Trane Technologies CVHE Installation, Operation And Maintenance Manual Download

Page: 11 / 95

Unit Components

Note:

Components are identified from a viewpoint that faces the front side of the control panel.

Figure 2. Typical CVHF CenTraVac Chiller

1.  Suction Elbow
2.  Compressor
3.  Terminal Box
4.  Control Panel
5.  Condenser
6.  Motor Housing
7.  Economizer
8.  Oil Tank  Assembly
9.  Purge
10. Evaporator
11. Display Panel

TCVHE-SVX04D-EN 11

Pre-Installation

RELEASED 10/Mar/2020 06:59:20 GMT

Summary of Contents for CVHE

Page 1: ...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 in the literature and on the...

Page 2: ...e the same potential impact to the environment Trane advo cates the responsible handling of all refrigerants includ ing industry replacements for CFCs and HCFCs such as HFCs Responsible Refrigerant Pr...

Page 3: ...fall protection electrical PPE and arc flash clothing ALWAYS refer to appropriate MSDS sheets and OSHA guidelines for proper PPE When working with or around hazardous chem icals ALWAYS refer to the ap...

Page 4: ...iping Connections 23 PressureTesting Waterside Piping 24 Purge Piping 25 EarthWise Purge Requirements Purge Instal lation 25 Vent Piping 26 Refrigerant Vent Line 26 General Recommendations 26 Purge Di...

Page 5: ...Machine Control 57 Free Cooling Cycle 59 Free Cooling FRCL 59 Hot Gas Bypass HGBP 59 Hot Water Control 60 Heat Recovery Cycle 60 Auxiliary Condensers 60 Control Panel Devices and Unit Mounted De vice...

Page 6: ...e or during parts identification Service Model Number The service model represents the unit as built for service purposes It identifies the se lections of variable unit features required when ordering...

Page 7: ...t Recovery Condenser Tube Bundle nominal tons 29 Heat Recovery Tubes 30 Heat Recovery Condenser Waterbox 31 Auxiliary Condenser Size Waterbox 32 Auxiliary Condenser Tubes 33 Orifice Size 34 Orifice Si...

Page 8: ...from the factory as a hermetically assembled package it is factory piped wired and test ed All openings except for the waterbox vent and drain holes are covered or plugged to prevent contamination du...

Page 9: ...condenser pressure interlock wiring AFD and remote mounted starters only Chilled water pump contactor and wiring including interlock Condenser water pump contactor and wiring including interlock Optio...

Page 10: ...en pressure using gauge located on the evaporator shell reads 3 to 5 psig 21 to 34 5 kPa Notify the local Trane office if charge has escaped Verify dry nitrogen pressure using gauge located on the eva...

Page 11: ...ol panel Figure 2 Typical CVHF CenTraVac Chiller 1 2 3 11 4 5 6 7 8 9 10 1 Suction Elbow 2 Compressor 3 Terminal Box 4 Control Panel 5 Condenser 6 Motor Housing 7 Economizer 8 OilTank Assembly 9 Purge...

Page 12: ...liary condenser optional Cooling condenser Economizer Motor C B A D E Per NEC article 110 18 45 72 cm Right hand tube pull shown apply tube pull clearance dimension to left end for left hand tube pull...

Page 13: ...27958 12682 24869 11281 650 910 957 080L 080L 32688 14827 28803 13065 34249 15535 30364 13773 650 910 957 080S 080L 30526 13847 27191 12334 32087 14555 28752 13042 650 910 957 080S 080S 2883 13070 257...

Page 14: ...21 142M 142L 44434 20155 38539 17481 45516 20646 39621 17972 1100 621 210L 210L 57399 26036 49455 22432 58481 26527 50537 22923 C V H E 190 270 242 032L 032L 16719 7584 15173 6882 17801 8075 16255 737...

Page 15: ...to lift the unit must be capable of supporting the entire weight of the unit Lifting cables chains or slings may not be of the same length Adjust as necessary for even unit lift Failure to properly l...

Page 16: ...tempt to rotate chiller on to side When lifting the chiller is either impractical or unde sirable attach cables or chains to the jacking slots shown in Figure 4 p 16 then push or pull the unit across...

Page 17: ...upper housing of each isolator down and could cause it to rest on the isolator s lower housing Figure 6 illustrates spring isolator construction 6 Check the clearance on each isolator If this dimen s...

Page 18: ...table alternative method to level the unit Immediately report any unit damage incurred during handling or installation at the job site to theTrane sales office 18 TCVHE SVX04D EN Installation Mechanic...

Page 19: ...taps in a straight length of pipe Place tap a minimum of one pipe diameter downstream of any elbow orifice etc Example for a 6 152 mm pipe the tap would be at least 6 152 mm from any elbow orifice et...

Page 20: ...result in severe equipment damage Evaporator and condenser proof of flow switches either flow or Delta P are required in series with the pump contactor auxiliary shown on wiring diagrams These switch...

Page 21: ...or multiple use cooling condenser water supply install a valved bypass leg optional between the supply and return pipes This valved bypass allows the operator to short circuit water flow through the...

Page 22: ...nual AM FND 8 titled Heat Recovery Engineering Seminar 5 Install a bypass valve system to avoid circulating water through the auxiliary shell when the unit is shut down On multiple pass condensers ent...

Page 23: ...cerning proper piping system de sign and construction methods for grooved water piping systems Note Flexible coupling gaskets require proper lubri cation before installation to provide a good seal Ref...

Page 24: ...nsure that the water box head rests tightly against the tube sheet then snugly tighten the 26 bolts in sequential order If excessive tube sheet crown prevents the head from contacting the tube sheet t...

Page 25: ...ome combustible in the presence of an ignition source leading to an explosion Excessive heat from soldering brazing or welding with refrig erant vapors present can form highly toxic gases and extremel...

Page 26: ...a lent is recommended Vent Line Sizing Vent line size must conform to local codes and require ments In most cases local codes are based on ASHRAE Standard 15 ASHRAE Standard 15 provides specific requi...

Page 27: ...to support the vent line piping 4 Use a flexible connection between the vent line and the rupture disc assembly to avoid placing stress on the rupture disc Stress can alter rupture pressure and cause...

Page 28: ...ments and refer to CFC Guide 2 Figure 13 Illustrates rupture disc location cross section of rupture disc bolt rupture disc gasket outside pipe suction connection cap assembly Note Pipe connection is 3...

Page 29: ...ooling or an auxiliary condenser add the applicable C values to this total With this new sum refer to Figure 15 p 30 to determine the vent line pipe diameter a EVSZ Evaporator shell size b CDSZ Conden...

Page 30: ...PS 3 068 5 NPS f 0 0173 5 048 f 0 0155 ANSI ASHRAE Standard 15 2007 f C2 R L 214d 5 P2 0 P2 2 6f d ln P0 P2 P0 0 5 15 P2 P2 14 7 psia f Moody Friction Factor in fully turbulent flow Note This chart pr...

Page 31: ...t 050 Short 385 63 398 72 050 Long 420 63 436 72 080 Short 505 84 515 97 080 Long 553 84 566 97 142 Medium 555 98 555 133 142 Long 578 98 578 133 142 Extended 603 104 629 133 210 Long 700 98 710 133 2...

Page 32: ...ns must be accessible after insu lating 2 Evaporators with ASME nameplates must have insulation cut out around the nameplate Do not glue insulation to the nameplate 3 All units with evaporator marine...

Page 33: ...corresponds to the numbered callouts in the illustration Figure 17 Wiring locations and connection ports LINK 24 VDC MBUS 6 Front View Bottom View 7 8 9 6 1 10 11 2 3 4 5 1 Rotary Switches for settin...

Page 34: ...f the Marquee LED is green solid the UC800 is powered and no problems exist Low power or malfunction If the Marquee LED is red solid the UC800 is powered but there are problems present Alarm The Marqu...

Page 35: ...24 1A17 1A18 1A13 1A14 1A15 1A16 1A22 X19091218 01 OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30V MAX 30V MAX 30V MAX...

Page 36: ...Support Arm To prevent unexpected movement of the spring loaded support arm ensure that the support arm is in the full upright position when removing the Tracer AdaptiView display from the support ar...

Page 37: ...20 Joint locations on the display arm 4 3 2 1 2 Joint 3 has a 6 mm hex screw controlling the tension on a gas spring which allows theTracer AdaptiView display to tilt up and down 3 Joints 1 and 2 are...

Page 38: ...Voltage Circuits Medium and High Voltage Circuits Ambient Air Tem perature The temperature of indoor electric should be at 5o C 40o C and the average temperature measured during 24 hours should be no...

Page 39: ...ng 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 cap...

Page 40: ...mm2 20 Low Voltage Circuits less than 30 Vac Starter Panel Terminals Unit Control Panel Terminations Standard Circuits Inter Processor Communica tions IPC Remote Mounted 2A1 J3 3 4 or 2X1 12 to 13 if...

Page 41: ...2 5 mm2 20 Transition complete 5X1 14 1A23 J12 2 14 ga 2 5 mm2 20 Low Voltage Circuits less than 30 Vac Starter Panel Termi nals Unit Control Panel Terminations Standard Circuits Current Transformers...

Page 42: ...9 1627 10 3357 1023 12 2112 643 14 1328 404 16 835 254 17 662 201 18 525 160 20 330 100 21 262 79 22 207 63 Note 1 Wire length is for copper conductors only 2 The above length is maximum round trip wi...

Page 43: ...er nameplate and transformer load on U1 and V1 Confirm that wire size is compatible with lug size stated in unit submittal Make sure that the incoming power wiring is prop erly phased each power suppl...

Page 44: ...ase unit capacitor Fused disconnector suitable breaker 1 Power 2 circuit 3 Current transformer Motor starter contactor Rule 2 PFCC wires routed through cur rent transformers Size motor overload protec...

Page 45: ...st be field supplied Use field provided crimp type wire terminal lugs properly sized for the application Note Wire size ranges for the starter line and load side lugs are listed on the starter submitt...

Page 46: ...tage circuits Failure to do so could result in electrical noise that may distort the signals carried by the low voltage wiring including the IPC wiring 1 If the starter enclosure must be cut to provid...

Page 47: ...weld nuts are provided on the top of the terminal box to allow the use of properly rated lifting d rings if removal is needed for clearance purposes Note If the box is removed for installation purpose...

Page 48: ...rovided on the motor terminals to retain the lugs and the final connection should be tightened to 22 25 ft lb 30 34 N m using a 7 8 22 mm socket on a torque wrench D D NOTICE Motor Terminal Damage Do...

Page 49: ...d for normal operation Optional Low Voltage Circuits External Base Loading Enable Input 1A18 J2 1 to 2 Binary Input Normally Open External Hot Water Control Enable Input 1A18 J2 3 to 4 Binary Input No...

Page 50: ...with the flow switch 5S2 installed in the condenser supply pipe 2 Connect circuit to control panel terminals 1X1 6 to 1A6 J2 2 Temperature Sensor Circuits All temperature sensors are factory installed...

Page 51: ...service the controls Schematic Wiring Drawings The chart below consist of typical wiring drawings for a CenTraVac chiller available through e Library However please refer to the submittals and drawing...

Page 52: ...through the condenser tubes absorbs heat from the refrigerant causing it to condense The liquid refrigerant then passes through orifice plate and into the economizer The economizer reduces the energy...

Page 53: ...oil tank Figure 28 Oil refrigerant pump compressor lubrication system Compressor lubrication system Oil reclaim system Motor cooling system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 Motor...

Page 54: ...er 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...

Page 55: ...relay with customer supplied power Based on the Restart Inhibit function and the Differen tial to Start setpoint the oil and refrigerant pump is energized and the oil vent line valve is closed to the...

Page 56: ...o 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 s...

Page 57: ...ilding can be entered from Front Panel or if hardware is specified the control panel will accept either an isolated contact closure 1A19 Terminals J2 1 and J2 2 Ground or a remote communi cated input...

Page 58: ...Figure 34 Sequence of operation ice making stopped to ice to ice building complete 58 TCVHE SVX04D EN Start up and Shut Down RELEASED 10 Mar 2020 06 59 20 GMT...

Page 59: ...nk 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...

Page 60: ...setpoints are used with respect to the hot water setpoint instead of with the chilled water setpoint The control panel provides a sep arate entry at theTracer AdaptiView to set the hot water setpoint...

Page 61: ...ing installation testing servicing and trouble shooting of this product it may be necessary to work with live electrical components Have a qual ified licensed electrician or other individual who has b...

Page 62: ...rge will start running and will run as long as the chiller is running Note If a manual reset diagnostic condition is detected during start up unit operation will be locked out and a manual reset is re...

Page 63: ...water circuit 5 If the evaporator was previously drained fill and vent the evaporator and chilled water circuit When all air is removed from the system including each pass close the vent valves in the...

Page 64: ...ation and Maintenance Guide EarthWise Purge system withTracer AdaptiV iew Control for Water Cooled CenTraVac Chillers with R 123 Refrigerant PRGF SVX001 EN For R 514A chillers recommended purge mainte...

Page 65: ...porator refrigerant temperature displayed on the control panel read out is outside this 4 degree tolerance range replace the sensor If the sensor is exposed to temperature extremes outside its normal...

Page 66: ...Draw the oil from the chiller through the oil charging valve on the chiller oil sump into an approved evac uated tank or Pump the oil from the chiller through the oil charging valve into an airtight r...

Page 67: ...ht 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 u...

Page 68: ...e services of a qualified chem ical cleaning firm be used Proper personal protec tive equipment as recommended by the chemical manufacturer should be used Refer to the chemicals MSDS sheet for proper...

Page 69: ...ge 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 theTrane sales eng...

Page 70: ...m with refrigerant vapor or circulate water to avoid tube damage 2 Always use refrigerant compatible hoses or cop per tubing with self sealing connections or shut off valves 3 Transfer the refrigerant...

Page 71: ...arm water or heat blankets to raise the tank temperature Do not exceed a temperature of 150 F Do not under any circumstances apply direct flame to any portion of the cylinder Failure to follow these s...

Page 72: ...lways 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 de...

Page 73: ...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 toTable 16 CenTraVac Refer toTable 16 for torqu...

Page 74: ...L Y 82 79 76 77 N 82 81 81 83 CVHF 870 910 080S 080L Y 82 79 77 78 N 82 82 81 83 142L Y 82 78 76 77 N 83 82 83 84 CVHF 1070 142L Y 82 79 77 77 N 82 81 83 85 210L 250L Y 82 79 77 78 N 82 82 83 85 CVHF...

Page 75: ...7 75 74 72 70 69 69 66 25 77 76 74 72 69 68 67 66 CVHE 500 100 71 69 69 69 70 71 75 65 75 70 70 69 68 69 70 72 65 50 67 68 68 68 69 69 70 66 25 66 67 67 67 68 69 68 65 CVHF 350 100 75 75 73 71 71 70 7...

Page 76: ...67 69 CDHF 1500 100 78 78 82 80 80 76 72 65 75 77 78 81 81 80 76 71 64 50 76 79 79 81 80 75 71 63 25 76 79 78 83 80 75 70 62 CDHF 2000 100 80 82 81 81 80 76 72 69 75 80 79 81 79 78 74 71 68 50 81 79 8...

Page 77: ...100 78 78 78 75 75 73 68 64 75 77 77 77 75 75 72 66 64 50 78 78 77 75 74 73 68 65 25 79 79 79 76 77 73 69 65 CVHG 565 100 79 78 77 74 76 73 70 65 75 79 79 79 74 74 71 67 65 50 80 81 79 76 74 72 68 65...

Page 78: ...e 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 t...

Page 79: ...ation 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 control panel is field wiri...

Page 80: ...s free of dust debris etc Power Up the control panel Non AFD Starters 1 Starter disconnect locked open 2 Fuse 2F4 must be removed from the starter 3 Connect auxiliary 115VAC power cord toTerminals 1X1...

Page 81: ...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...

Page 82: ...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 b...

Page 83: ...e for pressure testing Water supply connected to filling system Trace gas amounts of Refrigerant 22 or R 134a Systems filled available for leak testing if necessary Pumps run air bled from system Stra...

Page 84: ...ing 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 Comple...

Page 85: ...ump motor ground continuity check Run oil pump and check net oil pressure Condenser Visually inspect for scaling and fouling in tubes Note findings and make recommendations for cleaning Evaporator Onc...

Page 86: ..._______________________________ ________________________________________________________________ ________________________________________________________________ ______________________________________...

Page 87: ...ts AB BC CA Power KW Load PF Winding 1 Temp Winding 2 Temp Winding 3 Temp with AFD only AFD Freq AFD Speed AFD Transistor Temp Purge Time Until Next Purge Run Daily Pumpout 24 hrs Avg Daily Pumpout 7...

Page 88: ...High Pressure Cutout Impeller Diameter Options Line Voltage Sensing Free Cooling Hot Gas Bypass Second Condenser Hot Water Control Outdoor Air Temp Sensor External Chilled Water Setpoint External Cur...

Page 89: ...tage Voltage Transformer Ratio Rated Load Amps CT Meter Scale Current Unbalance Trip Point Current Unbalance Grace Period Maximum Acceleration Setting Acceleration Time Out Action Overload Type Phase...

Page 90: ...erence Acceleration Time Deceleration Time Starter Current Limit Current Limit Gain Power Loss Mode Power Loss Time Flying Start Flying Start Gain Use Trane Defaults RTD Type 90 TCVHE SVX04D EN Forms...

Page 91: ...ic Heat Evap Low Water Flow Warning Setpoint Low Differential Oil Pressure Cutout Setpoint Check Oil Filter Diagnostic Check Oil Filter Setpoint Restart Inhibit Diagnostic Minimum Capacity Limit Maxim...

Page 92: ...ge Exhaust Circuit Test Clear Restart Inhibit Timer Exhaust Circuit Pressure Test Exhaust Circuit Vacuum Test Adjustable Frequency Drive Maximum Frequency Minimum Frequency AFD Surge Capacity Increase...

Page 93: ...Oil Level ____________________________________________________________ __________________________________________________________ Vibration Levels _____________________________________________________...

Page 94: ...s Viewing Purge Operating Modes Data Graphs Viewing the Data Graphs Screen Viewing Data Graphs Changing the Scales on Data Graphs Creating Custom Data Graphs Editing Custom Data Graphs Deleting a Cust...

Page 95: ...or more information please visit trane com or tranetechnologies com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications wit...

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