Trane Agility HDWA Installation, Operation And Maintenance Manual Download Page 5

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HDWA-SVX001D-EN

LonTalk Interface (LCI-C). . . . . . . . . . . . . . 40
BACnet Interface (BCI-C) . . . . . . . . . . . . . . 40
MODBUS Remote Terminal Unit
Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installation: Controls . . . . . . . . . . . . . . . . . . . . . . 41

UC800 Specifications . . . . . . . . . . . . . . . . . . . . 41

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring and Port Descriptions. . . . . . . . . . 41
Communication Interfaces . . . . . . . . . . . . 42
Rotary Switches . . . . . . . . . . . . . . . . . . . . . 42
LED Description and Operation. . . . . . . . 42

Installing the Tracer AdaptiView
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the Tracer AdaptiView Display
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operating Principles . . . . . . . . . . . . . . . . . . . . . . . 47

General Requirements . . . . . . . . . . . . . . . . . . . 47

Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

HDWA Compressor . . . . . . . . . . . . . . . . . . 47

Compressor Motor . . . . . . . . . . . . . . . . . . . . . . 47

Adaptive Frequency Drive . . . . . . . . . . . . . . . . 47

Uninterruptible Power Supply . . . . . . . . . . . . 48

Evaporator and Condenser . . . . . . . . . . . . . . . 48

Drive Cooling System . . . . . . . . . . . . . . . . . . . . 48

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

Start-up and Shut-down . . . . . . . . . . . . . . . . . . . 49

Sequence of Operation. . . . . . . . . . . . . . . . . . . 49

Ice Making (Auto to Ice Making to Ice
Making Complete) . . . . . . . . . . . . . . . . . . . 59

Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 60

Control Panel Devices and Unit-Mounted
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Unit Control Panel . . . . . . . . . . . . . . . . . . . 60
User-defined Language Support . . . . . . 60

Unit Start-up and Shut-down
Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Unit Start-up. . . . . . . . . . . . . . . . . . . . . . . . . 61
Temporary Shut-down and
Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Extended Unit Shut-down . . . . . . . . . . . . 61
Seasonal Unit Start-up . . . . . . . . . . . . . . . 61

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Recommended Maintenance . . . . . . . . . . . . . 63

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Maintenance Procedures . . . . . . . . . . . . . . . . . 63

Drive Cooling System . . . . . . . . . . . . . . . . 63
Cleaning the Condenser . . . . . . . . . . . . . . 64
Cleaning the Evaporator . . . . . . . . . . . . . . 66

Waterbox Hinges . . . . . . . . . . . . . . . . . . . . . . . . 66

Adaptive Frequency Drive Periodic
Maintenance and Inspection . . . . . . . . . . . . . . 67

Visual Inspection—Power
Removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operational Inspection—Power
Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Appendix A: Forms and Check
Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Unit Start-up/Commissioning. . . . . . . . . . . . . 69

Appendix B: Agility

™

Chiller Installation

Completion and Request for Trane
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Appendix C: Settings . . . . . . . . . . . . . . . . . . . . . . 72

Appendix D: Operator Log . . . . . . . . . . . . . . . . . 74

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Summary of Contents for Agility HDWA

Page 1: ...owledge 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 in the li...

Page 2: ...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 i in nj ju ur ry y T Te ec ch hn ni ic ci ia a...

Page 3: ...following is required to preserve the factory warranty A Al ll l U Un ni it t I In ns st ta al ll la at ti io on ns s Startup MUST be performed by Trane or an authorized agent of Trane to VALIDATE thi...

Page 4: ...Pads 20 Leveling the Unit 21 Refrigerant Pressure Relief Valve Venting 21 Freeze Protection 23 Installation Water Piping 25 Overview 25 Water Treatment 25 Water Pressure Gauges 25 Valves Drains and V...

Page 5: ...Immediate Shutdown to Stopped or Run Inhibit 56 AFD Mains Phase Loss 57 Ice Making Running to Ice Making to Running 58 Ice Making Auto to Ice Making to Ice Making Complete 59 Limit Conditions 60 Cont...

Page 6: ...service or 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 var...

Page 7: ...internal and external compressor parts The model number begins with HDMA and the nameplate is located on the interstage pipe refer to Model Number Descriptions p 8 Figure 2 Compressor nameplate N No o...

Page 8: ...erformance Internal Surface Evaporator Tube S Special Digit 18 Evaporator Waterbox B 150 marine 2 pass F 150 psi Non marine 2 Pass Standard S Special Digit 19 Condenser Shell Size A 020A Condenser She...

Page 9: ...Liquid cooled Communicating with Tracer AdaptiView Controls Digit 5 6 7 8 Starter Size Use Rated Load Amps RLA Value Digit 9 Incoming Line Voltage Unit Drive Voltage B 208V Incoming Line 460V 60Hz 3P...

Page 10: ...etic package that is factory piped wired leak tested dehydrated charged and tested for proper control operation before shipment The following figures show typical Agility chillers and their components...

Page 11: ...HDWA SVX001D EN 11 Figure 4 Typical Agility chiller component location back view G Ge en ne er ra al l I In nf fo or rm ma at ti io on n...

Page 12: ...aptive Frequency Drive Figure 5 Assembly transformer options Fans Auto transformer Figure 6 Assembly harmonic filter options Capacitors Capacitors Contactor Inductor G Ge en ne er ra al l I In nf fo o...

Page 13: ...HDWA SVX001D EN 13 Unit Clearances Figure 7 Clearance requirements in cm G Ge en ne er ra al l I In nf fo or rm ma at ti io on n...

Page 14: ...Notes 1 All weights 5 percent 2 Shipping weights include standard 150 psig waterboxes 3 Operating weights include refrigerant glycol and water charges 4 Optional waterbox hinges each weigh 44 lb 19 9...

Page 15: ...75 5412 6425 Maximum 6845 6481 7650 Notes 1 All weights 5 percent 2 Shipping weights include standard 1034 2 kPaG waterboxes 3 Operating weights include refrigerant glycol and water charges 4 Optional...

Page 16: ...eck all items against the shipping list Display display arm and mounting water vessel drain plugs isolation pads and other optional components are shipped loose in the parts box Electrical diagrams an...

Page 17: ...erlock wiring Chilled water pump contactor and wiring Condenser water pump contactor and wiring Option relays and wiring Water piping Flow switches may be field supplied Condenser water regulating val...

Page 18: ...frigerant Make provisions to remove heat generated by unit operation from the equipment room Ventilation must be adequate to maintain an ambient temperature lower than 104 F 40 C Vent the evaporator c...

Page 19: ...scribed in Standard Chiller Lift p 20 N No ot te e The lifting beam used for HDWA Agility chillers must be at least 12 5 ft 3 8 m long I Im mp po or rt ta an nt t If unit must be disassembled for inst...

Page 20: ...t be moved using a standard chiller lift consider the following When job site conditions require rigging of the chiller at an angle greater than 45 from horizontal end to end the unit may require remo...

Page 21: ...he er r h ha az za ar rd do ou us s t to ox xi ic c o or r f fl la am mm ma ab bl le e g ga as s m ma ay y b be e l le ea ak ki in ng g R Re ef fr ri ig ge er ra an nt t o or r o ot th he er r g ga a...

Page 22: ...at ti io on ns s Relief valve discharge setpoints and capacities rates are provided in the following table After the relief valve has opened it will re close when pressure is reduced to a safe level...

Page 23: ...3 4 10 3 18 8 7 3 22 14 7 9 6 11 3 11 5 16 7 8 5 24 12 5 10 8 9 1 12 7 14 5 9 7 25 11 4 11 4 8 0 13 3 13 4 10 3 26 10 2 12 1 6 8 14 0 12 2 11 0 28 7 7 13 5 4 3 15 4 9 7 12 4 30 5 1 15 0 1 7 16 8 7 1 1...

Page 24: ...8 0 14 2 9 9 19 6 6 9 24 15 7 9 0 12 3 10 9 17 7 7 9 25 14 8 9 6 11 4 11 5 16 8 8 5 26 13 8 10 1 10 4 12 0 15 8 9 0 28 11 6 11 3 8 2 13 2 13 6 10 2 30 9 3 12 6 5 9 14 5 11 3 11 5 32 6 8 14 0 3 4 15 9...

Page 25: ...ter 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 and Vents N NO OT TI IC CE E W Wa at te er rb bo...

Page 26: ...9 cm from the end of the probe Do NOT insert more than 3 5 in 8 9 cm of the probe length into the pipe Refer to the following figure Figure 13 Installation of ifm efector flow detection controller an...

Page 27: ...ough the wire openings on the back side of the control panel see item labeled 3 in the preceding figure Install the supplied Micro DC Cable 29 5 ft 9 m in length to the Flow Probe and hand tighten the...

Page 28: ...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 are required These switches are used with control logic to confirm flow prior to start...

Page 29: ...n be detected and removed to prevent possible tube damage resulting from evaporator freeze up or erosion For condenser and evaporator connections arrange the water piping so that the water supply ente...

Page 30: ...ping systems Flexible coupling gaskets require proper lubrication before installation to provide a good seal Refer to the coupling manufacturer s guidelines for proper lubricant type and application F...

Page 31: ...d with the circular key section locating into the groove 5 Insert a standard hex head screw through the mating holes of the Victaulic flange to secure the flange firmly in the groove 6 Tighten fastene...

Page 32: ...g an eddy current inspection of the condenser and evaporator tubes in water cooled chillers every three years Eddy current tests are intended to identify defects on or within the walls of heat exchang...

Page 33: ...sor modules Table 11 Agility chiller insulation requirements Location 3 4 in 19 05 mm Insulation Square Feet Square Meters 020A Evaporator suction elbow pipe 105 9 8 040A Evaporator suction elbow pipe...

Page 34: ...boxes wrap waterbox shell insulation with strapping and secure strapping with seal Evaporators with ASME nameplates must have insulation cut out around the nameplate Do NOT glue insulation to the name...

Page 35: ...ve the following electrical requirements Follow all lockout tagout procedures prior to performing installation and or service on the unit Always wear appropriate personal protective equipment Wait the...

Page 36: ...l c co om mp po on ne en nt ts s h ha av ve e a a q qu ua al li if fi ie ed d l li ic ce en ns se ed d e el le ec ct tr ri ic ci ia an n o or r o ot th he er r i in nd di iv vi id du ua al l w wh ho o...

Page 37: ...PORATOR WATER PROOF OF FLOW DEVICES INSET F INSET F 5S17 1 2 158A 220E 5S18 1 2 159A 7 SECONDARY CONDENSER WATER PROOF OF FLOW DEVICES INSET G INSET G SECONDARY OPTIONAL 6 7 6 6 OPTIONAL BACNET OR MOD...

Page 38: ...n Condenser Refrigerant Pressure 1K7 J2 4 to 6 Analog Output 2 10 Vdc Chiller Capacity Output 1K7 J2 1 to 3 Analog Output 2 10 Vdc Evaporator Condenser Differential Pressure Output 1K7 J2 4 to 6 Analo...

Page 39: ...ing water temperature 6 4 4B BP P4 4 Condenser leaving water differential pressure LO 7 4 4B BP P4 4 Condenser entering water differential pressure HI 8 4 4B BP P5 5 Evaporator leaving water different...

Page 40: ...rs sa al l p pr ro ot te ec ct ti io on n c co ou ul ld d p pr re ev ve en nt t p pr ro op pe er r c ch hi il ll le er r o op pe er ra at ti io on n o or r c ca au us se e e eq qu ui ip pm me en nt t...

Page 41: ...er to Tracer AdaptiView Display for Water cooled Agility Chillers Operations Guide HDWA SVU001 EN UC800 Specifications Power Supply The UC800 1K20 receives 24 Vac 210 mA power from the 1T2 power suppl...

Page 42: ...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 the UC800 that support...

Page 43: ...blinks yellow at the data transfer rate when the UC800 receives data from other devices on the link Ethernet Link The LINK LED is solid green if the Ethernet link is connected and communicating The A...

Page 44: ...r voltage areas for proper routing of field wiring B C A 30 115 Volt Maximum 30 Volt Maximum 1K15 1K14 1K13 1K12 1K11 1K10 1XP5 1XJ5 Service Power 1XJ1 1XP1 1K22 1K23 1K9 1K8 1K7 1K6 1K5 1K4 1K3 1K1 1...

Page 45: ...ns st tr ru uc ct ti io on ns s b be el lo ow w c co ou ul ld d r re es su ul lt t i in n u un ne ex xp pe ec ct 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...

Page 46: ...hex 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 displ...

Page 47: ...ss the condenser tube bundle Cooling tower water circulated through the condenser tubes absorbs heat from the refrigerant causing it to condense The subcooled liquid refrigerant then flows out of the...

Page 48: ...with ASME Code for refrigerant side working side pressure of 200 psig 1379 0 kPaG The condenser is designed tested and stamped in accordance with ASME Code for refrigerant side working side pressure o...

Page 49: ...thought of as a state chart with the arrows and arrow text depicting the transitions between states The text in the circles is the internal software designations for each state The first line of text...

Page 50: ...ode text as viewed in the Tracer AdaptiView Text above the time line cylinder is used to illustrate inputs to the UC800 This may include user input to the Tracer AdaptiView touch screen control inputs...

Page 51: ...er Water Pump Relay Evaporator EXV Pre position Overdrive IGV Closed Energize Evaporator Water Pump Relay Confirm Evaporator Water Flow Within 20 Minutes 6 Second Filter Confirm Condenser Water Flow W...

Page 52: ...Clearance Check and Levitate Bearings 10 Seconds Confirm Condenser Water Flow 6 Second Filter AFD Parking 8 Seconds Restart Inhibit Temperature Checks Motor Winding Temp 90 of the Motor Winding Temp...

Page 53: ...ing Control Motor Cooling Control 200 Ton Only Condenser Liquid Level Control Modulate IGV AFD for Limit Control MBC Cooling Control Economizer Superheat Control AFD Cooling Control Motor Cooling Cont...

Page 54: ...fferential to Stop Setpoint Preparing Shutdown Shutting Down Auto Command IGV Closed Check for 24 Hour Overdrive Close Economizer Valve De energize Compressor De energize Condenser Water Pump Relay Cl...

Page 55: ...Shutting Down Stopped or Run Inhibit Command IGV Closed Close Economizer Valve De Energize Compressor De Energize Condenser Water Pump Relay De Energize Evaporator Water Pump Relay Close Motor Cooling...

Page 56: ...Diagnostic Immediate Shut down Latching Diagnostic Immediate Stop Running Shutting Down Stopped Run Inhibit or Stopped Run Inhibit Stopped Close IGV 0 to 50 Seconds MBC Levitation Will Stop When RPM...

Page 57: ...ol Running Starting Compressor Shutting Down Waiting to Start Close IGV 0 to 50 Seconds Establish Condenser and Evaporator Water Flow 6 Second Filter No Evap Pump Off Delay for Immediate Shutdown De E...

Page 58: ...ntial to Stop Running Running Running Ice Building Running Ice to Normal Transition Running Ice to Normal Transition Timer 0 10 Minutes Head Relief Request Relay Delay 1 60 Minutes Head Relief Request...

Page 59: ...opped Ice Building Complete Running Ice Building Preparing Shutdown Ice Building Complete Shutting Down Ice Building Complete MBC Levitation Will Stop When RPM 1200 For 60 Secconds Head Relief Request...

Page 60: ...ating controls are housed in the unit control paneland the starter panel The control panel operator interface is called Tracer AdaptiView and is located on an adjustable arm connected to the side of t...

Page 61: ...o on n t th he e e ev va ap po or ra at to or r o or r 3 30 00 0 p ps si ig g 2 20 06 68 8 4 4 k kP Pa aG G o on n t th he e c co on nd de en ns se er r Unit Start up N NO OT TI IC CE E E Eq qu ui ip...

Page 62: ...e e U Un ni in nt te er rr ru up pt ti ib bl le e P Po ow we er r S Su up pp pl ly y U UP PS S h ha as s b be ee en n o op pe er ra at ti in ng g p pr ro op pe er rl ly y f fo or r a a m mi in ni im m...

Page 63: ...ency N No ot te e Optimum condenser pressure is dependent on condenser water temperature and should equal saturation pressure of refrigerant at a temperature 2 F to 5 F 1 1 C to 2 8 C above that of le...

Page 64: ...st for pH level using litmus paper with a 0 5 resolution pH 8 indicates fluid to be changed Pressure Relief Cap The pressure relief cap is an automotive style pressure vent radiator cap refer to the f...

Page 65: ...echanical room limitations and determine the safest method or methods of rigging and lifting the waterboxes I Im mp po or rt ta an nt t Do NOT rotate waterboxes Be sure to replace water boxes right si...

Page 66: ...he job A standard condenser water circuit is composed solely of copper cast iron and steel Improper chemical cleaning can damage tube walls All of the materials used in the external circulation system...

Page 67: ...inst chassis of cabinets or other edges 4 Ensure the drive interior and exterior is clear of any dust or debris Fans vents etc must be clean I Im mp po or rt ta an nt t Only use a vacuum for cleaning...

Page 68: ...e specific electrical characteristics of a particular chiller refer to the nameplates mounted on the units Table 17 Wiring drawings Drawing Description 2311 4987 Diagram Schematic Wiring Standard 2311...

Page 69: ...s standalone literature the literature order number is also listed Appendix B Agility Chiller Installation Completion and Request for Trane Service p 70 HDWA ADF001 EN Appendix C Settings p 72 Appendi...

Page 70: ...nected to Evaporator Air handling units Pumps Flow switch or flow proving device installed if not factory provided Condenser piping connected to Condenser Pumps Flow switch or flow proving device inst...

Page 71: ...pparatus available Does the equipment room meet environmental condition requirements specified in the chiller Installation Operation and Maintenance manual 10 O Ow wn ne er r a aw wa ar re en ne es ss...

Page 72: ...mand Time Period Service Settings Value Low Evaporator Water Temp Cutout Low Refrigerant Temperature Cutout Local Atmospheric Pressure Maximum Capacity Limit Minimum Capacity Limit BAS Setpoint Power...

Page 73: ...verride Condenser Water Pump Override Manual Capacity Control Clear Energy Consumption Display Settings Value Date Format Date Separator Time Format Unit System Pressure Units Language Date Time UTC O...

Page 74: ...Log N No ot te e An Operator Log can be captured by using the Logsheet Report found on the Tracer AdaptiView display refer to the following figures Figure 47 Reports Log Sheet button highlighted Figu...

Page 75: ...ure Condenser Water Flow Status Approx Cond Water Flow Cond Differential Wtr Press Condenser Refrigerant Liquid Level Compressor Compressor Starts Compressor Running Time Compressor Refrigerant Discha...

Page 76: ...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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