (7 kPa–2758 kPa) in increments of 1 psid (1 kPa). The condenser refrigerant
pressure is based on the Condenser Refrigerant Temperature sensor if the Condenser Pressure
Option is selected as “Not Installed” at the display.
The evaporator refrigerant pressure is based on the Saturated Evaporator Refrigerant Temperature
Sensor.
See CTV-PRB006-EN for additional information about condenser water temperature control.
Figure 28. Delta pressure setting—Differential pressure based output (defaults shown)
10 Vdc
2 Vdc
Max. Delta
Pressure Setting
(Default 30 psi)
Min. Delta
Pressure Setting
(Default 0 psi)
In this example, 2 Vdc corresponds to 0 psi differential and 10 Vdc corresponds to 30 psi
differential. The min value of 0 psi, and the max value of 30 psi are individually adjustable via the
service tool.
Note: Typical settings for CVHE, CVHF, and CVHG with refrigerant pumps are as follows.
•
Min. pressure 0 psid (= 2 Vdc)
•
Max. pressure 6 psid (= 10 Vdc)
•
Target tower control at 4 psid
GBAS (Generic Building Automation System)
1A15 Optional Dual Analog
GBAS or CDRP
Signal #1 Percent RLA Compressor Output
J2-1 Output #1, J2-3 Ground
GBAS
Signal #1 External Current limit Setpoint
J2-2 Input #1, J2-3 Ground
GBAS
Signal #2 Chilled Water Reset input,
J2-5 Input #2, J2-6 Ground
Input/Output Module
1A16 Optional Dual Analog
Input/Output Module
1A16 Optional Dual Analog
Input/Output Module
or External Chiller Water Setpoint
Percent RLA Output
A 2 to 10 Vdc corresponds to 0 percent to 120 percent RLA. With a resolution of 0.146%. The Percent
RLA Output connections are on the terminals 1A15-J2-1 (+) to J2-3 (Ground). The Percent RLA
Output is polarity sensitive.
The following graph illustrates the output:
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Control System Components
Figure 29. Voltage versus percent RLA
% RLA
Voltage vs Percent RLA
Voltage
Notes:
•
0% RLA = 2 Vdc
•
120% RLA = 10 Vdc
Example: If RLA is 500 amps then 10 Vdc = 600 amps.
External Chilled Water Setpoint (ECWS)
The External Chilled Water Setpoint allows the chilled water setpoint to be changed from a remote
location. The External Chilled Water Setpoint is found on 1A16 J2-5 to J2-6 (Ground). 2–10 Vdc and
4–20 mA correspond to a 34°F to 65°F (-17.8 to 18.3°C) CWS range. Default 34°F to 65°F, adjustable
via service tool.
External Current Limit Setpoint
The External Current Limit is an option that allows the current limit setpoint to be changed from
a remote location. The External Limit Setpoint is found on 1A16 J2-2 to J2-3 (ground), 2–10 Vdc and
4–20 mA each correspond to a 40 percent to 100 percent RLA range. UCP limits the maximum ECLS
to 100%. Default 40% to 100%, adjustable via service tool.
Note: To use external inputs, the setpoint source setting on DynaView must be set to “Ext/FP.”
The ECWS or ECLS LLID will report either a very low or very high value when there is either an open
or short in the system.
When an open or short is detected (or the signal is severely beyond the valid range) on the 2–10 Vdc
or 4–20 mA ECLS input and when the ECLS option is installed, an informational diagnostic shall
be generated. The active current limit set point will default to the panel (or next priority) current
limit set point. Open and short criteria will be set as close to the end of the range values as possible
and still reliably detect an open and short.
WPSR (WFC Water Pressure Sensing Option)
1A21 Optional Dual Analog Input or Output Module
WPSR = WFC
Signal #1
Evaporator Differential Water Pressure
Not for field use
1A21 Optional Dual Analog Input or Output Module
WPSR = WFC
Signal #2
Condenser Differential Water Pressure
Not for field use
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Control System Components
Module Characteristics
1A1, 1A2 Power Supply
Unit Control Power Supply Module Converts 27 Vac to 24 Vdc.
Power Input Voltage: 23 VRMS minimum, 27 VRMS Nominal, 30 VRMS maximum
Frequency: 50–60 Hz
Current: Full load 27 Vac – 4.30 A (RMS)
Inrush 27 Vac (RMS) ~ 30 A (RMS)
Power Output: Class II Voltage 24 Vdc, Rated Current 2.44 Amps. Fused @ 3 amps. (FUS01513)
1A3, 1A5, 1A10 Dual Relay Output Modules
Relay #1 J2-1 NO, J2-2 NC, J2-3 common
Relay #2 J2 4 NO, J2-5 NC, J2-6 common
Relay Outputs at 120 Vac: 7.2 Amps resistive, 2.88 Amps pilot duty, 1/3 hp, 7.2 FLA at 240 Vac:
5 Amps general purpose, 14–26 AWG with a maximum of two 14 AWG.
Power, 24 ± 10 percent Vdc, 60 mA maximum, Trane IPC3 protocol. J1-1 +24 Vdc, J1-2 Ground, J1-3
COMM + J1-4 COMM -
1A4, 1A6 Dual High Voltage Binary Input Module
Binary Input Signal #1 J2-1 to 2
Binary Input Signal #2 J3-1 to 2
High Voltage Binary Input: Off Voltage: 0 to 40 Vac RMS , On Voltage: 70 to 276 Vac RMS
Input is not polarity sensitive (Hot and neutral can be switched), Input impedance 130K to
280K ohms
14–26 AWG with a maximum of two 14 AWG
Power, 24 ± 10 percent Vdc, 20 mA maximum. Trane IPC3 protocol. J1-1 +24 Vdc, J1-2 Ground, J1-3
COMM +, J1-4 COMM -
1A7 High Power Relay
Relay output contacts at 120 Vac: 16.0 Amps resistive, 6.4 Amps pilot duty, 1 hp, 16.0 FLA
J2 14–26 AWG with a maximum of two 14 AWG J2-1 NO, J2-2 NO, J2-3 NC, J2-4 COM, J2-5 COM.
Power, 24 ± 10 percent Vdc, 60 mA max. Communications, RS485 Physical layer, 19.2 Kbaud, Trane
IPC3 protocol.
J1: J1-1 +24 Vdc, J1-2 GND, J1-3 COMM +, J1-4 COMM - J11: J11-1 +24 Vdc, J11-2 GND, J11-3
COMM +, J11-4 COMM -
1A8, 1A9, 1A11, 1A12 Quad Relay Output Status
Relay #1 J2-1 NO, J2-2 NC, J2- common
Relay #2 J2-4 NO, J2-5 NC, J2-6 common
Relay #3 J2-7 NO, J2-8 NC, J2-9 common
Relay #4 J2-10 NO, J2-11 NC, J2-12 common
Relay Outputs: at 120 Vac: 7.2 Amps resistive, 2.88 Amps pilot duty, 1/3 hp, 7.2 FLA, at 240 Vac:
5 Amps general purpose 14–26 AWG, two 14 AWG Maximum Power, 24 ± 10 percent Vdc, 100 mA
maximum. Trane IPC3 protocol.
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Control System Components
1A13, 1A18, 1A19, 1A20 Dual Binary Input Module
J2-1 Binary Input Signal #1, J2-2 Ground, J2-3 Binary Input Signal #2, J2-4 Ground
Binary Input: Looks for a dry contact closure. Low Voltage 24 V 12 mA.
14–26 AWG with a maximum of two 14 AWG
Power, 24 ± 10 percent Vdc, 40 mA maximum Trane IPC3 protocol.
1A14 Communication Interface Module
Power, 24 ± 10 percent Vdc, 50 mA maximum. Trane IPC3 protocol.
J1-1 +24 Vdc
J2-1 COMM +.
J11-1+24 Vdc
J1-2
Ground
J2-2 COMM -
J11-2 Ground
J1-3
COMM +
J2-3 COMM +
J11-3 COMM +
J1-4
COMM -
J2-4 COMM -
J11-4 COMM -
1A15, 1A16, 1A17, 1A21 Dual Analog Input/output Module
Analog Output: The Analog Output is a voltage only signal. 2–10 Vdc at 22 mA
J2: 14–26 AWG with a maximum of two 14 AWG
J2-1 Output #1 to J2-3 (Ground), J2-4 Output #2 to J2-6 (Ground).
UCP provides a 2–10 Vdc analog signals as Outputs. The Output’s maximum source capability is
22 mA. The maximum recommended length to run this signal is included in the table below.
Recommended Length to Run external Output signals
Gauge
Ohms per Feet
Length (Feet)
Maximum Length (Meters)
14
16
0.002823
1062.7
324
0.004489
668.3
203.8
18
0.007138
420.3
128.1
20
0.01135
264.3
80.6
22
0.01805
166.3
50.7
24
0.0287
104.5
31.9
26
0.04563
65.7
20
28
0.07255
41.4
12.6
Note: This table is for copper conductors only.
Analog Input
The analog input can be software switched between a voltage input or a current input. When used
as a current input a 200 Ohm load resistor is switched in.
2–12 Vdc or 4–20 mA Analog Inputs
UCP accepts either a 2–10 Vdc or 4–20 mA analog input suitable for customer external control. The
type is determined at unit commissioning during feature installation.
J2: 14–26 AWG with a maximum of two 14 AWG
J2-2 Input #1 to J2-3 (Ground).
J2-5 Input #2 to J2-6 (Ground).
Power, 24 ± 10 percent Vdc, 60 mA maximum, Trane IPC3 protocol.
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Control System Components
Unit Mounted Devices
Vane Actuator Control
The Stepper Module within the stepper vane actuator (4M2) (and 4M4 extended capacity) pulses
a DC voltage to the windings of the Stepper Motor Actuator(s) to control inlet guide vane position.
While operation of this stepper motor is automatic, manual control is possible by going to the Mode
Overrides settings menu within the DynaView. Compressor Control Signal allow the operator to
manually increase or decrease the compressor load by adjusting the compressor control signal.
Note: If the chiller is operating in a limit mode (current limit, condenser limit, evaporator limit,
etcetera.) The limit operation has priority over all DynaView manual modes of operation.
On each UCP power-up, the inlet guide vanes are driven full closed to recalibrate the zero position
(Steps) of the Stepper motor vane actuator.
Temperature Sensors
Evaporator sensors 4R6 and 4R7, and condenser sensors 4R8, 4R9 entering and leaving, bearing
temperature sensors 4R1, 4R2, oil temperature sensor 4R5, outdoor air temperature 4R13, and
evaporator 4R10 and condenser 4R11 saturated refrigerant temperature sensors.
Probe Operating Temperature Range -40°F to 250°F (-40°C to 121°C)
Accuracy ± 0.25°C over the range -4°F to 122°F (-20°C to 50°C), ± 0.50°C over the range -40°F to 250°F
(-40°C to 121°C)
Power and Communications and Terminations Power 24 ± 10 percent Vdc, 20 mA maximum. Trane
IPC3 protocol Communications.
Pressure Sensors
Oil tank sump 4R4 and oil pump discharge 4R3, evaporator and condenser refrigerant pressure
4R22,
Working Pressure Range: 0 Psia to 50 Psia
Accuracy: ± 0.3% of full scale output at 68°F (20°C)
Power and Communications and Terminations
Power 24 ± 10 percent Vdc, 20 mA maximum. Communications, RS485 Physical Layer, 19.2 Kbaud,
Trane IPC3 protocol.
Starter Module
In the hierarchy of modules the Starter module 2A1 (1A23 when customer supplied starter
specified) is second only to the DynaView. The starter module is present in all starter selections
(except AFD). This includes Wye Delta, Across the Line, Solid State whether remote unit mounted
or supplied by others. The starter module provides the logic to provide the motor protection for
Current overload, phase reversal, phase loss, phase imbalance, and momentary power loss. These
functions are discussed in the motor protection section of this manual.
Relay outputs @ 120 Vac: 7.2 Amps resistive 2.88 Amps Pilot Duty 1/3 hp, 7.2 FLA.
Relay outputs @ 240 Vac: 5 Amps 6 general purpose.
EarthWise Purge
Trane has also revolutionized its controller-integrated purge, which features an automatic
regeneration system for high-efficiency, maintenance-free refrigerant containment. Air and
noncondensables are pumped out faster, and the lower temperature refrigeration system
enhances the base purge efficiency. See EarthWise purge operation and maintenance manual for
details.
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Control System Components
Unit-Mounted Medium-Voltage Starter
Take advantage of Tracer CH530’s new starter and save space in your equipment room. There is no
need for a remote or floor-mounted starter with our new, exclusive unit-mounted medium-voltage
starter from Cutler-Hammer.
Adaptive Frequency Motor Drive
Tracer CH530 complements Trane’s Adaptive Frequency™ motor drive (AFD) system for chillers
better than ever before. Brand new control logic allows safe, more efficient inlet vane and motor
speed control operation to maximize part-load performance and, when necessary, limit the starting
current.
When equipped with the Trane Adjustable Frequency Drive (AFD) the Unit Control Panels
DynaView also provides the Operator interface to the AFD control. The Service Tool, TechView is
also utilized for setting service items. See the Adjustable Frequency drive operation maintenance
manual that ships with the chiller for details.
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Control Sequence of Operation
Electrical Sequence
This section will acquaint the operator with the control logic governing CVHE, CVHF, and CVHG
chillers equipped with Tracer CH530 UCP based control systems. When reviewing the step-by-step
electrical sequences of operation, refer to the typical wiring schematics for Unit mounted Wye Delta
starter shown in the installation manual shipped with the chiller.
Note: The typical wiring diagrams are representative of standard units and are provided only for
general reference. They may not reflect the actual wiring of your unit. For specific electrical
schematic and connection information, always refer to the wiring diagrams that shipped
with the chiller.
With the supply power disconnect switch or circuit breaker (2Q1 or 2K3) closed, 115-volt control
power transformer 2T5 and a 40-amp starter panel fuse (2F4) to terminal (2X1-1) starter panel to
terminal 1X1-1 in the control panel. From this point, control voltage flows to:
1. Circuit Breaker 1Q1 which provides power to the starter module (2A1) relay outputs and the
High Pressure Cutout switch (3S1).
2. Circuit Breaker 1Q2 which provides power to the Purge circuitry.
3. Circuit Breaker 1Q3 which provides power to Transformer (1T1) which steps down the 115 Vac
to 24 Vac. This 24 Vac then powers the 24 Vdc power supply 1A1, and 1A2 if present. The 24 Vdc
is then connected to all modules via the Interprocessor communications Bus providing module
power.
1Q3 also provides power to the external chiller water proof of flow device connected between
terminal block 1X1-5 to 1A6-J3-2, and condenser water proof of flow device connected at 1X1-6
to 1A6-J2-2.
4. Circuit Breaker 1Q4 which provides power to the Oil Heater 4HR1 circuit and to Circuit Breaker
1Q5 oil and refrigerant pump circuits.
5. The DynaView display module 1A22, receives 24 Vdc power from the IPC bus.
UCP and Wye-Delta Starter Control Circuits
Logic Circuits within the various modules will determine the starting, running, and stopping
operation of the chiller. When operation of the chiller is required the chiller mode is set at ‘‘Auto’’.
Using customer supplied power, the chilled water pump relay (5K1) is energized by the 1A5 Module
output at 1A5-J2-4, and chilled water flow must be verified within 4 minutes 15 seconds by the 1A6
Module. The main processors logic decides to start the chiller based on the differential to start
setpoint. With the differential to start criteria met module 1A5 then energizes condenser water
pump relay (5K2) via customer supplied power at 1A5 J2-1.
Based on the restart inhibit function and the differential to start setpoint, oil and refrigerant pump
(4M3) will be energized by 1A7 Module (1A7-J1). The oil pressure must be at least 9 Psid for
60 continuous seconds and condenser water flow verified within 4 minutes 15 seconds for the
compressor start sequence to be initiated.
When less than 2.5 seconds remain before compressor start, a starter test is conducted to verify
contactor states prior to starting the compressor. The following test or start sequence is conducted
for ‘‘Wye-Delta’’ starters (also refer to Figure 30, p. 65):
A. Test for transition complete contact open (2A1-J12-2) –160 to 240 msec. An MMR diagnostic
will be generated if the contact is closed.
B. Delay time - 20 msec.
C. Close start contactor (2K1) and check for no current - 500 msec. If currents are detected, the
MMR diagnostic ‘‘Starter Fault Type I’’ is generated.
D. Stop relay (2A1-J10-3 to 1) closes for one second for test “C” above.
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Control Sequence of Operation
E. Delay time - 200 msec. (Opens 2K1).
F.
Close shorting contactor, (2K3) and check for no current - one second. If currents are detected
the MMR diagnostic ‘‘Starter Fault Type II’’ is generated. (Starter Integrity test)
G. If no diagnostics are generated in the above tests, the Stop Relay (2A1-J10) is closed for
2 seconds and the Start Relay (2A1-J8) is closed to energize the start contactor (2K1). The
shorting contactor (2K3) has already been energized from (F) above. The compressor motor
(4M1) starts in the ‘‘Wye’’ configuration, an auxiliary contact (2K1-AUX) locks in the start
contactor (2K1) coil.
H. After the compressor motor has accelerated and the maximum phase current has dropped
below 85 percent of the chiller nameplate RLA for 1.5 seconds, the starter transition to the
‘‘Delta’’ configuration is initiated.
J. The transition contactor (2K4) is closed through relay 2A1-J2, placing the transition resistors
(2R1, 2R2, and 2R3) in parallel with the compressor motor windings. The run relay (2A1-J6-3
to 1) is closed.
K. The shorting contactor (2K3) is opened through the opening of relay 2A1-J4 100 msec after the
closure of the transition relay 2A1-J2, and the run relay 2A1-J6.
L. The run contactor (2K2) is closed through auxiliary contacts on the shorting contactor (2K3),
shorting out the transition resistors. This places the compressor motor in the ‘‘Delta’’
configuration and the starter module waits to look for this transition for about 2.3 seconds
through the closure of the transition complete contacts 2K2-Aux at module 2A1-J12 input).
M. The starter module must now confirm closure of the transition complete contact (2K2-AUX)
within 2.5 seconds after the shorting relay (2A1-J4) is opened. Finally, the transition relay
(2A1-J2) is opened de-energizing the transition contactor (2K4) and the compressor motor
starting sequence is complete. An MMR diagnostic will be generated if the transition complete
contacts (2K2-AUX) do not close. A diagram of this test or start sequence is shown in Figure 30,
p. 65.
Now that the compressor motor (4M1) is running in the ‘‘Delta’’ configuration, the inlet guide vanes
will modulate, opening and closing to the chiller load variation by operation of the stepper vane
motor actuator (4M2) to satisfy chilled water setpoint. The chiller continues to run in its appropriate
mode of operation: Normal, Softload, Limit Mode, etcetera.
If the chilled water temperature drops below the chilled water set point by an amount set as the
‘‘differential to stop’’ setpoint, a normal chiller stop sequence is initiated as follows: (Refer to
Figure 11, p. 19.)
1. The inlet guide vanes are driven closed up to 50 seconds.
2. After the inlet guide vanes are closed, the stop relay (2A1-J10) and the condenser water pump
relays (1A5-J2) open to turn off. The oil and refrigerant pump motor (4B3) will continue to run
for 3 minutes post lube while the compressor coasts to a stop. The chilled water pump will
continue to run while the Main processor module (1A22) monitors leaving chilled water
temperature preparing for the next compressor motor start based on the ‘‘differential to start’’
setpoint.
If the STOP key is pressed on the operator interface, the chiller will follow the same stop sequence
as above except the chilled water pump relay (1A5-J2) will also open and stop the chilled water
pump after the chilled water pump delay timer has timed out after compressor shut down.
If the “Immediate Stop” is initiated, a panic stop occurs which follows the same stop sequence as
pressing the STOP key once except the inlet guide vanes are not sequence closed and the
compressor motor is immediately turned off.
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Control Sequence of Operation
Figure 30. Test and start timing sequence
2K1
Start
Closed
C
G
Open
Closed
D
Open
Closed
Stop
Open
2K2 Run
Closed
E
2K3 Short
Open
F
Closed
Open
2K4 Transition
Transition
Complete
J
B
Input
Closed
Don’t Care
Don’t Care
Don’t Care
M
N
Open
K
A
H
L
Maximum Phase Current
< or = to 85% RLA
Timing requirements to operate the “Stop”, “Start”, “Short”, “Transition”, and “Run” contact closure
outputs are shown below. Prior to closing the “Short” contact, the transition complete input shall
be verified to be open, otherwise an MMR diagnostic shall be generated.
Steps A to F: Starter Integrity Test.
Steps F to N: Starter Timing
Interval
Min.
Max.
Units
Actual Design
A.
(Test for transition complete input open)
160 to 240 milliseconds
B.
(Just delay time)
20 milliseconds
C.
(Close 1M (2K1) Contactor and test for no current.) (Starter integrity test)
500 milliseconds
D.
(Hold 1M (2K1) Contactor and test for no current.) (Starter integrity test)
1 second
E.
(Open 1M (2K1) Delay time
200 milliseconds
F.
(Close Shorting Contactor (2K3) and test for no current, then wait for Start
command.) (Starter integrity test)
100
milliseconds
1 second (Minimum)
G.
(Close 1M (2K1)
2
second
2 second
H.
(Wait 1.5 seconds after phase currents drop to 85 percent)
1
2
second
1.5 second
J.
(Begin Transition sequence)
85
100
milliseconds
100 milliseconds
K.
(Open S (Shorting) Contactor)
250
300
milliseconds
260 milliseconds
L.
Close 2M (2K2) Contactor
140 milliseconds
M. (Wait to look for Transition complete)
milliseconds
2.32 to 2.38 second
N.
milliseconds
160 to 240 milliseconds
(Filtering time on Transition complete input)
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Control Sequence of Operation
Current passing through fuse 1F2 reaches 2 normally open parallel sets of contacts: those of
refrigerant and oil pump relay (1A7-J2-5 to 1), and the start contactor 2K1-aux. Connector at module
1A7-J2-2 to 4.
Note: While the (1A7-J2-5 to 1) relay automatically is closed by the main processor 1A22 as a part
of the start sequence. It can also be closed manually by changing the oil pump status to
“ON” in the manual over ride mode menu of DynaView.
Closure of the (1A7-J2-5 to 1), or 2K1 auxiliary contacts also allows current to pass through the coil
of the refrigerant pump starter relay (4K8), to the start windings of the refrigerant pump. When
motor 4M3 first starts, current draw is high: This causes current sensing relay 4K8 to close its
normally open contacts and pull in pump Capacitor 4C1. Increasing motor speed and related
decreasing current through the main winding and relay coil reduce the magnetic force and the
armature “Drops out” to open the start contacts and disconnect the start windings and capacitor.
Current now flows only to the Run windings of the oil pump motor or refrigerant and oil pump
motor.
Maximum Acceleration Timer Setting by Starter Type
Wye-Delta
Auto-Transformer
16
Primary Reactor
16
Across the Line
66
27 Seconds
6
Solid State
25
AFD
30
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Machine Protection and Adaptive Control
Momentary Power Loss (MPL) Protection
Improved power measurement and protection algorithms allow the unit to accommodate more
power anomalies than ever. If the chiller must shut down, faster restarts get the machine up and
running as soon as possible.
Momentary power loss (MPL) detects the existence of a power loss to the compressor motor and
responds by initiating the disconnection of the compressor motor from the power source. Power
interruptions of less than 30 line-cycles are defined as momentary power losses. Tests have shown
that these short-term power interruptions can be damaging to the motor and compressor if the
chiller is reconnected to the line while the motor and line phases do not match. The chiller will be
shut down when a MPL is detected and will display a non-latching diagnostic indicating the failure.
The oil pump will be run for the post-lube time period when power returns. The compressor and
compressor motor are protected from damage from large torques and inrush currents resulting
from reconnecting the compressor motor to the power source following a momentary loss of
power.
MPL’s greater than two or three cycles are detected resulting in unit shut down. Disconnection from
the line is initiated within six line cycles of the power loss. MPL protection is active anytime the
compressor is in the running mode. (The transition complete input has been satisfied).
MPL is enabled however can be disabled, if required via the service tool.
Figure 31. CVHE, CVHF, and CVHG Sequence of operation: Momentary power loss (DynaView and starter module
remain powered)
Momentary Power Loss Detected
Shutting Down
Running
Close IGV (0–50 Seconds)
MPL Cleared and Need to Cool
Waiting to Start
Starting
Cprsr
Establish Cond Water Flow (6 sec
Minimum)
Energize Condenser
Water Pump Relay
Command IGV Closed
Confirm Condenser Water
Flow Within 4 mins 15
seconds (6 Sec Filter)
Enforce Stop to Start Timer (5 to 200 Seconds, 30 is Default)
De-Energize
Compressor
Confirm No
Compressor Currents
Within 0–30 Seconds
De-Energize Condenser
Water Pump Relay
Current Overload Protection
Motor currents are continuously monitored for over current protection and locked rotor protection.
This protects the Chiller itself from damage due to current overload during starting and running
modes but is allowed to reach full load amps. This overload protection logic is independent of the
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Machine Protection and Adaptive Control
current limit. The overload protection will ultimately shut the unit down anytime the highest of the
three phase currents exceeds the time-trip curve. A manual reset diagnostic describing the failure
will be displayed.
Overload protection for the motor starts based on the Maximum Time to Transition permitted for
a particular motor.
Running Over Current Protection
In the run mode, a “time-to-trip” curve is looked at to determine if a diagnostic should be called.
The UCP continuously monitors compressor line currents to provide running over current and
locked rotor protection. Over current protection is based on the line with the highest current. It
triggers a manually resettable diagnostic shutting down the compressor when the current exceeds
the specified time-trip curve. The compressor overload time trip curve is expressed as a percent
of the Rated Load Amps of the compressor and is not adjustable:
Overload Must Hold = 102 Percent RLA.
Overload Must Trip in 20 (+0 -3) seconds = 112 Percent RLA
(Note the above gives a nominal 20 second must trip point of 107 Percent RLA.)
Overload Must Trip in 1.5 seconds = 140 Percent RLA (Nominal)
The linear time-trip curve is as follows:
Figure 32. Overload trip time versus percent RLA
Nominal Triptime (sec)
Minimum Triptime (sec)
Maximum Triptime (sec)
The Maximum Acceleration Time Setting and Current Transformer Setting are factory set; however,
they can also be set with the service tool.
Current Limit Protection
Current Limit Protections exist to avoid motor current overload and damage to the compressor
motor during starting and running. Compressor motor current is continuously monitored and
current is controlled via a limit function that to prevent running into over current diagnostic trips.
The current limit control logic attempts to prevent the motor from shutting down on a diagnostic
trip by limiting compressor current draw relative to an adjustable current limit DynaView Current
Limit Setpoint. This setpoint can also be lowered to provide electrical demand limiting on the unit
as required. This could also be set to allow the Chiller to continue to run at a lower load to avoid
tripping off via a diagnostic.
The Current Limit function uses a PID algorithm (similar to the Leaving Water Temperature control)
that allows the chiller to run at the Current Limit Setpoint. At machine startup, or with any setpoint
change the new current limit setpoint reached after the is filtered setpoint time elapses. The
minimum current limit setpoint is default set to 40 percent RLA (20 percent–100 percent). The
filtering time is default set to 10 minutes (0 minutes–120 minutes), however these can be altered
via the service tool. This filtered setpoint allows for stable control if the Current Limit setpoint is
adjusted during a run.
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Machine Protection and Adaptive Control
The Current Limit Setpoint (CLS) can be changed from: Front Panel, External Analog input (with
GBAS option), or Tracer (Tracer option). However, If present Tracer current setpoint has the highest
priority, unless disabled in the DynaView Setpoint source override menu. The External CLS has
second priority, and will be used if Tracer is disabled or not installed. The Front Panel Setpoint has
the lowest priority, and will be used if Tracer and the External CLS are both disabled.
Phase Loss Protection
Loss of phase detection protects the chiller motor from damage due to a single-phasing condition.
The controls will shut down the chiller if any of the three phase currents feeding the motor are lost.
The shutdown will result in a latching diagnostic indicating the failure. The motor is protected from
over-current during a single-phase condition by the Current Overload Protection feature. Phase
Loss Protection provides redundant protection and a diagnostic that more accurately describes the
fault.
Reverse Rotation Protection
This function protects the compressor from being driven in the reverse direction. Incorrect phase
rotation detection results in a manually resettable diagnostic. Phase Reversal protection is default
to Enable, however can be disabled via the service tool.
Phase Imbalance Protection
CH530 provides phase imbalance protection based on the average three-phase current. The three
phase currents supplied to the motor are monitored for unequal amperage draw. Motor overload
is not considered to be a problem since each phase of the motor is monitored for overcurrent. In
addition, since each phase is monitored for loss of current, the motor will be protected against
single phasing.
Under and Over Voltage Protection
Under/over voltage protection can be enabled (default) or disabled via TechView.
If Disabled: No effect.
If Enabled:
and an Overvoltage condition occurs:
•
Diagnostic called when the average of the three line voltages is greater than 112.5% of the unit
line voltage set point for 60 seconds.
•
Diagnostic cleared when the average of the three line voltages is 110% or less of the unit line
voltage set point.
and an Undervoltage condition occurs:
•
Diagnostic called when the average of the three line voltages is less than 87.5% of the unit line
voltage set point for 60 seconds.
•
Diagnostic cleared when the average of the three line voltages is 90% or greater of the unit line
voltage set point.
Differential to Start or Stop
The Differential to Start setpoint is adjustable from 1°F to 10°F (0.55°C to 5.55°C) and the Differential
to Stop setpoint adjustable from 1°F to 10°F (0.55°C to 5.55°C). Both setpoints are with respect to
the Active Chilled Water Setpoint. When the chiller is running and the LWT (Leaving Water
Temperature) reaches the Differential to Stop setpoint the chiller will go through its shutdown
sequence to AUTO. (Refer to Figure 11, p. 19.)
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Machine Protection and Adaptive Control
Softloading
Softloading stabilizes the startup control during the initial chiller pulldown. Softloading is used to
bring the building loop temperature from its start value to the Chilled Water or Hot Water Setpoint
in a controlled manner. Without soft loading, the chiller controls will load the chiller rapidly and use
the full chiller capacity to bring the loop temperature to setpoint. Although the start temperature
of loop may have been high, the actual system load may be low. Thus, when the setpoint is met
the chiller must unload quickly to the system load value. If it is not able to unload quickly enough,
the supply water temperature will drop below setpoint and may even cause the chiller to cycle off.
Softloading prevents the chiller from going to full capacity during the pulldown period. After the
compressor has been started, the starting point of the filtered setpoint is initialized to the value of
the Evaporator Leaving Water temperature and the percent RLA.
There are three independent Softload setpoints:
•
Capacity Control Softload Time (default to 10 minutes, 0 minutes–120 minutes) This setting
controls the time constant of the Filtered Chilled Water Setpoint.
•
Current Limit Control Softload Time (default 10 minutes; 0 minutes–120 minutes) This Setting
controls the time constant of the Filtered Current Limit Setpoint.
•
Current Limit Softload Starting Percent (default is 40 percent RLA; 20 percent–100 percent):
This setting controls the Starting point of the Filtered Current Limit Setpoint
Service tool provides access to these three setpoints, if it is determined necessary to change from
the defaults.
Softloading is not active during Ice Making or during the Ice To normal Transition. Softloading will
be enabled after the Ice to normal Transition timer has expired.
Softloading is not active during Free Cooling, The softloading is active during the transition from
Free Cooling to Powered operation.
Softloading times can be active during Hot Gas Bypass Control
Minimum and Maximum Capacity Limit
A Minimum Capacity can be set to limit the unloading ability of the compressor thus forcing
differential to stop to be reached cycling the chillers. Minimum capacity limit will be displayed
when in this limit mode. This indicates when the chiller is running fully unloaded.
Similarly a maximum capacity can be set to limit normal chilled water temperature control, the
maximum capacity relay is energized which is a signal used by generic BAS systems to start
another chiller.
The minimum (default at 0 percent) and maximum (default at 100 percent) capacity are adjustable
via the service tool.
Evaporator Limit
Evaporator refrigerant temperature is continuously monitored to provide a limit function that
prevents low refrigerant temperature trips which allows the chiller to continue to run at a reduced
load instead of tripping off at the Low Evaporator Refrigerant Temperature Cutout Setpoint (LRTC).
Evaporator limit could occur with an initial pull down of a loop where the Condenser is colder than
the Evaporator (Inverted Start), the Evaporator refrigerant temperature may drop below the Low
Refrigerant Temperature Cutout (LRTC). This limit prevents the unit from shutting down on a
diagnostic during this type of pulldown. Another example is a Chiller that is low on refrigerant
charge will run with low Evaporator refrigerant temperatures. This limit allows the chiller to
continue to run at a reduced load.
Evaporator Limit uses the Evaporator Refrigerant Temperature sensor in a PID algorithm (Similar
to the Leaving Water Temperature control) that allows the chiller to run at the LRTC +2°F.
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Machine Protection and Adaptive Control
When actively limiting machine control “Evaporator Temperature Limit” will be displayed as a suboperating mode.
Leaving Water Temperature Cutout
Leaving water temperature cutout is a safety control that protects the chiller from damage caused
by water freezing in the evaporator. The cutout setpoint is factory set however is adjustable with
the Service tool.
The “Leaving Water Temperature Cutout Setpoint” is independently adjustable from the chilled
water setpoint and factory set. Shutdown of the compressor due to violation of the Leaving Water
Temperature Cutout results in an automatically resettable diagnostic (MAR). The DynaView
Operating Mode indicates when the “Leaving Water Temperature Cutout Setpoint” conflicts with
the chilled water temperature setpoint by a message on the display. The “Leaving Water
Temperature Cutout Setpoint” and chilled water setpoint, both active and front panel, are
separated by a minimum of 1.7°F. See Cutout Strategy, Figure 33, p. 72. When either difference is
violated, the UCP does not permit the above differences to be violated and the display exhibits a
message to that effect and remains at the last valid setpoint. After violation of the “Leaving Water
Temperature Cutout Setpoint” for 30°F seconds the chiller will shutdown and indicate a diagnostic.
High Evaporator Leaving Water Temperature Cutout
(Main Processor Software Revision 6.0 and higher)
A High Evaporator Water Temperature Diagnostic was implemented that will turn off the
Evaporator Water pump relay if the relay is being forced on due to a Loss of Evaporator Water Flow
Lost diagnostic (MAR Diagnostic) and the Evaporator Leaving Water Temperature exceeds an
adjustable High Evaporator Water Temperature Cutout for 15 continuous seconds. The High
Evaporator Water Temperature diagnostic is an immediate shutdown and is nonlatching. The
diagnostic will auto reset and the pump will return to normal control when the temperature falls
5°F below the cutout setting. High Evaporator Water Temperature Cutout is a setpoint that is
adjustable in TechView from 80°F and 150°F. The default is 105°F.
Low Refrigerant Temperature Cutout
The purpose of the low evaporator refrigerant temperature protection is to prevent water in the
evaporator from freezing. When the Low Evaporator Refrigerant Temperature Cutout (LRTC) trip
point is violated, a latching diagnostic indicating the condition is displayed. The Low Evaporator
Refrigerant Temperature Diagnostic is active in both the Running and Stopped modes.
The Low Evaporator Refrigerant Cutout Setpoint is factory set to 36°F. This can be altered via the
service tool. A Service Tool adjustable setpoint that should be based on the percentage of antifreeze
used in the customer’s water loop. The Service tool will display a warning message such as
“Warning: Adequate Antifreeze required” for any Evaporator Refrigerant Temperature Cutout
below 28°F and any Leaving Water Temperature Cutout below 35°F.
The percent of antifreeze required is a function of the leaving water temperature setpoint and the
worse case (lowest permitted water flow) approach temperatures of the chiller’s evaporator design.
Head Relief Relay
Note: See also: “Head Relief Request Output,” p. 54.
Surge, condenser limit, and certain conditions on ice mode will energize the head relief relay.
Note: There is a TechView programmable head relief relay filter times setpoint. The default is one
minute.
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Machine Protection and Adaptive Control
Figure 33. Cutout strategy
Cutout Strategy
Chilled Water Setpoint
Differential to Stop
Adjustment Range
2°F (1.1°C)
Evap Leaving Water Temp Cutout
Integrate to Trip
Limit Loading
Evap
Evap Limit Stpt
Limit
Unload
Integrate to Trip
Evap Rfgt Temp Cutout
Limit Loading: The potential to limit loading increases as the saturated evaporator temperature
approaches the evaporator limit setpoint.
Unload: The potential to unload increases as the saturated evaporator temperature falls further
below the evaporator limit setpoint.
Figure 33 illustrates these functions as follows:
•
chilled water setpoint
•
evap leaving water temp cutout
•
evap rfgt temp output
Evaporator Variable Flow Compensation
This option includes transducers for the differential evaporator and condenser water pressures
(psid). Flow switches or some other means to prove flow are still required and must be field
connected.
The following data will be shown at the DynaView and TechView displays and at Tracer Summit.
72
•
Evaporator and condenser differential water pressures (psid)
•
Evaporator and condenser gpm
•
Evaporator tons
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Machine Protection and Adaptive Control
How It Works
The Tracer chiller controller uses a patented, variable, water-flow compensation algorithm to
maintain stable, precise capacity control. Variable flow compensation is a new optional control
feature for CTV chillers.
It will automatically adjust capacity control to:
•
Maintain control stability at low flow.
•
Reject variable-flow disturbance.
If the water-pressure transducer fails and the flow switch continues to prove flow, water-flow
compensation will be disabled and the design delta T will be used.
For applications designed to operate with variable-primary (VPF) water-flow, variable flow
compensation allows the chiller to respond quickly to accelerating or decelerating water. By
automatically adjusting the control gain, large changes in the water-flow rate can be tolerated.
For details, refer to CTV-PRC007-EN.
Condenser Limit
Condenser pressure is continuously monitored to provide a limit function that prevents High
Pressure Cutout (HPC) trips. This protection is called Condenser Refrigerant Pressure Limit, or High
Pressure Limit. A fully loaded compressor, operating at high Evaporator Leaving Water
Temperature (ELWT) and high condenser temperatures causes high condenser pressures. The
purpose of this limit is to avoid High Pressure Cutout (HPC) trips by allowing the Chiller to continue
to run at a lower load instead of tripping off via HPC.
The Condenser Limit will be based from a pressure conversion from the Condenser Refrigerant
Temperature sensor, unless there is a Condenser Refrigerant Pressure sensor installed (CDRP
option). If the Condenser Refrigerant Pressure Sensor is installed, then the limit will be based from
the Pressure sensor.
When limited by this action, “Condenser Pressure Limit” will be displayed as a sub-operating
mode. The Condenser Limit Setpoint is factory set (93 percent of HPC), however can be altered via
the service tool.
Restart Inhibit
This function provides short cycle protection for the motor, and indirectly also short cycling
protection for the starter since the starter is designed to operate the motor under all the conditions
of motor performance.
The operation of the restart inhibit function is dependent upon two setpoints. The Restart Inhibit
Free Starts (1–5, 3 default), and the Restart Inhibit Start to Start Timer (10–30 min, 20 default). These
settings are adjustable via the service tool.
Restart Inhibit Free Starts
This setting will allow a number of rapid restarts equal to its value. If the number of free starts is
set to “1”, this will allow only one start within the time period set by the Start to Start Time Setting.
The next start will be allowed only after the start to start timer has expired. If the number of free
starts is programmed to “3”, the control will allow three starts in rapid succession, but thereafter,
it would hold off on a compressor start until the Start to Start timer expired. I.e., with three free
starts and 20 minute restart inhibit settings, it will take 60 minutes of run time to restore the total
of three free starts.
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Machine Protection and Adaptive Control
Restart Inhibit Start to Start Time Setting
This setting defines the shortest chiller cycle period possible after the free starts have been used.
If the number of free starts is programmed to “1”, and the Start to Start Time Setting is programmed
to 10 minutes, then the compressor will be allowed one start every 10 minutes. The start-to-start
time is the time from when the motor was commanded to energize to when the next command to
enter prestart is given.
Clear Restart Inhibit
A Clear Restart Inhibit “button” is provided within Settings; Manual Override on the DynaView
display. This provides a way for an operator to allow a compressor start when there is a currently
active Restart Inhibit that is prohibiting such a start. The “button” press will have no other function
than to remove the restart inhibit if there is one active. It does not change the count of any internal
restart inhibit timers or accumulators. command, but is inhibited, pending the expiration of the
timer.
The restart inhibit function, setpoints and clear features exist for each compressor and operate
independently of other compressors on that chiller.
During the time the start is inhibited due to the start-to-start timer, the DynaView shall display the
mode ‘Restart Inhibit’ and the also display the time remaining in the restart inhibit.
A “Restart Inhibit Invoked” warning diagnostic will exist when the attempted restart of a
compressor is inhibited.
If all three motor winding temperatures are less than the “Restart Inhibit Temperature” Setpoint
(default 165°F/74°C) then restart is allowed.
Restart inhibit mode exist when at least one of the three motor winding temperatures is greater
than or equal to the “Restart Inhibit Temperature” Setpoint but less than 265°F/129.4°C. Restart
inhibit mode is entered until all three motor winding temperatures are less than the ‘Restart Inhibit
Temperature’ Setpoint.
Notes:
•
When one of the three motor winding temperatures is 265°F/129.4°C or greater, a High Motor
Winding Temperature diagnostic shall be called.
•
When the start is inhibited by the restart inhibit function, the time remaining will be displayed
along with the restart inhibit mode.
High Vacuum Lockout
The oil sump pressure is below the lockout setpoint. Starting of compressor is inhibited as a result.
Low Oil Temperature Start Inhibit
The oil temperature is at or below the low oil temperature start inhibit setpoint (143°F/61.7°C). The
heater is energized to raise the oil temperature.
Low oil temperature is indicative of refrigerant dilution in the oil. Oil temperature is used to
estimate this dilution since the oil temperature directly corresponds to amount of refrigeration
dilution in the oil. It is required that oil contains minimal refrigerant in it. This is accomplished by
boiling the refrigerant out of the oil by maintaining a high enough oil temperature.
If the oil temperature is at or below a given Low Oil Temperature Inhibit setting (default 95°F/35°C)
the compressor cannot be started. This is an inhibit mode and will be reported to the operator
interface. The oil heater is energized in an attempt to raise the oil temperature over this inhibit
temperature setpoint. The compressor is inhibited from starting until the oil temperature is raised
five or more degrees above this setpoint.
The Low Oil Temperature Start Inhibit is tested on every start unless a quick restart is being
performed during post lube.
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If the Enhanced Oil Temperature Protection setting is enabled, the Low Oil Temperature Start Inhibit
value is the greater of 100°F/37.8°C or the Saturated Evaporator Refrigerant Temperature +30°F/
16.7°C.
If the Enhanced Oil Temperature Protection setting is not enabled, the Low Oil Temperature Start
Inhibit value is settable with the Low Oil Temperature Start Inhibit Setpoint via the service tool.
Oil Temperature Control
The oil heater is used to maintain the oil temperature within ± 2.5°F (1.4°C) of the oil temperature
control setpoint. The oil heater is commanded off when the oil pump is commanded on.
If the oil temperature is at or below the Low Oil Temperature Cutout setpoint, this diagnostic will
be issued and stops the compressor.
This diagnostic is ignored for the first 10 minutes of compressor run. After that, if the oil
temperature falls below this cutout temperature for more than 60 consecutive seconds, this
diagnostic is issued.
High Oil Temperature Cutout
Name: High Oil Temperature Cutout
Type of Diagnostic: Latching, results in Immediate Shutdown.
Default Setpoint value: 180°F (82.2°C)
Implemented to avoid overheating of the oil and the bearings.
If the oil temperature is at or above the High Oil Temperature Cutout setpoint this diagnostic will
be issued - which will stop the compressor.
If Oil Temperature violates this temperature cutout for more than 120 seconds this diagnostic is
issued.
Manual Oil Pump Control
The oil pump control accepts commands to turn on the oil pump. The manual oil pump choices will
be “Auto” or “On”. When the oil pump is commanded “On”, it will revert to “Auto” in 15 minutes.
Controls Chilled Water Reset (CWR)
Chilled water reset is designed for those applications where the design chilled water temperature
is not required at partload. In these cases, the leaving chilled water temperature setpoint can be
reset upward using the CWR features.
When the CWR function is based on return water temperature, the CWR feature is standard.
When the CWR function is based on outdoor air temperature, the CWR feature is an option
requiring an outdoor temperature sensor module installed in the UCP panel, and sensor installed
outdoors.
The type of CWR is selected in the Operator Interface settings Menu along with the Reset Ratio,
Start Reset Setpoint, and the Maximum Reset Setpoint.
The following equations and parameters apply for CWR.
Return Water
CWS’ = CWS + RATIO (START RESET - TWE - TWL) and CWS’ > or = CWS and CWS’ - CWS < or =
Maximum Reset.
Outdoor Air Temperature
CWS = CWS + RATIO (START RESET - TOD) and CWS’ > or = CWS and CWS - CWS < or = Maximum
Reset.
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Machine Protection and Adaptive Control
Where
CWS’ is the new chilled water setpoint.
CWS is the active chilled water setpoint before any reset has occurred.
RESET RATIO is a user adjustable gain.
START RESET is a user adjustable reference.
TOD is the Temperature Outdoor Sensor.
TWE is entering evaporator water temperature.
TWL is the Leaving Evaporator Temperature.
MAXIMUM RESET is a user adjustable limit providing the maximum amount of reset. For all types
of reset, CWS - CWS < or = Maximum Reset.
Both Return and Outdoor Reset do not apply to Heating Mode where the UCP is controlling the
Leaving Condensing Hot Water Temperature.
Constant Return Reset will reset the leaving water temperature setpoint so as to provide a constant
entering water temperature. The Constant Return Reset equation is the same as the Return Reset
equation except on selection of Constant Return Reset, the UCP shall automatically set RATIO,
START RESET, and MAXIMUM RESET to the following:
The RATIO = 100 percent
The START RESET = Design Delta
Temperature
The MAXIMUM RESET = Design
Delta Temperature
The equation for Constant Return is as follows:
Table 1.
Values for start reset types
The values for “RESET TYPE” are:
Reset Type
Disable
Outdoor Air Reset
Return Reset
Const Return Reset
Factory Default Value
The values for “RESET RATIO” for each of the reset types are:
Reset Type
Reset Ratio Range
Increment English Units
Increment SI Units
Return
10 to 120 percent
1 percent
1 percent
50 percent
Outdoor
-80 to 80 percent
1 percent
1 percent
10 percent
The values for “START RESET “ for each of the reset types are:
Reset Type
Start Reset Range
Increment English Units
Increment SI Units
Factory Default Value
Return
4°F to 30°F (2.2°C to 16.7°C)
0.1°F
0.1°C
10°F (5.6°C)
Outdoor
50°F to 130°F (10°C to 54.44°C) 0.1°F
0.1°C
90°F (32.22°C)
Factory Default Value
The values for “MAXIMUM RESET” for each of the reset types are:
Reset
Maximum Reset Range
Increment English Units
Increment SI Units
Return
0°F to 20°F (0.0°C to 11.11°C)
0.1°F
0.1°C
5°F (2.78°C)
Outdoor
0°F to 20°F (0.2°C to 11.11°C)
0.1°F
0.1°C
5°F (2.78°C)
Constant Return
CWS’ = CWS + 100 percent
(Design Delta Temperature) - (TWE-TWL) and CWS’ > or = CWS and CWS’ -CWS < or = Maximum
Reset
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Machine Protection and Adaptive Control
Notice that Constant Return is nothing more than a specific case of Return Reset offered for
operator convenience.
When any type of CWR is enabled, the UCP will step the CWS toward the desired CWS (based on
the above equations and setup parameters) at a rate of 1°F every five minutes until the Active CWS
equals the desired CWS’. This applies when the chiller is running only.
Using the Equation for calculating CWR for Outdoor Air Temperature
Equation
Degrees of Reset = Reset Ratio * (Start Reset - TOD)
The chiller will start at the Differential to Start value above a fully reset CWS or CWS for both Return
and Outdoor Reset.
Figure 34, p. 78 shows the reset function for Outdoor Air Temperature.
Note: This graph assumes that Maximum Reset is set to 20 degrees.
Degrees of Reset
Degrees of Reset = Active CWS - Front Panel CWS
or
Degrees of Reset = CWS’ - CWS
To obtain Active CWS from Degrees of Reset: Active CWS = Degrees of Reset + Front Panel CWS
Reset Ratio
The Reset Ratio is displayed as a percentage. To use it in the above equation it must be converted
to its decimal form.
Reset Ratio percent /100 = Reset Ratio decimal
Example of converting Reset Ratio:
If the Reset Ratio displayed on the CLD is 50 percent then use (50/100) = 0.5 in the equation
TOD = Outdoor Air Temperature
Start Reset = Outdoor Air Start Reset
Example of Calculating Reset for Outdoor Air Temperature:
If:
Reset Ratio = 35 percent
Start Reset = 80
TOD = 65
Maximum Reset = 10.5
How many Degrees of Reset will there be?
Degrees of Reset = Reset Ratio * (Start Reset - TOD)
Degrees of Reset = 0.35 * (80 - 65)
Degrees of Reset = 5.25
If:
Reset Ratio = -70 percent
Start Reset = 90
TOD = 100
Maximum Reset = 17
How many Degrees of Reset will there be?
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Machine Protection and Adaptive Control
Degrees of Reset = Reset Ratio* (Start Reset - TOD)
Degrees of Reset = -7 * (90 - 100)
Degrees of Reset = 7
Figure 34. Outdoor air temperature versus degrees of reset
Reset Ratio
Outdoor Air Temp vs Degrees of Reset
Degrees of Reset (F)
100 Degree Start Reset
90 Degree Start Reset
80 Degree Start Reset
70 Degree Start Reset
60 Degree Start Reset
Outdoor Air Temp (F)
Figure 35. Reset function for return CWR
Degrees of Reset vs Outdoor Air Temp
Positive Reset Ratio
Negative Reset Ratio
Degrees of Reset (F)
Maximum Reset
Start Reset (F)
Reset Ratio
Outdoor Air Temp
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Machine Protection and Adaptive Control
Figure 36. Reset function for return CWR
30 deg Start Reset
20 deg Start Reset
10 deg Start Reset
Degrees of Reset
Return CWR
TWE-TWL
Note: This figure assumes Maximum Reset is set to 20 degrees.
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Machine Protection and Adaptive Control
Example of Calculating Return Reset:
If:
Reset Ratio = 50%
Start Reset = 25
TWE = 65
TWL = 45
Maximum Reset = 8
How many Degrees of Reset will there be?
Degrees of Reset = Reset Ratio * (Start Reset - (TWE - TWL))
Degrees of Reset = 0.5 * (25 - (65 - 45))
Degrees of Reset = 2.5
If:
Reset Ratio = 70%
Start Reset = 20
TWE = 60
TWL = 53
Maximum Reset = 14
How many Degrees of Reset will there be?
Degrees of Reset = Reset Ratio * (Start Reset - (TWE - TWL))
Degrees of Reset = 0.7 * (20 - (60 - 53))
Degrees of Reset = 9.1
Figure 37. Return CWR
Degrees of Reset
Return CWR
(TWE-TWL)
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Machine Protection and Adaptive Control
Figure 38. Constant CWR
10 Degree Design Delta Temp
Degrees of Reset
Constant CWR
TWE-TWL
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Unit Startup
Unit Start-Up Procedures
Daily Unit Start-Up
1. Verify the chilled water pump and condenser water pump starter are in “ON” or “AUTO”.
2. Verify the cooling tower is in “ON” or “AUTO”.
3. Check the oil tank oil level; the level must be visible in or above the lower sight glass. Also, be
sure to check the oil tank temperature; normal oil tank temperature before start-up is 140°F to
145°F (60°C to 63°C).
Note: The oil heater is energized during the compressor off cycle. During unit operation, the oil
tank heater is de-energized.
4. If the chiller is equipped with the free cooling option, ensure that the free cooling option is
disabled in the Chiller Settings menu.
5. Check the chilled water setpoint and readjust it, if necessary, in the Chiller Settings menu.
6. If necessary, readjust the current limit setpoint in the Chiller Setpoints menu.
7.
Press “AUTO”.
The UCP also checks compressor motor winding temperature, and a start is initiated if the winding
temperature is less than 265°F. The chilled water pump relay is energized and evaporator water flow
is proven.
Next, the UCP checks the leaving evaporator water temperature and compares it to the chilled water
setpoint. If the difference between these values is less than the start differential setpoint, cooling
is not needed.
If the UCP determines that the difference between the evaporator leaving water temperature and
chilled water setpoint exceeds the start differential setpoint, the unit enters the initiate Start Mode
and the oil pump and Refrigerant pump and the condenser water pump are started. If condenser
water flow is not proven (flow switch 5S3 does not close) within 4 minutes 15 seconds, the unit is
locked out on an MMR Diagnostic.
Oil pressure must be verified within three minutes or an MMR diagnostic is generated.
When less than five seconds remain on the restart inhibit, the pre-start starter test is conducted on
Y-Delta starters. If faults are detected, the unit’s compressor will not start, and an MMR Diagnostic
will be generated.
If the compressor motor starts and accelerates successfully, “Unit is Running” appears on the
display. At this time the purge unit will start operating on “Automatic” and will continue to operate
as long as chiller compressor is running.
Note: Whenever the UCP detects an MMR diagnostic condition during start-up, unit operation is
locked out, and manual reset is required before the start-up sequence can begin again. If the
fault condition has not cleared, the UCP will not permit restart.
When the cooling requirement is satisfied, the UCP originates a “Shutting down” signal. The inlet
guide vanes are driven closed for 50 seconds, and the unit enters a three-minute post-lube period.
The compressor motor and condenser water pump starter are de-energized immediately, but the
oil pump continues to run during this three-minute interval; the evaporator pump will continue to
run.
Once the post-lube cycle is done, the unit returns to auto mode.
Seasonal Unit Start-Up
1. Close all drain valves, and re-install the drain plugs in the evaporator and condenser headers.
2. Service the auxiliary equipment according to the start-up and maintenance instructions
provided by the respective equipment manufacturers.
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Unit Startup
3. Vent and fill the cooling tower, if used, as well as the condenser and piping. At this point, all air
must be removed from the system (including each pass). Then close the vents in the condenser
water boxes.
4. Open all of the valves in the evaporator chilled water circuit.
5. If the evaporator was previously drained, vent and fill the evaporator and chilled water circuit.
When all air is removed from the system (Including each pass), close the vent valves in the
evaporator water boxes.
6. Lubricate the external vane control linkage as needed.
7.
Check the adjustment and operation of each safety and operating control.
8. Close all disconnect switches.
9. Perform instructions listed in “Daily Unit Start-Up,” p. 82.
 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.
 WARNING
Toxic Hazards!
•
Do not run evaporator water pump longer than 30 minutes after the chiller is shutdown.
•
Ensure that the evaporator is isolated from the hot water loop before changeover to heating
mode.
Do not allow the chiller to increase above 110°F in temperature while unit is off. Failure to
prevent high chiller temperature will cause the inside pressure to rise. The rupture disk is
designed to relieve and discharge the refrigerant from the unit if the pressure in the evaporator
exceeds 15 PSIG (103.4 Kpa). A significant release of refrigerant into a confined space due to a
rupture disk failure could displace available oxygen to breathe and cause possible asphyxiation.
Should a rupture disk fail, evacuate the area immediately and contact the appropriate rescue or
response authority. Failure to take appropriate precautions or react properly to a potential
hazard could result in death or serious injury.
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Unit Shutdown
Unit Shutdown Procedures
Daily Unit Shutdown
Note: Refer to Start-Run Shutdown sequence in Figure 8, p. 18.
1. Press STOP.
2. After compressor and water pumps shutdown turn Pump Contactors to OFF or open pump
disconnects.
Seasonal Unit Shutdown
NOTICE
Oil Pump Heater Operation!
CONTROL POWER DISCONNECT SWITCH MUST REMAIN CLOSED TO ALLOW OIL SUMP
HEATER OPERATION. Failure to do this will allow refrigerant to condense in the oil pump.
3. Open all disconnect switches except the control power disconnect switch.
4. Drain the condenser piping and cooling tower, if used. Rinse with clean water.
5. Remove the drain and vent plugs from the condenser headers to drain the condenser. Air dry
bundle of residual water.
6. Once the unit is secured for winter, the maintenance procedures described under “Annual
Maintenance,” p. 86 in “Periodic Maintenance,” p. 85 should be performed by qualified Trane
service technicians.
Note: During extended shutdown, be sure to operate the purge unit for a 2-hour period every
two weeks. This will prevent the accumulation of air and noncompensable in the machine.
To start the purge, change the purge mode to ON in the DynaView Settings Purge Menu.
Remember to turn the purge mode to Adaptive after the 2-hour run time.
Trouble Analysis
If the ALARM indicator on the control panel is flashing, an MMR diagnostic has occurred. Refer to
“Diagnostic Screen,” p. 37 for trouble shooting information.
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Periodic Maintenance
Overview
This section describes the basic chiller preventive maintenance procedures, and recommends the
intervals at which these procedures should be performed. Use of a periodic maintenance program
is important to ensure the best possible performance and efficiency from a CenTraVac chiller.
Recommended purge maintenance procedures for the Purifier Purge unit are covered by
PRGD-SVU01A-EN or the latest revision which can be obtained at the nearest Trane office.
Record Keeping Forms
An important aspect of the chiller maintenance program is the regular completion of records.
Copies of the “Annual Inspection Check List and Report”, “CenTraVac with UCP Commissioning
Checklist and ‘‘Start-Up Test Log’’, a ‘‘Start-Up Test Log for Water Cooled CenTraVacs with UCP
Control Panels’’, and ‘‘UCP ‘‘Settings Group’’ Menu Record’’ are provided in “Forms,” p. 102. When
filled out accurately by the machine operator, the completed logs can be reviewed to identify any
developing trends in the chiller’s operating conditions.
For example, if the machine operator notices a gradual increase in condensing pressure during a
month’s time, he can systematically check, then correct the possible cause(s) of this condition
(fouled condenser tubes, noncondensable in the system, etcetera)
Daily Maintenance and Checks
[ ] Check the chiller’s evaporator and condenser pressures, oil tank pressure, differential oil
pressure and discharge oil pressure. Compare the readings with the values provided in the Normal
Chiller Operating Characteristics table.
Important:
IT IS HIGHLY RECOMMENDED THAT THE OPERATING LOG BE COMPLETED ON A
DAILY BASIS.
Normal Chiller Operating Characteristics
Operating Characteristic
Normal Reading
Approx. Evaporator Pressure
(6 to 9 PSIA) (-9 to -6 PSIG)
Approx. Condenser Pressure
(17 TO 27 PSIA) 2 to 12 PSIG (Standard Condensers)
Oil Sump Temperature
Unit Not Running
140°F to 145°F (60°C to 63°C)
Unit Running
80°F to 162°F (26.6°C to 72°C)
Differential Oil Pressure
18 to 22 psid
Notes:
1. Condenser pressure is dependent on condenser water temperature, and should equal the saturation pressure of
HCFC-123 at a temperature above that of leaving condenser water at full load.
2. Normal pressure readings for ASME condensers exceed 12 PSIG.
3. Oil Tank Pressure 12” to 18” HG Discharge Oil Pressure 7 to 15 PSIG.
NOTICE
Moisture Contamination!
IF FREQUENT PURGING IS REQUIRED, MONITOR PURGE PUMPOUT RATE, IDENTIFY AND
CORRECT SOURCE OF AIR OR WATER LEAK AS SOON AS POSSIBLE. Failure to do so can
shorten chiller life expectancy, due to moisture contamination caused by leakage.
[ ] Check the oil level in the chiller oil sump using the two sight glasses provided in the oil sump
head. When the unit is operating, the oil level should be visible in the lower sight glass.
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Periodic Maintenance
 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-SVB06A-FR.
Weekly Maintenance
[ ] Complete all recommended daily maintenance procedures and checks. Complete logs on a daily
basis.
Every 3 Months
[ ] Complete all recommended weekly maintenance procedures. Refer to the previous sections for
details.
[ ] Clean all water strainers in the CenTraVac water piping system.
Every 6 Months
[ ] Complete all recommended quarterly maintenance procedures.
[ ] Lubricate the vane control linkage bearings, ball joints, and pivot points; as needed a few drops
of light machine oil (SAE-20) is sufficient.
[ ] Lubricate vane operator tang
O-rings as described in the maintenance section.
[ ] Lubricate the oil filter shutoff valve O-rings by removing the pipe plug and adding several drops
of Trane OIL00022. Replace plug.
[ ] Drain the contents of the rupture disc and purge discharge ventline drip-leg, into an evacuated
waste container minimally and more often if the purge is operated excessively.
Also, apply one or two drops of oil on the vane operator shaft and spread it into a very light film;
this will protect the shaft from moisture and rust.
Off-Season Maintenance
During those periods of time when the chiller is not operated, be sure the control panel is energized.
This is to keep the purge operational, the oil heater warm and will also keep air out of the machine.
Annual Maintenance
Shut down the chiller once each year to check the items listed; a more detailed inspection checklist
is provided on the ‘‘Model CVHE, CVHF, and CVHG CenTraVac Annual Inspection Checklist and
Report’’ in “Forms,” p. 102.
[ ] Perform the annual maintenance procedures referred to in the Maintenance Section of the purge
manual.
[ ] Use an ice water bath to verify that the accuracy of the evaporator refrigerant temperature sensor
(4R10) is still within tolerance (± 2.0°F at 32°F [1°C at 0°C]). If the evaporator refrigerant temperature
displayed on the UCP’s read-out is outside this 4-degree tolerance range, replace the sensor.
Note: If the sensor is exposed to temperature extremes outside its normal operating range (0°F
to 90°F) (-18°C to 32°C), check its accuracy at six-month intervals.
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Oil Maintenance
Compressor Oil Change on CVHE, CVHF, CVHG
After the first 6 months or 1000 hours operation, whichever comes first, it is recommended to
change the oil and filter. After this oil change, recommendations are to subscribe to an annual oil
analysis program rather than automatically change the oil as part of scheduled maintenance.
Change the oil only if indicated by the oil analysis. Use of an oil analysis program will reduce the
chillers overall lifetime waste oil generation and minimize refrigerant emissions. The oil analysis
should be performed by a qualified laboratory that is experienced in refrigerant and oil chemistry
and in the servicing of Trane centrifugal chillers.
In conjunction with other diagnostics performed by a qualified service technician, oil analyses can
provide valuable information on the performance of the chiller to help minimize operating and
maintenance costs and maximize it’s operating life. A drain fitting is installed in the oil filter top,
after the oil filter, for obtaining oil samples.
Note: Use only Trane OIL00022. A full oil change is 9 gallons of OIL00022.
Oil Change Procedure
When oil analysis indicates the need to change compressor oil, use the following procedure for
removing oil.
NOTICE
Heater Damage!
The oil sump heater must be de-energized before draining the sump. Failure to do so could burn
out the oil sump heater.
[ ] Draw the oil from the chiller through the oil charging valve on the chiller oil sump into an
approved, evacuated tank; or,
[ ] Pump the oil from the chiller through the oil charging valve into an airtight resealable container,
using a magnetically-driven auxiliary pump.
Forcing the oil from the oil sump by pressurizing the chiller (by raising chiller temperature or adding
nitrogen) is not recommended.
Refrigerant dissolved in the oil can be removed and returned to the chiller by using an appropriate
deep-vacuum recovery unit and heating and agitating the oil container. Follow all Federal, State
and Local regulations with regard to disposal of waste oil.
Replacing Oil Filter
Replace oil filter: (1) annually, (2) at each oil change, (3) or if erratic oil pressure is experienced
during chiller operation.
Oil Filter Replacement
Use the following procedure to service the oil filter.
1. Run the oil pump for two to three minutes to insure that the oil filter is warmed up to the oil
sump temperature.
2. Turn the oil pump motor off.
3. Pull the “D” handle on the rotary valve locking pin out of its detent and rotate the valve to the
“DRAIN” position. An offset pointer is located on top of the valve with wrench flats to allow
turning. The spring force on the locking pin should allow the pin to drop into a detent at this
position.
4. Allow at least 15 minutes for the oil to drain from the filter back into the oil sump.
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Oil Maintenance
5. Pull the “D” handle to unlock the pin and rotate the valve to the “Change Filter” position. This
isolates the filter from the unit. The locking pin should drop into a detent in this position.
6. Remove and replace the filter as quickly as possible. Tighten filter 2/3- to 3/4-turn per
instructions written on the filter. Place the used filter in a reusable container. Follow all local,
state and federal regulations to dispose of the filter. Pull the “D” handle to unlock the pin and
rotate the valve to the “RUN” position. The locking pin should drop into a detent in this position.
The chiller is now ready for operation.
7.
Purge unit.
8. Check oil pressure 18 psi–22 psi.
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Maintenance
Other Maintenance Requirements
Compressors using new seal technology will not use O-rings. The O-ring has been replaced by
Loctite® 515 applied at a minimum film thickness of 0.010 applied across the width of the flange.
The current jack bolt holes remain for disassembly.
NOTICE
Oil Supply System Problems!
Plugging of oil supply system could lead to bearing failure. Failure to use care could result in
Loctite getting into the chiller which could cause problems with the oil supply system and
eductor system.
[ ] Inspect the condenser tubes for fouling; clean if necessary.
 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-SVB06A-FR.
[ ] Measure the compressor motor winding resistance to ground; a qualified service technician
should conduct this check to ensure that the findings are properly interpreted.
Contact a qualified service organization to leak-test the chiller; this procedure is especially
important if the system requires frequent purging.
[ ] Use a nondestructive tube test to inspect the condenser and evaporator tubes at 3-year intervals.
Note: It may be desirable to perform tube tests on these components at more frequent intervals,
depending upon chiller application. This is especially true of critical process equipment.
[ ] Depending on chiller duty, contact a qualified service organization to determine when to conduct
a complete examination of the unit to discern the condition of the compressor and internal
components.
Note: (a) Chronic air leaks, which can cause acidic conditions in the compressor oil and result in
premature bearing wear; and, (b) Evaporator or condenser water tube leaks. Water mixed
with the compressor oil can result in bearing pitting, corrosion, or excessive wear.
[ ] Submit a sample of the compressor oil to a Trane qualified laboratory for comprehensive
analysis on an annual basis; this analysis determines system moisture content, acid level and wear
metal content of the oil, and can be used as a diagnostic tool.
Lubrication
The only CVHE, CVHF, and CVHG chiller component that requires periodic lubrication is the external
vane linkage assembly and Rotary oil valve.
Lubricate the vane linkage shaft bearings and rod end bearings as needed with a few drops of lightweight machine oil.
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Maintenance
The CenTraVac inlet guide vane tang operators should be serviced annually with R-123 compatible
grease. Use only Rheolube 734A, available from Trane as LUB00033 (16 oz. standard grease gun
cartridge) or LUB00063 (3 oz. mini grease gun cartridge).
To service the 1st stage tang operator of all units except CVHF extended
capacity chillers with 1470 or 1720 compressors:
1. The chiller must be off.
2. Carefully remove any insulation that may have been placed over the two lubrication ports of
the tang operator base. This insulation will need to be replaced after the service is complete.
3. Note the position of the tang operator arm, note the placement of spacing washers etc., then
disconnect the linkage rod from the tang operator arm. Manually move the tang operator arm
and note the amount of effort required to operate the assembly.
4. Loosen but DO NOT REMOVE the 1/16” NPT lubrication port plug that is highest on the
assembly.
5. Loosen and remove the remaining lower 1/16” NPT plug.
6. Using a grease gun with an appropriate fitting, insert ONLY Rheolube grease into the open port
until clean grease is seen to appear around the threads of the plug in the opposite port.
7.
Tighten the plug that was loosened in Step 4. Tighten the plug to hand tight plus 1/4- to 1/2-turn.
8. Remove the grease fitting, if used.
DO NOT LEAVE GREASE FITTINGS INSTALLED.
If grease fittings have been used for this procedure then they MUST BE REMOVED before
returning the unit to service. Grease fittings are not vacuum-tight and will become a leak path.
9. Using a clean wooden dowel or other similar tool, remove excess grease from the remaining
open lubrication port.
10. Clean and then lightly coat the threads of the plug with Rheolube grease and re-install it into
the lubrication port. Tighten the plug to hand tight plus 1/4- to 1/2-turn.
11. Before reconnecting the vane linkage, grasp the tang operator arm and manually operate the
vane assembly. If it is now difficult to move, then the tang operator may have become
“hydraulically locked” because of excess grease in the assembly. This situation could cause
damage to the O-rings of the assembly. If this occurs then remove one of the lubrication plugs,
remove some of the grease, then re-install the plug.
12. Reconnect the linkage to the tang operator arm. Ensure the spacer washers between the linkage
and the arm are properly placed and that the assembly does not bind. Re-install any insulation
that was cut or removed. The unit may be restarted.
To service the 1st and 2nd stage tang operators on CVHF and CDHF extended
capacity chillers with 1470 or 1720 compressors:
The 1st and 2nd stage rotary inlet guide vane tang operators of the extended capacity chillers also
require periodic lubrication, at least annually, with R-123 compatible Rheolube grease. These
actuators have two 1/8” NPT plugs located 180 degrees apart, with one on the top and the other
on the bottom of the operator base. Use the same procedure as described above, except that it will
be necessary to temporarily disconnect the vane actuators from the tang operator arms in order
to test for a “hydraulically locked” condition.
The oil valve block rotary valve uses dual O-rings to seal to atmosphere. These should be manually
lubricated by removing the pipe plug at the valve lubrication port and placing a few drops of Trane
OIL00022 in the cavity. Be sure to reinstall the pipe plug when lubrication is completed.
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Maintenance
Figure 39. Rotary valve in drain position
Note: Rotary valve shown in drain position.
Top View
Front view with refrigerant pump
Refrigerant Charge
 WARNING
Contains Refrigerant!
System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to
relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use
non-approved refrigerants, refrigerant substitutes, or refrigerant additives.
Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant
substitutes, or refrigerant additives could result in death or serious injury or equipment damage.
CVHE-SVU01F-EN
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Maintenance
The refrigerant charging procedure for Trane centrifugal chillers is:
1. If water is present in the tubes, break machine vacuum with refrigerant vapor, or circulate water,
to avoid tube damage.
2. Always use refrigerant compatible hoses or copper-tubing with self-sealing connections or
shut-off valves.
3. Transfer the refrigerant using one of the following (listed in order of preference):
a. An approved Trane low-pressure refrigerant recovery and recycle unit.
b. The available pressure differential.
c. Gravity. (Use a return vent line to refrigerant drums to equalize pressure.)
4. Do not use dry nitrogen to push refrigerant into the chiller as was common practice in the past.
This will contaminate the charge and require excessive purging, which will result in
unnecessary release of refrigerant.
5. Weigh in the proper charge.
6. Use recovery and recycle unit or vacuum pump to evacuate hoses; discharge outdoors.
7.
If refrigerant is supplied in new returnable cylinders, be sure and refer to General Service
Bulletin CVHE-SB-48B, or the most recent version, for information on returning cylinders. This
service bulletin is available at the nearest Trane office.
Depending on the chiller duty, contact a qualified service organization to determine when to
conduct a complete examination of the unit to discern the condition of the compressor and internal
components.
Note: If your chiller is covered by a Trane extended warranty, the terms of that warranty may
require that the procedures listed in “Periodic Maintenance,” p. 85 be followed for your
extended warranty to remain in force. The terms may also require that the chiller be
inspected by a Trane authorized warranty agent every four years or 40,000 operating hours,
whichever occurs first. This inspection will include, at a minimum, a review of the annual
inspection checklists and the daily operating logs, as well as performance of a leak test and
a general inspection of the chiller. The owner is then required to follow the
recommendations made as a result of this inspection at the owners expense.
Recovery and Recycle Connections
To facilitate refrigerant removal and replacement, newer-design CVHE, CVHF, and CVHG units are
provided with a 3/4-inch vapor fitting with shutoff valve on the chiller suction and with a 3/4-inch
liquid connection with shutoff valve at the bottom of the evaporator shell. (Refer to Refrigerant
Handling Guidelines.)
Leak Testing
To leak-test a chiller containing full refrigerant charge, raise chiller pressure using a controlled hot
water or electric-resistance system to a maximum of 8 psig. Do not use nitrogen, which will cause
excessive refrigerant discharge by the purge system.
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Maintenance
Cleaning the Condenser
NOTICE
Proper Water Treatment!
The use of untreated or improperly treated water in a CenTraVac may result in scaling, erosion,
corrosion, algae or slime. It is recommended that the services of a qualified water treatment
specialist be engaged to determine what water treatment, if any, is required. Trane assumes no
responsibility for equipment failures which result from untreated or improperly treated water, or
saline or brackish water.
See Figure 40 which shows a Typical Chemical Cleaning Setup.
Figure 40. Typical chemical cleaning setup
Pipe Connections
Circulator Pump
Shutoff Valve
Cleaning Solution
Condenser tube fouling is indicated when the approach temperature (the difference between the
condensing refrigerant temperature and the leaving condenser water temperature) is higher than
predicted.
If the annual condenser tube inspection indicates that the tubes are fouled, two cleaning methods,
mechanical and chemical, can be used to rid the tubes of contaminants.
Use the mechanical cleaning method to remove sludge and loose material from smooth-bore
tubes.
To clean other types of tubes including internally-enhanced types, consult a qualified service
organization for recommendations.
1. Remove the retaining nuts and bolts from the water box covers at each end of the condenser.
Use a hoist to lift the covers off the water box. (A threaded connection is provided on each water
box cover to allow insertion of an eyebolt).
2. Work a round nylon or brass bristled brush (attached to a rod) in and out of each of the
condenser water tubes to loosen the sludge.
3. Thoroughly flush the condenser water tubes with clean water.
Scale deposits may be best removed by chemical means. Be sure to consult a qualified chemical
house in the area (one familiar with the local water supply’s chemical mineral content) for a
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Maintenance
recommended cleaning solution suitable for the job. Remember, a standard condenser water
circuit is composed solely of copper, cast iron and steel.
NOTICE
Unit Corrosion Damage!
Proper procedures must be followed when using corrosive chemicals to clean water side of unit.
It is recommended that the services of a qualified chemical cleaning firm be used. Proper
personal protective equipment as recommended by the chemical manufacturer should be used.
Refer to the chemicals MSDS sheet for proper safety procedures. Failure to follow proper
procedures could result in corrosion damage to the unit and tubes.
Important:
ALL OF THE MATERIALS USED IN THE EXTERNAL CIRCULATION SYSTEM, THE
QUANTITY OF THE SOLUTION, THE DURATION OF THE CLEANING PERIOD, AND
ANY REQUIRED SAFETY PRECAUTIONS SHOULD BE APPROVED BY THE
COMPANY FURNISHING THE MATERIALS OR PERFORMING THE CLEANING.
REMEMBER, HOWEVER, THAT WHENEVER THE CHEMICAL TUBE CLEANING
METHOD IS USED, IT MUST BE FOLLOWED UP WITH MECHANICAL TUBE
CLEANING, FLUSHING AND INSPECTION.
Cleaning the Evaporator
Since the evaporator is typically part of a closed circuit, it does not accumulate appreciable
amounts of scale or sludge. Normally, cleaning every three years is sufficient. However, on open
CVHE, CVHF, and CVHG systems, such as air washers, periodic inspection and cleaning is
recommended.
Control Settings and Adjustments
Time delays and safety control cutout settings need to be checked annually. For control calibration
and check-out, contact a Trane qualified service organization.
Purge System
Because some sections of the chiller’s refrigeration system operate at less-than-atmospheric
pressure, the possibility exists that air and moisture may leak into the system. If allowed to
accumulate, these noncondensables become trapped in the condenser; this increases condensing
pressure and compressor power requirements, and reduces the chiller’s efficiency and cooling
capacity.
The Trane EarthWise Purge is the only purge system available for the CVHE, CVHF and CVHG chiller.
The purge is designed to remove noncondensable gases and water from the refrigeration system.
EarthWise Purge unit operation, maintenance and trouble shooting is covered by a separate
operation and maintenance manual, which may be obtained from the nearest Trane office.
Leak Checking Based on Purge Pump Out Time
A formula has been developed which allows the annual refrigerant leakage rate to be calculated
based on the daily purge pump out time and the unit refrigerant charge. This formula is as follows:
% annual leakage rate = [(X min/day )*(.00001 lb R-123/min)/(Y lb)]*100
Where
X= minutes/day of purge pump out operation
Y= initial refrigerant charge
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Maintenance
A graph has been developed to aid in determining when to do a leak check of a chiller based on the
purge pump out time and unit size (see Figure 41). This graph depicts normal purge pump out
times, small leaks and large leaks based on the chiller tonnage. If the purge pump out time is in the
“small leak” region, then a leak check should be performed and all leaks repaired at the earliest
convenience. If the purge pump out time is in the “large leak” region, a thorough leak check of the
unit should be performed immediately to find and fix the leaks.
Figure 41. Typical purge operation
Large Leak
Small Leak
Purge minutes/day
Typical Operation
Chiller tons (per circuit)
Overview
This section describes extended storage requirements for UCP installed CVHE, CVHF, and CVHG
chillers to be removed from service for an undetermined length of time.
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Maintenance
Unit Preparation
The following steps are necessary in order to properly prepare a unit for storage.
1. Remove all liquid refrigerant if the unit is charged.
 WARNING
Contains Refrigerant!
System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to
relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use
non-approved refrigerants, refrigerant substitutes, or refrigerant additives.
Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant
substitutes, or refrigerant additives could result in death or serious injury or equipment damage.
2. After the liquid refrigerant is removed, using a recovery or recycle unit or vacuum pump, pull
a vacuum to remove remaining refrigerant vapor from the unit.
3. After all traces of refrigerant are out of the unit, a positive nitrogen charge should be put into
the unit (6 to 8 psig). This positive pressure must be checked monthly to insure no
noncondensables get into the unit. Use a pressure gage on the evaporator shell to verify that
the 6 to 8 psig dry nitrogen holding charge is still in the chiller. If this charge has escaped,
contact a qualified service organization and the Trane sales engineer that handled the order.
4. The refrigerant charge should be stored in proper refrigerant containers. Due to possible
leakage, do not store in used drums.
5. Maintain control power to the control panel. This will maintain oil temperature in the oil sump
and the capability of the control panel to present report information. The Chiller Reports should
be viewed once a week for normal readings. Any abnormal observation must be reported to the
Trane Sales Engineer that handled the order.
 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-SVB06A-FR
6. Remove the factory installed jumper or the field installed wiring on terminals in the unit control
panel. This will prevent unwanted chiller operation.
7.
Set the purge operating mode to OFF on UCP chillers.
8. The oil can be left in the unit.
9. The water side should not cause a problem if shut down and drained. There may be slight
scaling inside the tubes, but not enough to cause a problem. The customer should inspect and
clean tubes before the unit is returned to service.
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Maintenance
NOTICE
Proper Water Treatment!
The use of untreated or improperly treated water in a CenTraVac could result in scaling, erosion,
corrosion, algae or slime. It is recommended that the services of a qualified water treatment
specialist be engaged to determine what water treatment, if any, is required. Trane assumes no
responsibility for equipment failures which result from untreated or improperly treated water, or
saline or brackish water.
Important:
SCALE DEPOSITS ARE BEST REMOVED BY CHEMICAL MEANS. BE SURE TO
CONSULT ANY QUALIFIED CHEMICAL HOUSE IN THE AREA (ONE FAMILIAR WITH
THE LOCAL WATER SUPPLY’S CHEMICAL MINERAL CONTENT) FOR A
RECOMMENDED CLEANING SOLUTION SUITABLE FOR THE JOB.
10. Motor bearings: If the motor sits for a long time the bearings could take a set and cause bearing
problems or replacement later. Once every six months the chiller oil pump must be started and
the compressor motor bump started to rotate the shaft. Contact a qualified service organization
to perform this task. If the compressor motor cannot be bump started, then the shaft must be
rotated manually by a qualified service organization.
11. Obtain an oil analysis initially after six months of storage, and once each succeeding year. If no
oil breakdown is evident do not change the oil. If breakdown is evident, the oil must be replaced.
12. If the unit is stored for more than five years, and the storage is expected to be indefinite, the
unit should be examined for leaks every five years from the initial storage date.
13. When the unit is to be returned to service, the services of a qualified service organization should
be obtained to conduct all activities associated with the startup of a new chiller.
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Waterbox Removal and Installation
Note: This is only for La Crosse-Built CTV units.
Important:
ONLY QUALIFIED TECHNICIANS SHOULD PERFORM THE INSTALLATION AND
SERVICING OF THIS EQUIPMENT.
Discussion
This section will discuss recommended hoist ring/clevises and lifting. Proper lifting technique will
vary based on mechanical room layout.
•
It is the responsibility of the person(s) performing the work to be properly trained in the safe
practice of rigging, lifting, securing, and fastening the of water box.
•
It is the responsibility of the person(s) providing and using the rigging and lifting devices to
inspect these devices to insure they are free from defect and are rated to meet or exceed the
published weight of the waterbox.
•
Always use rigging and lifting devices in accordance with the applicable instructions for such
device.
Procedure
 WARNING
Heavy Objects!
Each of the individual cables (chains or slings) used to lift the waterbox must be capable of
supporting the entire weight of the waterbox. The cables (chains or slings) must be rated for
overhead lifting applications with an acceptable working load limit. Failure to properly lift
waterbox could result in death or serious injury.
 WARNING
Eyebolts!
The proper use and ratings for eyebolts can be found in ANSI/ASME standard B18.15. Maximum
load rating for eyebolts are based on a straight vertical lift in a gradually increasing manner.
Angular lifts will significantly lower maximum loads and should be avoided whenever possible.
Loads should always be applied to eyebolts in the plane of the eye, not at some angle to this
plane. Failure to properly lift waterbox could result in death or serious injury.
Review mechanical room limitations and determine the safest method or methods of rigging and
lifting the waterboxes.
1. Determine the type and size of chiller being serviced. (CVH, CVG) Refer to Trane Nameplate
located on chiller control panel.
Important:
This bulletin contains rigging and lifting information for Trane CTV chillers built in
La Crosse only. For Trane CTV chillers built outside the US, refer to literature
provided by the applicable manufacturing location.
2. Select the proper lift connection device from the Connection Devices table. The rated lifting
capacity of the selected lift connection device must meet or exceed the published weight of the
waterbox.
Verify the waterbox weight from the latest published literature.
3. Insure the lift connection device has the correct connection for the waterbox. Example: thread
type (course/fine, English/metric). Bolt diameter (English/ metric).
4. Properly connect the lift connection device to the waterbox. Refer to Figure 42, p. 99. Ensure lift
connection device is securely fastened.
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Waterbox Removal and Installation
CTV units—Install hoist ring on to the lifting connection on the waterbox. Torque to 100 ft·lb
for 3/4” threaded connections and 28 ft·lb for 1/2” threaded connections.
Figure 42. Waterbox rigging and lifting—Vertical lift only
CenTraVac
Cables, Chains, or Slings
Connection Device
Waterbox
5. Disconnect water pipes, if connected.
6. Remove water box bolts.
7.
Lift the waterbox away from the shell.
 WARNING
Overhead Hazard!
Never stand below or in close proximately to heavy objects while they are suspended from, or
being lifted by, a lifting device. Failure to follow these instructions could result in death or
serious injuries.
8. Store waterbox in a safe and secure location and position.
Note: Do not leave waterbox suspended from lifting device.
Reassembly
Once service is complete the waterbox should be reinstalled on the shell following all previous
procedures in reverse. Use new O-rings or gaskets on all joints after thoroughly cleaning each
joint.
9. Torque waterbox bolts. Refer to the following tables.
CenTraVac
Torque refer to the CenTraVac Torque table and CVHE-SVN02D-EN, or the most recent version,
for CVHE torquing procedure.
CenTraVac Torque
Bolt Size
Inch (mm)
CVHE-SVU01F-EN
Gasket Type O-Ring
ft·lb (Nm)
Flat
ft·lb (Nm)
3/8 (9.5)
25 (34)
12–18 (16–24)
1/2 (13)
70 (95)
33–50 (45–68)
5/8 (16)
150 (203)
70–90 (95–122)
3/4 (19)
250 (339)
105–155 (142–210)
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Waterbox Removal and Installation
Waterbox Weights
CenTraVac Waterbox Weights
Fabricated Non-Marine
Waterbox, Welded Flat
Plate
Shell
Size Description
032
050
080
142
210
250
Fabricated Non-Marine
Waterbox, Welded
Marine Style Waterbox
Dome
Cover
Non-Marine Cast
Waterbox
Weight
lb (kg)
Lifting
Connection
Weight
lb (kg)
Lifting
Connection
Weight
lb (kg)
Lifting
Connection
Weight
lb (kg)
Lifting
Connection
Evaporator, 150 psi
265 (120)
3/4 - 10
N/A
N/A
N/A
N/A
176 (80)
1/2 - 13
Evaporator, 300 psi
265 (120)
3/4 - 10
N/A
N/A
N/A
N/A
176 (80)
1/2 - 13
Condenser, 150 psi
N/A
N/A
176 (80)
1/2 - 13
N/A
N/A
176 (80)
1/2 - 13
Condenser, 300 psi
265 (120)
3/4 - 10
N/A
N/A
N/A
N/A
221 (100)
1/2 - 13
Evaporator, 150 psi
397 (180)
3/4 - 10
397 (180)
Lifting Fixture
N/A
N/A
265 (120)
1/2 - 13
Evaporator, 300 psi
353 (160)
3/4 - 10
N/A
N/A
N/A
N/A
265 (120)
1/2 - 13
Condenser, 150 psi
265 (120)
1/2 - 13
265 (120)
1/2 - 13
N/A
N/A
265 (120)
1/2 - 13
Condenser, 300 psi
551 (250)
3/4 - 10
N/A
N/A
N/A
N/A
441 (200)
1/2 - 13
Evaporator, 150 psi
662 (300)
3/4 - 10
662 (300)
Lifting Fixture
N/A
N/A
441 (200)
3/4 - 10
Evaporator, 300 psi
882 (400)
3/4 - 10
N/A
N/A
N/A
N/A
551 (250)
3/4 - 10
Condenser, 150 psi
551 (250)
3/4 - 10
551 (250)
3/4 - 10
N/A
N/A
441 (200)
1/2 - 13
Condenser, 300 psi
882 (400)
3/4 - 10
N/A
N/A
N/A
N/A
882 (400)
3/4 - 10
Evaporator, 150 psi
882 (400)
3/4 - 10
N/A
N/A
N/A
N/A
662 (300)
3/4 - 10
Evaporator, 300 psi
1323 (600)
3/4 - 10
N/A
N/A
N/A
N/A
882 (400)
3/4 - 10
Condenser, 150 psi
1543 (700)
3/4 - 10
N/A
N/A
441 (200)
3/4 - 10
1323 (600)
3/4 - 10
Condenser, 300 psi
1985 (900)
3/4 - 10
N/A
N/A
N/A
N/A
1764 (800)
3/4 - 10
Evaporator, 150 psi
1544 (700)
3/4 - 10
N/A
N/A
N/A
N/A
1323 (600)
3/4 - 10
Evaporator, 300 psi
2205 (1000)
3/4 - 10
N/A
N/A
N/A
N/A
1764 (800)
3/4 - 10
Condenser, 150 psi
2205 (1000)
3/4 - 10
N/A
N/A
662 (300)
3/4 - 10
1764 (800)
3/4 - 10
Condenser, 300 psi
2867 (1300)
3/4 - 10
N/A
N/A
N/A
N/A
2426 (1100)
3/4 - 10
Evaporator, 150 psi
1985 (900)
3/4 - 10
N/A
N/A
N/A
N/A
1544 (700)
3/4 - 10
Evaporator, 300 psi
3087 (1400)
3/4 - 10
N/A
N/A
N/A
N/A
2205 (1000)
3/4 - 10
Condenser, 150 psi
2867 (1300)
3/4 - 10
N/A
N/A
662 (300)
3/4 - 10
2205 (1000)
3/4 - 10
Condenser, 300 psi
3528 (1600)
3/4 - 10
N/A
N/A
N/A
N/A
3087 (1400)
3/4 - 10
Note: Refer to product block identifier on the model number plate which identifies the evaporator and condenser shell sizes and the rated pressure. The
designators are as follows:
Evaporator Size = EVSZ, Condenser Size = CDSZ, Evaporator Pressure = EVPR, Condenser Pressure = CDPR
Weights shown are maximum for waterbox size. Verify the waterbox from the latest published literature.
Parts Ordering Information
This section is informational only and does not authorize any parts or labor.
Use the following table to review the parts involved in this section.
Connection Devices
100
Unit
Product
Part Number
Order Information
CTV
Safety Hoist Ring 3/4-10
RNG01884
Contact Trane Part Department
CTV
Safety Hoist Ring 1/2-13
RNG01885
Contact Trane Part Department
CTV
Evap Lifting Fixture
BAR00400
Contact Trane Part Department
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Waterbox Removal and Installation
Figure 43. Lifting fixture installed on waterbox
5/8-11 Fastener
Grade 5 or Better
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Forms
CenTraVac®
Annual Inspection Check List and Report:
Compressor Motor
Motor Continuity check
Good
Open
Control Circuits
Low refrigerant temperature sensor check
___°F set point ___°F trip point (ice water)
Check and tighten motor terminals
Meg Motor
Phase 1
Phase 2
Leaving Evaporator water temperature
sensor check-out
___°F set point ___°F trip point (ice water)
Phase 3
Check nameplate rating
Amps
Starter
Check condition of starter contacts
Good
Fair
Replace
Check, tighten if necessary all connections
per manufactures specs
Oil Sump
Change oil
If oil analysis, refer to program procedure
Gallons (9) required
Refrigerant/Oil pump motor ground check
Good
Open
Check motor terminal
Change oil filter
Condenser
Visually inspect for scaling in tubes;
not findings and make recommendations
Condenser High Pressure Switch check-out
___psig set point
___psig trip point
Check Net Oil Pressure
Check adjustment and operation of inlet
guide vane actuator stepper motor
(Note: each machine is unique and must have
the full open position number of steps input.)
Leak Test Chiller
Refrigerant and oil analysis for acid content
Sample refrigerant and oil for laboratory
analysis (attach a copy of analysis to next
monthly inspection report)
Purge Unit
Review the purge operation maintenance
manual and follow maintenance and/or
inspection items identified.
Comments:
Recommendations:
102
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Forms
CenTraVac®
Checksheet and Request for Serviceman
Trane Service Company
Serial #s:
To:
S.O. No.:
Job/Project Name:
Address:
The following items are being installed and will be completed by:
Check boxes if the task is complete or if the answer is "yes".
1. CenTraVac
In place and piped. Do not insulate CenTraVac or
adjacent piping. The contractor is responsible for
any foreign material left in the unit.
2. Piping
Chilled water piping connected to:
CenTraVac
Air handling units
Pumps
Condenser and heat recovery condenser
(as applicable) piping connected to:
CenTraVac
Pumps
Cooling tower
Heating loop (as applicable)
Make-up water connected to cooling tower
Water supply connected to filling system
Systems filled
Pumps run, air bled from system
Strainers cleaned
3. Flow Balancing Valves Installed
Leaving chilled water
Leaving condenser water
Heat recovery condenser leaving water
4. Gauges, Thermometers and Air Vents
Installed on both sides of evaporator
Installed on both sides of condenser and heat
recover condenser (as applicable)
5. Wiring
Compressor motor starter has been furnished
by or approved by Trane La Crosse, WI
Full Power available
Interconnecting wiring, starter to panel (as req'd)
External interlocks (flow swtch, pumps aux, etc)
Chiller motor connection (remote starters)*
Chilled water pump (connected and tested)
Condenser water pump (connected and tested)
Cooling tower fan rotation checked
Heat recovery condenser water
pump (as applicable)
Power available for Service tools 115 Vac
All controls installed and connected
All magnetic starters installed and connected
*Note: Do not make final remote starter to compressor
motor connections until requested to do so by the
Trane Service representative.
6. Testing
Dry nitrogen available for pressure testing
Trace gas amounts of Refrigerant-22 or R-134a
available for leak testing, if necessary
7. Refrigerant On Job Site
8. Systems Can Be Operated Under
Load Conditions
9. Electrical, Control Man and Contractor's
Representative Are Available to Evacuate,
Charge and Test the CenTraVac under
Serviceman's Supervision
10. Equipment Room
Does the equipment room have a refrigerant
monitor/sensor capable of monitoring and
alarming within the allowable exposure level
of the refirgerant?
Does the installation have properly placed and
operating audible and visual refrigerant
alarms?
Continued on next page………………..
CVHE-SVU01F-EN
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Forms
10. Equipment Room (continued)
Does the equipment room have proper
mechanical ventilation?
If it is required by local code, is a
self-contained breathing apparatus available?
11. Owner Awareness
Has the owner been fully instructed on the
proper use of refrigerant HCFC-123?
Does the owner have a copy of the MSDS for
refrigerant HCFC-123?
Was the owner given a copy of the
Refrigerant Handling Guidelines?
Note: Additional time required to properly complete the start-up and commissioning, due to any
incompleteness of the of the installation, will be invoiced at prevailing rates.
This is to certify that the CenTraVac chiller(s) has/have been properly and completely installed,
and that the applicable items listed above have been satisfactorily completed.
Checklist Completed By
Signed:
Date:
In accordance with your quotation and our purchase order number __________, we will therefore
require the presence of Trane service on the site, for the purpose of start-up and commissioning,
by: Date:
Note: Advance notification is required to allow scheduling of the start-up as close as possible to
the requested date.
Additional Comments/Instructions
A copy of this completed form must be submitted to the Trane Service Agency that will be
responsible for the start-up of the chiller.
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CenTraVac Commissioning Checklist
Job Name
Model #
Sales Order #
Location
Serial #
Start-up Date
Note: The Unit Installation, Operation and Maintenance Manuals including Warning and Cautions,
Applicable Service Alerts and Bulletins, Submittals, and Design Specifications must be used in
conjunction with this checklist.
I. PRE-COMMISSIONING PROCEDURES
A. Obtain Pre-commissioning Check Sheet
This must be prepared by installer for a particular unit, verifying the unit is ready for commissioning.
B. Obtain Design (order) Specification Data
This indicates the design criteria of the particular unit. A unit cannot be properly commissioned unless this
data is known. It is the responsibility of the selling office to furnish this data.
C. Obtain Wiring Diagrams
The "as-wired" electrical diagram should be compatible with the recommended Trane submittals and
diagrams. Are customer added external/remote control circuits compatible?
Yes
No
D. General Installation Observations
1. Is there any apparent shipping or rigging damage?
Yes
No
2. Record the unit pressure upon receipt:________psig. If there is no pressure, a leak test will have to be
done before the unit can be evacuated and charged.
3. Is the water piping correctly installed?
Flow Switches
Yes
No
Isolations Valves
Yes
No
Thermometer Wells
Yes
No
Pressure Gauges
Flow Balancing Valves
Vent Cocks and Drains
Yes
Yes
Yes
No
No
No
4. Have proper clearances around the unit been maintained per submittal and/or Installation?
Are there Manual guidelines available
Yes
No
5. Is power wiring of adequate ampacity and correct voltage?
Yes
No
6. Is the unit base acceptable, level, and is the unit on isolators (rubber as supplied by Trane or spring
type)?
Yes
No
7. Have the low voltage circuits been properly isolated from the higher voltage control and power
circuits?
Yes
No
E. Comments
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II. COMMISSIONING PROCEDURES
A. Pre-start Operations
1. Holding Charge
________psig. Must be positive pressure or leak test must be done.
2. Before relieving the holding charge, calibrate the H.P.C. high-pressure control
This is a check of pressure to the H.P.C. as well as calibration of the control.
Disconnect and cap the flare. Calibrate H.P.C. and reconnect flare.
Relieve the holding charge.
Check and if necessary, tighten all connections per proper specs.
3. Megohm the Motor (500 volt Meggar)
Compressor motor Megohms - refer to temp/resistance chart for acceptable values. Remove surge
suppressors before Megging. Never Meg test with the unit in a vacuum.
T1 to Earth____
T4 to Earth____T1 to T2
T1 to T4____
T2 to Earth____
T5 to Earth____T1 to T3
T2 to T5____
T3 to Earth____
T6 to Earth____T2 to T3
T3 to T6____
4. Evacuation
Connect the vacuum pump to start evacuation. Use a 2-stage pump with at least 5 CFM capacity.
Connect to the evaporator-charging valve with a hose no smaller than 3/4 inch ID.
a. For the IT Cutler-Hammer Solid State Starter it is necessary to shut off all power to the unit prior to
evacuating the chiller. The IT starter has terminals 4, 5, & 6 hot when the unit is off. Failure to shut off
power to the chiller, with the vacuum pump hook up, will cause a motor failure.
5. Condenser
Isolation and flow valves installed
Calibrated thermometers and pressure gauges installed in/out condenser on machine side of any
valve or elbow.
If condenser pump controlled by UCP, is field wiring correct and complete?
Condenser pump(s) run, system and strainers properly cleaned and/or flushed.
Condenser water strainer in close proximity to entering connection of condenser.
Previsions installed to properly maintain water treatment additives.
Initial water treatment added to system
Flow or differential pressure switch installed and where possible, wired in series with auxiliary of pump
motor starter. Verify correct operation of flow proving circuit.
Condenser water flow balance.
PSID design_____
PSID actual_____
GPM design_____
GPM actual_____
6. Evaporator
_____psig. Must be positive pressure or leak test must be done.
Calibrated thermometers and pressure gauges installed in/out of evaporator on machine side of any
valve or elbow.
If the evaporator pump controlled by UCP, is field wiring correct and complete?
Evaporator pump(s) run 24 hrs. System and strainers properly cleaned and/or flushed.
Evaporator water strainer in close proximity to entering connection of evaporator.
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Provisions installed to properly maintain water treatment additives.
Initial water treatment added to system.
Flow or differential pressure switch installed and where possible, wired in series with auxiliary of pump
motor starter. Verify correct operation of flow proving circuit.
Evaporator water flow balanced.
PSID design_____
PSID actual_____
GPM design_____
GPM actual_____
7. Electrical and Controls
a. Motor Starter Panel
All terminals tightened.
Wiring free from abrasion, kinks, and sharp corners.
Contactors and relays have freedom of movement.
All contacts are free of corrosion or dirt. Panel is free of dust, debris etc.
Check the ratio of the current transformers. Record the part numbers on the start-up log.
Use only twisted shielded pair for the IPC circuit between the starter and UCP on remote starters.
Recommended wire is Belden 8760, 18 AWG. Polarity is critical.
The low voltage IPC link ( 30 volts) must be in separate conduit from the 115-volt wiring.
IPC link routing within the starter panel must stay a minimum of 6 inches from higher voltages.
Remote starter to UCP connections are complete and comply with Trane requirements. Verify oil
pump interlock circuit to 1A7J2-4 and J2-2.
Check the correctness of the power connections from the starter to the motor.
Check the wiring to the starter for size, voltage and correct phase rotation (A-L1, B-L2, & C-L3)
Check the equal phase representation in each power-wiring conduit.
b. Control Panel
All terminals tightened.
Wiring free from abrasion, kinks, and sharp corners.
Low voltage wires are isolated from high voltage wires.
Panel is free of dust, debris etc.
"Power Up" the control panel. (Non-AFD Starters)
1. Starter disconnect locked open.
2. Fuse 2F4 must be removed from the starter.
3. Connect auxiliary 115 Vac-power cord to Terminals 1X1-5(L1) and 1X1-17(L2) in the starter
panel. MAKE SURE OF THE POLARITY. THE 'HOT' SIDE MUST BE CONNECTED TO
TERMINAL 1X1-5(L1) AND THE 'NEUTRAL' SIDE TO 1X1-17(L2).
4. Plug in cord to 115 Vac-power source. Control panel is now energized.
Record the configuration and setpoints of the CH530 control system, using Service Tool.
Using the unit nameplate data and the order specification, double check and reset, if required, the
settings of RLA & STMS, using Service Tool.
If Evaporator and condenser water pumps are controlled by the UCP, use the DynaView (or Service
Tool) manual override menu to manually start and test the control of the pumps.
Check the setting of the oil pressure-regulating valve.
1. Use the DynaView manual override of the UCP to manually start the oil pump.
2. Proceed to the Compressor Report menu and observe the Differential Oil Pressure
3. Adjust the oil pressure-regulating valve to maintain 18 to 22 psid. The oil pressureregulating valve may require adjustment as the unit is started.
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4. This procedure also checks to ensure correct sensing of oil pressure. The Oil Pressure
Cutout setting is adjustable within via the CH530 Service Tool.
5. Return Oil Pump control to 'Auto' from within the DynaView.
Check vane operator and vanes (Service Tool).
1. Use the Service Tool manual override menu to manually override the vane control.
2. Enter targets from 0% to 100% and observe vane operation. At minimum and maximum
travel the operator should not exert any force on the vane assembly, adjust as required.
3. Vane movement is smooth to open/close.
4. Vane movement is reported back to the UCP.
5. Return Vane control to 'Auto'.
Dry run the starter (Service Tool).
1. Make sure the starter disconnect is safety locked open.
2. Use the Service Tool menu of the UCP to initiate the Starter Dry Run.
3. Observe correct operation of starter contactors.
4. Observe correct operation of transition complete signal (if required).
5. Disable Starter Dry Run when complete.
Remove Power
Disconnect and remove temporary power cord.
B. Preparation for Start-up.
1. Evacuation and charging
Evacuation leak test. When vacuum has been drawn down to 500 microns to 1000 micons, secure the
vacuum pump. Wait for 12 hours for a valid vacuum leak test. If the rise in vacuum is less than 500
microns per 12 hours start-up may proceed.
Charge refrigerant. MAKE SURE THE CHILLED WATER IS FLOWING THROUGH THE
EVAPORATOR. Charge the prescribed amount of refrigerant through the liquid charging valve at the
liquid inlet to the evaporator. Check that all drums contain a full amount of refrigerant. Amount
charged _____lgs and kg.
2. Electrical
Disconnect all temporary power cords, replace all fuses, connect motor leads, make final electrical
inspection.
Power up the motor starter. Check for control voltage at control panel terminals 1X1-1 and 1X1-17.
______ Volts
Check current to the oil sump heater.
______ Amperes
As the oil heats up, finish any operations not yet completed in preparation for starting the unit.
C. Chiller Start-up
1. Make all preliminary checks.
Oil temp, oil level, chilled water flow, chilled water load available (cooling units on) etc.
2. Start the unit
If the phase rotation of the electrical power has not been positively confirmed, the actual rotation of the
motor must be checked. Observe the rotation of the motor shaft through the sight glass on the end of
the motor at the moment of start-up. Rotation must be CLOCKWISE. If the phase sequence is
incorrect, confirmed by observation of the Phase Reversal diagnostic on the UCP, then the incoming
power leads to the stator must be adjusted by authorized personnel.
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As the unit starts and runs, observe closely all operating conditions.
Adjust the oil pressure regulator if necessary to 18 to 22 psi net.
In the DynaView Purge Settings menu of the UCP, place the Purge Operating Mode to 'on' to allow the
removal of non-condensables. It may also be necessary to disable the Purge Pumpout Limit timer
found in the Purge Settings menu.
After the unit has the system down to design leaving chilled water temp and is under control, and the
purge is no longer relieving non-condensables, begin taking the start-up test log. Log the unit a
minimum of 3 times at 15-minute intervals.
In the DynaView Purge Settings menu of the UCP, return the purge-operating mode to 'Adaptive'.
Restart the chiller and carefully observed the starting and loading sequence.
3. Instructions to the Chiller Operator.
Instructions for starting, operating, and shutting down.
Instructions for logging the unit.
Instructions for periodic maintenance.
D. After 2 weeks of operation (International Units Only)
1. Remove the water box covers on both the evaporator and condenser. Mechanically brush clean all the
tubes. This is to assure there is no debris blocking any of the tubes. A piece of debris partially blocking a
tube may cause that tube to fail prematurely.
2. Replace the oil filter with the spare oil filter included in the control panel at time of shipment.
E. Comments and/or Recommendations:
Service Technician
CVHE-SVU01F-EN
Signature
Date
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Forms
STARTUP Chiller Report - Water Cooled CenTraVac
With CH530 Controller
Job Name
Job Location
Sales Order #
Elevation
________________________
________________________
________________________
________________________
Serial #
Model #
Ship Date
Start Date
____________________________
____________________________
____________________________
____________________________
DATE:
__________________________________________________________________________________________________________________
Starter Data:
Manufacturer
Type
Vendor ID#
Model #
Volts 7 Hz
Amps
Current
Transformers
Primary
X_________________-
Primary
X_________________-
Primary
X_________________-
Dyna View Display
Settings:
Date Format
Secondary (if present)
X_________________-
Date
Secondary (if present)
X_________________-
Time Format
Secondary (if present)
X_________________-
Time of Day
Design Data
RLA
KW
Volts & Hz
Evap Flow _____
Evap PD _____
Cond Flow _____
Cond PD _____
Actual ____
Keypad/Display Lockout
Motor Data:
Manufacturer
Type & Frame
Drawing#
Serial#
Display units
Pressure Units
Language
Dyna View Purge Settings
Purge Operating Mode
Daily Pumpout Limit
Pumpout Limit Disable
Nameplate Data
RLA
KW
Volts & Hz
Machine Press
At Arrival
At Startup
Leak Test Vacuum
Vac Rise Test
Unit Refrigerant Charge
High Pressure Cutout
Purge Liquid Temp Inhibit
Purge Liquid Temp Limit
Purge Run Time
_______PSIG
_______PSIG
_______Microns
_______Microns
after _________hours
_______lbs of
R- _________
HPC (3S1)
_____Open
Notes
___________________________________________
___________________________________________
___________________________________________
HPC (3S1)
_____Close
110
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STARTUP Chiller Report - Water Cooled CenTraVac
With CH530 Controller
Dyna View
Reports
Evaporator
Entering
Leaving
Saturated
Refrig Press
Approach
Flow Sw status
Condenser
Entering
Leaving
Saturated
Refrig Press
Approach
Flow Sw status
Compressor
Starts
Running Time
Oil Tank Press
Oil Dischrg. Press
Oil Diff Press
Oil Tank Temp
IGV Position %
IGV Steps
Motor
% RLA L1, L2, L3
Amps L1, L2, L3
Volts AB, BC, CA
Power KW
Load PF
Winding #1 temp
Winding #2 temp
Winding #3 temp
w/AFD only:
AFD Freq
AFD Speed
AFD Transistor temp
Purge
Time Until Next Purge Run
Daily Pumpout – 24 hrs.
Avg. Daily Pumpout – 7 days
Daily Pumpout Limit/Alarm
Chiller On 7 days
Pumpout Chiller On 7 days
Pumpout Chiller Off 7 days
Pumpout- Life
Purge Rfgt Cprsr Suction Temp.
Purge Liquid Temp.
Carbon Tank Temp.
Log 1
Log 2
Log 3
Date:
Technician:
Owner:
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STARTUP Chiller Report - Water Cooled CenTraVac
With CH530 Controller
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
112
TECHVIEW SETTINGS RECORDS
TechView:
TechView:
Record
Configuration View
Configuration View
Setting
33 Comm 4 Tracer Interface
UNIT TYPE
Unit Type
34 Comm 5 Tracer Interface
35 ICS Address Comm 4
CH530 Tab
Control Sequence
36 ICS Address Comm 5
Unit Capacity
37 Purge Control
Starter Type
38 Compressor Power Source
Refrigerant Type
39 % RLA and Rfgt Press Analog Output
Line Voltage Sensing
40 Rfgt Pressure Analog Output (TYPE)
Free Cooling
41 Min Delta Rfgt Press Output Cal
Hot Gas Bypass
42 Max Delta Rfgt Press Output Cal
Second Condenser
43 Max Capacity Relay Filter Time
Hot Water Control
44 Head Relief Relay Filter Time
Outdoor Air Temp Sensor
45 Base Loading
TechView: Starter (non AFD)
External Chilled Water Setpoint
ECWS Minimum Temperature
46 Stop Delay Time (Contactor Interupt Failure)
ECWS Maximum Temperature
47 Unit Line Voltage
External Current Limit Setpoint
48 Voltage Transformer Ratio
ECLS Minimum %RLA
49 Rated Load Amps
ECLS Maximum %RLA
50 CT Meter Scale
Ice Building
51 Current Unbalance Trip Point
EHWS Minimum Temperature
52 Current Unbalance Grace Period
EHWS Maximum Temperature
53 Maximum Acceleration Setting
Refrigerant Monitor Type
54 Acceleration Time Out Action
Condenser Pressure Sensor
55 Overload Type
Evap. Diff. Wtr Press Sensing
56 Phase Reversed Protection Enable
Cond. Diff. Wtr Press Sensing
57 Contactor Integrity Test
Enhanced Oil Temp Protection
58 Phase Reversed Grace Period
Discharge Temp Sensors
59 Surge Protection Enable
Bearing Temp Sensors
60 Momentary Power Loss Protection
High Pressure Cutout
61 Restart Inhibit Stop to Start Time
Impeller Diameter
62 Surge Sensitivity
IGV Actuators
63 Power Loss Reset Time
Alarm, Limit Warning, Cprsr Run
Relays
Max Cap, Head Relief Request Purge
Relays
Record
Setting
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STARTUP Chiller Report - Water Cooled CenTraVac
With CH530 Controller
64
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66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
SETPOINT VIEW: Chiller
Front Panel Chilled Water Setpoint
Front Panel Current Limit Setpoint
Front Panel Heating or Cooling Mode
Front Panel Hot Water Setpoint
Front Panel Base Loading Command
Front Panel Base Load Setpoint
Front Panel Free Cooling Command
Front Panel Ice Building Command
Front Panel Ice Termination Setpoint
Ice To Normal Cooling Timer
Differential to Start Setpoint
Differential to Stop Setpoint
Setpoint Source
Power Up Start Delay
Evaporator Pump Off Delay
Condenser Pump Off Delay
Evaporator Design Delta Temp
Condenser Design Delta Temp
Evaporator Leaving Water Temp
Cutout
Inlet Guide Vane Max Steps First Stage
Inlet Guide Vane Max Steps Second
Stage
Low Refrigerant Temp Cutout
Condenser Limit Setpoint
Evaporator Water Flow 1
Evaporator Pressure Drop 1
Evaporator Water Flow 2
Evaporator Pressure Drop 2
Evaporator Fluid Specific Gravity
Evaporator Fluid Specific Heat
Evaporator Low Water Flow Warning
Setpoint
Condenser Water Flow 1
Condenser Pressure Drop 1
Condenser Water Flow 2
Condenser Pressure Drop 2
Oil Temp Control Setpoint
Low Oil Temp Inhibit (Enhanced
disabled)
Low Differential Oil Pressure
Cutout
CVHE-SVU01F-EN
101
102
103
104
105
106
107
108
109
110
111
112
113
Check Oil Filter Diagnostic
Check Oil Filter Setpoint
Restart Inhibit Free Starts
Restart Inhibit Start to Start
Restart Inhibit Diagnostic
Time Permitted at Minimum Capacity
HGBP Mode, Vane Target Compressor
Maximum HGBP Time
High Discharge Temp Cutout
Local Atmosphere Pressure
Minimum Capacity Limit
Maximum Capacity Limit
Start Sequence Type
114
115
116
117
SETPOINT VIEW: Feature Settings
Evap Pump Control Type
Chilled Water Reset
Return Reset Ratio
Return Start Reset
118
119
Return Max Reset
Outdoor Reset Ration
120
121
122
123
124
125
126
127
128
Outdoor Start Reset
Outdoor Max Reset
External Current Limit Setpoint Enable
Ice Building Feature Enable
Hot Gas Bypass Feature
Hot Gas Bypass Maximum Timer Enable
Hot Gas Bypass Maximum Timer Setpoint
Hot Gas Bypass Compressor Control
Command
Hot Gas Bypass Valve Travel Time
129
130
131
132
133
134
External Base Loading Enable
Capacity Control Softload Time
Current Limit Control Softload Time
Current Limit Softload Start Point
Phase Unbalance Protection
Over/Under Voltage
135
Protection
136
Control Algorithm Flow Compensation
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Literature Order Number
CVHE-SVU01F-EN
Date
April 2011
Supersedes
CVHE-SVU01E-EN (April 2005)
www.trane.com
For more information, contact your local Trane
office or e-mail us at [email protected]
Trane has a policy of continuous product and product data improvement and reserves the right to
change design and specifications without notice. Only qualified technicians should perform the
installation and servicing of equipment referred to in this literature.
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