Trane CenTraVac CDHF Series Installation, Operation And Maintenance Manual Download Page 7

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CDHF-SVX01N-EN

Recommended Maintenance . . . . . . . . . . . . . . 85

Record Keeping Forms . . . . . . . . . . . . . . . . . . . 85

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . 85

Recommended Compressor Oil
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Leak Checking Based on Purge Pump
Out Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Long Term Unit Storage. . . . . . . . . . . . . . . . . . 88

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 89

Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Recommended System
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Waterbox and Tubesheet Protective
Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Sacrificial Anodes . . . . . . . . . . . . . . . . . . . . 90

Waterbox Removal and Installation . . . . . . . 92

Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 93
Torque Requirements and Waterbox
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Connection Devices Information . . . . . . . . . . 94

Appendix A: Forms and Check
Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Unit Start-up/Commissioning. . . . . . . . . . . . . 95

Appendix B: CenTraVac™ Chiller
Installation Completion and Request for
Trane Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Appendix C: CDHF and CDHG
CenTraVac™ Chiller Start-up Tasks to be
Performed by Trane . . . . . . . . . . . . . . . . . . . . . . . 98

Appendix D: CDHF and CDHG
CenTraVac™ Chiller Annual Inspection
List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Appendix E: CDHF and CDHG
CenTraVac™ Chiller Operator Log . . . . . . . . 101

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Summary of Contents for CenTraVac CDHF Series

Page 1: ...vice the equipment The installation starting up and servicing of heating ventilating and air conditioning equipment 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 label...

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 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 ...

Page 3: ...g R R 5 51 14 4A A r re ef fr ri ig ge er ra an nt t a an nd d O OI IL L0 00 03 33 34 4 O OI IL L0 00 03 33 35 5 c co om mp pr re es ss so or r o oi il l V Ve er ri if fy y p pr ro op pe er r r re ef fr ri ig ge er ra an nt t a an nd d o oi il l f fo or r y yo ou ur r c ch hi il ll le er r a an nd d d do o N NO OT T m mi ix x r re ef fr ri ig ge er ra an nt ts s o or r o oi il ls s This Installati...

Page 4: ...arks referenced in this document are the trademarks of their respective owners Factory Training Factory training is available through Trane University to help you learn more about the operation and maintenance of your equipment To learn about available training opportunities contact Trane University Online www trane com traneuniversity Phone 855 803 3563 Email traneuniversity trane com Revision Hi...

Page 5: ...g Connections 28 Waterbox Locations 29 Grooved Pipe Coupling 29 Flange connection Adapters 29 Victaulic Gasket Installation 30 Screw Tightening Sequence for Water Piping Connections 31 Flanges with 4 8 or 12 Screws 31 Flanges with 16 20 or 24 Screws 31 Flanges with More than 24 Screws 32 Evaporator Waterbox Covers 32 Pressure Testing Waterside Piping 32 Eddy Current Testing 32 Vent Piping 34 Refri...

Page 6: ...5 Optional Tracer Communication Interface 65 Starter Module Configuration 66 Schematic Wiring Drawings 66 Operating Principles 67 General Requirements 67 Cooling Cycle 67 CDHG 3 Stage Compressor 1 or 2 67 CDHF 2 Stage Compressor 1 or 2 67 Duplex Compressor Sequencing 68 Fixed Sequence Compressor 1 Compressor 2 Default Mode 68 Fixed Sequence Compressor 2 Compressor 1 69 Sequencing Balanced Starts a...

Page 7: ... 90 Waterbox Removal and Installation 92 Discussion 92 Procedure 92 Reassembly 93 Torque Requirements and Waterbox Weights 93 Connection Devices Information 94 Appendix A Forms and Check Sheets 95 Unit Start up Commissioning 95 Appendix B CenTraVac Chiller Installation Completion and Request for Trane Service 96 Appendix C CDHF and CDHG CenTraVac Chiller Start up Tasks to be Performed by Trane 98 ...

Page 8: ...ce 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 variable unit features required when ordering replacements parts or requesting service N No ot te e Unit mounted starters are identified by a separate number found on the starter P Pr ro od du uc ct t D De es ...

Page 9: ...t 27 Condenser Tubes Digit 28 RuptureGuard Digit 29 Condenser Waterbox Digit 30 Condenser Waterbox Connection Digit 31 Control Enclosure Digit 32 Orifice Size Left Hand Circuit Digit 33 Orifice Size Right Hand Circuit Digit 34 Starter Type Left Hand Digit 35 Starter Type Right Hand Digit 36 Enhanced Protection Digit 37 Generic BAS Digit 38 Water Flow Control Digit 39 Tracer Communication Interface...

Page 10: ...s factory assembled wired and tested All openings except for the waterbox vent and drain holes are covered or plugged to prevent contamination during shipment and handling Unit Components p 14 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 integrity of t...

Page 11: ... install isolation springs if they block serviceable parts such as the oil tank system service valves etc Electrical Circuit breakers or fusible disconnects optional Unit mounted starter optional Power factor correction capacitors PFCCs optional Jumper bars Temperature sensor optional outdoor air Flow switches may be field supplied for installation instructions for the ifm efector flow detection c...

Page 12: ...cifically authorized to perform start up of Trane products Post commissioning transport of empty refrigerant containers for return or recycling Move empty refrigerant containers to an easily accessible point of loading a Start up must be performed by Trane or an agent of Trane specifically authorized to perform start up and warranty of Trane products Contractor shall provide Trane or an agent of T...

Page 13: ... charge the chiller with refrigerant If additional refrigerant is on site follow manufacturer s storage requirements Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig 20 7 to 34 5 kPaG Notify the local Trane office if charge has escaped Verify dry nitrogen pressure using gauge located on the evaporator shell reads 3 to 5 psig 20 7 to 34 5 kPaG Notify the lo...

Page 14: ...ed to as referred to as Side 1 and the right side of the unit is referred to as Side 2 Figure 3 Typical Duplex CenTraVac chiller 1 2 3 4 5 6 7 8 9 0 0 1 3 4 2 7 6 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 P Pr re e I In ns st ta al ll la at ti io on n ...

Page 15: ...00V require 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 requirements C 3 ft 92 cm A 18 in 46 cm Economizer Cooling condenser Evaporator Motor Right hand tube pull shown apply tube pull clearance dimension to left end for left hand tube pull Optional un...

Page 16: ...r Transformer CPTR option add 130 lb 8 Supplemental Motor Protection SMP option add 500 lb Table 3 Representative weights 50 Hz chillers lb Model Comp Size CPKW Evap Size Cond Size Weights without Starters Weights with Starters NTON EVSZ CDSZ Operating Shipping Operating Shipping CDHG 1250 621 210D 210D 99463 84013 100577 85127 1750 621 210D 210D 99463 84013 100577 85127 2150 892 210D 210D 103720 ...

Page 17: ...Transformer CPTR option add 59 kg 8 Supplemental Motor Protection SMP option add 227 kg Table 5 Weights 50 Hz chillers kg Model Comp Size CPKW Evap Size Cond Size Weights without Starters Weights with Starters NTON EVSZ CDSZ Operating Shipping Operating Shipping CDHG 1250 621 210D 210D 45116 38108 45621 38613 1750 621 210D 210D 45116 38108 45621 38613 2150 892 210D 210D 47047 40051 47552 40557 225...

Page 18: ...er to Weights lb p 16 and Weights kg p 16 respectively N No ot te e For specific weight information refer to the unit submittal package I Im mp 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 chillers Suggested lifting arrangements for standard units ...

Page 19: ...ator pads or spring isolators beneath the chiller feet refer to Unit Isolation p 20 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 chiller working from end to end in small increments to maintain stability 6 When lift is complete detach the rigging shackl...

Page 20: ...s su ul lt t i in n e eq qu ui ip pm me en nt t o or r p pr ro op pe er rt ty y o on nl ly y d da am ma ag ge e D Do o n no ot t u us se e a a f fo or rk k l li if ft t t to o m mo ov ve e t th he e c ch hi il ll le er r N NO OT TI IC CE E C Co om mp pr re es ss so or r A Al li ig gn nm me en nt t F Fa ai il lu ur re e t to o p pr re es se er rv ve e c co om mp pr re es ss so or r a al li ig gn nm...

Page 21: ...piping connected to the chiller must be properly isolated and supported so that it does not place any stress on the unit Spring Isolators Spring isolators should be considered whenever chiller installation is planned for an upper story location Base isolator placement is shown in the following figure Figure 7 Isolation spring placement by shell size and evaporator and condenser length Condenser Ev...

Page 22: ...a an nt t The chiller must be level to within 1 16 in 1 6 mm over its length and width and the clearance of each isolator must be at least 1 4 in 6 35 mm Figure 8 Chiller foot and isolator orientation Side View of Unit End View of Unit Center tube sheet support leg Outside edge of tube sheet Center of isolator spring Note The spring isolator must be centered in relation to the tube sheet Do not al...

Page 23: ...ser level is an acceptable alternative method to level the unit I Im mp po or rt ta an nt t Immediately report any unit damage incurred during handling or installation at the job site to the Trane sales office 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 24: ...meter 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 ox x 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 r re es su ul lt t i in n d da am ma ag ge e t to o t th he e w wa at te...

Page 25: ...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 interference 3 Pipe coupling 4 Flow switch paddle 5 Five 5 pipe diameters no turns or fittings Paddle switch installation 1 Mount the flow paddle switch upright in horizontal section of pipe Allow at least five ...

Page 26: ...cm of the probe length into the pipe 3 Install the Micro DC Cable by inserting it through 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 connector nut 4 Plug the other end of the Micro DC Cable into the Flow Control Monitor with the Combicon connector...

Page 27: ... 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 are used with control logic to confirm flow prior to starting a unit and to stop a running unit if flow is lost For troubleshooting a viewable diagnostic is generated if a proof of flow switch does no...

Page 28: ...rator freeze up or erosion For applications that include an infinite source 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 cooling condenser when the supply water temperature is too low For additional application information refer to Engineering Bu...

Page 29: ...Customer piping connection types Flanged Victaulic Waterbox Waterbox Customer Flange Adaptor Trane provided Style 77 Flexible Customer provided N No ot te es s Refer to the coupling manufacturer s guidelines for specific information concerning proper piping system design and construction methods for grooved water piping systems Flexible coupling gaskets require proper lubrication before installati...

Page 30: ...s sk ke et t c co on nt ta ac ct t s su ur rf fa ac ce es s o of f a ad da ap pt te er r m mu us st t b be e f fr re ee e o of f g go ou ug ge es s u un nd du ul la at ti io on ns s o or r d de ef fo or rm mi it ti ie es s Figure 18 Modifying 300 psig 2068 4 kPaG flange adaptors for flat faced flange application Remove to mate to flat faced flanges Victaulic Gasket Installation 1 Inspect supplied ...

Page 31: ...ghtening any of the screws align the flanges Flange screw torque requirements are provided in the following table Table 11 Flange screw torque recommendations for O ring and flat gasket piping connections Screw Size Gasket Type O Ring Flat in mm ft lb N m ft lb N m 3 8 9 5 25 34 12 18 16 24 1 2 13 70 95 33 50 45 68 5 8 16 150 203 70 90 95 122 3 4 19 250 339 105 155 142 210 Note Screw size is deter...

Page 32: ... ip pm me 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 t th he es se e i in ns st tr ru uc ct ti io on ns 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 D Do o n no ot t o ov ve er r p pr re es ss su ur ri iz ze e t th he e s sy ys st te em m o or r e ex xc ce ee ed d d de es si ig gn n p pr re es ss su ur re e A Al lw wa ay...

Page 33: ...CDHF SVX01N EN 33 maintenance by providing information about eddy current technology and heat exchanger tubing I In ns st ta al ll la at ti io on n W Wa at te er r P Pi ip pi in ng g ...

Page 34: ...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 pump connector from Vibration Mounting and Control Inc or equivalent is recommended Vent Line Sizing Vent line size must conform to local codes and requirements In most cases local codes are based on ...

Page 35: ...on view that appears in the following figure rupture disk location and cross section Install the two bottom hex head screws though the pipe flanges Install the rupture disk with a gasket on each side between the pipe flanges Orient the disk with the reference arrow or vacuum support bar facing the chiller side as shown in the following figure rupture disk location and cross section Install the two...

Page 36: ... m from any building opening Provide a vent line termination that cannot be blocked by debris or accumulate rainwater Provide a drip leg on the vent line refer to the following figure arrangement for rupture disk relief piping Provide a standard 1 4 in FL x 1 4 in NPT capped refrigerant service valve to facilitate liquid removal 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 F...

Page 37: ... 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 be connected to the downstream side piping to vent purge exhaust out the vent line to the outdoors it may need to be extended to the drip leg Field acquired tubing may be required to extend to the fie...

Page 38: ...he evaporator standard condenser and economizer If the unit is equipped with any options e g heat recovery free cooling or an auxiliary condenser add the applicable C values to this total With this new sum refer to the following figure to determine the vent line pipe diameter 3 If piping multiple rupture disks to a common vent line first determine the total C value for each rupture disk then add a...

Page 39: ...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 a reference is based on ASHRAE Standard 15 Vent line size is typically dictated by state or local code which may be different from ASHRAE Standard 15 requirements V Ve en nt t P Pi ip pi in ng g ...

Page 40: ...t 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 allowed back pressure absolute at the outlet of pressure relief device psi kPa P0 0 50 P atmospheric pressure N No ot te e For rupture disks on CenTraVac chillers P is 15 lb 6 8 kg Atmospheric press...

Page 41: ... 3 4 in 19 05 mm a Insulation Square Feet 3 8 in 9 525 mm Insulation b Square Feet 3 4 in 19 05 mm Insulation a Square Feet 3 8 in 9 525 mm Insulation b Square Feet 210 Duplex 1270 193 Not Available Not Available 250 Duplex 1308 193 Not Available Not Available 250 Duplex Medium 1410 280 Not Available Not Available 250 Duplex Extended 1500 280 Not Available Not Available Note Chillers equipped with...

Page 42: ...s drain and vent connections must be accessible after insulating All units with evaporator marine waterboxes 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 nameplate Apply 2 in 50 8 mm wide black tape on overlap joints Where possible apply 3 in 76 2 mm wide...

Page 43: ...fer to Tracer AdaptiView Display for Water cooled CenTraVac Chillers Operations Guide CTV SVU01 EN UC800 Specifications Power Supply The UC800 1A22 receives 24 Vac 210 mA power from the 1A2 power supply located in the chiller control panel Wiring and Port Descriptions The following figure illustrates the UC800 controller ports LEDs rotary switches and wiring terminals The numbered list following t...

Page 44: ...rvice 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 the communication interfaces listed Refer to the figure in Wiring and Port Descriptions p 43 for the locations of each of these ports BACnet MS TP MODBUS Slave LonTalk using LCI C from the IPC3 bus Com...

Page 45: ...D 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 ACT LED blinks yellow at the data transfer rate when data flow is active on the link Service The Service LED is solid green when pressed For qualified service technicians only Do NOT use I Im mp po or...

Page 46: ... left hand panel showing low voltage and higher voltage areas for proper routing of field wiring 528 OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30 Volt Maximum 30 115 Volt Maximum I In ns st ta al ll la at ti io on n C Co on nt tr ro ol ls s ...

Page 47: ...iView main unit assembly right hand panel showing low voltage and higher voltage areas for proper routing of field wiring OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30 Volt Maximum 30 115 Volt Maximum I In ns st ta al ll la at ti io on n C Co on nt tr ro ol ls s ...

Page 48: ... 1A21 1A20 1A19 1A18 1A17 1A16 1A15 1A14 1A13 1A22 X19091218 01 1K8 1K26 1K27 1F1 1Q1 1Q2 1Q3 1Q4 1Q5 1Q6 OR OR 1A25 1K9 30V MAX 30V MAX 30V MAX 30V MAX 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V MAX 30V MAX 30V MAX OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30 Volt...

Page 49: ...1 1T1 1A2 1A1 1A24 1A21 1A20 1A19 1A18 1A17 1A16 1A15 1A14 1A13 1A22 X19091218 01 1K8 1K26 1K27 1F1 1Q1 1Q2 1Q3 1Q4 1Q5 1Q6 OR OR 1A25 1K9 X A M V 0 3 X A M V 0 3 30V MAX V 5 1 1 O T V 0 3 X A M V 0 3 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V TO 115V 30V MAX 30V MAX 30V MAX OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30 Volt Maximum 30 115 Vo...

Page 50: ...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 m mo od de er ra at te e i in nj ju ur ry y E En ns su ur re e t th ha at t t th he e s su up pp po or rt t a ar rm m i is s i in n t th he e f fu ul ll l u up pr ri ig gh ht t p po os si it ti io on...

Page 51: ... 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 display to tilt up and down Joints 1 1 and 2 2 are covered by a plastic cap Remove the plastic cap to access the screw Adjust using a 13 mm wrench as necessary To adjust the swivel rotation tension of the...

Page 52: ... Before wiring begins observe 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 required time to allow the capacitor s to discharge this could be up to 30 minutes Verify that all capacitors are discharged prior to service using a properly rated volt me...

Page 53: ...AWG b Minimum Circuit Ampacity 120 Vac Power Supply from Starter to Control Panel 2X1 1 2X1 2 2X1 20 Ground 1X1 1 1X1 12 1X1 18 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 Voltage Circuits Less Than 30 Vac Starter Panel Terminals Unit Control Panel Terminations Standard Circuit...

Page 54: ...rd Circuits Current Transformers refer to table in Current Transformer and Potential Transformer Wire Sizing p 54 Required b 5CT4 white black 5CT5 white black 5CT6 white black 1A23 J7 1 2 1A23 J7 3 4 1A23 J7 5 6 Note Phasing must be maintained Potential Transformers Required b 5T17 236 237 5T18 238 239 5T19 240 241 1A23 J5 1 2 1A23 J5 3 4 1A23 J5 5 6 Note Phasing must be maintained Solid State Sta...

Page 55: ...e listed value a Wires lugs and fuses breakers are sized based on National Electric Code NEC NFPA 70 and UL 1995 Table 19 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 933 711 217 10 1924 586 447 136 12 1211 369 281 85 14 761 232 177 53 16 478 145 111 33 17 379 115 88 26...

Page 56: ...d du uc ct to or rs s O On nl ly y F Fa ai il lu ur re e t to o u us se 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 no ot t d de es si ig gn ne ed d o or r q qu ua al li if fi ie ed d t to o a ac cc ce ep pt t o ot th he er r t ty yp pe es s o of...

Page 57: ... 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 nn 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 F Fo or r v va ar ri ia ab bl le e f fr re eq qu ue en nc cy y d dr ri iv ve es s o or r o 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 i...

Page 58: ...t 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 1 portion of the until control panel 7 Lead power wiring N No ot te e Refer to the unit field connection diagram for approximate unit control panel knock out locations To prevent damage to the unit con...

Page 59: ...T connect the power leads between the starter and compressor motor These connections will be completed under supervision of a qualified Trane service engineer after the pre start inspection Figure 44 Terminal stud clamp and lug assembly 4160V and below 1 2 3 4 5 1 Belleville washer 2 Terminal lugs 3 Terminal clamp 4 Motor terminal stud 5 3 8 in bolt Bus Bars N NO OT TI IC CE E C Co om mp po on ne ...

Page 60: ...g is critical for proper operation Separate low voltage less than 30V refer to the tables in Trane supplied Starter Wiring p 53 and Customer supplied Remote Starter Wiring p 54 wiring from the 115V wiring by running each in its own conduit When routing the IPC circuit out of the starter enclosure ensure that it is at least 6 in 16 cm from all wires carrying a higher voltage W WA AR RN NI IN NG G P...

Page 61: ...A etc In all cases of non Trane supplied starters the Trane Engineering Specification for UC800 Starter By Others available through your local Trane office must be followed in order to ensure proper function and protection of the chiller A disconnecting means and short circuit protection must be installed ahead of the starter unless they are included as part of the starter N No ot te e Trane assum...

Page 62: ...the 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 the motor terminals Follow all instructions provided with the field provided lugs to ensure proper connections I Im mp po or rt ta an nt t The use of stress cones is highly recommended to reduce and...

Page 63: ...rnates Circuit 1 Running Circuit 2 Running Chiller Alarm Circuit 1 Alarm Circuit 2 Alarm Purge Alarm Standard Low Voltage Circuits Less than 30 Vac c Unit Control Panel Terminations Input or Output Type Contacts External Auto Stop Input 1A13 J2 1 to 2 Binary Input Closure Required for Normal Operation Emergency Stop Input 1A13 J2 3 to 4 Binary Input Closure Required for Normal Operation Circuit 1 ...

Page 64: ... 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 y e en ne er rg gi iz ze e...

Page 65: ...and the sensor two wire leads be extended and routed to the outdoor temperature sensor probe sensing location This ensures the four wire inter processor control IPC bus protection and provides access to the module for configuration at start up The sensor probe lead wire between the sensor probe and the module can be separated by cutting the two wire probe lead leaving equal lengths of wire on each...

Page 66: ...o power up the control circuits This needs to be done in each panel Use the as built starter schematic to ensure correct fuse and terminals Verify that the correct fuse is removed and that the control circuit connections are correct then apply the 115 Vac separate source power to service the controls Schematic Wiring Drawings Please refer to the submittals and drawings that shipped with the unit A...

Page 67: ...CDHG 3 Stage Compressor 1 or 2 Compressed gas from the first stage impeller flows through the fixed second stage inlet vanes and into the second stage impeller Here the refrigerant gas is again compressed and then discharged through the third stage variable guide vanes and into the third stage impeller After the gas is compressed a third time it is discharged into the condenser Baffles within the ...

Page 68: ...art the available compressor will be started N No ot te e The following description assumes Compressor 1 is the downstream compressor Fixed Sequence Compressor 1 Compressor 2 Default Mode If the chiller is in the Auto mode and all interlocks have been satisfied Compressor 1 will be started based on the leaving water temperature rising above the Differential to Start setting Compressor 2 will stage...

Page 69: ... and 2 Chiller Capacity Less than 30 De Energize Cprsr with Most Starts and Hours Single Comp Capacity Greater than 80 No Time Delay Sequencing Balanced Starts and Hours When desired to balance the wear between the compressors this method will extend the time between maintenance on the lead compressor When balanced starts and hours is selected the compressor with the fewest starts will start If th...

Page 70: ... same load command The load command will be converted to inlet guide vane IGV position that will be the same on each compressor Balancing compressor load results in the best overall efficiency and with both circuits operating with nearly the same refrigerant pressures When both compressors are running the overall chiller load command will be split evenly between the two compressors unless limit co...

Page 71: ...features exist for each compressor and operate independently of other compressors on that chiller During the time the start is inhibited due to the start to start timer the Tracer AdaptiView shall display the mode Restart Inhibit and the also display the time remaining in the restart inhibit A Restart Inhibit Invoked warning diagnostic will exist when the attempted restart of a compressor is inhib...

Page 72: ...to drive oil reclaim eductors 0 375 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 refrigerant to pump 1 625 in 41 275 mm OD 12 Economizer 13 Oil supply to bearings 0 625 in 15 875 mm OD 14 Purge 15 Compressor 16 Liquid refrigerant motor coolant supply 1 125...

Page 73: ... the tank 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 suction cover and evaporator to the eductors and then discharge into the oil tank The evaporator eductor line has a shut off valve mounted by the evaporator The position of the shut off valve w...

Page 74: ...are 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 corresponds to the shading on the time lines that show the chiller s state There are five generic states that the software can be in Power Up Stopped Starting Running Stopping Figure 56 Software operation...

Page 75: ...rows indicate 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 operation of the chiller When operation of the chiller is required the chiller mode is set at Auto Using customer supplied power the chilled water pump relay is energized and chilled water flow m...

Page 76: ...nes 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 appropriate mode of operation Normal Softload Limit Mode and so on refer to the following figure running N No ot te e For more information refer to Duplex Compressor Sequencing p 68 If the chilled water temperature...

Page 77: ...ressor 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 pressure is opened Oil Differential Pressure Switch If the STOP key is pressed on the operator interface the chiller will follow the same stop sequence as described earlier except the chilled water pu...

Page 78: ...ater 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 seconds 6 seconds Filter Energize Evaporator Water Pump Relay Only if Evaporator Pump Off Delay Timer has Expired De Energize Compressor Confirm Evaporator Water Flow Within 4 minutes 15 seconds 6 sec...

Page 79: ...feature when the Ice Building option is installed Ice Building 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 communicated input BAS to initiate the ice building mode where the unit runs fully loaded at all times Ice building will be terminated either by opening the contact...

Page 80: ...ng Ice to Normal Transition Timer 0 to 10 minutes Head Relief Request Relay Delay 1 to 60 minutes Head Relief Request Relay Delay 1 to 60 minutes Open IGV at Max Rate Max AFD Frequency Close IGV Min AFD Frequency Modulate IGV AFD for LWT Control Ignore Softloading and Set CLS to 100 Energize Ice Building Relay De Energize Ice Building Relay De Energize Head Relief Request Relay Energize Head Relie...

Page 81: ...tor load heat such as well or lake water The chiller has only one condenser N No ot te e Hot Water Temperature Control mode does NOT convert the chiller to a heat pump Heat pump refers to the capability to change from a cooling driven application to a heating driven application by changing the refrigerant path on the chiller This is impractical for centrifugal chillers as it would be much easier t...

Page 82: ...d LLIDs and can be temperature sensors or pressure transducers These and other functional switches provide analog and binary inputs to the control system User defined Language Support Tracer AdaptiView is capable of displaying English text or any of 26 other languages 27 total languages Switching languages is simply accomplished from a Language Settings menu The following languages are available A...

Page 83: ...ater is energized during the compressor off cycle During unit operation the oil tank heater may be de energized The oil heater may be energized during unit operation with R 514A 4 Check the chilled water setpoint and readjust it if necessary in the Chiller Settings menu 5 If necessary readjust the current limit setpoint in the Chiller Setpoints menu 6 Press AUTO The control panel also checks compr...

Page 84: ...ow oil sump heater operation Failure to do this will allow refrigerant to condense in the oil pump 1 Open all disconnect switches except the control power disconnect switch 2 Drain the condenser piping and cooling tower if used Rinse with clean water 3 Remove the drain and vent plugs from the condenser headers to drain the condenser Air dry bundle of residual water 4 Once the unit is secured for t...

Page 85: ... Do o N No ot t U Us se e 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 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 nt t d da am ma ag ge e O On nl ly y g ge en nu ui in ne e T Tr ra an ne e r re ep pl la ac ce em me en nt t...

Page 86: ...ly and check for any abnormalities Lubricate the oil filter shutoff valve O rings Drain contents of the rupture disk and purge discharge vent line drip leg into an evacuated waste container Do this more often if the purge is operated excessively Apply oil to any exposed metal parts to prevent rust Shut down the chiller once each year to check the items listed on the Appendix D CDHF and CDHG CenTra...

Page 87: ...g ge e i in nc cl lu 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 pu ur rg ge e p pu um mp p o ou ut t i in n h hi ig gh h h he ea ad d h hi ig gh h a am mb bi ie en nt t a ap pp pl li ic ca at ti io on ns s C Ce en nT Tr ra aV Va ac c c ch hi i...

Page 88: ...the purge pump out time and unit size This figure depicts normal purge pump out times small leaks and large leaks based on chiller tonnage If the purge pump out time is in the small leak region then a leak check should be performed and all leaks repaired at the earliest convenience If the purge pump out time is in the large leak region a thorough leak check of the unit should be performed immediat...

Page 89: ...s o or r o oi il ls s This Installation Operation and Maintenance manual applies to CenTraVac chillers with two different refrigerant and compressor oil systems R 123 refrigerant and OIL00022 compressor oil R 514A refrigerant and OIL00334 OIL00335 compressor oil I Im mp po or rt ta an nt t Verify proper refrigerant and compressor oil for your chiller before proceeding For chillers with R 123 refri...

Page 90: ...d in the external circulation system the quantity of the solution the duration of the cleaning period and any required safety precautions should be approved by the company furnishing the materials or performing the cleaning Remember however that whenever the chemical tube cleaning method is used it must be followed up with mechanical tube cleaning flushing and inspection Evaporator Since the evapo...

Page 91: ... or r e eq qu ui iv va al le en nt t m ma ay y b be e a ap pp pl li ie ed d t to o p pr re ev ve en nt t l le ea ak ka ag ge e w wh he en n i in ns st ta al ll li in ng g a an n a an no od de e b bu ut t d do o n no ot t a ap pp pl ly y s so o m mu uc ch h s se ea al la an nt t t th ha at t i it t p pr re ev ve en nt ts s t th he e n ne ec ce es ss sa ar ry y e el le ec ct tr ri ic ca al l c co on...

Page 92: ...d r ra 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 re ea as si in ng g m ma an nn ne er r A An ng gu ul la ar r l li if ft ts s w wi il ll l s si ig gn ni if fi ic ca an nt tl ly y l lo ow we er r m ma ax xi im mu um m l lo oa ad ds s a an nd d ...

Page 93: ... nt t Torque waterbox screws as specified in Torque Requirements and Waterbox Weights p 93 Torque Requirements and Waterbox Weights N No ot te e These chillers are assembled with SAE fasteners Table 24 CenTraVac chiller screw torques SAE Screw Size Torque Gasket type O ring Torque Flat in ft lb N m ft lb N m 3 8 25 33 9 12 18 16 3 24 4 1 2 70 94 9 33 50 44 7 67 8 5 8 150 203 4 70 90 94 9 122 0 3 4...

Page 94: ...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 Evaporator 150 psig 1034 2 kPaG 595 270 0 469 1323 600 3 4 10 Evaporator 300 psig 2068 4 kPaG 1871 848 0 469 0 469 1764 800 3 4 10 Condenser 150 psig 1034 2 kPaG 588 267 0 469 1764 800 3 4 10 Condenser 30...

Page 95: ...enTraVac Chiller Installation Completion and Request for Trane Service p 96 CTV ADF001 EN Appendix C CDHF and CDHG CenTraVac Chiller Start up Tasks to be Performed by Trane p 98 Appendix D CDHF and CDHG CenTraVac Chiller Annual Inspection List p 100 Appendix E CDHF and CDHG CenTraVac Chiller Operator Log p 101 Unit Start up Commissioning I Im mp po or rt ta an nt t Start up must be performed by Tr...

Page 96: ...ation Operation and Maintenance manual Do NOT block serviceable parts when installing isolation springs Expenses that result in improper installation of CenTraVac chillers including optional components will NOT be paid by Trane Check box if the task is complete or if the answer is yes 1 C Ce en nT Tr ra aV Va ac c C Ch hi il ll le er r In place and piped N No ot te e Do not insulate the CenTraVac ...

Page 97: ...te container return or recycling 8 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 and test the CenTraVac chiller under serviceman s supervision 10 E Eq qu ui ip pm me en nt t r ro oo om m Does the equipment room have a refrigerant monitor sensor cap...

Page 98: ...h is not 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 the completed Non Compliance Form will become part of the start up record submitted with a Start up Check Sheet and a Chiller Service Report 2 P Pr re e S St ta ar rt t O Op pe er ra at ti io o...

Page 99: ... is working properly and moves without binding Dry run test starter non AFD Remove separate source power and reconnect wiring 3 P Pr re ep pa ar ra at ti io on n f fo or r S St ta ar rt t u up p Relieve nitrogen holding charge Evacuate and charge the system Apply power to the starter panel Verify current to the oil sump heater 4 C Ch hi il ll le er r S St ta ar rt t u up p Set Purge mode to On Bum...

Page 100: ...w sensing device Factory recommendation to eddy current test tubes every three years 6 C Co on nt tr ro ol l C Ci ir rc cu ui it ts s Verify control parameters Test appropriate sensors for accuracy Ensure sensors are properly seated in wells with thermopaste installed Check evaporator leaving water temperature low temperature cutout setpoint Condenser high pressure switch check out Check adjustmen...

Page 101: ...ondenser Entering Leaving Saturated Refrig Press Approach Flow Sw Status Compressor 1 Starts Running Time Oil Tank Press Oil Discharge Press Oil Diff Press Oil Tank Temp IGV Position IGV Steps Motor 1 RLA L1 L2 L3 Amps L1 L2 L3 Volts AB BC CA Power KW Load PF Winding 1 Temp Winding 2 Temp Winding 3 Temp Compressor 2 Starts Running Time Oil Tank Press Oil Discharge Press Oil Diff Press Oil Tank Tem...

Page 102: ...istor Temp Purge Time Until Next Purge Run Daily Pumpout 24 hrs Avg Daily Pumpout 7 days Daily Pumpout Limit Alarm Chiller On 7 days Pumpout Chiller On 7 days Pumpout Chiller Off 7 days Pumpout Life Purge Rfgt Cprsr Suction Temp Purge Liquid Temp Carbon Tank Temp if present Date Technician Owner A Ap pp pe en nd di ix x E E C CD DH HF F a an nd d C CD DH HG G C Ce en nT Tr ra aV Va ac c C Ch hi il...

Page 103: ...CDHF SVX01N EN 103 N No ot te es s ...

Page 104: ... are committed to using environmentally conscious print practices Trane by Trane Technologies NYSE TT a global climate innovator creates comfortable energy efficient indoor environments for commercial and residential applications For more information please visit trane com or tranetechnologies com CDHF SVX01N EN 14 Mar 2020 Supersedes CDHF SVX01M EN Oct 2019 ...

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Trane CenTraVac CDHF Series, Installation, Operation And Maintenance Manual

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