Trane Technologies CenTraVac CVHE Installation, Operation And Maintenance Manual Download Page 55

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CVHE-SVX005B-EN

Module Installation

Air-Fi

For installation instructions, see BAS-SVN038*-EN,

Air-

Wireless Communications Interface (WCI)

Installation Instructions

Recommended routing path for supplied Air-Fi cable is
shown in figure below. Device may be remote mounted
in order to obtain a stronger signal.

Figure 36.

Air-Fi wire harness routing path

Summary of Contents for CenTraVac CVHE

Page 1: ...rly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and on the tags sti...

Page 2: ...a ar r p pr ro op pe er r P PP PE E f fo or r t 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...

Page 3: ...i il ll le er rs s u us si in ng g R R 5 51 14 4A A r re ef fr ri ig ge er ra an nt t a an nd d v va ar ri io ou us s T Tr ra an ne e P PO OE E b ba as se ed d c co om mp pr re es ss so or r o oi il l...

Page 4: ...embly work and the required qualified personnel to operate the necessary rigging equipment Copyright This document and the information in it are the property of Trane and may not be used or reproduced...

Page 5: ...porator and Condenser Water Piping 33 Water Piping Connections 34 Waterbox Locations 35 Grooved Pipe Coupling 35 Flange connection Adapters 36 Victaulic Gasket Installation 36 Screw Tightening Sequenc...

Page 6: ...covery Proof of Flow 69 Temperature Sensor Circuits 70 CWR Outdoor Option 70 Optional Control and Output Circuits 70 Starter Module Configuration 70 Schematic Wiring Drawings 70 Operating Principles 7...

Page 7: ...ox Removal and Installation 95 Discussion 95 Procedure 95 Reassembly 96 Torque Requirements and Waterbox Weights 96 Connection Devices Information 97 Appendix A Forms and Check Sheets 98 Unit Start up...

Page 8: ...during parts identification S Se er rv vi ic ce e M Mo od de el l N Nu um mb be er r The service model represents the unit as built for service purposes It identifies the selections of variable unit...

Page 9: ...ser Tube Bundle Nominal Tons Digit 29 Heat Recovery Tubes Digit 30 Heat Recovery Condenser Waterbox Digit 31 Auxiliary Condenser Size and Waterbox Digit 32 Auxiliary Condenser Tubes Digit 33 Orifice S...

Page 10: ...4 shows an illustration of a typical unit and its components As soon as the unit arrives at the job site inspect it thoroughly for damage and material shortages In addition 1 Verify the hermetic integ...

Page 11: ...p 31 or Trane literature that shipped with the device Remote mounted starter optional Air Fi wireless communication optional Wi Fi wireless communication optional Circuit breakers or fusible disconne...

Page 12: ...ee ez zi in ng g especially if any shipping materials have been removed N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e F Fa ai il lu ur re e t to o p pr ro ot te ec ct t t th he e...

Page 13: ...it Verify waterbox and tube bundles are clean and dry Verify waterbox and tube bundles are clean and dry Conduct an oil analysis and verify no oil breakdown a Repeat yearly Replace oil if breakdown ha...

Page 14: ...ed as the front side of the unit Figure 3 Typical CVHF CenTraVac chiller 1 2 3 4 5 6 7 8 9 0 0 1 Suction Elbow 2 Compressor 3 Terminal Box 4 Control Panel 5 Condenser 6 Motor Housing 7 Economizer 8 Oi...

Page 15: ...re a 48 inch 122 cm clearance and 2501 to 9000V require a 60 inch 152 cm clearance Refer to NEC and local electrical codes for starter and control panel clearance requirements Figure 4 Clearance requi...

Page 16: ...259 250 Extended Extended Long 63 160 209 530 475 1206 43 109 115 292 Note All dimensions are approximate refer to the unit submittal package for exact dimensions for your unit General Weights Weights...

Page 17: ...50S 050S 20035 17599 21715 19279 230 320 289 050S 050L 21001 18356 22681 20036 230 320 289 050L 050L 22352 19304 24032 20984 360 500 455 050S 050S 20717 18281 22397 19961 360 500 455 050S 050L 21683 1...

Page 18: ...080L 142L 45710 38559 48710 41559 1070 1300 1062 142M 142L 49116 41210 52116 44210 1070 1300 1062 142L 142L 50337 42123 53337 45123 1070 1300 1062 142E 142L 51762 43109 54762 46109 1070 1300 1062 142M...

Page 19: ...0 215 050S 050S 19696 17195 231 21419 18918 190 320 215 050S 050L 20712 17952 231 22435 19675 190 320 215 050L 050L 21829 18682 231 23636 20502 300 500 360 050S 050S 21307 18806 379 22608 20107 300 50...

Page 20: ...210L 56984 47879 57541 48436 920 1100 892 142L 210L 58205 48792 58762 49349 920 1100 892 142E 210L 59630 49778 60187 50335 920 1100 892 210L 210L 63821 53751 64378 54308 Notes 1 TECU tubes 0 028 in t...

Page 21: ...89 050S 050S 9088 7983 9850 8745 230 320 289 050S 050L 9526 8326 10288 9088 230 320 289 050L 050L 10139 8756 10901 9518 360 500 455 050S 050S 9397 8292 10159 9054 360 500 455 050S 050L 9835 8635 10597...

Page 22: ...L 20734 17490 22094 18851 1070 1300 1062 142M 142L 22279 18693 23639 20053 1070 1300 1062 142L 142L 22832 19107 24193 20467 1070 1300 1062 142E 142L 23479 19554 24840 20915 1070 1300 1062 142M 210L 24...

Page 23: ...5 050S 050S 8934 7800 231 9715 8581 190 320 215 050S 050L 9395 8143 231 10176 8924 190 320 215 050L 050L 9901 8474 231 10721 9300 300 500 360 050S 050S 9665 8530 379 10255 9120 300 500 360 050S 050L 1...

Page 24: ...19105 670 780 621 142L 142L 23038 19266 23290 19519 920 1100 621 080L 142L 20904 17812 21157 18065 920 1100 892 142M 142L 23128 19519 23380 19772 920 1100 892 142L 142L 23704 19933 23957 20186 920 11...

Page 25: ...p po or rt ta an nt t Trane will not assume responsibility for equipment problems resulting from an improperly designed or constructed foundation Rigging Lifting is the recommended method for moving c...

Page 26: ...p 27 for instructions N No ot te e Follow instructions provided by the spring isolator manufacturer being careful to not damage isolator adjustment screw 5 Once the isolators are in place lower the ch...

Page 27: ...e greater than 45 from horizontal end to end the unit may require removal of the compressor Contact Trane or an agent of Trane specifically authorized to perform start up and warranty of Trane product...

Page 28: ...to the isolators insert cap screws through the chiller base and into holes drilled and tapped in the upper housing of each isolator I Im mp po or rt ta an nt t Do NOT allow the screws to protrude belo...

Page 29: ...m the bottom of each foot of the chiller 2 Suspend a clear plastic tube along the length of the chiller as shown in the following figure 3 Fill the tube with water until the level aligns with the punc...

Page 30: ...f pipe Place each tap a minimum of one pipe diameter downstream of any elbow orifice etc For example for a 6 in 16 cm pipe the tap would be at least 6 in 16 cm from any elbow orifice etc Valves Drains...

Page 31: ...lowing general flow switch installation guidelines Paddle Switches Figure 10 Flow paddle switch installation 1 2 3 4 5 5 1 Flow switch body 2 One 1 pipe size larger bushing to avoid paddle interferenc...

Page 32: ...igure for cable wiring N NO OT TI IC CE E D Do o N No ot t A Ap pp pl ly y E El le ec ct tr ri ic ca al l P Po ow we er r t to o a a U Un ni it t i in n a a V Va ac cu uu um m F Fa ai il lu ur re e t...

Page 33: ...tu ur re e f fa ai il lu ur re e o of f t th he e c ch hi il ll le er r Evaporator and condenser proof of flow switches either flow or Delta P are required as shown on wiring diagrams These switches a...

Page 34: ...and removed to prevent possible tube damage resulting from evaporator freeze up or erosion For condenser and large evaporator connections arrange the water piping so that the water supply enters the...

Page 35: ...t baffle arrangements Use a new gasket with each waterbox cover Grooved Pipe Coupling A customer supplied standard flexible grooved pipe coupling Victaulic Style 77 or equivalent should be used to com...

Page 36: ...ded The Style 741 150 psig 1034 2 kPaG flange adapter requires a smooth hard surface for a good seal Connection to other type flange faces i e raised serrated rubber etc requires the use of a flange w...

Page 37: ...asher must be used Table 10 Installation data for 300 psig 2068 4 kPaG flange adapters Style 743 Nominal Pipe Size Assembly Screw Size a Number of Assembly Screws Required Screw Pattern Diameter Weigh...

Page 38: ...screw tightening sequence 16 20 or 24 screws 16 screws 20 screws 24 screws 1 5 9 20 2 3 4 6 7 8 10 19 18 17 16 15 14 13 12 11 1 24 5 9 20 2 23 3 4 22 6 7 8 10 19 18 17 21 16 15 14 13 12 11 1 5 9 2 3...

Page 39: ...ss su ur re e t te es st t w wi it th h w wa at te er r p pr re es se en nt t i in n p pi ip pi in ng g a an nd d w wa at te er rb bo ox xe es s Waterside design pressure is either 150 psig 1034 2 kPa...

Page 40: ...exible connection devices for vibration isolation must also be compatible with the vented refrigerant A flexible stainless steel pump connector such as the stainless steel type MFP style HNE flexible...

Page 41: ...16 in socket Tighten screws in a star pattern one half turn each to maintain even pressure on the disk Final torque on all screws should be 240 in lb 27 1 N m When attaching the vent line to the chil...

Page 42: ...ld d r re es su ul lt t i in n e eq qu ui ip pm me en nt t d da am ma ag ge e A Al ll l v ve en nt t l li in ne es s m mu us st t b be e e eq qu ui ip pp pe ed d w wi it th h a a d dr ri ip p l le eg...

Page 43: ...external vent line and drip leg not provided Metal RuptureGuard disk Purge exhaust Flange Vent to outdoors Flange Drain line Chiller flange Drain valve Drip leg Important The purge exhaust line MUST b...

Page 44: ...250X 164 74 Notes 1 Rupture disk diameter is 3 in 76 2 mm with the exception of 250E evaporator 250L condenser units with heat recovery which have a rupture disk diameter of 4 in 101 6 mm 2 To determi...

Page 45: ...S 5 048 f 0 0155 4 NPS 4 026 f 0 0163 3 NPS 3 068 f 0 0173 Pipe Size I D Friction Factor C Value lb min L Pipe Length Equivalent Feet Feet x 0 305 Meters N No ot te e The preceding figure provided as...

Page 46: ...C C in lb min to kg s for SI f Moody friction factor in fully turbulent flow d inside diameter of pipe or tube in mm ln natural logarithm P2 absolute pressure at outlet of discharge piping psi kPa P0...

Page 47: ...t th he e s st tr ra ai in n r re el li ie ef f w wi it th h t th he e s se en ns so or r c co ou ul ld d r re es su ul lt t i in n e eq qu ui ip pm me en nt t d da am ma ag ge e D Do o N NO OT T a a...

Page 48: ...a as s t to o p pr re ev ve en nt t e ex xp po os su ur re e D Do o n no ot t u us se e t th hi in nn ne er rs s a an nd d s so ol lv ve en nt ts s o or r o ot th he er r t ty yp pe es s o of f p pa a...

Page 49: ...e tool is required Non Trane personnel contact your local Trane office for software purchase information Tracer TU adds a level of sophistication that improves service technician effectiveness and min...

Page 50: ...50 CVHE SVX005B EN Figure 29 Tracer TU I In ns st ta al ll la at ti io on n C Co on nt tr ro ol ls s...

Page 51: ...l Figure 30 Standard control panel main unit assembly showing low voltage and higher voltage areas for proper routing of field wiring 30 Volt Maximum 30 115 Volt Maximum I In ns st ta al ll la at ti i...

Page 52: ...e 31 Optional control panel main unit assembly showing low voltage and higher voltage areas for proper routing of field wiring 30 Volt Maximum 30 115 Volt Maximum I In ns st ta al ll la at ti io on n...

Page 53: ...te ed d m mo ov ve em me en nt t o of f t th he e s sp pr ri in ng g l lo oa ad de ed d s su up pp po or rt t a ar rm m w wh hi ic ch h c co ou ul ld d r re es su ul lt t i in n m mi in no or r t to o...

Page 54: ...bolt or screw is labeled with l lo oo os se en n t ti ig gh ht te en n or indicators Joint 3 3 has a 6 mm hex screw controlling the tension on a gas spring which allows the Tracer AdaptiView display...

Page 55: ...ess Communications Interface WCI Installation Instructions Recommended routing path for supplied Air Fi cable is shown in figure below Device may be remote mounted in order to obtain a stronger signal...

Page 56: ...Fi Module Installation Instructions Recommended routing path for supplied Wi Fi cable is shown in figure below Device may be remote mounted in order to obtain a stronger signal Figure 37 Wi Fi wire h...

Page 57: ...the enclosure Refer to installation information shipped with the starter or submittal drawings Electrical Requirements Before wiring begins observe the following electrical requirements Follow all lo...

Page 58: ...Ground 1X1 1 1X1 12 1X1 30 Ground 8 40 High Pressure Cutout to Starter 2X1 4 1X1 4 14 20 1Q1 Circuit Breaker to Starter c 1X1 3 14 20 Oil Pump Interlock 2X1 7 2X1 8 1A7 J2 4 1A7 J2 2 14 20 Low Voltag...

Page 59: ...hite black 5CT6 white black 1A23 J7 1 2 1A23 J7 3 4 1A23 J7 5 6 Note Phasing must be maintained Potential Transformers Required 5T17 236 237 5T18 238 239 5T19 240 241 1A23 J5 1 2 1A23 J5 3 4 1A23 J5 5...

Page 60: ...L 1995 Table 18 Maximum recommended total wire length to and from for PT leads in a dual PT system Wire AWG a Max Wire Length Primary Max Wire Length Secondary Feet Meters Feet Meters 8 3061 933 711 2...

Page 61: ...e e c co op pp pe er r c co on nd du uc ct to or rs s c co ou ul ld d r re es su ul lt t i in n e eq qu ui ip pm me en nt t d da am ma ag ge e a as s t th he e e eq qu ui ip pm me en nt t w wa as s n...

Page 62: ...ot th he er r e en ne er rg gy y s st to or ri in ng g c co om mp po on ne en nt ts s p pr ro ov vi id de ed d b by y T Tr ra an ne e o or r o ot th he er rs s r re ef fe er r t to o t th he e a ap p...

Page 63: ...ot te e Must enter the low voltage Class 2 portion of the unit control panel 1000 feet 304 8 m maximum 5 Motor terminal box 6 115V control conduit N No ot te e Must enter the higher than 30 Vdc Class...

Page 64: ...l clamp with a 3 8 in 9 525 mm bolt is provided on each motor terminal stud use the factory supplied Belleville washers on the wire lug connections The following figure illustrates the junction betwee...

Page 65: ...t 304 8 m The polarity of the IPC wiring is critical for proper operation Separate low voltage less than 30V refer to the tables in and wiring from the 115V wiring by running each in its own conduit W...

Page 66: ...ansformer or solid state starting Refer to the unit nameplate for motor data including RLA LRA etc In all cases of non Trane supplied starters a disconnecting means and short circuit protection must b...

Page 67: ...he terminal or premature terminal failure could result Motor Terminals Field provided ring type lugs with no sharp edges or corners must be used by a qualified installer to connect the power wiring to...

Page 68: ...l Operation Emergency Stop Input 1A13 J2 3 to 4 Binary Input Closure Required for Normal Operation Optional Low Voltage Circuits External Base Loading Enable Input 1A18 J2 1 to 2 Binary Input Normally...

Page 69: ...inside of the control panel for field wiring This is a dry binary input normally open closure for flow Apply no external power 1 With factory installed ifm efector flow sensing devices a field provide...

Page 70: ...nsor probe and the sensor module N No ot te e This sensor and module are matched and must remain together or inaccuracy may occur These wires can then be spliced with two 14 to 18 AWG 600V wires of su...

Page 71: ...third stage impeller After 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 condens...

Page 72: ...orator Compressor Second Stage Compressor First Stage 6 5 4 3 1 2 Pressure Enthalpy P3 P1 P2 Figure 48 Refrigerant flow 2 stage Oil and Refrigerant Pump Compressor Lubrication System A schematic diagr...

Page 73: ...in 9 525 mm OD 7 Oil return to tank 8 Oil tank 9 Oil cooler within economizer 0 625 in 15 875 mm OD coiled tubing 10 Oil reclaim from evaporator second eductor 0 25 in 6 35 mm OD 11 Liquid refrigeran...

Page 74: ...drive oil reclaim eductors 0 375 in 9 525 mm OD 7 Oil return to tank 8 Oil tank 9 Oil reclaim from evaporator second eductor 0 25 in 6 35 mm OD 10 Liquid refrigerant to pump 1 625 in 41 275 mm OD 11 E...

Page 75: ...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 suc...

Page 76: ...re designations for each state The first line of text in the circles is the visible top level operating modes that can be displayed in Tracer AdaptiView The shading of each software state circle corre...

Page 77: ...fixed timers Dashed double arrows indicate variable timers Start up Sequence of Operation Wye delta Logic circuits within the various modules will determine the starting running and stopping operatio...

Page 78: ...t guide vanes will modulate opening and closing to the chiller load variation by operation of the stepper vane motor actuator to satisfy chilled water setpoint The chiller continues to run in its appr...

Page 79: ...essor Currents Within 0 to 30 seconds De Energize Condenser Water Pump Relay Command IGV Closed Enforce All Running Mode Diagnostics Note CVH No oil pressure is less than 3 psid 20 7 kPaD CVG No oil p...

Page 80: ...ter Flow 6 seconds minimum Enforce Restart Inhibit Timer Evaporator Pump Off Delay Time 0 to 30 minutes Close IGV Energize Condenser Water Pump Relay Confirm Condenser Water Flow Within 4 minutes 15 s...

Page 81: ...ng feature when the Ice Building option is installed Building can be entered from Front Panel or if hardware is specified the control panel will accept either an isolated contact closure 1A19 Terminal...

Page 82: ...s Ice Building Command 1 Front Panel 2 Tracer 3 External Input Energize Ice Building Relay Ignore Softloading and Set CLS 100 Energize Head Relief Request Relay Running Ice to Normal Transition Evap L...

Page 83: ...rator interface or by means of a BAS request The following components must be factory or field installed to equip the unit for free cooling operation a refrigerant gas line and electrically actuated s...

Page 84: ...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 valv...

Page 85: ...t te e The heat recovery cycle is possible only 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 Though physically ident...

Page 86: ...co on nt ta ac ct t t th he e a ap pp pr ro op pr ri ia at te e r re es sc cu ue e o or r r re es sp po on ns se e a au ut th ho or ri it ty y W Wh hi il le e t th he e u un ni it t i is s o of ff f d...

Page 87: ...de Seasonal Unit Start up 1 Close all drain valves and reinstall the drain plugs in the evaporator and condenser headers 2 Service the auxiliary equipment according to the start up and maintenance ins...

Page 88: ...Ma at te er ri ia al ls s U Us se e o of f n no on n c co om mp pa at ti ib bl le e p pa ar rt ts s o or r m ma at te er ri ia al ls s c co ou ul ld d r re es su ul lt t i in n e eq qu ui ip pm me en...

Page 89: ...operator tang O rings Operate the tang operators manually and check for any abnormalities Lubricate the oil filter shutoff valve O rings Drain contents of the rupture disk and purge discharge vent lin...

Page 90: ...ud di in ng g b be ea ar ri in ng g d da am ma ag ge e i in nt tr ro od du uc ct ti io on n o of f a ac ci id ds s i in nt to o t th he e c ch hi il ll le er r o or r c co on nt ti in nu uo ou us s p...

Page 91: ...s the chiller s efficiency and cooling capacity Therefore proper maintenance of the purge system is required The purge is designed to remove non condensable gases and water from the refrigeration syst...

Page 92: ...ni in ng g t th he e s sy ys st te em m S Se ee e u un ni it t n na am me ep pl la at te e f fo or r r re ef fr ri ig ge er ra an nt t t ty yp pe e D Do o n no ot t u us se e n no on n a ap pp pr ro...

Page 93: ...ty y f fo or r e eq qu ui ip pm me en nt t f fa ai il lu ur re es s w wh hi ic ch h r re es su ul lt t f fr ro om m u un nt tr re ea at te ed d o or r i im mp pr ro op pe er rl ly y t tr re ea at te...

Page 94: ...being placed into service If the observed loss of anode material is small then the interval between subsequent inspections can be lengthened Replace the anode and or shorten the inspection interval if...

Page 95: ...at ti in ng g f fo or r e ey ye eb bo ol lt ts s a ar re e b ba as se ed d o on n a a s st tr ra ai ig gh ht t v ve er rt ti ic ca al l l li if ft t i in n a a g gr ra ad du ua al ll ly y i in nc cr...

Page 96: ...nt t Torque waterbox screws as specified in Torque Requirements and Waterbox Weights p 96 Torque Requirements and Waterbox Weights N No ot te e These chillers are assembled with SAE fasteners Table 2...

Page 97: ...0 3 4 10 Evaporator 300 psig 2068 4 kPaG 456 207 0 469 882 400 3 4 10 Condenser 150 psig 1034 2 kPaG 457 207 0 469 1323 600 3 4 10 Condenser 300 psig 2068 4 kPaG 683 309 0 469 1764 800 3 4 10 210 Evap...

Page 98: ...iterature the literature order number is also listed CTV Form Installation Completion and Request for Trane Service CTV ADF001 EN CenTraVac Chiller Start up Tasks to be Performed by Trane CenTraVac Ch...

Page 99: ...hiller Installation Operation and Maintenance manual Do NOT block serviceable parts when installing isolation springs Expenses that result in improper installation of CenTraVac chillers including opti...

Page 100: ...S Sy ys st te em m Systems can be operated under load conditions 9 A Av va ai il la ab bi il li it ty y Electrical control personnel and contractor s representative are available to evacuate charge a...

Page 101: ...05B EN 101 A Ap pp pe en nd di ix x B B C Ch hi il ll le er r I In ns st ta al ll la at ti io on n C Co om mp pl le et ti io on n a an nd d R Re eq qu ue es st t f fo or r T Tr ra an ne e S Se er rv v...

Page 102: ...t corrected prior to start up must be noted in the Non Compliance Form PROD ADF001 EN by the start up technician this information must also be signed by responsible site personnel before start up and...

Page 103: ...regulating valve setting Verify vane operator is working properly and moves without binding Dry run test starter non AFD Remove separate source power and reconnect wiring Install optional Air Fi and o...

Page 104: ...v ve er ry y Inspect for fouling and scaling in tubes Check operation of heat recovery water flow sensing device Factory recommendation to eddy current test tubes every three years 7 C Co on nt tr ro...

Page 105: ...proach Temperature Condenser Saturated Rfgt Temp Condenser Refrigerant Pressure Condenser Approach Temperature Condenser Saturated Rfgt Temp Condenser Refrigerant Pressure Condenser Differential Water...

Page 106: ...tor Winding Temp 1 Motor Winding Temp 2 Motor Winding Temp 3 Motor Temperature MTC Switch Motor Coolant Temperature Speed Command Motor Speed Motor Frequency or Frequency Command AFD Transistor Temper...

Page 107: ...CVHE SVX005B EN 107 N No ot te es s...

Page 108: ...or more information please visit trane com or tranetechnologies com Trane has a policy of continuous product and product data improvements and reserves the right to change design and specifications wi...

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