Ingersoll-Rand Trane Ascend ACS Installation, Operation And Maintenance Manual Download

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AC-SVX002C-EN

Refrigerant Cycle . . . . . . . . . . . . . . . . . . . . . . . . 44

Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Condenser and Fans . . . . . . . . . . . . . . . . . . . . . 44

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

UC800 Specifications . . . . . . . . . . . . . . . . . . . . 45

Wiring and Port Descriptions. . . . . . . . . . 45
Communication Interfaces . . . . . . . . . . . . 46
Rotary Switches . . . . . . . . . . . . . . . . . . . . . 46
LED Description and Operation. . . . . . . . 46

Tracer AdaptiView TD7 Display . . . . . . . . . . . 48

Tracer TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Integrated Rapid Restart. . . . . . . . . . . . . . . . . . 59

Pre-Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Start-up and Shutdown. . . . . . . . . . . . . . . . . . . . 61

Unit Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Temporary Shutdown And Restart . . . . . . . . 61

Extended Shutdown Procedure . . . . . . . . . . . 61

Seasonal Unit Start-up Procedure . . . . . . . . 62

System Restart After Extended
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Sequence of Operation. . . . . . . . . . . . . . . . . . . 64

Software Operation Overview. . . . . . . . . 64
Power Up Diagram . . . . . . . . . . . . . . . . . . 64
Power Up to Starting . . . . . . . . . . . . . . . . . 65

Stopped to Starting . . . . . . . . . . . . . . . . . . 66
Normal Shutdown to Stopped or
Run Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Recommended Maintenance . . . . . . . . . . . . . 68

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Refrigerant and Oil Charge
Management . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Lubrication System . . . . . . . . . . . . . . . . . . . . . . 69

Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Oil Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Condenser Maintenance . . . . . . . . . . . . . . . . . 69

Condenser Coil Cleaning . . . . . . . . . . . . . 69
Repair/Replacement of Microchannel
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Condenser Coil Corrosion Protection
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Evaporator Maintenance . . . . . . . . . . . . . . . . . 70

Water Strainer Maintenance . . . . . . . . . . . . . . 70

Units without Pump Package. . . . . . . . . . 70
Units with Pump Package . . . . . . . . . . . . . 71

Pump Package Maintenance . . . . . . . . . . . . . . 71

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

General Diagnostics Information . . . . . . . . . . 72

Main Processor Diagnostics . . . . . . . . . . . . . . 72

Sensor Failure Diagnostic . . . . . . . . . . . . . . . . 79

Communication Diagnostics. . . . . . . . . . . . . . 80

Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Log and Check Sheets . . . . . . . . . . . . . . . . . . . . . 85

Ascend

™

Model ACS Installation

Completion Check Sheet and Request for
Trane Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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Summary of Contents for Trane Ascend ACS

Page 1: ...ecific knowledge and training Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions...

Page 2: ...th he e j jo ob b b be ei in ng g u un nd de er rt ta ak ke en n c co ou ul ld d r re es su ul lt t i in n d de ea at th h o or r s se er ri io ou us s i in nj ju ur ry y T Te ec ch hn ni ic ci ia an...

Page 3: ...o od di in ng g w wh hi ic ch h c co ou ul ld d r re es su ul lt t i in n d de ea at th h s se er ri io ou us s i in nj ju ur ry y o or r e eq qu ui ip pm me en nt t d da am ma ag ge e T Th he e u un...

Page 4: ...tors 20 Evaporator Piping 22 Evaporator Piping Components 22 Evaporator Label 24 Pressure Drop Curves 25 Pump Curves 27 Freeze Avoidance 29 Low Evaporator Refrigerant Cutout Glycol Requirements 30 Hig...

Page 5: ...Operation 64 Software Operation Overview 64 Power Up Diagram 64 Power Up to Starting 65 Stopped to Starting 66 Normal Shutdown to Stopped or Run Inhibit 67 Maintenance 68 Recommended Maintenance 68 W...

Page 6: ...ber Coding System Model numbers are composed of numbers and letters that represent features of the equipment Shown below is a sample of typical unit model number ACSA 1802 EUA0 XUXA XNB2 ACAH SMEX 1TA...

Page 7: ...Switch Setpoint 60 Digit 23 Insulation A Factory Insulation All Cold Parts 0 75 inch B Evaporator Only Insulation for High Humidity Low Evap Temp 1 25 inch Digit 24 Unit Application X Standard Ambien...

Page 8: ...ot Used X Selection1 Digit 43 Special Requirement 0 None S Special Requirement F Ship to Final Finisher Compressor Information Model Number Digit 1 2 3 Compressor Type DSH Danfoss Digit 4 5 6 Capacity...

Page 9: ...nnections in the water piping The condenser is an air cooled slit or serpentine fin coil arranged in a transverse V layout General Data Table 1 General data I P Unit Size tons 140 160 180 200 215 230...

Page 10: ...2 92 80 Power per motor HP 20 9 22 6 22 9 27 1 26 3 26 5 a Data shown for one circuit only The second circuit always matches b Minimum and maximum flow rates apply to constant flow chilled water syste...

Page 11: ...speed m s 39 3 39 3 39 3 39 3 39 3 39 3 General Unit Refrigerant circuits 2 2 2 2 2 2 Capacity steps 21 43 71 100 25 50 75 100 17 33 50 67 83 100 15 30 50 65 80 100 14 32 50 64 82 100 17 33 50 67 83...

Page 12: ...ted within 15 days Request an immediate joint inspection of the damage with the carrier and consignee Stop unpacking the unit Do not remove damaged material from receiving location Take photos of the...

Page 13: ...and wiring including interlock Option relays and wiring Water piping Flow switch Water strainer Taps for thermometers and gauges Thermometers Water flow pressure gauges Isolation and balancing valves...

Page 14: ...60 4 1535 D 172 6 4383 172 6 4383 225 4 5725 225 4 5725 189 1 4803 189 1 4803 E 275 8 7006 275 8 7006 F 75 6 1920 75 6 1920 116 9 2970 116 9 2970 116 9 2970 116 9 2970 G 134 6 3420 134 6 3420 176 0 44...

Page 15: ...383 225 4 5725 225 4 5725 189 1 4803 189 1 4803 E 275 8 7006 275 8 7006 F 75 6 1920 75 6 1920 116 9 2970 116 9 2970 116 9 2970 116 9 2970 G 134 6 3420 134 6 3420 176 0 4470 176 0 4470 211 4 5370 211 4...

Page 16: ...placement Preferred side for coil replacement is shown left side of the unit as facing control panel however either side is acceptable Weights Table 3 Unit weights Unit Size tons Standard Unit Options...

Page 17: ...it t b be ei in ng g l li if ft te ed d E Ea ac ch h o of f t th he e c ca ab bl le es s c ch ha ai in ns s o or r s sl li in ng gs s h ho oo ok ks s a an nd d s sh ha ac ck kl le es s u us se ed d t...

Page 18: ...ed on other side of the unit Control Panel Figure 3 6 point lift configuration 215 230 ton units Lifting Location 1 Lifting Location 2 located on other side of the unit Lifting Location 3 Lifting Loca...

Page 19: ...230 122 3099 46 1168 41 1041 153 3886 47 1194 36 914 Isolation and Sound Emission The most effective form of isolation is to locate the unit away from any sound sensitive area Structurally transmitte...

Page 20: ...olator to the unit with a nut 4 Level the unit carefully Fully tighten the isolator mounting bolts Figure 5 Elastomeric isolator 0 50 in 1 60 0 25 Mounting molded in neoprene 3 0 2 75 0 38 1 2 13NC 2B...

Page 21: ...Location 1 2 3 4 5 6 7 8 140 Red 62 Green 63 Red 62 Green 63 Brown 61 Brown 61 Brown 61 Brown 61 160 Red 62 Green 63 Red 62 Green 63 Brown 61 Brown 61 Brown 61 Brown 61 180 Red 62 Green 63 Red 62 Gre...

Page 22: ...ge er r d da am ma ag ge e I If f a an n a ac ci id di ic c c co om mm me er rc ci ia al l f fl lu us sh hi in ng g s so ol lu ut ti io on n i is s u us se ed d b by yp pa as ss s t th he e E EV VP P...

Page 23: ...7 Strainer 8 Water Heater Entering Chilled Water Piping Air vents to bleed air from system Water pressure gauges with shutoff valves Vibration eliminators Shutoff isolation valves Thermometers if des...

Page 24: ...proof of flow See schematics in AC SVE002 EN for more details N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e I In nc co or rr re ec ct t w wi ir ri in ng g o of f a au ux xi il li i...

Page 25: ...00 250 300 350 400 450 500 550 600 650 700 750 800 850 PRESSURE DROP FT of H20 FLOW GPM 140T 160T 180T 200T 215T 230T Figure 10 Pressure drop curve unit with pump package 0 5 10 15 20 25 30 35 40 45 5...

Page 26: ...0 600 700 800 PRESSURE HEAD Ft of H2O FLOW RATE GPM 160 200 180 230 215 140 Figure 12 Pump package available head pressure dual pump 0 20 40 60 80 100 120 140 0 100 200 300 400 500 600 700 800 PRESSUR...

Page 27: ...ead Ft of H2O Power hp NPSH ft FLOW RATE Usgpm Effy Head Effy Power NPSH Figure 14 Pump curve series 4380 at 3291 rpm 215 to 230 ton units 0 10 20 30 40 50 60 70 80 90 0 20 40 60 80 100 120 140 160 18...

Page 28: ...d Ft of H2O Power hp NPSH ft FLOW RATE Usgpm Effy Head Effy Power NPSH Figure 16 Pump curve series 4392 at 3373 rpm 215 to 230 ton units 0 10 20 30 40 50 60 70 80 0 20 40 60 80 100 120 140 160 180 200...

Page 29: ...lowest ambient expected Drain Water Circuit Below 20 F Shut off the power supply to the unit and to all heaters Purge the water circuit Blow out the evaporator to ensure no liquid is left in the evapo...

Page 30: ...out LERTC and low water temperature cutout LWTC ethlyene glycol Glycol Percentage Solution Freeze Point F Minimum Recommended LERTC F Minimum Recommended LWTC F Minimum Chilled Water Set Point F 0 32...

Page 31: ...9 21 0 7 0 0 0 47 25 1 21 0 7 0 0 0 48 27 3 21 0 7 0 0 0 49 29 7 21 0 7 0 0 0 50 32 1 21 0 7 0 0 0 51 34 5 21 0 7 0 0 0 52 37 1 21 0 7 0 0 0 53 39 7 21 0 7 0 0 0 54 42 3 21 0 7 0 0 0 55 45 0 21 0 7 0...

Page 32: ...0 21 18 4 12 4 22 4 28 1 22 17 6 11 6 21 6 27 3 23 16 7 10 7 20 7 26 4 24 15 7 9 7 19 7 25 4 25 14 8 8 8 18 8 24 5 26 13 8 7 8 17 8 23 5 27 12 7 6 7 16 7 22 4 28 11 6 5 6 15 6 21 3 29 10 5 4 5 14 5 20...

Page 33: ...the chiller controller The unit controller displays evaporator pump starts and run times Freeze protection down to an ambient of 4 F 20 C for water or 20 F 29 C for ethylene glycol or propylene glycol...

Page 34: ...on Item Description Item Description 1 Pump Single or Dual 6 Water Pressure Relief Valve T1 Evap Inlet Temp Sensor 2 Water Strainer 7 BPHE T2 Evap Outlet Temp Sensor 3 Drain Valve 8 Antifreeze Protect...

Page 35: ...Req gal 26 29 33 37 40 42 Acceptance volume gal 28 36 36 49 49 49 Tank Volume Required gal 33 37 42 46 50 53 2 Maximum Pressure psi 45 45 45 45 45 45 Acceptance Expansion Tanks Volume Req gal 22 25 28...

Page 36: ...ig ge er ra an nt t M Mo ot to or r t te er rm mi in na al ls s a ac ct t a as s a a s se ea al l a ag ga ai in ns st t t th hi is s r re ef fr ri ig ge er ra an nt t C Ca ar re e s sh ho ou ul ld d b...

Page 37: ...re es su ul lt t i in n d de ea at th h o or r s se er ri io ou us s i in nj ju ur ry y A Al ll l f fi ie el ld d w wi ir ri in ng g M MU US ST T b be e p pe er rf fo or rm me ed d b by y q qu ua al...

Page 38: ...y y o of f t th he e i in ns st ta al ll li in ng g c co on nt tr ra ac ct to or r a an nd d o or r t th he e c cu us st to om me er r t to o e en ns su ur re e t th ha at t a a p pu um mp p w wi il l...

Page 39: ...relay output configurations continued Description Evaporator Water Freeze Avoidance Request This relay output is energized any time either the Low Evaporator Water Temperature Unit Off or the Low Evap...

Page 40: ...closed When the contact opens the unit will trip on a latching diagnostic This latched condition requires either a manual reset at the front of the control panel or a power cycle of the UC800 to clea...

Page 41: ...ion The input defines the setpoint This input is primarily used with generic building automation systems BAS When the unit is in cooling mode the external water setpoint EWS corresponds to the chilled...

Page 42: ...h ho ot t w wa at te er r s se et tp po oi in nt t IF it is the highest priority and it is a valid source THEN use this external setpoint for active chilled water setpoint E Ex xt te er rn na al l d...

Page 43: ...tio on the User Interface 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...

Page 44: ...ir cooled heat exchanger Liquid refrigerant is metered into the brazed plate evaporator using an electronic expansion valve to maximize chiller efficiency at full and part load operation The chiller i...

Page 45: ...acer UC800 Controller Tracer AdaptiView TD7 Operator Interface UC800 Specifications Wiring and Port Descriptions The following figure illustrates the UC800 controller ports LEDs rotary switches and wi...

Page 46: ...e B connection for the service tool Tracer TU 10 The Ethernet connection can only be used with the Tracer AdaptiView display 11 USB Host not used Communication Interfaces There are four connections on...

Page 47: ...n at the data transfer rate when the UC800 transfers data to other devices on the link The RX LED blinks yellow at the data transfer rate when the UC800 receives data from other devices on the link Et...

Page 48: ...lar areas for each chiller component Touching any touch target displays a screen containing more chiller status information related to each component Figure 24 Home screen Table 22 Home screen items D...

Page 49: ...by Low Ambient Temp The chiller is inhibited based on the outdoor air temperature This is a Chiller Level Mode when the chiller is in Hot Water Control with Supplemental Heat not installed Start Inhib...

Page 50: ...s mutually exclusive with the Hot Water Control mode Manual Evaporator Pump Override The evaporator water pump relay is on due to a manual command Diagnostic Evap Pump Override The evaporator water pu...

Page 51: ...Limit The circuit is being inhibited from loading due to low suction pressure High Discharge Temp Limit The circuit is being inhibited from loading due to high discharge temperature Compressor Involut...

Page 52: ...s screen The Reports screen contains the following buttons to access the selected report Custom Report1 Custom Report2 Custom Report3 Evaporator Condenser Compressor About Operating Modes Log Sheet AS...

Page 53: ...er Entering Water Temperature X X F C Condenser Leaving Water Temperature X X F C Condenser Water Flow Status Flow No Flow Text Condenser Water Pump Override Auto On Text Condenser Approach Temperatur...

Page 54: ...n contains more than one page up down arrows also appear for viewing the other pages as in figure below Figure 33 Equipment settings screen chiller settings To change an equipment setting click desire...

Page 55: ...creen items continued Description Resolution Units Capacity Control Softload Time XXXX Sec Local Atmospheric Pressure XXX X psi kPa Power Up Start Delay XXX Min Feature Settings External Chilled Hot W...

Page 56: ...kPaG PSIA default if I P is chosen for display units PSIG N Nu um mb be er r F Fo or rm ma at t 1000000 0 1000000 0 Viewing and Changing Language On the Settings screen click L La an ng gu ua ag ge e...

Page 57: ...rity PIN is 1111 S Se ec cu ur ri it ty y L Le ev ve el l 2 2 Allows users to change all secure settings The default security PIN is 7123 Tracer TU service tool is used to set an alternate PIN or to r...

Page 58: ...adequately service chillers Tracer TU service tool is required Non Trane personnel contact your local Trane office for software purchase information Tracer TU adds a level of sophistication that impr...

Page 59: ...estart In the event of a power interruption the chiller will start a compressor before the front panel display is fully powered up eliminating the need for an uninterrupted power supply UPS Advanced f...

Page 60: ...ck Sheet chapter I Im mp po or rt ta an nt t Start up must be performed by Trane or an agent of Trane specifically authorized to perform start up and warranty of Trane products Contractor shall provid...

Page 61: ...rmation Section I Im mp po or rt ta an nt t A clear sight glass alone does not mean that the system is properly charged Also check system subcooling liquid level control and unit operating pressures I...

Page 62: ...alves oil line compressor discharge service valves and suction service valves are open backseated N NO OT TI IC CE E C Co om mp pr re es ss so or r D Da am ma ag ge e F Fa ai il lu ur re e t to o f fo...

Page 63: ...AC SVX002C EN 63 evaporator waterbox 9 Stop the water pump The unit is now ready for start up as described previously S St ta ar rt t u up p a an nd d S Sh hu ut td do ow wn n...

Page 64: ...ing color of the cylinder indicates the software state Text in parentheses indicates sub mode text as viewed in the Tracer AdaptiView Text above the time line cylinder is used to illustrate inputs to...

Page 65: ...o starting Power Applied Last Mode Was Auto Auto Waiting for Evaporator Water Flow Call for Cooling Differential to Start is met Energize Evaporator Water Pump Relay Confirm Evaporator Water Flow With...

Page 66: ...ting for Evaporator Water Flow Energize Evaporator Water Pump Relay Confirm Evaporator Water Flow Within 20 minutes 10 Sec Filter Waiting to Start Confirm Evaporator Water Flow 10 Second Filter Auto W...

Page 67: ...y De Energize Pumpdown Compressors Waiting for EXV to Close 0 to 10 Seconds Time out Evap Pump Off Delay adj 0 30 minutes De Energize Evaporator Water Pump De Energize all Non Pumpdown Compressors De...

Page 68: ...su ul lt t i in n d de ea at th h o or r s se er ri io ou us s i in nj ju ur ry y D Di is sc co on nn ne ec ct t a al ll l e el le ec ct tr ri ic c p po ow we er r i in nc cl lu ud di in ng g r re em...

Page 69: ...t tl ly y f fr ro om m t th he e a ai ir r T Th hi is s w wa at te er r i is s n ne ea ar rl ly y i im mp po os ss si ib bl le e t to o r re em mo ov ve e f fr ro om m t th he e c co om mp pr re es ss...

Page 70: ...um manifold If damaged or missing wrap new Prestite Insulated tar tape STR01506 on joint to cover area from the aluminum header body to at least 2 inches of the copper tube Seal insulation using hand...

Page 71: ...port protection plates must not be removed until the pump is ready to connect to the piping Rotate the shaft periodically at least monthly to keep rotating element free and bearings fully functional F...

Page 72: ...ostic and its effects are to be manually reset Latched or can be either manually or automatically reset when and if the condition returns to normal Nonlatched A Ac ct ti iv ve e M Mo od de es s I In n...

Page 73: ...between units with and without SLHX will be managed in next release R2b Downside of this extension to every heatpumps is loose limit to detect that temp sensor is failing if unit does not have SLHX Lo...

Page 74: ...efault CWS HWS to next level of priority e g Front Panel SetPoint This Warning diagnostic will automatically reset if the input returns to the normal range Remote External Demand Limit Setpoint Chille...

Page 75: ...entering or leaving water temp fell below the cutout setpoint for 30 F seconds while the compressor was running Automatic reset occurs when both of the temperature rises 2 F 1 1 C above the cutout set...

Page 76: ...The evaporator water pump relay will be de energized to stop the pump regardless of why the pump is running The diagnostic will auto reset and the pump will return to normal control when all circuits...

Page 77: ...tor Water Flow Lost Pump 1 Chiller Warning and Special Action NonLatch All For dual evaporator pump configurations only Evaporator Water Flow Lost diagnostic occurred while Pump 1 was the selected pum...

Page 78: ...turated Temperature Circuit Normal Latch Ckt Energized Ckt Not Energized The discharge saturated temperature for the respective circuit was below 10 C for more than 2250 C sec with a 10 minutes ignore...

Page 79: ...Active Modes Inactive Modes Criteria Reset Level Evaporator Entering Water Temp Sensor Chiller Normal Latch All Bad Sensor or LLID Remote Evaporator Leaving Water Temp Sensor Chiller Normal Latch All...

Page 80: ...the MP and the Functional ID has occurred for a 35 40 second period Remote Comm Loss Evap Leaving Water Temp Chiller Normal Latch All Continual loss of communication between the MP and the Functional...

Page 81: ...and the Functional ID has occurred for a 35 40 second period Comm Loss Fan Speed Select Board Relay X Circuit Normal Latch All Continual loss of communication between the MP and the Functional ID has...

Page 82: ...al Latch All Continual loss of communication between the MP and the Functional ID has occurred for a 35 40 second period Remote Comm Loss Evap Pump Inverter 1 Speed Chiller Normal Latch All Continual...

Page 83: ...lay X Chiller Warning Latch All Continual loss of communication between the MP and the Functional ID has occurred for a 35 40 second period Remote Comm Loss Liquid Line Temperature Circuit Normal Latc...

Page 84: ...tents Sheet 2 Legend Sheet 3 Incoming Power Circuit 1 Compressors and Transformers Sheet 4 Power Circuit 2 Compressors Sheet 5 Controls Compressor Fault Sheet 6 Controls Transformer and Power Supply S...

Page 85: ...n before Trane start up is scheduled and for reference during the Trane start up Where the log or check sheet also exists outside of this publication as standalone literature the literature order numb...

Page 86: ...ace and piped Isolation pads or elastomeric isolators installed Chiller is level to within 1 4 end to end and side to side Record and report any damage to the chiller 2 P Pi ip pi in ng g Water piping...

Page 87: ...t to o d do o s st ta ar rt t u up p If unit has nitrogen charge model number digit 20 2 contact Trane Service for unit charging prior to start up 8 O Ow wn ne er r A Aw wa ar re en ne es ss s Does th...

Page 88: ...protect food and perishables and increase industrial productivity and efficiency We are a global business committed to a world of sustainable progress and enduring results ingersollrand com Ingersoll...

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Ingersoll-Rand Trane Ascend ACS, Installation, Operation And Maintenance Manual

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