Trane Arctic Manhattan Gen II Installation, Operation And Maintenance Manual Download Page 49 | Manualshive

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Federal Clean Air Act

Responsible refrigerant practices are important to the
environment, our customers, and the air conditioning
industry. All technicians who handle refrigerants must
be properly certified. The Federal Clean Air Act
prescribes procedures for handling, reclaiming,
recovering, and recycling of refrigerants and the
equipment that must be used in maintenance
procedures involving potential leakage of HVAC
refrigerants. State and local governments may have

additional requirements that must be followed to
responsibly handle HVAC refrigerants.

Inspection and Maintenance
Schedule

Proactive measures should be taken to prevent
potential problems with the chillers. These include
maintaining a operational log and conducting weekly,
quarterly, and annual inspections of the chiller. See
following table.

Daily

A daily visual inspection can reveal obvious problems.
Keep notes of the chiller performance:

•

Log pressures and temperatures.

•

Visually inspect of the unit.

Table 10.

Recommended chiller service intervals

Task

Frequency

Visually inspect the chiller

Daily

Log pressure and temperatures

Daily

Inspect touchscreen interface panel for alarm history

Weekly

Clean strainers on the inlet water pipe

Monthly

Check the compressor oil level sight glass

Monthly

Confirm the glycol concentration

Monthly

Confirm the refrigeration pressures

Monthly

Check the refrigeration liquid line sight glass

Monthly

Inspect refrigerant pressures and temperature set points

Quarterly

Inspect superheat (10 °F to 12 °F [5°C to 6°C]) and sub-cooling temperatures (10°F to 15°F [5°C to 8°C])

Quarterly

Inspect the evaporator entering and leaving evaporator temperature

Quarterly

Collect water/glycol mixture sample for analysis

Quarterly

Inspect crankcase heaters

Quarterly

Inspect piping for signs of leaks

Quarterly

Inspect refrigerant piping for oil or refrigerant leaks

Quarterly

Observe refrigeration operating pressures

Quarterly

Confirm motor amperage draw and voltage

Quarterly

Confirm chiller superheat and sub-cooling

Quarterly

Check for worn or burned contactors

Quarterly

Inspect all electrical connections and fuses

Annually

Inspect each compressor for refrigerant pressures, overheating, oil leaks

Annually

Inspect compressor terminals for pitting, corrosion, and loose connections

Annually

Inspect compressor oil level

Annually

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Summary of Contents for Arctic Manhattan Gen II

Page 1: ...nt can be hazardous and requires specific 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 in the literature and on the tags stickers and labels that are attached to the equipment Manhattan Gen II Air Cooled Modular Chiller Installation Operation and Maint...

Page 2: ...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 i in nj ju ur ry y T Te ec ch hn ni ic ci ia an ns s i in n o or rd de er r t to o p pr ro ot te ec ct t t th he em ms se el lv ve es s f fr ro om m p po ot te en nt ti ia al l e el le ec ct tr ri ic ca...

Page 3: ... an nd dl li in ng g e et tc c W Wh he er re e l lo oc ca al l r re eg gu ul la at ti io on ns s a ar re e m mo or re e s st tr ri in ng ge en nt t t th ha an n t th he es se e p po ol li ic ci ie es s t th ho os se e r re eg gu ul la at ti io on ns s s su up pe er rs se ed de e t th he es se e p po ol li ic ci ie es s N No on n T Tr ra an ne e p pe er rs so on nn ne el l s sh ho ou ul ld d a al l...

Page 4: ...Electrical 20 Connecting Module Power and Control Wires 20 Chiller Module Main Power 20 Phase Monitor Installation 20 Power Interlock Switch 20 Module Control Wiring 20 Operating Principles 21 Operating Procedures 22 Operator Interface 22 Chiller Power Panels 22 Panel Mounted Disconnect Switch 22 Power Distribution Panels 22 Module Electrical and Control Panel 23 Electronic Control 23 Controllers ...

Page 5: ...ethods 52 Critical Cleaning Tasks 53 Compressor Tasks 54 Pump Tasks 55 Controller Tasks 57 Chiller Troubleshooting 58 General Approach to Fault Isolation 58 Controller Diagnostic Codes 58 Compressor Diagnostic Codes 59 CoreSense Flash Codes 59 CoreSense Flash Code Description 59 Variable Frequency Drive Diagnostic Codes Optional 61 Diagnostic Indicators 61 Phase Monitor Protection 62 Symptoms and ...

Page 6: ...r Capacity 0030 3 Ton Capacity 0300 30 Ton Capacity Digit 12 Refrigeration Circuits D Dual Independent Refrigeration Circuits S Single Refrigeration Circuit R Redundant Refrigeration T Tandem Compressors Set in Single Circuit Digit 13 Voltage 1 208 230 60 1 2 460 60 1 3 208 230 60 3 4 460 60 3 5 575 60 3 7 380 50 3 Digit 14 15 Chiller Application MM Modular Digit 16 17 Additional Features VS Varia...

Page 7: ...Data Refer to the Trane nameplate on each module in the installed unit for the serial number and model number See figure below for example nameplate Table 1 Chiller reference data Module Model Number Serial Number 1 2 3 4 5 6 7 8 9 10 Model Number Critical information for contacting Trane technical support Reference to the actual chiller module serial number may also be beneficial Each module has ...

Page 8: ...As required under Federal regulations installation initial start up and technical servicing should only be performed by fully qualified personnel W WA AR RN NI IN NG G H Ha az za ar rd do ou us s V Vo ol lt ta ag ge e F Fa ai il lu ur re e t to o d di is sc co on nn ne ec ct t p po ow we er r b be ef fo or re e s se er rv vi ic ci in ng g c co ou ul ld d r re es su ul lt t i in n d de ea at th h o...

Page 9: ...iently cooling the fluid to the required temperature Models with the brazed plate heat exchanger are typically made of SAE Grade 316 stainless steel and 99 9 copper brazing materials Interconnecting headers are carbon steel N No ot te e A optional configuration with shell and tube evaporators having a carbon steel outer shell and copper tubing may be found in some chillers Optional Tank and Pump M...

Page 10: ...e power distribution panel Validate de energization using voltage meter 5 Inspect all electrical connections to ensure terminals are secure 6 Inspect all fuses and overload settings to ensure they conform to specifications 7 Inspect all refrigerant pressures for each module to ensure no refrigerant has been lost 8 Check that pressure switches and thermostats have correct cut in and cut out setting...

Page 11: ...____________________ Voltage 3 ___________________ Check the box if there are any field supplied wiring junction boxes located between the chiller and any remote panels Check the box if there are any splices made in the field supplied wiring junction boxes Check the box if there are any customer supplied devices connected to the chiller wiring List devices _________________________________________...

Page 12: ...ll responsible installing contractors and sub contractors have been notified to have representatives available on site to provide technical support for the initial start up procedure Check the box if full load will be available for chiller on the initial start up date Touchscreen Interface Panel Record version and date of the software loaded into the touchscreen interface panel Version ___________...

Page 13: ...Request an immediate joint inspection by the carrier and consignee A determination of responsibility will be made and the carrier will authorize repairs in the event of admission of fault 7 Notify Trane customer service department 803 321 1891 immediately Trane will coordinate repairs with the owner and carrier Do not attempt to make repairs locally without permission Warranty Issues Trane is not ...

Page 14: ... rd ds s y yo ou u M MU US ST T f fo ol ll lo ow w r re eq qu ui ir re em me en nt ts s f fo or r f fi ie el ld d w wi ir ri in ng g i in ns st ta al ll la at ti io on n a an nd d g gr ro ou un nd di in ng g a as s d de es sc cr ri ib be ed d i in n N NE EC C a an nd d y yo ou ur r l lo oc ca al l s st ta at te e n na at ti io on na al l e el le ec ct tr ri ic ca al l c co od de es s W WA AR RN NI...

Page 15: ...m any fence Failure to follow these minimum requirements may result in performance degradation Modules located in a sub level or pit require special considerations to avoid air recirculation and heat buildup The top of each fan grill must be level with or higher than the top of the pit All sides of the chiller should be a minimum of three feet away from any side of the pit Do not attach ductwork t...

Page 16: ... These clearances are general recommendations Each installation has specific considerations Contact Trane for definitive guidance and approval on a job by job basis I In ns st ta al ll la at ti io on n M Me ec ch ha an ni ic ca al l ...

Page 17: ...gurations of modules can be top heavy Move modules slowly with consideration for each module s center of gravity Rig lift and move by strapping and lifting using a properly configured floor jack or fork lift or by overhead means Position lifting beams to prevent lifting straps from rubbing or contacting module side panels or electrical boxes Do not use cables chains or any other type of metalized ...

Page 18: ...tribution panel attached to it If part of the chiller system the tank and pump module must be installed last at the opposite end of the chiller modules The power distribution panel is typically installed on the tank and pump module when so equipped Figure 4 Chiller installation on mounting rails While the compressors are installed with rubber in shear isolation pads for additional vibration isolat...

Page 19: ...ining cleaning compounds ID10 needs to be verified with CPCO controller Fill with Water Glycol Solution The installing contractor is responsible for charging glycol into the chiller hydronic system 1 Mix the concentrate of propylene glycol in a tank or drum for transfer into the chiller Use Table 7 p 39 to determine the appropriate glycol concentration for the chiller 2 Mix the glycol and water ex...

Page 20: ...pment This adjustment automatically sets the under voltage trip point Check the phase monitor after initial startup If it fails to energize the LED glows red or blinks check the wiring of all three phases voltage and phase sequence If phase sequence is incorrect the LED flashes green red To correct this swap any two line voltage connections at the mounting socket No further adjustment should be re...

Page 21: ...l mixture is cooled via a compact brazed plate evaporator An externally adjustable thermal expansion valve meters the proper flow of refrigerant to the evaporator where it evaporates and the heat in the system water glycol mixture transfers to the refrigerant The compressor then compresses the vapor to a higher pressure so that the condensing pressure of the refrigerant is at a higher temperature ...

Page 22: ...power to the individual electrical components in that module Panel Mounted Disconnect Switch SomeManhattan Gen II Chiller systems are optionally equipped with a panel mounted disconnect switch installed on the outside of the power distribution panel or on each module s electrical and control panel if the chiller has power supplied to each individual module The disconnect switch must be turned to t...

Page 23: ...the functioning of all the modules that make up the chiller unit For units consisting of more than a single chiller each module has its own controller There are five BMS communication options N No ot te e BMS is not included as standard but available as an option 1 BACnet MS TP Connection through built in BMS2 port 2 BACnet IP BACnet router is used 3 Modbus RTU Connection through built in BMS2 por...

Page 24: ...ary microprocessor controller and is the only way to access many primary controller functions N NO OT TI IC CE E C Co om mp po on ne en nt t D Da am ma ag ge e F Fa ai il lu ur re e t to o f fo ol ll lo ow w i in ns st tr ru uc ct ti io on ns s c co ou ul ld d d da am ma ag ge e s se en ns si it ti iv ve e e el le ec ct tr ro on ni ic c c co om mp po on ne en nt ts s b be ey yo on nd d r re ep pa ...

Page 25: ... used to adjust set points clear alarms and perform detailed setup of the microprocessor controllers The touchscreen interface panel displays information on its touchscreen whenever specific combinations and sequences of keys and buttons are pressed by the operator See following figure Basic operator tasks are described in the following sequence of illustrations that comprise a controller tutorial...

Page 26: ...ace screens are organized according to system primary module and secondary modules functions See Figure 11 p 26 Figure 11 Interface navigation scheme Home Screen Features Figure 12 HMI home screen O Op pe er ra at ti in ng g P Pr ro oc ce ed du ur re es s ...

Page 27: ...p user logging screen where user name and password have to be entered Log Out unhidden for admin and tech users only It logs out from admin or tech user to a default user which is user Figure 13 User logging screen 3 Module Layout Access The module layout access button provides fast access to the module layout screen 4 Active Alarm Access The active alarm access button provides fast access to a li...

Page 28: ... well as continuous value in There is also a bar graph representation of Cooling or Heating Demand beside the value 11 Power ON OFF Press and hold this button to toggle the software switch which powers the chiller and all its modules on and off 12 Module Access The module access buttons display the overview screen for each module These buttons provide access to all chiller modules screens individu...

Page 29: ... the PLC If alarm is Not Active Not Triggered its Source Value 0 and it can be reset using Reset button Both Active and Not Active alarms can be acknowledged When Not Active alarm is acknowledged it can be reset which will remove it from the list so only Active alarms will remain on the list Select This column indicates if the alarm is selected or unselected for acknowledgment or resetting ID This...

Page 30: ...ve alarms the default selection Ack Pressing this button acknowledges the alarm and removes it from the active alarms list Reset Pressing this button allows a specific non active alarm to remain on the active alarms list Save Pressing this button saves the changes made to the active alarms list Any changes that are made without saving will be lost Reset PLC This button located in the upper right p...

Page 31: ...l update accordingly Alarm Time This is the time stamp that is displayed when the alarm state changes Event Type This is the alarm event that is logged on the alarm record Only active alarms Event Type Triggered are recorded Alarm State This is the same as State for active alarms Only two alarms states apply to alarm history screen TRIGGERED NOT ACKNOWLEDGED TRIGGERED ACKNOWLEDGED Tag Value This i...

Page 32: ...e is off by one of the System Off conditions 8 Man Mode Module is in manual mode Module Cntrl Status Possible options 1 Primary Module acts as a primary module Primary module performs temperature control for either heating or cooling loads It also acts as a Supervisor when communicating with secondary modules and defines how many modules need to run its compressors in order to satisfy heating or c...

Page 33: ...rn secondary PLC module on off in Stand alone Mode For primary PLC module On Off Button on the Home Screen serves the same purpose Overview Circuits Refrigerant temperatures pressures are displayed suction pressure discharge pressure suction temperature suction super heat temperature Liq Line Solenoid Status of the solenoid valve installed on the liquid line pipe EX Valve Indicates the position of...

Page 34: ...Analog input AI data includes these parameters AI1 This input indicates suction pressure AI2 This input indicates discharge pressure AI3 AI4 These inputs indicate the evaporator inlet or outlet temperatures AI5 These inputs indicates ambient temperature AI6 These inputs indicates free cooling controlled temperature AI7 AI8 These inputs indicate the inlet or outlet chilled water temperatures This a...

Page 35: ...ch DI closed flow present DI opened flow absent DI8 Phase Monitor This is feedback for the three phase power supply protection feature If the digital input for this switch indicates closed there are no power supply issues If the digital input for this switch indicates open a power supply failure has been detected If common power supply protection module is used for the chiller its failure will aff...

Page 36: ...ing normal range threshold faulty state DI5 This is the feedback for Pump down pressure switch of Circuit 2 DI closed pressure is in the normal range DI opened pressure is exceeding normal range threshold faulty state DO1 DO2 DO6 This digital output is used to turn fans of Fan Bank 2 on and off Trend Screen When on the primary module screen pressing the trend button displays the trend screen There...

Page 37: ... 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 mo ot te e d di is sc co on nn ne ec ct ts s b be ef fo or re e s se er rv vi ic ci in ng g F Fo ol ll lo ow w p pr ro op pe er r l lo oc ck ko ou ut t t ta ag go ou ut t p pr ro oc ce ed du ur re es s t to o e en ns su ur re e t th he e p po ow we er r c ca an n n no ot t b be e i in na ad ...

Page 38: ...ty Value Unit Hydrogen Carbonate HCO3 60 200 ppm HCO3 SO4 2 1 5 Ca Mg HCO3 0 5 Chloride Cl 200 ppm Notes 1 Total Hardness corrosion Water with high hardness can cause corrosion problems due to its high ion content Ca 2 Mg 2 Fe 2 which also means a high electrical conductivity and a high total dissolved solid TDS For this reason too high hardness values should be avoided not only due to higher risk...

Page 39: ...nd in volume upon cooling This expansion may cause pipes and other enclosed systems containing a liquid to rupture or burst when exposed to low temperature conditions Burst protection is needed to protect piping and other enclosed systems when they are inactive as they could rupture due to expansion during cold weather or low refrigerant pressure Freeze points and burst points of glycol water solu...

Page 40: ...of glycol for a particular chiller is affected by several key factors such as ambient temperature extremes entering and leaving water temperatures and chiller size A chiller s optimum glycol concentration is modified by these considerations as reflected in Table 7 p 39 These capacity correction factors are the best informed estimates for chillers with copper evaporators The percentages may vary de...

Page 41: ... set up of the microprocessor controllers Chiller Control The operator uses three different types of controls and indicators to monitor and maintain the desired operating parameters in the Manhattan Gen II Chiller These controls and indicators are located in the power panels and the microprocessor controllers Power Distribution There are two different electrical panels used in the Manhattan Gen II...

Page 42: ...ower distribution panel power is fed to the individual chiller modules and connects to each module s electrical and control panel See the following figure Electrical Controls The Manhattan Gen II Chiller is provided with controls and indicators to monitor the electrical activity and notify operators if problems arise Figure 23 Module electrical and control panel Flow Switch A flow switch is wired ...

Page 43: ...s a motor from operating in reverse if any of the three legs of power are landed incorrectly and will shut the system down upon detection of a reversed phase condition Refrigeration Controls Controls on the refrigeration system are designed to provide safety for the major components and for proper operation of the system Pressure transducers convert pressure into an electronic signal that the micr...

Page 44: ...g point of the evaporator water glycol mixture The set points are typically just below the freezing point For R410A refrigerant and using water the pressure is set at a 90 psi cut out corresponding to 50 F 10 C and a 105 psi cut in corresponding to 40 F 4 4 C cut in For any other water glycol mixture contact Trane technical support for proper set points High and Low Ambient Controls Condenser coil...

Page 45: ...equalize the run time among the modules 11 If power is removed and then returned to a chiller system i e power failure the compressors will restart every five seconds for the next five minutes as needed In a power return restart once all the compressors have restarted every five seconds as needed within five minutes any subsequent cycling of compressors will be every five minutes 12 When a redunda...

Page 46: ... to the next operating point so as not to limit flow to the operating chillers as the valve time to close is approximately 150 seconds 12 This process occurs throughout the operating range of the chiller system At all in between stages of system capacity and demand balancing the digital scroll compressor on the primary module will modulate its capacity within the temperature control band limits to...

Page 47: ...emperature 95 F 35 C Leaving Fluid Temperature 44 F 7 C Evaporator Pressure Drop 5 8 psi Maximum Evaporator Operating Pressure 650 psi refrigerant side System Capacity 1 2274 000 btu hr 106 2 tons Refrigerant R410A Connections 6 in roll grooved Chiller Modules 4 Compressors two per module Rated Load Amps 46 amps each Horsepower 15 Total Full Load Amps 123 amps per module Locked Rotor Amps 340 amps...

Page 48: ... includes small checks which can significantly extend service life Other considerations such as weather and equipment age are taken into account maintenance and equipment replacement is often performed before the hottest time of the year Figure 24 An approach to chiller maintenance Power Disconnect Switch Some Manhattan Gen II Chiller units are optionally equipped with a panel mounted disconnect s...

Page 49: ...ekly quarterly and annual inspections of the chiller See following table Daily A daily visual inspection can reveal obvious problems Keep notes of the chiller performance Log pressures and temperatures Visually inspect of the unit Table 10 Recommended chiller service intervals Task Frequency Visually inspect the chiller Daily Log pressure and temperatures Daily Inspect touchscreen interface panel ...

Page 50: ...s s a an nd d d de eg gr ra ad de e p pe er rf fo or rm ma an nc ce e P Pe er rf fo or rm m v va ac cu uu um m e ev va ac cu ua at ti io on n o of f s sy ys st te em m t to o r re em mo ov ve e m mo oi is st tu ur re e 4 When the compressor is not operating the oil level should be at least at the bottom of the sight glass up to two thirds full When the compressor is operating the oil level will no...

Page 51: ...fittings 9 Inspect refrigerant piping circuit for signs of oil or refrigerant leakage Conduct sniffer test to find refrigerant leaks Inspect all pressure switch bellows 10 Tighten all refrigeration piping connections e g rotalocks Schrader valves caps and ball valves 11 Install a manifold and gauge set to observe chiller s refrigeration operating pressures a Verify that the pressure controls low p...

Page 52: ...iller can retain the previous 200 alarms with time and date of occurrence 14 If equipped inspect crankcase heaters to verify proper operation 15 Sample refrigerant to analyze for moisture or acid 16 Inspect operating pressures and temperatures and ensure the chiller has a full refrigerant charge Pump and Tank Maintenance Tasks For chillers equipped with a tank and pump module additional maintenanc...

Page 53: ...4 Inspect the gasket and service cap for abrasions tears excessive dirt or deterioration Replace gasket if necessary 5 Remove the strainer from the housing 6 Clean the strainer inside and out using a soft natural bristle brush and tap water 7 Clean the interior of the end cap or service cap and the gasket using a soft natural bristle brush and tap water Apply a light coating of lubrication to the ...

Page 54: ...co on nn ne ec ct ts s b be ef fo or re e s se er rv vi ic ci in ng g F Fo ol ll lo ow w p pr ro op pe er r l lo oc ck ko ou ut t t ta ag go ou ut t p pr ro oc ce ed du ur re es s t to o e en ns su ur re e t th he e p po ow we er r c ca an n n no ot t b be e i in na ad dv ve er rt te en nt tl ly y e en ne er rg gi iz ze ed d V Ve er ri if fy y t th ha at t n no o p po ow we er r i is s p pr re es ...

Page 55: ...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 mo ot te e d di is sc co on nn ne ec ct ts s b be ef fo or re e s se er rv vi ic ci in ng g F Fo ol ll lo ow w p pr ro op pe er r l lo oc ck ko ou ut t t ta ag go ou ut t p pr ro oc ce ed du ur re es s t to o e en ns su ur re e t th he e p po ow we er r c ca an n n no ot t b be e i in na ad dv ve er rt te en nt tl ly...

Page 56: ...disconnected 1 Confirm module power is OFF by testing with known operational voltmeter Once confirmed install lockout tagout equipment to ensure power is not turned on while service work is being performed W WA AR RN NI IN NG G H Ha az za ar rd do ou us s V Vo ol lt ta ag ge e F Fa ai il lu ur re e t to o d di is sc co on nn ne ec ct t p po ow we er r b be ef fo or re e s se er rv vi ic ci in ng g...

Page 57: ...harge sides of the pump 25 Observe the newly installed pump to verify that all connections have been seated and tightened correctly and not leaking 26 Restore power to the module by removing the lockout tagout equipment and turning the pump module breaker back to the on position 27 Turn pump on and record amp draws for your records Controller Tasks Replace PLC Logic Controller Prior to servicing t...

Page 58: ...y ALARM RESET ACTION BMS offline Auto Warning Compressor 1 2 CoreSense Failure Auto Shuts down compressor 1 2 Compressor 1 2 Failure Auto Shuts down compressor 1 2 Compressor 1 2 Lockout Auto Shuts down Circuit 1 2 Compressor 1 2 Offline Auto Shuts down compressor 1 2 Compressor 1 2 Warning Auto Warning Condenser Flow Alarm User Shuts down Circuits Circuit 1 in Constant Flow systems Condenser LWT ...

Page 59: ...ure Auto Warning Wrong local rotation control parameters Auto Warning Wrong primary rotation control parameters Auto Warning Wrong temperature control parameters Auto Warning Compressor Diagnostic Codes Copeland compressors used in Trane chillers are highly automated with digital capability to record and report a range of operating parameters and critical events This technology can be employed to ...

Page 60: ...ge is established C CO OD DE E 1 10 0 Over Current Protection When the current at the PROT terminal is greater than 2A for 40 milliseconds the module will flash a CODE10 The red LED will flash 10 times with the yellow LED remaining off This event will cause a lockout of the compressor and indicates that the module is mis wired or the contactor coil is shorted to ground Table 12 Compressor fault co...

Page 61: ...hen multiple drives are connected to the same panel bus Red FAULT Active fault in the drive To reset the fault press RESET from the control panel or switch off the drive power Red FAULT Active fault in the drive To reset the fault switch off the drive power Control Panel LEDs The control panel has one LED found at the left edge of the panel See table below for control panel LED indications Table 1...

Page 62: ...hase sequence is incorrect the LED flashes green red To correct this swap any two line voltage connections at the mounting socket No further adjustment should be required Symptoms and Solutions This section lists the most common troubleshooting symptoms and the closest potential solution for each The References column will list a reference within this manual if applicable This is not an exhaustive...

Page 63: ...r burnout Motor electrical trouble Tighten all terminal screws 3 Symptom Compressor has excessive noise or vibration Possible Causes Potential Solutions Flooding of refrigerant into crankcase Check setting of expansion valve Improper discharge piping support Relocate add or remove supports Improper or worn compressor supports Replace supports Worn compressor Replace or rebuild compressor 4 Symptom...

Page 64: ...Mis adjusted or defective TXV Adjust or replace valve Receiver service valve closed Turn counterclockwise completely Do not fully backseat if pressure switch is installed on service port Compressor service valves closed Dangerous Turn counterclockwise completely Clogged liquid line filter drier Replace cartridges Excessive glycol concentration Drain refill deionized water retest Liquid line soleno...

Page 65: ...place motor controller fuse Condensing fans not operating Reset fan cycle setting replace motor controller fuse Restricted bypass line Check valves obstructed flush line blow out line with dry nitrogen gas Discharge shut off valve partially closed Open valve Condenser is undersized Check condenser rating tables with operating parameters High ambient conditions exist Check condenser rating tables w...

Page 66: ...e Recharge refrigerant as per data plate Improperly adjusted superheat valve setting Reset valve settings to factory specifications 16 Symptom Thermal expansion valve superheat too low Possible Causes Potential Solutions Sensing bulb not properly located Check if secured to pipe or insulated check sensor position on pipe at 4 8 10 2 clock positions Defective thermostatic element Replace power head...

Page 67: ... to reread the rating ID If the fault reappears cycle the power to the drive You may have to be repeat this If the fault persists contact your local ABB representative 2310 Overcurrent Output current has exceeded internal fault limit In addition to an actual overcurrent situation this fault may also be caused by an earth fault or supply phase loss Check motor load Check acceleration times in param...

Page 68: ...nsient overvoltage Check brake chopper and resistor if present Check deceleration time Use coast to stop function if applicable Retrofit drive with brake chopper and brake resistor Check that the brake resistor is dimensioned properly and the resistance is between acceptable range for the drive 3220 DC link undervoltage Intermediate circuit DC voltage is not sufficient because of a missing supply ...

Page 69: ...dware failure STO hardware diagnostics has detected hardware failure Contact your local ABB representative for hardware replacement 5091 Safe torque off Programmable fault 31 22 STO indication run stop Safe torque off function is active ie safety circuit signal s connected to connector STO is broken during start or run Check safety circuit connections For more information see chapter The Safe torq...

Page 70: ...ing power If the problem persists contact your local ABB representative 64A1 Internal file load File read error Reboot the control unit using parameter 96 08 Control board boot or by cycling power If the problem persists contact your local ABB representative 64B2 User set fault Loading of user parameter set failed because requested set does not exist set is not compatible with control program driv...

Page 71: ...ontrol panel connection Check control panel connector Disconnect and reconnect the control panel 7121 Motor stall Programmable fault 31 24 Stall function Motor is operating in stall region because of e g excessive load or insufficient motor power Check motor load and drive ratings Check fault function parameters 7181 Brake resistor Brake resistor broken or not connected Check that a brake resistor...

Page 72: ...s been too long under the underload curve See parameter 37 04 ULC underload actions 8002 ULC overload fault User load curve Signal has been too long over the overload curve See parameter 37 03 ULC overload actions 80A0 AI supervision Programmable fault 12 03 AI supervision function An analog signal is outside the limits specified for the analog input Check signal level at the analog input Check th...

Page 73: ...e Fault in external device 5 Check the external device Check setting of parameter 31 09 External event 5 source FA81 Safe torque off 1 Safe torque off function is active ie STO circuit 1 is broken Check safety circuit connections For more information see chapter The Safe torque off function in the Hardware manual of the drive and description of parameter 31 22 STO indication run stop page 183 Chec...

Page 74: ...tan Gen II Air Cooled Modular Chiller models are available in a range of voltage amperage phase configurations to meet the demands of a worldwide market The high voltage configuration for a chiller module is listed on each module s name plate The chiller is designed to operate with high voltage power supplied to the unit at all times See Figure 26 p 74 and Figure 27 p 75 Figure 26 High voltage log...

Page 75: ...voltage logical flow of chiller bank Control Logical Flow The chiller uses low voltage for controller and sensor circuits See following figure Figure 28 Expansion board wiring L Lo og gi ic ca al l F Fl lo ow w D Di ia ag gr ra am ms s ...

Page 76: ...76 ARTC SVX001B EN Figure 29 Control logical flow L Lo og gi ic ca al l F Fl lo ow w D Di ia ag gr ra am ms s ...

Page 77: ...he leaving temperature of the chilled water maintaining a minimum flow of water through the evaporator Figure 30 Refrigeration logical flow Pumpdown Switch Pumpdown Switch Water Glycol Mixture Logical Flow Trane recommends using a water glycol mixture instead of an all water fluid The water glycol mixture is used within a closed system as shown in the following figure L Lo og gi ic ca al l F Fl lo...

Page 78: ...78 ARTC SVX001B EN Figure 31 Water glycol mixture logical flow L Lo og gi ic ca al l F Fl lo ow w D Di ia ag gr ra am ms s ...

Page 79: ...ial Pressure Dly Delay DP Differential Pressure ECM Electrically Commutated Motor EER Energy Efficiency Rating Table 16 Acronyms and abbreviations continued Item Expansion EMC Electromagnetic Compatibility EMI Electromagnetic Interference EPC Extended Performance Compressor EvapFl Evaporator Flow EVC Electronic expansion Valve Controller EXP1 Expansion Board 1 EXV Electronic expansion Valve F Fahr...

Page 80: ...own Pump Down PumpMod Pump Module PWM Pulse Width Modulation Pwrup Stg Up Power Up Stage Up REFRIG Refrigeration RemOff Remote Off Table 16 Acronyms and abbreviations continued Item Expansion RMA Returned Merchandise Authorization Rot Rotation rpm revolutions per minute RP Redundant Pump s second SAT Saturday SDT Saturated Discharge Temperature SP Set Point SSS Solid State Starter SST Saturated Su...

Page 81: ... the system expansion characteristics of the tank could not be exploited The sealed tank also contains a vacuum vent to protect the tank from imploding Dual lead lag pumps each with 100 pumping capacity are provided in each tank and pump module If the lead pump fails to operate the lag pump activates and an alarm signal is generated on the microprocessor controller indicating primary pump failure ...

Page 82: ...mps to deliver the required flow through each operating evaporator The pump speed varies proportionally to the number of modules that are operating electronic valves open in the chiller 5 Since the electronic isolation valve of the primary module is already energized the pump must produce the minimum flow required by the primary module A system bypass with valve must be provided by the customer an...

Page 83: ...to a new primary module each week to equalize the running time among the modules 14 When a redundant primary microprocessor controller is provided on a chiller module the redundant primary microprocessor will without downtime and without any operational deficiency perform the primary microprocessor functions should it fail All operational sequences shall be uninterrupted and uninhibited should the...

Page 84: ...e eq qu ui ir re em me en nt ts s Mandatory Tasks Date Completed Initialed Complete All chiller modules are installed with minimum clearances available from all sides Refrigeration gauges are indicating equal pressures Chilled water lines from chiller to customer s equipment are permanently connected Chilled water lines have been flushed clean of mud slag and other construction debris All chilled ...

Page 85: ...aborted startup will be forfeited Rescheduled initial startups are subject to any additional costs that may have been incurred by the technician An approved purchase order or payment in advance will be required to reschedule an aborted initial startup Name Printed ____________________________________ Date ______________________________________ Signature _________________________________________ Co...

Page 86: ...86 ARTC SVX001B EN N No ot te es s ...

Page 87: ...ARTC SVX001B EN 87 N No ot te es s ...

Page 88: ...ates comfortable energy efficient indoor environments for commercial applications For more information please visit trane com or americanstandardair com Arctic designs cost efficient leading edge chillers and applied solutions to meet individual customer needs from large medium to smaller scale systems For more information please visit www arcticchillergroup com ARTC SVX001B EN 15 Dec 2021 Superse...

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